DOWNLOAD PDF KCM 70Z7 70TM7 Wheel Loader CUMMINS QSB6.7 Engine Shop Manual PN 93208-00772 by www.heydownloads.com

70Z7/70TM7

93208-00772

SHOP MANUAL Disassembly & Reassembly Vol.1

Printed in Japan (K) （アメリカ用）

93208-00772

February 2016

Volume 1

SHOP MANUAL WHEEL LOADER

70Z7/70TM7 Disassembly & Reassembly

93208-00772 Vol.1/2

SECTION AND GROUP SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling CONTENTS Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Pressure Release Procedure Group 6 Preparation WORKSHOP MANUAL

SECTION 2 MAINTENANCE STANDARD Group 1 Body Group 2 Travel System Group 3 Front Attachment Group 4 Front Attachment (Parallel Link)

SECTION 3 BODY

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

Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Pilot Valve Group 11 Brake Charge Valve Group 12 Manifold Valve Group 13 Solenoid Valve Group 14 Priority Valve Group 15 Cooling Fan System Group 16 Ride Control Device Group 17 Parallel Link (Special Parts)

SECTION 1

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

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

Group 3 Painting Painting .............................................................................W1-3-1-1 Painting (Parallel Link) ..................................................W1-3-2-1

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 ..................................W1-4-1-3 Bleeding Air from Radiator .........................................W1-4-1-4 Bleeding Air from Brake (Axle) ..................................W1-4-1-5

Group 5 Releasing Pressure Front Attachment Hydraulic Circuit Pressure Release Procedure ....................................................W1-5-1-1 Ride Control Accumulator Pressure Release Procedure ....................................................................W1-5-1-2 Parking Brake Accumulator Pressure Release Procedure ....................................................................W1-5-1-3

Group 6 Preparation Preparation before Inspection and Maintenance ..............................................................W1-6-1-1

70Z7/70TM7 D&R

(Blank)

70Z7/70TM7 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 dCAUTION: to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure. IMPORTANT:  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Clean the bolt and nut threads and remove dirt or corrosion before installing.

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 2013/09 Bolt Dia.

Hexagon Head Bolt

Socket Bolt Wrench Socket Bolt Size mm

WDAA-01-02-002

N·m M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36

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

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

WDAA-01-02-003

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

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

Wrench Size mm

WDAA-01-02-004

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

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

W1-2-1-1

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

20 50 90 140 210 300 400

(lbf·ft) (15) (37) (66) (103) (155) (220) (300)

5 6 8 10 12 14 14 17

SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.  Use the bolts of correct length. The bolts that are too long cannot be tightened as the bolt tip comes into contact with the bottom of bolt hole. Also the bolts that are too short cannot develop sufficient tightening force.  The torque given in the chart on the previous page are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Clean the nut and bolt threads and remove dirt or corrosion before installing.

Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

1 1.4

4 2 2.3

W105-01-01-003 a-

Equally tighten upper and lower alternately

Tighten diagonally

W1-2-1-2

Tighten from center diagonally

SECTION 1 GENERAL Group 2 Tightening Precautions for Split Flange IMPORTANT:  Clean the sealing surfaces. Check if there are any scratches and roughness on the surface of the seal that cause oil leaks and damage to the O-ring.  Use only specified O-rings. Inspect O-rings for any damage. Do not file the O-ring surfaces. When installing O-ring into a groove, use grease in order to hold O-ring in place.  While tightening the bolt by hand, check that flange is installed to the port correctly. Do not pinch the O-ring.  Tighten the bolts up and down, left and right alternately, in order to ensure even tightening to the specified torque.  Do not use air wrenches. Using an impact wrench often causes tightening of one bolt fully before tighten the others, resulting in damage to O-rings or uneven tightening of bolts.

WDAA-01-02-005

Incorrect

WDAA-01-02-006

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

W105-01-01-008

Incorrect

Correct

 Split Pin IMPORTANT: Do not turn in the loosening direction in order to align the grooves and holes on the nut. Always turn in the tightening direction. Do not reuse the split pins.

b Incorrect

Correct

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

Bend along edge sharply

Correct

Do not bend it round

Correct

Incorrect

WDAA-01-02-008 c-

W1-2-1-3

Tighten

Loosen

SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT:  The torque given in table below are for general use only, however, a different torque is given for a specific application. Use the specified torque.  Apply lubricant, such as the Grease Spray to the bolts and nuts in order to reduce friction coefficient of them.  Torque tolerance is ±10 %.  Slightly apply lubricant onto the threads first by using the Grease Spray.

W1-2-1-4

SECTION 1 GENERAL Group 2 Tightening Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. 1

IMPORTANT:  Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications.  Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting / disconnecting.

Joint Body

WDAA-01-02-009

37 °

Description Wrench Size mm Union Nut 30 ° male 17 19 22 27 32 36 41 50 55 60 37 ° female 17 19 22 27 32 36 41 50

2013/09 Tightening Torque N·m 25 30 40 80 140 180 210 350 380 380 25 30 40 80 140 180 210 350

30 °

(lbf·ft) (18.5) (22) (29.5) (59) (103) (133) (155) (260) (280) (280) (18.5) (22) (29.5) (59) (103) (133) (155) (260)

Male Union Joint

c c-

Female Union Joint WDAA-01-02-010

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

W1-2-1-5

SECTION 1 GENERAL Group 2 Tightening Pipe Joint Pipe connection (metal joint) (Union Nut Wrench Size: 17, 19, 22, 27 mm Metal (3) of adapter (1) and pipe (2) seals pressure oil.  Precautions for use Do not damage sealing surfaces (4) and (5) when disassembling and assembling.

Tightening Torque Use the specified tightening torque in the table below. 2013/09 Wrench Size (mm) 17 19 22 27 Tightening N·m 25 30 40 80 Torque (lbf·ft) (18.5) (22) (29.5) (59)

M1M7-07-005

O-ring Seal Joint O-ring (6) is installed against the end surface of adapter (7) and seals pressure oil. IMPORTANT:  Replace O-ring (6) with a new one when reinstalling.  Before tightening union nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening union nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.  Do not damage O-ring groove (8) of adapter (7) or sealing surface (10) on the hose side. Damage to O-ring (6) may cause oil leakage.  If union nut (9) is found to be loose, causing oil leakage, do not tighten it to stop the leak. Instead, replace O-ring (6) with a new one, then tighten union nut (9) after confirming that O-ring (6) is securely seated in O-ring groove (8).

8 a-

W1-2-1-6

Joint Body

Wrench Size mm (in) Union Nut 19 (0.75) 22 (0.87) 27 (1.06) 32 (1.26) 36 (1.42) 41 (1.61) 50 (1.97)

2013/09 Tightening Torque N·m 30 70 95 140 180 210 350

(lbf·ft) (22) (52) (70) (103) (133) (155) (260)

WDAA-01-02-011

SECTION 1 GENERAL Group 2 Tightening Quick Coupling 3

1. Coupling procedure  Push socket ring (1) into plug (3) by rotating it fully counterclockwise and then pulling it toward you.  Release socket ring (1). Check that socket ring (1) is returned by the spring force and the coupling is locked completely by ball (2). At this time, check if socket ring (1) is returned to the original position (to the rightmost direction). 2. Separating procedure  Remove the hose by rotating socket ring (1) fully counterclockwise and then pulling it. Because no check function is attached inside, be careful that oil flows out.  Cap the removed hoses using special plug. CAUTION:

 When disconnecting, do not damage joint surface.  When disconnecting, clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering.  Complete the joint disconnecting / connecting procedure. Check enough if oil leaks especially after installation.  After installation, check if socket ring (1) is returned to the original position (to the rightmost direction).

W1-2-1-7

M1M7-07-006

SECTION 1 GENERAL Group 2 Tightening R

Screw-In Connection

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 Straight Thread W105-01-01-018

Wrench Size mm Joint Body 19 22 27 36 41 50 60

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 overlap.  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.

Male Tapered Thread

2013/09 Tightening Torque Cast iron Structural rolled steel 15 (11) 35 (26) 30 (22) 50 (37) 50 (37) 95 (70) 70 (52) 160 (118) 110 (81) 200 (148) 160 (118) 330 (245) 200 (148)

fNOTE: Unit: N·m (lbf·ft) c

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 dCAUTION: genuine KCM/Hitachi service parts. Using hoses

Correct

Incorrect

other than genuine KCM/Hitachi hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine. Do not install 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 Cylinder) Pipe Bracket (Control Valve) Cab (Outside) Plate Handrail Rear Console (Inner) Seat Bracket Cockpit Skirt Cockpit Side Console (Inner) Cab (Inner)

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

6 13

7 WNDB-01-03-002

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

Surfaces to Be Painted Light Bracket Hydraulic Oil Tank Exhaust Pipe Air Duct Grill Bracket (Work Light) Rear Cover (Side) Handrail Side Cover (Lower) Lower Cover Articulate Lock Bar Pipe Pipe Guard

Painting Color High Grade Black High Grade Black Black Heat-Resistant Painting High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black High Grade Black Red 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

8 11

1 2 3 4 5 6 7 8 9 10 11

Surfaces to Be Painted Handrail (Front) Tool Box Rear Fender Handrail (Rear) Fender Cover (Rear) Full Fender Bracket (Full Fender) Bracket (Mud Guard) Deck Plate Step Fender Cover (Front)

Painting Color High Grade Black High Grade Black High Grade Black High Grade Black Do not paint it. Do not paint it. High Grade Black High Grade Black High Grade Black High Grade Black Do not paint it.

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

W1-3-1-3

WNDB-01-03-003

SECTION 1 GENERAL Group 3 Painting

WNEC-01-03-005

1 2 3 4 5

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

Painting Color High Grade Black High Grade Black Refer to W1-3-1-5 Refer to W1-3-1-6 High Grade Black

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

W1-3-1-4

SECTION 1 GENERAL Group 3 Painting

View A

View C

WNEC-01-03-008 View B

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

1 2 3 4 5 6 7 8 9 10

Surfaces to Be Painted Rear Axle Rim (Wheel) Mounting Part End of Axle and Rim (Wheel) Boss Part Boss Part Guard Mounting Part (Thread Part ) Flange Part Name Plate End of Boss Part Guard Mounting Part (Thread 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. Do not paint it. Do not paint it.

W1-3-1-5

WNEC-01-03-007

SECTION 1 GENERAL Group 3 Painting

View A

WNEC-01-03-012

1 2 3 4 5 6 7 8 9 10

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

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. Do not paint it. Do not paint it. Do not paint it.

W1-3-1-6

WNEC-01-03-011

SECTION 1 GENERAL Group 3 Painting Painting (Parallel Link)

View A

4 2

3 B WNDB-01-03-102 View B

WNDB-01-03-101

WNDB-01-03-103

1 2 3 4 5

Surfaces to Be Painted Pin (Lift Arm) Pin (Link) Pin (Lift Arm Cylinder) Lift Arm Auto Leveler Quick Coupler Indicator

Painting Color YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] YR1-01 [TAXI Yellow] TCM Red

Paint the painted surface of the front attachment except the above list in P1-01 [High Grade Black].

W1-3-2-1

SECTION 1 GENERAL Group 3 Painting

9 3

4 8

WNDB-01-03-001

1 2 3 4 5 6 7 8 9

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

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

W1-3-2-2

SECTION 1 GENERAL Group 3 Painting

6 13

7 WNDB-01-03-104

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

Surfaces to Be Painted Light Bracket Hydraulic Oil Tank Exhaust Pipe Air Duct Grill Bracket (Work Light) Rear Cover (Side) Handrail Side Cover Lower Cover Articulation Lock Bar Pipe Pipe Guard Pipe (Steering Cylinder)

Painting Color P1-01 [High Grade Black] P1-01 [High Grade Black] B701K [Black Heat-Resistant Painting] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Refer to W1-3-2-4. P1-01 [High Grade Black] TCM Red P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black]

Paint the painted surface except the above list in YR1-01 [TAXI yellow].

W1-3-2-3

SECTION 1 GENERAL Group 3 Painting

2 WNDB-01-03-108

1 2

Surfaces to Be Painted Side Cover (Upper Part ) Side Cover (Lower Part)

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

W1-3-2-4

SECTION 1 GENERAL Group 3 Painting

8 11

9 WNDB-01-03-105

1 2 3 4 5 6 7 8 9 10 11

Surfaces to Be Painted Handrail (Front) Tool Box Rear Fender Handrail (Rear) Fender Cover (Rear) Full Fender Bracket (Full Fender) Bracket (Mud Guard) Deck Plate Step Fender Cover (Front)

Painting Color P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Do not paint it. Do not paint it. P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] P1-01 [High Grade Black] Do not paint it.

Paint the painted surface except the above list in YR1-01 [TAXI yellow].

W1-3-2-5

SECTION 1 GENERAL Group 3 Painting

4 5

1 2 3 4 5

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

WNDB-01-03-106

Painting Color P1-01 [High Grade Black] P1-01 [High Grade Black] Refer to W1-3-2-8. Refer to W1-3-2-9. P1-01 [High Grade Black]

Paint the painted surface except the above list in YR1-01 [TAXI yellow].

W1-3-2-6

SECTION 1 GENERAL Group 3 Painting

WNDB-01-03-107

1 2

Surfaces to Be Painted Bracket (Under Mirror ) Rim

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

W1-3-2-7

SECTION 1 GENERAL Group 3 Painting

View A

View C

WNEC-01-03-008 View B

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

1 2 3 4 5 6 7 8

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

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

W1-3-2-8

WNEC-01-03-007

SECTION 1 GENERAL Group 3 Painting

View A

WNEC-01-03-012

1 2 3 4 5 6 7 8

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

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

W1-3-2-9

WNEC-01-03-011

SECTION 1 GENERAL Group 3 Painting (Blank)

W1-3-2-10

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank 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 until oil cools before starting any work. Do not turn cap (2) of hydraulic oil tank (3) quickly. Cap (2) may fly off by internal pressure. Release any remaining pressure before removing cap (2). Preparation 1. Park the machine on a solid and level surface. Set the front attachment in position for checking hydraulic oil level.

2, 5

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

3. Remove socket bolt (4)(4 used). Remove cap (2) and O-ring (5) of hydraulic oil tank (3). l : 5 mm m : 9 N·m(0.9 kgf·m, 6.6 lbf·ft)

W1R7-01-04-001

4. Install vacuum pump (a) to the position where cap (2) has been removed. Operate vacuum pump (a) and maintain negative pressure in hydraulic oil tank (3).

fNOTE: Operate vacuum pump (a) continuously while

working.

W1R7-01-04-002 abc-

W1-4-1-1

Vacuum Pump Hose Adapter

SECTION 1 GENERAL Group 4 Bleeding Air 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 pump device and cylinders have been removed/installed. IMPORTANT: If air is accumulated inside of the pump and if the engine starts in lacking of hydraulic oil, the pump may be damaged.  Bleeding Air from Pump  Remove the air bleed plug on top of the pump. Add hydraulic oil to the pump.  After the pump is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run it at slow idle speed.  Slightly loosen the plug and bleed air from the pump until hydraulic oil comes out from the gap.  After bleeding all air, securely tighten the plug.

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  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.  As the pilot circuit has an air bleed device, air in the pilot circuit will be bled while performing the above operation.  Reset the front attachment in position for checking hydraulic oil level.  Stop the engine. Check hydraulic oil level. Replenish hydraulic oil if necessary.

W1-4-1-2

SECTION 1 GENERAL Group 4 Bleeding Air Bleeding Air from Fuel System IMPORTANT: Air in the fuel system may make the engine hard to start or make it run rough or not run at all. After running the fuel tank dry, draining water from fuel filter or fuel pre-filter (1) or replacing the fuel filter, be sure to bleed the air from the fuel system. a

1. Loosen air bleed plug (1), operate feed pump (2) until no air bubble is observed in the fuel from the air bleed plug. 2. After no air bubble is spouted from air bleed plug (1), tighten air bleed plug (1) and operate the feed pump (2) until it becomes difficult to move.

b MNDB-07-002 a-

3. Once the feed pump (2) becomes difficult to move, push the disk part of feed pump (2) back to the original position.

Pre-Filter

Main Filter

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

MNDB-07-017

W1-4-1-3

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 cap slowly. Release all pressure and remove the 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.

W1-4-1-4

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) 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) 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. 4

W1-4-1-5

T4GB-05-04-006

SECTION 1 GENERAL Group 4 Bleeding Air (Blank)

W1-4-1-6

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

MNDB-01-055

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

1 2

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.)

WNEC-04-08-003

4. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm IMPORTANT: Loosen nut (5) while securing drain plug (4) by using a hexagonal wrench in order not to turn them. 5. Loosen nut (5) of ride control valve (3). j : 13 mm l : 4 mm IMPORTANT: Do not loosen drain plug (4) 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).

l : 4 mm m : 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).

TNED-03-02-003

Detail A

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

WNDB-01-05-001

W1-5-1-2

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

1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Run the engine at slow idle speed without load for five minutes. 4. Set key switch (2) to the OFF position. Stop the engine. 5. Depress brake pedal (3) at least 50 times in order to decrease the accumulated pressure left in the service brake circuit.

MNDB-01-001

6. Set key switch (2) to the ON position again. Turn parking brake switch (1) ON or OFF at least 50 times in order to decrease the accumulated pressure left in the parking brake circuit.

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

W1-5-1-3

OFF

MNEC-01-058

SECTION 1 GENERAL Group 5 Releasing Pressure (Blank)

W1-5-1-4

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 Chassis Before beginning to work near center dWARNING: pin (4), install articulation lock bar (2) and securely lock the front and rear chassis. Avoid accidents due to unexpected movement of the machine.

1. Align the front and rear chassis centers with each other. 2. Remove β-form pin (5). Remove set pin (1) from the hole.

5 2

MNEC-01-060

3. Rotate articulation lock bar (2) and fit it to hole (3) of the front chassis. 4. Install set pin (1) to hole (3) of the front chassis 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 Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance .....................................................................W2-3-2-2 Cylinder .............................................................................W2-3-3-1

Group 4 Front Attachment (Parallel Link) Pin and Bushing..............................................................W2-4-1-1 Standard Dimensions for Quick Coupler and Bucket ...........................................................................W2-4-2-1 Cylinder .............................................................................W2-4-3-1

70Z7/70TM7 D&R

(Blank)

70Z7/70TM7 D&R

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

 Lower Hinge Part (B)

WNDB-03-03-007

WNDB-03-03-005

A B

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

Standard (a) 85 (3.35) 85 (3.35) 75 (2.95) 75 (2.95)

W2-1-1-1

Allowable Limit (a) 84.0 (3.30) 86.5 (3.40) 74.0 (2.91) 76.5 (3.01)

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 1 Body (Blank)

W2-1-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System Axle

 Axle equipped with TPD

WNDB-04-03-009

8 1

7 12

 Axle equipped with LSD

WNDB-04-03-010

8 1234-

Brake Disc (4 Used) Brake Ring (4 Used) Brake Piston (2 Used) Spring (16 Used)

5678-

Side Gear (2 Used) Thrust Washer (2 Used) Oil Seal Yoke

9101112-

Spider Thrust Washer (4 Used) Pinion (4 Used) Disc (4 Used)

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

7 13- Plate (4 Used) 14- Plate (2 Used)

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 1. Inner diameter (a) of pinion (11)

Unit: mm (in) Standard Allowable Limit 28.70 to 28.75 (1.130 to 1.132) -

WNDB-02-02-001

2. Pin hole outer diameter of spider (9)

 Axle equipped with TPD Unit: mm (in) Standard Allowable Limit 28.55 to 28.58 (1.124 to 1.125) -

 Axle equipped with LSD Unit: mm (in) Standard Allowable Limit 28.53 to 28.58 (1.123 to 1.125) -

WNDB-02-02-002

3. Clearance (c) between pinion (11) and spider (9) Standard -

Unit: mm (in) Allowable Limit 0.25 (0.010)

c=a−b

4. Oil seal (7) sliding part (d) of outer diameter of yoke (8)

Unit: mm (in) Standard Allowable Limit 79.926 to 80.000 (3.147 to 3.150) 79.876 (3.145)

WNDB-02-02-008

W2-2-1-2

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 5. Thickness (e) of brake ring (2) Standard 4.9 to 5.1 (0.193 to 0.201)

Unit: mm (in) Allowable Limit 4.5 (0.177)

6. Thickness (f ) of brake disc (1) Standard 5.85 to 6.15 (0.230 to 0.242)

Unit: mm (in) Allowable Limit 5.58 (0.220)

f WNDB-04-03-014

7. Free height (g) of spring (4) of brake piston (3) Standard 33 (1.299)

Unit: mm (in) Allowable Limit 31.7 (1.248)

WNDB-02-02-004

W2-2-1-3

SECTION 2 MAINTENANCE STANDARD Group 2 Travel System 8. Thrust washer (10) thickness (h) of pinion (11)

 Axle equipped with TPD Unit: mm (in) Standard Allowable Limit 1.576 to 1.625 (0.062 to 0.064) 1.46 (0.057) WNDB-02-02-005 h

9. Thrust washer (6) thickness (i) of side gear (5)

6 i

 Axle equipped with TPD Standard 2.31 to 2.36 (0.091 to 0.093)

Unit: mm (in) Allowable Limit 2.24 (0.088) WNDB-02-02-006

10. Thickness (j) of plate (13)  Axle equipped with LSD Standard 3.42 to 3.58 (0.135 to 0.141)

Unit: mm (in) Allowable Limit 3.2 (0.126)

13 j

11. Thickness (k) of plate (14)  Axle equipped with LSD Standard 3.42 to 3.58 (0.135 to 0.141)

Unit: mm (in) Allowable Limit 3.2 (0.126)

12. Thickness (l) of disc (12)

 Axle equipped with LSD Standard 4.2 to 4.4 (0.165 to 0.173)

Unit: mm (in) Allowable Limit 3.8 (0.150)

W2-2-1-4

WNDB-02-02-007

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 (Lever)) Pin Bushing (Bucket Cylinder) Pin Bushing (Bucket Cylinder) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Bucket Link)

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

W2-3-1-1

Bushing

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

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment (Blank)

W2-3-1-2

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

d b

a e f

c WNEC-02-03-003

a b c d e f g h i

Bucket

Lift Arm

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

W2-3-2-1

SECTION 2 MAINTENANCE STANDARD Group 3 Front Attachment Bucket Stopper Clearance, Lever (Bell Crank) Stopper Clearance a b

T4GB-04-04-010

T4GB-04-04-008 a-

Bucket Dump Stopper

Cross Pipe Dump Stopper

Bucket Roll Back Stopper

Bucket Dump Stopper

Bucket Tilt (Roll Back) Stopper

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

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

 Bucket Dump Angle (C) C (deg.) 50±2

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

 Clearance between Cross Pipe Dump Stopper and Lever (b) Clearance between Stopper and Lever mm (in) Standard 0 (Even contact both sides)

 Height from Ground to Bucket Lowest Point (G) G (mm) (in) 395 (15.6)  Clearance between Bucket Roll Back Stopper and Lift Arm (c)

 Clearance between Bucket Dump Stopper and Lift Arm (a) Maximum allowable stop difference - one side to other mm (in)

Standard 0 to 2 (0 to 0.08) Limit -

Maximum length and width out of square stopper tolerance mm (in)

0 5 (0.2)

fNOTE: Refer to Troubleshooting Shop Manual T4-4-8 for the details.

W2-3-2-2

Maximum allowable stop difference - one side to other mm (in)

Standard 0

Maximum length and width out of square stopper tolerance mm (in)

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) 75-0.01-0.023 (2.95-0.0004-0.0011) 85-0.012-0.027 (3.37-0.0005-0.0010) 45-0.009-0.020 (1.78-0.0004-0.0008)

ab-

Cylinder Rod Dial Gauge

Bend 0.5 (0.02) 1.0 (0.04)

W2-3-3-1

d cd-

Run Out 1.0 (0.04) 2.0 (0.08)

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 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link) Pin and Bushing 1

F G

E D

a H

C B

WNEC-02-03-001

J K

WNDF-02-04-001

A B C D E F

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

Standard (a) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 75 (2.95) 75 (2.95) 75 (2.95) 75 (2.95) 60 (2.36) 60 (2.36)

W2-4-1-1

Bushing

Allowable Limit (a) 59.0 (2.32) 61.5 (2.42) 59.0 (2.32) 61.5 (2.42) 59.0 (2.32) 61.5 (2.42) 74.0 (2.91) 76.5 (3.01) 74.0 (2.91) 76.5 (3.01) 59.0 (2.32) 61.5 (2.42)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link)

F G

E D

a H

C B

WNEC-02-03-001

J K

WNDF-02-04-001

G H I J K L

Part Name Pin Bushing (Lift Arm) Pin Bushing (Link) Pin Bushing (Lift Arm Cylinder) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm) Pin Bushing (Lift Arm)

Standard (a) 100 (3.94) 100 (3.94) 75 (2.95) 75 (2.95) 85 (3.35) 85 (3.35) 85 (3.35) 85 (3.35) 60 (2.36) 60 (2.36) 75 (2.95) 75 (2.95)

W2-4-1-2

Bushing

Allowable Limit (a) 99.0 (3.80) 101.5 (4.00) 74.0 (2.91) 76.5 (3.01) 84.0 (3.31) 86.5 (3.41) 84.0 (3.31) 86.5 (3.41) 59.0 (2.32) 61.5 (2.42) 74.0 (2.91) 76.5 (3.01)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link) Standard Dimensions for Quick Coupler and Bucket Bucket

f a

b c g

WNDF-02-04-002

Quick Coupler i

l n k

a b c d e f g

Dimension 30.75 mm (1.21 in) 13° 647 mm (25.5 in) 52.5 mm (2.07 in) 193 mm (7.60 in) 80 mm (3.15 in) 473 mm (18.6 in)

W2-4-2-1

WNDF-02-04-003

SECTION 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link) Bucket

f a

b c g

WNDF-02-04-002

Quick Coupler

l n k

h i j k l m n

Dimension 50 mm (1.97 in) 61.5 mm (2.42 in) 600 mm (23.6 in) 139 mm (5.47 in) 50 mm (1.97 in) 55 mm (2.17 in) 470 mm (18.5 in)

W2-4-2-2

WNDF-02-04-003

SECTION 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link) 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 Quick Coupler

Unit: mm (in) Recommended Size after ReManufacturing (A) 75-0.010/-0.023 (2.95-0.0004/-0.0009) 65-0.010/-0.023 (2.56-0.0004/-0.0009) 45-0.009/-0.020 (1.77-0.0004/-0.0008) 25-0.020/-0.053 (0.98-0.0008/-0.0021)

ab-

Cylinder Rod Dial Gauge

Bend 0.5 mm/1 m (0.020 in/39.4 in)

d cd-

V Block 1 m (39.4 in)

Run Out 1.0 mm/1 m (0.039 in/39.4 in)

Remedy Replace

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

W2-4-3-1

SECTION 2 MAINTENANCE STANDARD Group 4 Front Attachment (Parallel Link) (Blank)

W2-4-3-2

SECTION 3

BODY CONTENTS Group 1 Cab Removal and Installation of Cab ..............................W3-1-1-1 Removal and Installation of Cab (Parallel Link) ...W3-1-2-1

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 and Installation of Battery Box (With Battery Disconnect Switch).......................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 Removal and Installation of Center Hinge (Parallel Link) ..............................................................W3-3-2-1

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, Rear Cover, and Cover (Lower) .............................W3-4-2-2 Removal and Installation of Side Cover............W3-4-2-4 Removal and Installation of Rear Fender (Rear) .............................................................................W3-4-2-6 Removal and Installation of Rear Fender (Front)/Deck and Step (Front) ..............................W3-4-2-8 Removal and Installation of Front Fender .... W3-4-2-11 Removal and Installation of Rear Grill ............ W3-4-2-12 Removal and Installation of Inspection Cover and Step (Rear) ....................................................... W3-4-2-13 Removal and Installation of Side Cover (Rear) .......................................................................... W3-4-2-14 Removal and Installation of Air Cleaner ................W3-4-3-1

Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, Intercooler, Torque Converter Cooler, and Fuel Cooler ..................................................................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 Pump Device ....................................W3-8-2-1 Assembly of Pump Device ..........................................W3-8-2-3 Disassembly of Main Pump ........................................W3-8-3-1 Assembly of Main Pump..............................................W3-8-3-5 Disassembly of Regulator ...........................................W3-8-4-1 Assembly of Regulator .................................................W3-8-4-3 Structure of Pilot Pump ...............................................W3-8-5-1

Group 9 Control Valve Removal and Installation of Control Valve ............W3-9-1-1 Removal and Installation of Control Valve (Parallel Link) ..............................................................W3-9-2-1 Disassembly of Control Valve ....................................W3-9-3-1 Assembly of Control Valve ..........................................W3-9-3-5 Disassembly of Control Valve (Parallel Link) .........W3-9-4-1 Assembly of Control Valve (Parallel Link) ........... W3-9-4-10

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 Removal and Installation of Auxiliary Pilot Valve ........................................................................... W3-10-3-1 Disassembly of Pilot Valve ....................................... W3-10-4-1 Assembly of Pilot Valve ............................................. W3-10-4-4 Disassembly of Pilot Valve (Two Lever Type)..... W3-10-5-1 Assembly of Pilot Valve (Two Lever Type) .......... W3-10-5-7 Disassembly of Auxiliary Pilot Valve ..................... W3-10-6-1 Assembly of Auxiliary Pilot Valve .......................... W3-10-6-4

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

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

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

70Z7/70TM7 D&R

Group 13 Solenoid Valve Removal and Installation of Parking Brake Solenoid Valve Unit............................................... W3-13-1-1 Structure of Parking Brake Solenoid Valve Unit ...................................................................................... W3-13-2-1 Structure of Parking Brake Solenoid Valve ........ W3-13-3-1 Removal and Installation of Quick Coupler Solenoid Valve (Parallel Link)............................. W3-13-4-1 Disassembly of Quick Coupler Solenoid Valve ........................................................................... W3-13-5-1 Assembly of Quick Coupler Solenoid Valve....... W3-13-5-3

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

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

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

Group 17 Parallel Link (Special Parts) Removal and Installation of Bucket Regenerative Valve ............................................... W3-17-1-1 Structure of Bucket Regenerative Valve ............. W3-17-2-1 Removal and Installation of Bucket Regenerative Selector Valve .............................. W3-17-3-1 Structure of Bucket Regenerative Selector Valve ........................................................................... W3-17-4-1

70Z7/70TM7 D&R

SECTION 3 BODY Group 1 Cab Removal and Installation of Cab

5 2, 3

M4GB-07-044

WNDB-03-01-001

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. Do not turn the cap of hydraulic oil tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. 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 (1). dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 4. Open the cover of battery box (6).

5. Loosen nut (7). Disconnect ground (5).

W3-1-1-1

j : 10 mm

SECTION 3 BODY Group 1 Cab

1 1

WNDB-03-07-002

WNDB-03-02-004

6. Open side covers (1) at left and right sides. 7. Remove rubber plate (2). (Refer to W3-4-2.) 8. Bleed air from the radiator. (Refer to W1-4-1.) 9. Place a container under hose (4). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 28 L (7.4 US gal)

10. Release refrigerant of the air conditioner. (Refer to T5-7 in the separated volume, Shop Manual, Troubleshooting.)

WNEE-03-04-003

W3-1-1-2

SECTION 3 BODY Group 1 Cab

11. Remove following parts at the right and left sides. (Refer to W3-4-2.)

WNDB-03-04-001

WNDB-03-14-001

12. Remove following parts. (Refer to W3-4-2.)

 Rear Fender (Front) (4)

Deck (1)  Cover (3)

 Rear Fender (Rear) (5)

 Tool Box (6)

Step (2)

 Cover (Lower) (7)

W3-1-1-3

SECTION 3 BODY Group 1 Cab 7 1

2 8

11 3

WNEC-03-01-001

10 9 WNDB-03-06-006

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

16. Remove bolts, washers (7) (3 used). Remove cover (11). j : 17 mm

j : 17 mm 14. Remove bolts, washers (4) (6 used). Remove covers (3) (2 used). j : 17 mm

17. Remove the harnesses from all clips of the cover (10) assembly. Remove bolt, washer (8) and bolts, washers (9) (2 used). Remove the cover (10) assembly.

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

W3-1-1-4

j : 17 mm

SECTION 3 BODY Group 1 Cab

View A 6

4, 5 A

10, 11

8, 9

WNDB-03-01-003

WNDB-03-01-002

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

24. Remove bolt, washer (8) and bracket (9) (the machine with the secondary steering attached: 2 used).

j : 17 mm 19. Disconnect connectors (3) (3 used).

j : 17 mm

20. Disconnect connector (2).

25. Remove bolt, washer (10). Remove bracket (11).

21. Disconnect connector (1).

j : 17 mm

22. Disconnect connector (6). 23. Disconnect connector (7) only with the secondary steering attached.

W3-1-1-5

SECTION 3 BODY Group 1 Cab

Brake Valve

Pressure Sensor Block

26. Disconnect hoses (1) (4 used). j : 19 mm 27. Disconnect hose (2). j : 27 mm 28. Disconnect hose (3). j : 27 mm

W3-1-1-6

WNDB-03-01-004

SECTION 3 BODY Group 1 Cab 1

4, 5, 6

12, 13

WNDB-03-01-005

WNDB-03-01-006

33. Disconnect hose (8).

29. Remove bolt, washer (4), nut (5), and clip (6).

j : 27 mm

j : 17 mm 30. Disconnect hoses (2) (2 used) from washer fluid tank (3). 31. Remove hoses (2) (2 used) from clips (1) (2 used).

34. Disconnect hose (7). j : 19 mm 35. Remove bolt, washer (12) and bracket (13).

32. Disconnect hose (9). j : 27 mm

j : 17 mm 36. Remove clamps (10) (2 used). Disconnect hoses (11) (2 used).

W3-1-1-7

SECTION 3 BODY Group 1 Cab

Detail A a

2, 3, 4

WNDB-03-11-001 a-

37. Remove bolt, washer (2), nut (3), and clips (4) (2 used). j : 17 mm 38. Disconnect hoses (1) (2 used). j : 22 mm

W3-1-1-8

Brake Charge Valve

WNDB-03-13-001

SECTION 3 BODY Group 1 Cab

3, 4 a-

1, 2

WNDB-03-01-007

Manifold Valve

39. Disconnect connector (5). 40. Remove bolt, washer (3) and bracket (4). j : 17 mm 41. Remove bolt, washer (1) and clip (2). j : 17 mm 42. Disconnect hose (7). j : 22 mm 43. Disconnect hoses (6) (2 used). j : 19 mm

W3-1-1-9

WNDB-03-01-008

SECTION 3 BODY Group 1 Cab

7 2

3 WNDB-03-01-009

WNEC-03-01-009 a-

44. Disconnect hose (2).

Eyebolt Mounting Hole

The cab (7) assembly weight: 1150 kg dCAUTION: (2540 lb)

j : 19 mm 45. Disconnect hoses (3) (2 used). j : 27 mm 46. Disconnect the pipe mounting (4) side of hose (1).

48. Install eyebolts (M16, Pitch 2 mm (0.08 in)) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (7) assembly. Attach the nylon slings onto the eyebolts (4 used). Hoist and hold the cab (7) assembly.

j : 27 mm 47. Remove caps (6) (4 used) and plates (5) (4 used).

W3-1-1-10

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

1 2 b

7 WNEC-03-01-010 WNEC-03-01-011 ab-

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

Rubber Cushion Chassis

j : 30 mm

13 9 10

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

j : 46 mm

WNDB-03-01-010

NOTE: LOCTITE #262 has been applied on the thread part of bolt (8). 51. Remove the mounting bolts and nuts for the other side of cab (1) assembly in the same way as step 49 to step 50. 52. Remove nuts (4, 15) (2 used for each) and washers (3, 14) (2 used for each). j : 24 mm

ab-

Rubber Cushion Chassis

IMPORTANT: Do not contact the front chassis and hydraulic oil tank when removing and installing the cab (1) assembly from the machine. 53. Remove the cab (1) assembly and washers (2, 12, 13) (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).

W3-1-1-11

SECTION 3 BODY Group 1 Cab

WNEC-03-01-009 a-

Eyebolt Mounting Hole

Installation The cab (1) assembly weight: 1150 kg dCAUTION: (2540 lb) 1. Install eyebolts (M16, Pitch 2 mm (0.08 in)) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (1) assembly. Attach the nylon slings onto the eyebolts (4 used). Hoist the cab (1) assembly.

W3-1-1-12

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

1 2 b

7 WNEC-03-01-010 WNEC-03-01-011 ab-

Rubber Cushion Chassis

IMPORTANT: Do not contact the front chassis and hydraulic oil tank when removing and installing the cab (1) assembly from the machine. 2. Install the cab (1) assembly and washers (2, 12, 13) (2 used for each) to chassis (b).

15 WNDB-03-01-010

ab-

Rubber Cushion Chassis

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

13 9 10

3. Apply LOCTITE #262 onto the thread part of rubber cushion (a). Install washers (3, 14) (2 used for each) and nuts (4, 15) (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.

W3-1-1-13

SECTION 3 BODY Group 1 Cab

3 WNEC-03-01-009

7. Install plates (4) (4 used) and caps (5) (4 used). 8. Connect the pipe mounting (4) side of hose (1). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 9. Connect hoses (3) (2 used). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 10. Connect hose (2). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-14

WNDB-03-01-009

SECTION 3 BODY Group 1 Cab

a a-

3, 4

WNDB-03-01-008

1, 2

Manifold Valve

11. Connect hoses (6) (2 used). j : 19 mm

14. Connect connector (5). 15. 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)

12. Connect hose (7). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 13. Install bracket (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-15

WNDB-03-01-007

SECTION 3 BODY Group 1 Cab

Detail A a

2, 3, 4

WNDB-03-11-001 a-

16. Connect hoses (1) (2 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 17. Install clips (4) (2 used) with nut (3) and bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-16

Brake Charge Valve

WNDB-03-13-001

SECTION 3 BODY Group 1 Cab 1

12, 13

WNDB-03-01-006

4, 5, 6

WNDB-03-01-005

22. Add compressor oil. (Refer to T5-7 in the separated volume, Technical Manual.)

18. Connect hoses (11) (2 used) with clamps (10) (2 used). m : 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)

23. Connect hose (9).

19. Install bracket (13) with bolt, washer (12).

j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm

24. Connect hoses (2) (2 used) to washer fluid tank (3).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

25. Install hoses (2) (2 used) to clips (1) (2 used).

20. Apply ND-OIL8 onto the O-ring of hose (7) connecting part. Connect hose (7).

26. Install clip (6) with nut (5) and bolt, washer (4).

j : 19 mm

j : 17 mm

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

m : 50 N·m (5 kgf·m, 37 lbf·ft)

21. Apply ND-OIL8 onto the O-ring of hose (8) connecting part. Connect hose (8). j : 27 mm m : 29.4 to 34.3 N·m (2.9 to 3.4 kgf·m, 21.5 to 25.5 lbf·ft)

W3-1-1-17

SECTION 3 BODY Group 1 Cab

Brake Valve

Pressure Sensor Block

27. Connect hose (3). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 28. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 29. Connect hoses (1) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-18

WNDB-03-01-004

SECTION 3 BODY Group 1 Cab

View A 6

4, 5 A

10, 11

8, 9

WNDB-03-01-002

34. Connect connector (1).

30. Install bracket (11) with bolt, washer (10).

35. Connect connector (2).

j : 17 mm

36. Connect connectors (3) (3 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 31. Install bracket (9) (the machine with the secondary steering attached: 2 used) with bolt, washer (8).

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

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) 32. Connect connector (7) only with the secondary steering attached. 33. Connect connector (6).

W3-1-1-19

WNDB-03-01-003

SECTION 3 BODY Group 1 Cab

5 2, 3

M4GB-07-044

fNOTE: Amount of coolant: 28 L (7.4 US gal)

j : 10 mm

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

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

NOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 40. Install O-ring (3). 41. Install the cover (2) assembly with bolts, washers (4) (6 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

WNDB-03-01-001

42. Connect ground (5). Tighten nut (7).

38. Add coolant to the radiator.

j : 17 mm

43. Close the cover of battery box (6). 44. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks. 45. Fill refrigerant in the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

W3-1-1-20

SECTION 3 BODY Group 1 Cab 1

6 1

4 3 WNDB-03-06-006

WNDB-03-07-002

46. Install the cover (4) assembly with bolts, washers (3) (2 used) and bolt, washer (2). Install the harnesses to all clips of the cover (4) assembly. j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 47. Install cover (5) with bolts, washers (1) (3 used).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 48. Install rubber plate (6). (Refer to W3-4-2.) 49. Install covers (11) (2 used) with bolts, washers (12) (4 used).

WNEC-03-01-001

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 50. Install covers (9) (2 used) with bolts, washers (10) (6 used).

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

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)

W3-1-1-21

SECTION 3 BODY Group 1 Cab

WNDB-03-04-001

52. Install following parts. (Refer to W3-4-2.)  Cover (Lower) (7)

WNDB-03-14-001

53. Install following parts at the right and left sides. (Refer to W3-4-2.) Step (2)

 Tool Box (6)

 Rear Fender (Rear) (5)

 Cover (3)

 Rear Fender (Front) (4)

Deck (1)

54. Close side covers (8) at left and right sides.

W3-1-1-22

SECTION 3 BODY Group 1 Cab Removal and Installation of Cab (Parallel Link) 8, 9 1

5 2, 3

M4GB-07-044

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

WNDB-03-01-001

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

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

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

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 4. Open the cover of battery box (6).

5. Remove bolt, washer (8) and clip (9). j : 17 mm 6. Loosen nut (7). Disconnect ground (5).

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. Operate the brake pedal more than 50 dCAUTION: times and release any pressure in the circuit.

W3-1-1-1

j : 10 mm

SECTION 3 BODY Group 1 Cab

1 1

WNDB-03-07-002

WNDB-03-02-004

7. Open side covers (1) at the right and left sides. 8. Remove rubber plate (2). (Refer to W3-4-2.) 9. Bleed air from the radiator. (Refer to W1-4-1.) 10. Place a container under hose (4). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 28 L (7.4 US gal)

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

WNEE-03-04-003

W3-1-1-2

SECTION 3 BODY Group 1 Cab

WNDB-03-01-101

WNDB-03-01-102

12. Remove the following parts at the right and left sides. (Refer to W3-4-2.)

13. Remove the following parts. (Refer to W3-4-2.) Deck (1)

 Rear Fender (Front) (4)

 Cover (3)

 Rear Fender (Rear) (5)

 Tool Box (6)

Step (2)

 Cover (Lower) (Right) (7)

W3-1-1-3

SECTION 3 BODY Group 1 Cab 7 1

6 a

2 8

12 3

7 9 11 4

WNEC-03-01-001

9 10 a-

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

Hydraulic Oil Tank

WNDB-03-06-006

17. Remove bolts, washers (7) (3 used). Remove cover (12). j : 17 mm

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

18. Remove the wire harnesses from all clips of cover (11). Remove bolt, washer (8) and bolts, washers (9) (4 used). Remove rubber plate (10) and cover (11).

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

W3-1-1-4

j : 17 mm

SECTION 3 BODY Group 1 Cab 1 a

View A 6

4, 5

12, 13

B a-

8, 9, 10, 11

WNDB-03-01-003

WNDB-03-01-104

Detail B

Cab

15 16

19. Remove bolt, washer (4) and clip (5). j : 17 mm 20. Disconnect connectors (1, 2) and connectors (3) (3 used). 21. Disconnect connector (6) (only the machine with the ride control device). 22. Disconnect connector (7) (only the machine with the secondary steering). 23. Remove bolt, washer (8), bracket (9) (only the machine with the ride control device), bracket (10) (only the machine with the secondary steering), and tube (11). j : 17 mm 24. Remove bolt, washer (12). Remove bracket (13). j : 17 mm

17 WNDB-03-01-105

25. Disconnect connectors (14) (2 used). 26. Remove bolt, washer (15), brackets (16, 18), and tube (17). j : 17 mm

W3-1-1-5

SECTION 3 BODY Group 1 Cab 3

Brake Valve

Pressure Sensor Block

27. Disconnect hoses (1) (6 used). j : 19 mm 28. Disconnect hose (2). j : 27 mm 29. Disconnect hose (3). j : 27 mm

W3-1-1-6

WNDB-03-01-103

SECTION 3 BODY Group 1 Cab 1 a

8, 15 a-

7, 14

4, 5, 6

12, 13

WNDB-03-01-005

WNDB-03-01-006

Hydraulic Oil Tank

35. Disconnect hose (7). Remove O-ring (14) from hose (7).

30. Remove bolt, washer (4), nut (5), and clip (6). j : 17 mm 31. Disconnect hoses (2) (2 used) from washer fluid tank (3).

j : 19 mm 36. Remove bolt, washer (12) and bracket (13).

32. Remove hoses (2) (2 used) from clips (1) (2 used).

j : 17 mm

33. Disconnect hose (9).

37. Remove clamps (10) (2 used). Disconnect hoses (11) (2 used).

j : 27 mm 34. Disconnect hose (8). Remove O-ring (15) from hose (8). j : 27 mm

W3-1-1-7

SECTION 3 BODY Group 1 Cab

Detail A a

2, 3, 4

WNDB-03-11-001 a-

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

W3-1-1-8

Brake Charge Valve

WNDB-03-13-001

SECTION 3 BODY Group 1 Cab

3, 4 a-

Manifold Valve

1, 2 b-

WNDB-03-01-007 Hydraulic Oil Tank

40. Disconnect connector (5). 41. Remove bolt, washer (3) and bracket (4). j : 17 mm 42. Remove bolt, washer (1) and clip (2). j : 17 mm 43. Disconnect hose (7). j : 22 mm 44. Disconnect hoses (6) (2 used). j : 19 mm

W3-1-1-9

WNDB-03-01-008

SECTION 3 BODY Group 1 Cab

7 2

3 WNDB-03-01-009

WNEC-03-01-009 a-

45. Disconnect hose (2). j : 19 mm 46. Disconnect hoses (3) (2 used). j : 27 mm 47. Disconnect the pipe mount (4) side of hose (1).

Eyebolt Mounting Hole

The cab (7) assembly weight: 1150 kg dCAUTION: (2540 lb) 49. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of the cab (7) assembly. Attach nylon slings onto the eyebolts (4 used). Hoist and hold the cab (7) assembly.

j : 27 mm 48. Remove caps (6) (4 used) and plates (5) (4 used).

W3-1-1-10

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

1 2 b

7 WNEC-03-01-010 WNEC-03-01-011

50. Remove bolts (7) (2 used), plates (6) (2 used), and spacers (5) (2 used).

ab-

Rubber Cushion Chassis

13 9 10

j : 30 mm

51. Remove bolts (8) (2 used), nuts (11) (2 used), plates (10) (2 used), and spacers (9) (2 used).

WNDB-03-01-010

j : 46 mm

ab-

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of bolt (8). 52. Remove nuts (4, 15) (2 used for each) and washers (3, 14) (2 used for each). j : 24 mm

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

Rubber Cushion Chassis

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front chassis and hydraulic oil tank when removing/installing the cab (1) assembly. 53. Remove the cab (1) assembly and washers (2, 12, 13) (2 used for each) from chassis (b). Place the cab (1) assembly on wooden blocks.

W3-1-1-11

SECTION 3 BODY Group 1 Cab

WNEC-03-01-009 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.

W3-1-1-12

SECTION 3 BODY Group 1 Cab

Detail A

Detail B

1 2 b

7 WNEC-03-01-010 WNEC-03-01-011 ab-

Rubber Cushion Chassis

IMPORTANT: Do not allow the cab (1) assembly to come in contact with the front chassis and hydraulic oil tank when removing/installing the cab (1) assembly. 2. Install the cab (1) assembly and washers (2, 12, 13) (2 used for each) to chassis (b). 3. Apply LOCTITE #263 or equivalent to the thread part of rubber cushions (a) (4 used). Install washers (3, 14) (2 used for each) and nuts (4, 15) (2 used for each).

13 9 10

15 WNDB-03-01-010

ab-

Rubber Cushion Chassis

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

j : 24 mm

j : 30 mm

m : 210 N·m (21 kgf·m.l 155 lbf·ft)

m : 216 N·m (21.6 kgf·m, 159 lbf·ft)

4. Apply LOCTITE #263 or equivalent to the thread part of bolts (8) (2 used). Install bolts (8) (2 used), spacers (9) (2 used), plates (10) (2 used), and nuts (11) (2 used). j : 46 mm m : 216 N·m (21.6 kgf·m, 159 lbf·ft)

W3-1-1-13

SECTION 3 BODY Group 1 Cab

3 WNEC-03-01-009

6. Install plates (4) (4 used) and caps (5) (4 used). 7. Connect the pipe mount (6) side of hose (1). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 8. Connect hoses (3) (2 used). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 9. Connect hose (2). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-14

WNDB-03-01-009

SECTION 3 BODY Group 1 Cab

a a-

Manifold Valve

3, 4

WNDB-03-01-008

1, 2

Hydraulic Oil Tank

10. Connect hoses (6) (2 used). j : 19 mm

13. Connect connector (5). 14. 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)

11. Connect hose (7). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 12. Install bracket (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-15

WNDB-03-01-007

SECTION 3 BODY Group 1 Cab

Detail A a

2, 3, 4

WNDB-03-11-001 a-

15. Connect hoses (1) (2 used). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 16. Install clips (4) (2 used) with nut (3) and bolt, washer (2). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-16

Brake Charge Valve

WNDB-03-13-001

SECTION 3 BODY Group 1 Cab 1 a

12, 13 a-

8, 15

WNDB-03-01-006

7, 14

4, 5, 6

WNDB-03-01-005

Hydraulic Oil Tank

21. Add compressor oil. (Refer to T5-7 in the separated volume, Technical Manual.)

17. Connect hoses (11) (2 used) with clamps (10) (2 used). m : 4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)

22. Connect hose (9).

18. Install bracket (13) with bolt, washer (12).

j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm

23. Connect hoses (2) (2 used) to washer fluid tank (3).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Apply ND-OIL8 to O-ring (14). Install O-ring (14) to hose (7). Connect hose (7).

24. Install hoses (2) (2 used) to clips (1) (2 used). 25. Install clip (6) with nut (5) and bolt, washer (4).

j : 19 mm

j : 17 mm

m : 11.8 to 14.7 N·m (1.18 to 1.47 kgf·m, 8.7 to 11 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

20. Apply ND-OIL8 to O-ring (15). Install O-ring (15) to hose (8). Connect hose (8). j : 27 mm m : 29.4 to 34.3 N·m (2.94 to 3.43 kgf·m, 21.5 to 25.5 lbf·ft)

W3-1-1-17

SECTION 3 BODY Group 1 Cab 3

Brake Valve

Pressure Sensor Block

26. Connect hose (3). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 27. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 28. Connect hoses (1) (6 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-18

WNDB-03-01-103

SECTION 3 BODY Group 1 Cab 1 a

View A 6

4, 5

12, 13

B a-

8, 9, 10, 11

WNDB-03-01-003

WNDB-03-01-104

Detail B

Cab

15 16

29. Connect connectors (14) (2 used). 30. Install tube (17) and brackets (16, 18) with bolt, washer (15). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 31. Install bracket (13) with bolt, washer (12). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

17 WNDB-03-01-105

32. Install tube (11), bracket (10) (only the machine with the secondary steering), and bracket (9) (only the machine with the ride control device) with bolt, washer (8). j : 17 mm

34. Connect connector (6) (only the machine with the ride control device). 35. Connect connectors (1, 2) and connectors (3) (3 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 33. Connect connector (7) (only the machine with the secondary steering).

36. Install clip (5) with bolt, washer (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-19

SECTION 3 BODY Group 1 Cab

8, 9 1

5 2, 3

M4GB-07-044

WNDB-03-01-001

42. Install clip (9) with bolt, washer (8).

37. Add coolant to the radiator.

fNOTE: Amount of coolant: 28 L (7.4 US gal)

j : 17 mm

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

m : 50 N·m (5 kgf·m, 37 lbf·ft)

NOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 39. Install O-ring (3). 40. Install the cover (2) assembly with bolts, washers (4) (6 used).

43. Close the cover of battery box (6). 44. Bleed air from the hydraulic system. (Refer to W1-41.)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: Check the hydraulic oil level and the coolant level. Start the engine and check for any oil and coolant leaks. 45. Operate the steering cylinder to the stroke end several times and bleed air from the circuit.

41. Connect ground (5). Tighten nut (7).

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

j : 17 mm

j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

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

W3-1-1-20

SECTION 3 BODY Group 1 Cab 1

6 1 3 13 3 4 a-

Hydraulic Oil Tank

WNDB-03-06-006

WNDB-03-07-002

48. Install cover (13) and rubber plate (4) with bolts, washers (3) (4 used) and bolt, washer (2). Install the wire harnesses to all clips of cover (13). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 49. Install cover (5) with bolts, washers (1) (3 used).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 50. Install rubber plate (6). (Refer to W3-4-2.) 51. Install covers (11) (2 used) with bolts, washers (12) (4 used).

WNEC-03-01-001

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 52. Install covers (9) (2 used) with bolts, washers (10) (6 used).

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

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)

W3-1-1-21

SECTION 3 BODY Group 1 Cab

WNDB-03-01-101

WNDB-03-01-102

54. Install the following parts. (Refer to W3-4-2.)  Cover (Lower) (Right) (7)

55. Install the following parts at the right and left sides. (Refer to W3-4-2.) Step (2)

 Tool Box (6)

 Rear Fender (Rear) (5)

 Cover (3)

 Rear Fender (Front) (4)

Deck (1)

56. Close side covers (8) at the right and left sides.

W3-1-1-22

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

1 2

4 1 5

2 a

6 7

9 5 a-

7 WNDB-03-02-001

Hoisting Position

Removal

Counterweight (3) weight: 1350 kg dCAUTION: (2980 lb)

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the battery box.  Without battery disconnect switch: Refer to W3-2-2.  Attached battery disconnect switch: Refer to W3-2-3. 3. Remove bolts (5) (4 used). Remove rear combination light (4).

6. Attach the nylon slings onto hoisting positions (a) of counterweight (3). Hoist and hold counterweight (3). 7. Remove bolts (7) (2 used) and washers (8) (2 used). j : 46 mm 8. Remove bolts (6) (2 used), nuts (1) (2 used), and washers (2) (4 used). Remove counterweight (3).

l : 5 mm 4. Remove bolts (5) (4 used). Remove rear combination light (9). l : 5 mm IMPORTANT: If the rear grill is kept closed and counterweight (3) is removed, the rear grill may be damaged. 5. Open the rear grill.

W3-2-1-1

j : 46 mm

SECTION 3 BODY Group 2 Counterweight a

1 2

4 1 5

2 a

6 7

9 5 a-

7 WNDB-03-02-001

Hoisting Position

4. Install rear combination light (4) with bolts (5) (4 used).

Installation Counterweight (3) weight: 1350 kg dCAUTION: (2980 lb)

l : 5 mm

1. Attach the nylon slings onto hoisting positions (a) of counterweight (3). Hoist and fit counterweight (3) to mounting hole on the rear chassis. 2. Install counterweight (3) with bolts (6) (2 used), washers (2) (4 used), and nuts (1) (2 used).

m : 20 N·m (2 kgf·m, 15 lbf·ft) 5. Install rear combination light (9) with bolts (5) (4 used). l : 5 mm

j : 46 mm m : 1510 N·m (151 kgf·m, 1110 lbf·ft) 3. Install washers (8) (2 used) and bolts (7) (2 used). j : 46 mm

m : 20 N·m (2 kgf·m, 15 lbf·ft) 6. Install the battery box.  Without battery disconnect switch: Refer to W3-2-2.  Attached battery disconnect switch: Refer to W3-2-3. 7. Close the rear grill.

m : 1510 N·m (151 kgf·m, 1110 lbf·ft)

W3-2-1-2

SECTION 3 BODY Group 2 Counterweight 21

Removal and Installation of Battery Box (Without Battery Disconnect Switch)

8, 9

20 7 6

19 18

10, 11 12 13

WNDB-03-02-002

WNEE-03-02-002

7. Remove bolts, washers (7) (3 used), clip (21), and clips (6) (2 used).

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

j : 17 mm

Removal of Battery Box (Right)

8. Disconnect connector (23). Remove the harnesses from all clips of battery box (5).

2. Open cover (4).

9. Remove rubber bushings (20, 22).

3. Loosen nut (10). Disconnect ground (11).

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

j : 10 mm

10. Remove nuts (1) (4 used) and washers (2, 3) (4 used for each). Remove battery box (5) while pulling connector (23), terminal (9), and ground (19) out of it.

4. Loosen nut (8). Disconnect terminal (9). j : 10 mm

dCAUTION: Battery (15) weight: 44kg (98 lb)

j : 19 mm

5. Remove nut (12), washer (13), and bolt, washer (17). Remove rod (14) and bracket (16). Remove battery (15). j : 17 mm 6. Remove bolt, washer (18). Disconnect grounds (11, 19). j : 17 mm

W3-2-2-1

SECTION 3 BODY Group 2 Counterweight 15 21 6, 7

16 18

8, 9 17 10 11 12 13

WNEE-03-02-005

WNDB-03-02-003

16. Disconnect connector (19). Remove the harnesses from all clips of battery box (5).

Removal of Battery Box (Left) 11. Open cover (1).

17. Remove rubber bushings (20, 21).

12. Loosen nut (6). Disconnect terminal (7).

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

j : 10 mm

18. Remove nuts (2) (4 used) and washers (3, 4) (4 used for each). Remove battery box (5) while pulling connector (19) and terminals (7, 9) out of it.

13. Loosen nut (8). Disconnect terminal (9). j : 10 mm

j : 19 mm

dCAUTION: Battery (14) weight: 44 kg (98 lb)

14. Remove nut (10), washer (11), and bolt, washer (17). Remove rod (13) and bracket (12). Remove battery (14). j : 17 mm

15. Remove bolts, washers (16) (2 used) and clips (15, 18). j : 17 mm

W3-2-2-2

SECTION 3 BODY Group 2 Counterweight 15 21 6, 7

16 18

8, 9 17 10 11 12 13

WNEE-03-02-005

WNDB-03-02-003

5. Install bracket (12) and rod (13) with bolt, washer (17), washer (11), and nut (10).

Installation Installation of Battery Box (Left)

j : 17 mm

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

Nut (10):

1. Pass connector (19) and terminals (7, 9) through battery box (5). Install battery box (5) with washers (3, 4) (4 used for each) and nuts (2) (4 used).

m : 20 N·m (2 kgf·m, 15 lbf·ft) Bolt, Washer (17):

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

6. Connect terminal (7). Tighten nut (6).

2. Install rubber bushings (20, 21). j : 10 mm

3. Connect connector (19). Install the harnesses to all clips of battery box (5).

dCAUTION: Battery (14) weight: 44 kg (98 lb)

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to3 lbf·ft) 7. Connect terminal (9). Tighten nut (8).

4. Place battery (14) on battery box (5).

j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 8. Install clips (15, 18) with bolts, washers (16) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Close cover (1).

W3-2-2-3

SECTION 3 BODY Group 2 Counterweight 21

8, 9

20 7 6

19 18

10, 11 12 13

WNDB-03-02-002

WNEE-03-02-002

15. Install bracket (16) and rod (14) with bolt, washer (17), washer (13), and nut (12).

Installation of Battery Box (Right)

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

j : 17 mm

10. Pass connector (23), terminal (9), and ground (9) through battery box (5). Install battery box (5) with washers (2, 3) (4 used for each) and nuts (1) (4 used).

Nut (12): m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm

Bolt, Washer (17):

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Install rubber bushings (20, 22).

16. Connect terminal (9). Tighten nut (8).

12. Connect connector (23). Install the harnesses to all clips of battery box (5).

j : 10 mm

13. Connect grounds (11, 19) with bolt, washer (18).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

j : 17 mm

17. Connect ground (11). Tighten nut (10). j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

dCAUTION: Battery (15) weight: 44 kg (98 lb) 14. Place battery (15) on battery box (5).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 18. Install clip (21) and clips (6) (2 used) with bolts, washers (7) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Close cover (4).

W3-2-2-4

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Battery Box (With Battery Disconnect Switch) 10, 11

8, 9 6, 7

18, 19

17 16 24 10, 20 WNDB-03-02-002

WNEE-03-02-006

7. Remove bolts, washers (10) (3 used), clip (11), and clips (20) (2 used).

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

j : 17 mm

Removal of Battery Box (Right)

8. Disconnect connector (23). Remove the harnesses from all clips of battery box (5).

2. Open cover (4).

9. Remove rubber bushings (21, 22).

dCAUTION: Battery box (5) weight: 30 kg (67 lb)

3. Loosen nut (8). Disconnect terminal (9).

10. Remove nuts (1) (4 used) and washers (2, 3) (4 used for each). Remove battery box (5) while pulling connector (23), terminal (7), and ground (16) out of it.

j : 10 mm 4. Loosen nut (6). Disconnect terminal (7). j : 10 mm

j : 19 mm

dCAUTION: Battery (12) weight: 44 kg (98 lb)

5. Remove nut (18), washer (19), and bolt, washer (14). Remove rod (17) and bracket (13). Remove battery (12). j : 17 mm 6. Remove bolt, washer (15). Disconnect grounds (16, 24). j : 17 mm

W3-2-3-1

SECTION 3 BODY Group 2 Counterweight 15 21 6, 7

16 18

8, 9 17 10 11 12 13

WNEE-03-02-005

WNDB-03-02-003

16. Disconnect connector (19). Remove the harnesses from all clips of battery box (5).

Removal of Battery Box (Left) 11. Open cover (1).

17. Remove rubber bushings (20, 21).

12. Loosen nut (6). Disconnect terminal (7).

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

j : 10 mm

18. Remove nuts (2) (4 used) and washers (3, 4) (4 used for each). Remove battery box (5) while pulling connector (19) and terminals (7, 9) out of it.

13. Loosen nut (8). Disconnect terminal (9). j : 10 mm

j : 19 mm

dCAUTION: Battery (14) weight: 44 kg (98 lb)

14. Remove nut (10), washer (11), and bolt, washer (17). Remove rod (13) and bracket (12). Remove battery (14). j : 17 mm

15. Remove bolts, washers (16) (2 used) and clips (15, 18). j : 17 mm

W3-2-3-2

SECTION 3 BODY Group 2 Counterweight 15 21 6, 7

16 18

8, 9 17 10 11 12 13

WNEE-03-02-005

WNDB-03-02-003

5. Install bracket (12) and rod (13) with bolt, washer (17), washer (11), and nut (10).

Installation Installation of Battery Box (Left)

j : 17 mm

dCAUTION: Battery box (5) weight: 27 kg (60 lb)

Nut (10):

1. Pass connector (19) and terminals (7, 9) through battery box (5). Install battery box (5) with washers (3, 4) (4 used for each) and nuts (2) (4 used).

m : 20 N·m (2 kgf·m, 15 lbf·ft) Bolt, Washer (17):

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

6. Connect terminal (7). Tighten nut (6).

2. Install rubber bushings (20, 21). j : 10 mm

3. Connect connector (19). Install the harnesses to all clips of battery box (5).

dCAUTION: Battery (14) weight: 44 kg (98 lb)

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 7. Connect terminal (9). Tighten nut (8).

4. Place battery (14) on battery box (5).

j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 8. Install clips (15, 18) with bolts, washers (16) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Close cover (1).

W3-2-3-3

SECTION 3 BODY Group 2 Counterweight

10, 11

8, 9 6, 7

18, 19

17 16 24 10, 20 WNDB-03-02-002

WNEE-03-02-006

15. Install bracket (13) and rod (17) with bolt, washer (14), washer (19), and nut (18).

Installation of Battery Box (Right)

dCAUTION: Battery box (5) weight: 30 kg (67 lb)

j : 17 mm

10. Pass connector (23), terminal (7), and ground (16) through battery box (5). Install battery box (5) with washers (2, 3) (4 used for each) and nuts (1) (4 used).

Nut (18): m : 20 N·m (2 kgf·m, 15 lbf·ft)

j : 19 mm

Bolt, Washer (14):

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

11. Install rubber bushings (21, 22).

16. Connect terminal (7). Tighten nut (6).

12. Connect connector (23). Install the harnesses to all clips of battery box (5).

j : 10 mm

13. Connect grounds (16, 24) with bolt, washer (15).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

j : 17 mm

17. Connect terminal (9). Tighten nut (8). j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

dCAUTION: Battery (12) weight: 44 kg (98 lb) 14. Place battery (12) on battery box (5).

m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft) 18. Install clip (11) and clips (20) (2 used) with bolts, washers (10) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Close cover (4).

W3-2-3-4

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

2 1

WNEE-03-02-006

WNDB-03-02-004 View A

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

6, 7

3, 4

5 WNEE-03-02-006

4. Remove nut (2). Disconnect terminal (1). j : 17 mm 5. Remove nut (4). Disconnect ground (3). 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

6, 7

3, 4

5 WNEE-03-02-006

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 (3) with nut (4). 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-

2 WNEE-03-02-006

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

WNDB-03-02-004

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

a a-

WNEC-03-03-019

Stand

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

WNDB-03-09-001

dCAUTION: Machine weight 10200 kg (22500 lb) 3. Support front chassis (1) and rear chassis (2) by using stable stands (a). 4. Disconnect hoses (3) (3 used). j : 19 mm 5. Disconnect hoses (4) (2 used).

2. Remove the following parts.  Front Attachment (With Lift Arm Kickout) (Refer to 5-1-1.)  Front Attachment (With Lift Arm Auto Leveler) (Refer to 5-1-2.)  The Cab Assembly (Refer to 3-1-1.)  Propeller Shaft (Refer to 4-4-1.)  Steering Cylinder (Refer to 4-6-3.)

W3-3-1-1

j : 41 mm

SECTION 3 Body Group 3 Center Hinge

1 a-

Control Valve

WNDB-03-09-003 b-

6. Disconnect hoses (1) (3 used). j : 19 mm 7. Disconnect hoses (2) (2 used). j : 17 mm

W3-3-1-2

Ride Control Valve

WNDB-03-16-006

SECTION 3 Body Group 3 Center Hinge

8, 9 1, 2

5, 6, 7

10 a-

Control Valve

3, 4

WNDB-03-03-001

Front Axle

WNDB-03-03-002

11. Remove bolts, washers (8) (2 used) and clips (9) (2 used).

8. Remove bolt, washer (1) and clip (2). j : 17 mm 9. Remove bolts, washers (5) (2 used) and clips (6, 7) (2 used for each).

j : 17 mm 12. Disconnect hose (10). j : 27 mm

j : 17 mm 10. Remove bolts, washers (3) (2 used) and clips (4) (2 used). j : 17 mm

W3-3-1-3

SECTION 3 Body Group 3 Center Hinge

1, 2

9, 10, 11 3

6 a-

Rear chassis

4, 5

Front chassis

13. Remove bolt, washer (4) and clip (5). j : 17 mm 14. Disconnect connectors (6) (2 used). 15. Remove bolts, washers (9) (2 used), washers (10) (2 used), and nuts (11) (2 used). Remove plate (7) and clamp (8). j : 19 mm 16. Remove bolts, washers (1) (2 used) and nuts (2) (2 used). Remove clamp (3). j : 19 mm

W3-3-1-4

WNDB-03-03-003

SECTION 3 Body Group 3 Center Hinge

3 5 6

Upper Hinge

Lower Hinge

WNDB-03-03-004

 Upper Hinge (a) Side 17. Remove bolts (2) (4 used), bolts (4) (3 used), and washers (3) (7 used). Remove flange (5) and shim (6). j : 24 mm

Remove pin (7) while holding it. Do dCAUTION: not drop pin (7). 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.

fNOTE: LOCTITE #205 has been applied on bolts (2, 4).

18. Remove pin (7) by using a round bar and a hammer.

W3-3-1-5

SECTION 3 Body Group 3 Center Hinge

8 b

Upper Hinge

Lower Hinge

WNDB-03-03-004

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. IMPORTANT: If bushing (1) has been removed, replace it with a new one. 19. Weld and install the handrails in diagonal position on the upper side of bushing (1). Attach the nylon slings onto the handrails. Raise bushing (1) until front chassis (8) can be removed. Tap the bottom of bushing (1) by using a round bar and a hammer. Remove bushing (1).

W3-3-1-6

SECTION 3 Body Group 3 Center Hinge

1 2 3 4 b

Upper Hinge

Lower Hinge

WNDB-03-03-004

 Lower Hinge (b) Side 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. 20. Remove bolt (1) and washers (2, 3). Remove pin (4) by using a round bar and a hammer. j : 24 mm

W3-3-1-7

SECTION 3 Body Group 3 Center Hinge 1

2 4

Upper Hinge

Lower Hinge

WNDB-03-03-004

The front chassis (1) assembly weight: dCAUTION: 2730 kg (6020 lb) Support front chassis (1) by using the dCAUTION: stable stand.

Upper Hinge (a) Part (Section)

IMPORTANT: Take care that cap (3) and bushing (4) do not come in contact with rear chassis (2). 21. Attach the nylon slings onto the front chassis (1) assembly. Hoist and hold the front chassis (1) assembly. Move the front chassis (1) assembly forward. Remove the front chassis (1) assembly from rear chassis (2). Support it by using the stand.

3 1

4 2

WNDB-03-03-005

W3-3-1-8

SECTION 3 Body Group 3 Center Hinge

2 a

8 7

Upper Hinge

Lower Hinge

WNDB-03-03-004

 Upper Hinge (a) Part

23. Remove bolts (6) (6 used). Remove caps (1, 8) and shim (2).

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

j : 19 mm

such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: If bushing (7) has been removed, replace it with a new one. 22. Remove busing (7) by using a round bar and a hammer.

fNOTE: LOCTITE #262 has been applied on bolt (6).

W3-3-1-9

SECTION 3 Body Group 3 Center Hinge

3 1 4 a

5 8

Upper Hinge

Lower Hinge

WNDB-03-03-004

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

25. Remove grease fitting (5).

such as goggles, helmets, etc in order to prevent personal injury. IMPORTANT: If dust seal (3) has been removed, replace it with a new one. 24. Remove dust seals (3) (2 used) from caps (1, 8) 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, helmets, etc in order to prevent personal injury. 26. Remove bearing (4) by using a round bar and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of dust seal (3).

W3-3-1-10

SECTION 3 Body Group 3 Center Hinge

7 2 3 4

Upper Hinge

Lower Hinge

WNDB-03-03-004

 Lower Hinge (b) Side 27. Remove bolts (2) (6 used). Remove caps (3, 7) and shim (4). j : 19 mm

fNOTE: LOCTITE #262 has been applied on bolt (2).

W3-3-1-11

SECTION 3 Body Group 3 Center Hinge

8 5 1 1

Upper Hinge

Lower Hinge

WNDB-03-03-004

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. IMPORTANT: If dust seal (1) has been removed, replace it with a new one. 28. Remove dust seals (1) (2 used) from caps (3, 7) by using a screwdriver and a hammer.

such as goggles, helmets, etc in order to prevent personal injury. 30. Remove bearing (6) by using a round bar and a hammer.

fNOTE: LOCTITE #262 has been applied on the outer surface of dust seal (1). 29. Remove grease fitting (5). j : 10 mm

W3-3-1-12

SECTION 3 Body Group 3 Center Hinge

6 2 5 4 a

3 1

8 7

2 6

5 mm (0.2 in)

WNDB-03-03-008

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 W2-1-1.) 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, helmets, etc in order to prevent personal injury. 1. Install bushings (6) (2 used) to rear chassis (2) by using the special tool (ST 7881) and a hammer.

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

W3-3-1-13

j : 19 mm m : 88 N·m (8.8 kgf·m, 65 lbf·ft)

SECTION 3 Body Group 3 Center Hinge

9 9 4 3

6 1

8 mm (0.31 in)

WNDB-03-03-006

 Upper Hinge Side

9. Apply LOCTITE #262 onto bolts (9) (6 used). Install caps (10, 4) and shim (3) to front chassis (1) with bolts (9) (6 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. 6. Install bearing (5) to front chassis (1) by using a copper hammer. IMPORTANT: Face the end of grease fitting (6) to the left side of body. 7. Install grease fitting (6). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

j : 19 mm m : 88 N·m (8.8 kgf·m, 65 lbf·ft) 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. IMPORTANT: Check the position to install bearing (5). 10. Install busing (7) to the position where it comes in contact with bearing (5) by using a copper hammer.

8. Apply LOCTITE #262 onto the outer surface of dust seals (8) (2 used). Install dust seals (8) (2 used) to caps (4, 10) by using a plastic hammer. Crimp the cap (4, 10) side by using a punch (2 places).

W3-3-1-14

SECTION 3 Body Group 3 Center Hinge 1

2 4

Upper Hinge

Lower Hinge

WNDB-03-03-004

The front chassis (1) assembly weight: dCAUTION: 2730 kg (6020 lb) Support front chassis (1) by using the dCAUTION: stable stand.

Upper Hinge (a) Part (Section)

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

3 1

4 2

WNDB-03-03-005

W3-3-1-15

SECTION 3 Body Group 3 Center Hinge 4, 5, 6

WNDB-03-03-008

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

12. Fit pin (3) to the boss (c) hole. Install pin (3) to the lower hinge by using a hammer. Install bolt (4) and washers (5, 6). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-3-1-16

SECTION 3 Body Group 3 Center Hinge 6, 5

4, 5

3 10

7 8

WNDB-03-03-006

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

17. Apply LOCTITE #205 onto bolts (6) (3 used). Install bolts (6) (3 used) and washers (5) (3 used). Remove the jack. j : 24 mm m : 205 N·m (20.5 kgf·m, 151 lbf·ft)

13. Install busing (7) to the position where it comes in contact with bearing (8) by using a copper hammer.

dCAUTION: Do not drop pin (9).

14. Install and hold pin (9) by using the jack. 15. Fit shim (10) to the mounting hole of bolts (4) (4 used). Fit flange (3) to the mounting holes of bolts (4) (4 used) and bolts (6) (3 used). 16. Apply LOCTITE #205 onto bolts (4) (4 used). Install flange (3) and shim (10) with bolts (4) (4 used) and washers (5) (4 used). j : 24 mm m : 205 N·m (20.5 kgf·m, 151 lbf·ft)

W3-3-1-17

SECTION 3 Body Group 3 Center Hinge

3, 4

a a-

WNEC-03-03-019

Stand b-

Front Axle

WNDB-03-03-002

WNDB-03-16-006

18. Remove stands (a) from front chassis (1) and rear chassis (2). Secure the tires (4 used) by using wheel stoppers. 19. Connect hose (5). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 20. Install clips (4) (2 used) with bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 21. Connect hoses (6) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) c-

W3-3-1-18

Ride Control Valve

SECTION 3 Body Group 3 Center Hinge

a a

1 a-

WNDB-03-09-003

Control Valve

2 WNDB-03-09-001

22. Connect hoses (1) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 23. Connect hoses (3) (2 used). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 24. Connect hoses (2) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-3-1-19

SECTION 3 Body Group 3 Center Hinge

1, 2

9, 10, 11 3

6 a-

Rear chassis

4, 5

WNDB-03-03-003

Front chassis

25. Install clamp (3) with bolts, washers (1) (2 used) and nuts (2) (2 used).

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

j : 19 mm

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

m : 90 N·m (9 kgf·m, 66 lbf·ft) 26. Connect connectors (6) (2 used). 27. Install clamp (8) and plate (7) with bolts, washers (9) (2 used), washers (10) (2 used), and nuts (11) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-3-1-20

SECTION 3 Body Group 3 Center Hinge

1, 2

5, 6, 7

Control Valve

29. Install clips (4) (2 used) with bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 30. Install clips (6, 7) (2 used for each) with bolts, washers (5) (2 used). j : 17 mm

3, 4

WNDB-03-03-001

32. Install the following parts.  Front Attachment (With Lift Arm Kickout) (Refer to W5-1-1.)  Front Attachment (With Lift Arm Auto Leveler) (Refer to W5-1-2.)  The Cab Assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (Refer to W4-6-3.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

m : 50 N·m (5 kgf·m, 37 lbf·ft) 31. Install clip (2) with bolt, washer (1). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-1-21

SECTION 3 Body Group 3 Center Hinge (Blank)

W3-3-1-22

SECTION 3 BODY Group 3 Center Hinge Removal and Installation of Center Hinge (Parallel Link)

View A

2 3

a a-

WNDF-03-03-006

Stand

4 b-

Removal IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.)

WNDB-03-17-117

Control Valve

dCAUTION: Machine weight: 11050 kg (24400 lb) 3. Support front chassis (1) and rear chassis (2) by using stable stands (a). 4. Disconnect hoses (4) (4 used). j : 19 mm 5. Disconnect hoses (3) (2 used).

2. Remove the following parts.  Front Attachment (Parallel Link) (Refer to W5-3-1.)  Cab Assembly (Parallel Link) (Refer to W3-1-2.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (2 Used) (Refer to W4-6-3.)

W3-3-2-1

j : 41 mm

SECTION 3 BODY Group 3 Center Hinge Detail A A

WNDB-03-13-101

WNDB-03-13-102 a-

6. Disconnect hoses (1) (2 used). j : 17 mm

W3-3-2-2

Quick Coupler Solenoid Valve

SECTION 3 BODY Group 3 Center Hinge Detail A a A

WNDB-03-17-104

WNDB-03-17-103 a-

7. Disconnect hose (1). j : 22 mm

W3-3-2-3

Bucket Regenerative Selector Valve

SECTION 3 BODY Group 3 Center Hinge

1 a-

Control Valve

2, 3, 4 WNDB-03-09-105

8. Disconnect hoses (1) (4 used). j : 19 mm 9. Remove bolts, washers (2) (2 used) and clips (3, 4) (2 used for each). j : 17 mm 10. Remove bolts, washers (5) (2 used) and clips (6, 7) (2 used for each). j : 17 mm

W3-3-2-4

5, 6, 7 WNDB-03-03-105

SECTION 3 BODY Group 3 Center Hinge

1, 2, 3

4, 5, 6

7 b

WNDB-03-03-106 a-

Control Valve

11. Remove bolt, washer (1) and clips (2, 3). j : 17 mm 12. Remove bolts, washers (4) (2 used) and clips (5, 6) (2 used for each). j : 17 mm 13. Disconnect hose (7). j : 27 mm

W3-3-2-5

Front Axle

WNDB-03-03-002

SECTION 3 BODY Group 3 Center Hinge

1, 2

9, 10, 11 8 7

4, 5 WNDB-03-03-108

Rear Chassis

Front Chassis

17. Remove bolts, washers (1) (2 used) and nuts (2) (2 used). Remove clamp (3).

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

j : 19 mm

15. Disconnect connectors (6) (2 used). 16. Put the matching marks on the clamp (8) and each hose in order to be clear about the position for securing the hoses when installing. Remove bolts, washers (9) (2 used), washers (10) (2 used), and nuts (11) (2 used). Remove plate (7) and clamp (8).

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

j : 19 mm

W3-3-2-6

SECTION 3 BODY Group 3 Center Hinge

1 2 3 4 a

Lower Hinge

WNDB-03-03-009 Section of Lower Hinge (a)

 Lower Hinge (a) Side

2 3

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.

19. Remove bolt (1) and washers (2, 3). Remove pin (4) from lower hinge (a) by using a round bar and a hammer. j : 24 mm

WNDB-03-03-010

W3-3-2-7

SECTION 3 BODY Group 3 Center Hinge

7 8 9 10

Upper Hinge

WNDB-03-03-009 Section of Upper Hinge (b)

 Upper Hinge (b) Side

8 9

20. Remove bolts (5) (4 used), bolts (6) (3 used), and washers (7) (7 used). Remove flange (8) and shim (9) from rear chassis (10).

j : 24 mm

fNOTE: LOCTITE #263 or equivalent has been applied to bolts (5, 6).

WNDB-03-03-005

W3-3-2-8

SECTION 3 BODY Group 3 Center Hinge

12 11 b

Upper Hinge

WNDB-03-03-009

Remove pin (12) while holding it. Do dCAUTION: not drop pin (12). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

Section of Upper Hinge (b)

such as goggles, hard hat, etc. in order to prevent personal injury. 21. Remove pin (12) from upper hinge (b) by using a round bar and a hammer. IMPORTANT: When bushing (11) has been removed, replace it with the new one. 22. Weld and install handles in diagonal position on the upper side of bushing (11). Attach a pry bar onto the handles. Raise and remove bushing (11) from the upper hinge (b).

WNDB-03-03-005

W3-3-2-9

SECTION 3 BODY Group 3 Center Hinge 13

10 15 b

Upper Hinge

WNDB-03-03-009

Section of Upper Hinge (b)

The front chassis (13) assembly dCAUTION: weight: 2900 kg (6400 lb) Support front chassis (13) by using dCAUTION: stable stands.

IMPORTANT: Do not allow cap (14) and bushing (15) to come in contact with rear chassis (10). 23. Attach nylon slings onto the front chassis (13) assembly. Hoist and hold the front chassis (13) assembly. Move the front chassis (13) assembly forward. Remove the front chassis (13) assembly from rear chassis (10). Support the front chassis (13) assembly by using the stand.

14 13

15 10

WNDB-03-03-005

W3-3-2-10

SECTION 3 BODY Group 3 Center Hinge

14 17

18 15

Upper Hinge

WNDB-03-03-011

 Upper Hinge (b) Side IMPORTANT: When bushing (15) has been removed, replace it with the new one. 24. Remove bushing (15) from cap (18) by using pry bars. 25. Remove bolts (16) (6 used). Remove caps (14, 18) and shim (17) from front chassis (13). j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to bolt (16).

W3-3-2-11

SECTION 3 BODY Group 3 Center Hinge

19 14

20 b

21 19 18

Upper Hinge

WNDB-03-03-011

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

27. Remove grease fitting (21) from front chassis (13).

such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: When dust seal (19) has been removed, replace it with the new one. 26. Remove dust seals (19) (2 used) from caps (14, 18) by using a screwdriver and a hammer. Smooth the punch marks (2 places for each) of caps (14, 18).

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. 28. Remove bearing (20) from front chassis (13) by using a round bar and a hammer.

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

fNOTE: Caps (14, 18) have been crimped by using a

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

W3-3-2-12

SECTION 3 BODY Group 3 Center Hinge

23 24

Lower Hinge

WNDB-03-03-012

 Lower Hinge (a) Side 29. Remove bolts (22) (6 used). Remove caps (23, 25) and shim (24) from front chassis (13). j : 19 mm

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

W3-3-2-13

SECTION 3 BODY Group 3 Center Hinge

26 23

26 25 WNDB-03-03-013

WNDB-03-03-012

Lower Hinge

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. IMPORTANT: When dust seal (26) has been removed, replace it with the new one. 30. Remove dust seals (26) (2 used) from caps (23, 25) by using a screwdriver and a hammer. Smooth the punch marks (2 places for each) of caps (23, 25).

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

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

31. Remove grease fitting (28) from front chassis (13). 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. 32. Remove bearing (27) from front chassis (13) by using a round bar and a hammer. IMPORTANT: When bushing (29) has been removed, replace it with the new one. 33. Remove bushings (29) (2 used) from rear chassis (10) by using a round bar and a hammer if necessary.

punch (2 places for each) in order to secure dust seals (26) (2 used).

W3-3-2-14

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

29 10 22 23 c

24 13

5 mm (0.20 in)

WNDB-03-03-008

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 W2-1-1.) IMPORTANT: The seals and bushings which have been removed cannot be reused. IMPORTANT: Apply grease to the inner circumference of bushings and dust seals when installing the pin.

IMPORTANT: Check the direction to install dust seal (26). 3. Apply LOCTITE #263 or equivalent to the outer circumference of dust seals (26) (2 used). Install dust seals (26) (2 used) to caps (23, 25) by using a plastic hammer. Crimp caps (23, 25) (2 places for each) by using a punch. Therefore, dust seals (26) (2 used) are secured. 4. Apply LOCTITE #263 or equivalent to bolts (22) (6 used). Install shim (24) and caps (23, 25) to front chassis (13) with bolts (22) (6 used).

 Lower Hinge (a) Side

j : 19 mm

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

m : 90 N·m (9 kgf·m, 66 lbf·ft)

such as goggles, hard hat, etc. in order to prevent personal injury. 1. Install bushings (29) (2 used) to rear chassis (10) by using special tool (ST 7881) and a hammer. IMPORTANT: Check the position to install the bearing (27). 2. Install bearing (27) to front chassis (13) by using a copper hammer.

W3-3-2-15

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

16 16 14 17

8 mm (0.32 in)

WNDB-03-03-006

 Upper Hinge (b) Side Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. 5. Install bearing (20) to front chassis (13) by using a copper hammer.

such as goggles, hard hat, etc. in order to prevent personal injury. 8. Insert bushing (15) to cap (18) by using a copper hammer until bushing (15) comes in contact with bearing (20).

6. Apply LOCTITE #263 or equivalent to the outer circumference of dust seals (19) (2 used). Install dust seals (19) (2 used) to caps (14, 18) by using a plastic hammer. Crimp caps (14, 18) (2 places for each) by using a punch. Therefore, dust seals (19) (2 used) are secured. 7. Apply LOCTITE #263 or equivalent to bolts (16) (6 used). Install shim (17) and caps (14, 18) to front chassis (13) with bolts (16) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-3-2-16

SECTION 3 BODY Group 3 Center Hinge

10 15 b

Lower Hinge

Upper Hinge

WNDB-03-03-009

Section of Upper Hinge (b)

The front chassis (13) assembly dCAUTION: weight: 2900 kg (6400 lb) Support front chassis (13) by using dCAUTION: stable stands.

IMPORTANT: Do not allow cap (14) and bushing (15) to come in contact with rear chassis (10). 9. Attach nylon slings onto the front chassis (13) assembly. Hoist the front chassis (13) assembly. Fit the mounting holes of upper hinge (b) and lower hinge (a) of the front chassis (13) assembly and rear chassis (10) assembly. Support them by using stands.

14 13

15 10

WNDB-03-03-005

W3-3-2-17

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

10 11 20

13 21

WNDB-03-03-006

 Upper Hinge (b) 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.

IMPORTANT: Face the end of grease fitting (21) to the left side of the machine. 13. Install grease fitting (21) to front chassis (13). Apply grease.

10. Insert bushing (11) to upper hinge (b) by using a copper hammer until bushing (11) comes in contact with bearing (20).

dCAUTION: Do not drop pin (12).

11. Install and hold pin (12) to upper hinge (b) by using a jack. 12. Apply LOCTITE #263 or equivalent to bolts (6) (3 used) and bolts (5) (4 used). Install shim (9) and flange (8) to rear chassis (10) with bolts (6) (3 used), bolts (5) (4 used), and washers (7) (7 used). Remove the jack. j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-3-2-18

j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

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

1 2 3

WNDB-03-03-008

 Lower Hinge (a) 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.

14. Fit pin (4) to the boss (e) hole of rear chassis (10). Install pin (4) to lower hinge (a) by using a hammer. Install bolt (1) and washers (2, 3). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) IMPORTANT: Face the end of grease fitting (28) to the left side of the machine. 15. Install grease fitting (28) to front chassis (13). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W3-3-2-19

SECTION 3 BODY Group 3 Center Hinge

3, 4, 5 1

a a-

WNDF-03-03-006

Stand

6 b b-

dCAUTION: Machine weight: 11050 kg (24400 lb)

16. Remove the stands (a) from front chassis (1) and rear chassis (2). Secure tires (4 used) by using wheel stoppers. 17. Connect hose (6). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 18. Install clips (4, 5) (2 used for each) with bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-2-20

Front Axle

WNDB-03-03-002

SECTION 3 BODY Group 3 Center Hinge Detail A A

1 WNDB-03-13-101

WNDB-03-13-102 a-

19. Connect hoses (1) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-3-2-21

Quick Coupler Solenoid Valve

SECTION 3 BODY Group 3 Center Hinge Detail A a A

WNDB-03-17-104

WNDB-03-17-103 a-

20. Connect hose (1). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W3-3-2-22

Bucket Regenerative Selector Valve

SECTION 3 BODY Group 3 Center Hinge

1 a-

Control Valve

3 WNDB-03-09-105

21. Connect hoses (1) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 22. Connect hoses (3) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 23. Connect hoses (2) (2 used). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-3-2-23

WNDB-03-17-117

SECTION 3 BODY Group 3 Center Hinge

1, 2

9, 10, 11 8 7

4, 5 WNDB-03-03-108

Rear Chassis

Front Chassis

24. Install clamp (3) with bolts, washers (1) (2 used) and nuts (2) (2 used).

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

j : 19 mm

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

m : 90 N·m (9 kgf·m, 66 lbf·ft) 25. Connect connectors (6) (2 used). 26. Fit the matching marks on clamp (8) and each hose made when removing. Install clamp (8) and plate (7) with bolts, washers (9) (2 used), washers (10) (2 used), and nuts (11) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-3-2-24

SECTION 3 BODY Group 3 Center Hinge

View A

b a

A a-

1, 2, 3

30°

WNDB-03-03-109

4, 5, 6 WNDB-03-03-105

Control Valve

IMPORTANT: Check the angle to install clip (6). 28. Install clips (5, 6) (2 used for each) with bolts, washers (4) (2 used).

29. Install clips (2, 3) (2 used for each) with bolts, washers (1) (2 used). j : 17 mm

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-2-25

SECTION 3 BODY Group 3 Center Hinge

1, 2, 3

WNDB-03-03-106 a-

Control Valve

30. Install clips (2, 3) with bolt, washer (1). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 31. Install the following parts.  Front Attachment (Parallel Link) (Refer to W3-5-1.)  Cab Assembly (Parallel Link) (Refer to W3-1-2.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (2 Used) (Refer to W4-6-3.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-3-2-26

SECTION 3 BODY Group 4 Engine Removal and Installation of Engine

5 2, 3

M4GB-07-044

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 until oil cools before starting any work. Do not turn the cap of hydraulic oil tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. 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.

WNDB-03-01-001

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

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 4. Open the cover of battery box (6).

5. Loosen nut (7). Disconnect ground (5).

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

W3-4-1-1

j : 10 mm

SECTION 3 BODY Group 4 Engine

2 WNDB-03-04-028

WNDB-03-07-002

6. Remove the following parts at the right and left sides. (Refer to W3-4-2.)  Rear Fender (Front) (4)  Rear Fender (Rear) (2)  Side Cover (1)  Cover (Lower) (3) 7. Remove rubber plate (5). (Refer to W3-4-2.) 6

8. Bleed air from the radiator. (Refer to W1-4-1.) 9. Place a container under hose (7). Loosen cock (6). Drain off coolant. Close cock (6).

fNOTE: Amount of coolant: 28 L (7.4 US gal)

WNEE-03-04-003

10. Release refrigerant of the air conditioner. (Refer to T5-7 in the separated volume, Shop Manual, Troubleshooting.)

W3-4-1-2

SECTION 3 BODY Group 4 Engine

3 8

WNEE-03-04-002

11. Place a container under drain plug (1). Loosen drain plug (1). Drain off engine oil. Tighten drain plug (1).

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

WNDB-03-04-017

14. Remove clamps (8) (2 used). Disconnect the both ends of hose (7).

j : 24 mm m : 93 N∙m (9.3 kgf∙m, 69 lbf∙ft)

j : 7 mm 15. Remove propeller shafts (4, 5) from the drive unit. (Refer to W4-4-1.)

12. Remove clip (3). Disconnect hose (2). IMPORTANT: Do not apply the liquid packing to drain plug (6). 13. Place a container under drain plug (6). Remove drain plug (6). Drain transmission oil. Install drain plug (6). j : 22 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

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

W3-4-1-3

SECTION 3 BODY Group 4 Engine

WNDB-03-04-018

16. Remove the air cleaner (4) assembly. (Refer to W3-43.) 17. Remove rear cover (3). (Refer to W3-4-2.) 18. Remove the engine cover (2) assembly and hydraulic oil tank (1). (Refer to W3-6-1.) 19. Remove the cab (5) assembly. (Refer to W3-1-1.)

W3-4-1-4

SECTION 3 BODY Group 4 Engine

2, 3

View A

13 14

5 10

WNDB-03-04-019

20. Remove clips (8, 9, 12). Disconnect hoses (7, 10, 11). j : 7 mm 21. Remove bolts, washers (13) (2 used). Remove the pipe (14) assembly. j : 17 mm 22. Remove bolt, washer (2) and bracket (3). j : 17 mm 23. Remove rubber plates (1, 4) and covers (5, 6). (Refer to W3-4-2.)

W3-4-1-5

WNDB-03-04-020

SECTION 3 BODY Group 4 Engine

7 a-

Radiator

6 b-

WNDB-03-04-021

Engine

24. Remove clamp (6). Disconnect the engine (b) side of hose (7). j : 7 mm

NOTE: THREEBOND #1207B has been applied on hose (7) connecting surface. 25. Remove clamps (2) (2 used). Disconnect the radiator (a) side of hose (7).

26. Remove bolts, washers (8) (4 used). j : 17 mm 27. Remove clamps (1) (2 used). Disconnect the pipe (3) assembly. j : 11 mm 28. Remove clamp (5). Disconnect the engine (b) side of hose (4).

j : 7 mm

j : 11 mm

NOTE: THREEBOND #1207B has been applied on hose (7) connecting surface.

fNOTE: THREEBOND #1207B has been applied on hose

W3-4-1-6

(4) connecting surface.

SECTION 3 BODY Group 4 Engine

3 6, 7, 8

4, 5

29. Remove bolts, washers (4, 6), clamps (5, 7), and spacer (8). j : 17 mm 30. Remove clamps (2) (2 used). Disconnect hoses (1, 3). j : 7 mm

W3-4-1-7

WNDB-03-04-029

SECTION 3 BODY Group 4 Engine

Detail A

7, 8, 9

14, 15, 16, 17 a-

Alternator

10, 11, 12, 13 WNDB-03-04-023

1 View B

3 2 3

4 6

18, 19, 20, 21

WNDB-03-04-022 b-

Starter

WNDB-03-04-024

35. Disconnect connector (5).

31. Remove bolt, washer (1) and bracket (2).

36. Remove connector (5) from bracket (6).

j : 17 mm 32. Remove screw (7) and washer (8). Disconnect terminal (9).

37. Disconnect connector (3).

33. Remove covers (10) (2 used) , nuts (11) (2 used), and washers (12) (2 used). Disconnect terminals (13) (2 used).

39. Remove nut (18) and washer (19). Disconnect terminals (20, 21).

38. Remove connector (3) from bracket (4).

j : 19 mm

j : 8 mm 34. Remove cover (14), nut (15), and washer (16). Disconnect terminal (17). j : 13 mm

W3-4-1-8

SECTION 3 BODY Group 4 Engine

11 22, 23 10 20, 21 9 2, 3, 4 7, 8

13 14, 15 6

WNDB-03-04-025

40. Remove bolts, washers (11) (2 used). Remove cover (10).

18, 19

16, 17

WNDB-03-04-026

45. Disconnect connectors (13, 24). 46. Remove bolt, washer (18). Disconnect ground (19).

j : 17 mm

41. Remove bolt, washer (7). Remove clamps (8) (2 used).

47. Remove bolt, washer (20) and bracket (21). j : 17 mm

j : 17 mm

48. Remove bolt, washer (16) and clip (17).

42. Remove bolts, washers (1) (2 used). Disconnect hoses (9, 12).

j : 17 mm 49. Remove socket bolt (22). Disconnect connector (23).

j : 10 mm 43. Remove clamps (6) (2 used). Disconnect the both ends of hose (5).

l : 4 mm 50. Remove nut (14). Disconnect ground (15).

j : 11 mm

j : 13 mm

44. Remove nut (2) and washer (3). Disconnect terminal (4). j : 10 mm

W3-4-1-9

SECTION 3 BODY Group 4 Engine

1 a-

WNDB-03-15-012

Window Washer Tank

51. Disconnect connectors (1) (4 used). 52. Disconnect hoses (2) (2 used). 53. Remove bolts, washers (4) (2 used) and bracket (5). Remove and place the fuel filter (3) assembly outside the work area. j : 17 mm

W3-4-1-10

WNDB-03-15-013

SECTION 3 BODY Group 4 Engine

1, 2 a-

Fan Pump

54. Disconnect hose (3). j : 41 mm 55. Disconnect hose (4). j : 27 mm 56. Remove clamps (1) (2 used). Disconnect hoses (2) (2 used). j : 7 mm

W3-4-1-11

WNEE-03-04-014

SECTION 3 BODY Group 4 Engine

4 a-

2, 3

WNDB-03-08-015

Secondary Steering Block

60. Disconnect hoses (7) (2 used).

57. Disconnect connectors (1) (2 used). 58. Remove bolts, washers (2) (2 used) and washers (3) (2 used). Remove and place the bracket (4) assembly outside of the work area. j : 17 mm

fNOTE: Step 58 is only for the machine with the secondary steering attached. 59. Disconnect hose (5) and hoses (6) (2 used). j : 17 mm

W3-4-1-12

j : 19 mm

WNDB-03-08-016

SECTION 3 BODY Group 4 Engine

6, 7

WNDB-03-08-017

65. Disconnect hoses (8) (2 used).

61. Disconnect hoses (1, 3). j : 36 mm

j : 41 mm

62. Disconnect hose (2).

66. Disconnect hose (9).

j : 41 mm

j : 19 mm

63. Disconnect hose (4). j : 27 mm 64. Place the containers under the disconnecting part of suction pipe (6). Remove socket bolts (5) (4 used). Remove the suction pipe (6) assembly. Remove O-ring (7). l : 10 mm

W3-4-1-13

WNDB-03-04-027

SECTION 3 BODY Group 4 Engine

Detail A

Detail B

3 4

WNEE-03-04-041

5 4

5 4 6

6 WNEE-03-04-042 ab-

Lifting Bracket (Engine) Lifting Bracket (Drive Unit)

Engine Mount of Rear chassis Side

The engine (2) assembly weight: 1230 dCAUTION: kg (2720 lb) 67. Install shackles (4 used) to lifting brackets (a, b) (2 places for each) of engine (2) and drive unit (1). Attach the nylon slings onto the shackles (4 used). Hoist and hold the engine (2) assembly. 68. Remove bolts (3) (4 used), washers (4) (8 used), plates (5) (4 used), nuts (6) (4 used), and rubbers (7,8) (4 used for each) from the engine (2) assembly. j : 27 mm

W3-4-1-14

SECTION 3 BODY Group 4 Engine

3 2

b a

Stand

W4GC-03-02-189

Stand

Place the engine (2) assembly onto dCAUTION: stable stands (a, b) in order to not tip it over. 69. Hoist and remove the engine (2) assembly from the body.

fNOTE: Secure the engine (3) side onto stand (b) with

engine mount bracket (rear side) (4). 70. Remove pump device (1) from drive unit (2). (Refer to W3-8-1.) 71. Remove drive unit (2) from engine (3). (Refer to W42-1.) 72. Remove the adapter with engine (3) attached if necessary.

W3-4-1-15

SECTION 3 BODY Group 4 Engine

Detail A

Detail B

3 4

WNEE-03-04-041

5 4

4 6

WNEE-03-04-042 ab-

Lifting Bracket (Engine) Lifting Bracket (Drive Unit)

Engine Mount of Rear chassis Side

Installation 1. Install all removed adapters to engine (2). 2. Install drive unit (1) to engine (2). (Refer to W4-2-1.) 3. Install the pump device to drive unit (1). (Refer to W3-8-1.) The engine (2) assembly weight: 1230 dCAUTION: kg (2720 lb) 4. Install shackles (4 used) to lifting brackets (a, b) (2 places for each) of engine (2) and drive unit (1). Attach the nylon slings onto the shackles (4 used). Hoist the engine (2) assembly.

IMPORTANT: The hardness of rubbers (7, 8) are different. Install rubber (7) with the white mark to the drive unit (1) side of engine (2). Install rubber (8) with the yellow mark to the radiator side. 5. Install rubbers (7, 8) (2 used for each) to the engine mount (c) holes of the rear chassis side. 6. Install the engine (2) assembly to the engine mount (c) of the rear chassis side with bolts (3) (4 used), washers (4) (8 used), plates (5) (4 used), and nuts (6) (4 used). j : 27 mm m : 315 N·m (31.5 kgf·m, 230 lbf·ft)

fNOTE: Bolts (d) for the engine mounting bracket should not be removed here (The bracket is to be removed with the engine as is installed). For reference only: m (d): 81.2 N·m (8.3 kgf·m, 60 lbf·ft) Apply LOCTITE 262

W3-4-1-16

SECTION 3 BODY Group 4 Engine

8 B

3 A

6, 7

WNDB-03-08-017

7. Connect hose (9).

WNDB-03-04-027

View A

View B

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 8. Connect hoses (8) (2 used). 4

j : 41 mm a-

25˚

WNDB-03-08-019

3 b-

20˚

WNDB-03-08-020

m : 110 N·m (11 kgf·m, 81 lbf·ft) 9. Install O-ring (7). Install the suction pipe (6) assembly with socket bolts (5) (4 used). l : 10 mm

IMPORTANT: Check the angle to install hose (3). 11. Connect hose (3). j : 36 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft) IMPORTANT: Check the angle to install hose (4). 10. Connect hose (4).

m : 93 N·m (9.3 kgf·m, 69 lbf·ft) 12. Connect hose (2).

j : 27 mm

j : 41 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

m : 210 N·m (21 kgf·m, 155 lbf·ft) 13. Connect hose (1). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

W3-4-1-17

SECTION 3 BODY Group 4 Engine

WNDB-03-08-016 a-

2, 3

WNDB-03-08-015

Secondary Steering Block

View A

14. Connect hoses (7) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (5). 15. Connect hoses (6) (2 used) and hose (5).

5 c

j : 17 mm c-

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 16. Install the bracket (4) assembly with washers (3) (2 used) and bolts, washers (2) (2 used).

25˚

17. Connect connectors (1) (2 used).

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

fNOTE: Step 16 is only for the machine with the secondary steering attached.

W3-4-1-18

WNDB-03-08-022

SECTION 3 BODY Group 4 Engine

a View A

3 4

3 WNEE-03-04-034 a-

1, 2 A a-

Fan pump

WNEE-03-04-014

18. Connect hoses (2) (2 used) with clamps (1) (2 used). j : 7 mm m : 4 N∙m (0.4 kgf∙m, 3 lbf·ft) 19. Connect hose (4). j : 27 mm m : 95 N∙m (9.5 kgf∙m, 70 lbf·ft) IMPORTANT: Check the angle to install hose (3). 20. Connect hose (3). j : 41 mm m : 210 N∙m (21 kgf∙m, 155 lbf·ft)

W3-4-1-19

Fan pump

35°

SECTION 3 BODY Group 4 Engine

WNDB-03-15-013 a-

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

W3-4-1-20

Window Washer Tank

WNDB-03-15-012

SECTION 3 BODY Group 4 Engine 1

11 22, 23 10 20, 21 9 2, 3, 4 7, 8

13 14, 15 18, 19

16, 17

WNDB-03-04-026

WNDB-03-04-025

30. Connect terminal (4) with washer (3) and nut (2).

24. Connect ground (15) with nut (14). j : 13 mm

j : 10 mm

m : 10 N∙m (1 kgf∙m, 7.4 lbf·ft)

m : 3 to 4 N∙m (0.3 to 0.4 kgf∙m, 2.2 to 3 lbf·ft) 31. Connect the both ends of hose (5) with clamps (6) (2 used).

25. Connect connector (23) with socket bolt (22). l : 4 mm

j : 11 mm

m : 2.8 to 3.4 N·m (0.28 to 0.3 kgf·m, 2.1 to 2.5 lbf·ft) 26. Install clip (17) with bolt, washer (16). j : 17 mm m : 50 N∙m (5 kgf∙m, 37 lbf·ft) 27. Install bracket (21) with bolt, washer (20).

m : 12 N∙m (1.2 kgf∙m, 8.9 lbf·ft) 32. Add compressor oil. (Refer to T5-7 in the separated volume, Technical Manual.) 33. Apply ND-OIL8 onto the O-ring of the connecting part of hoses (9, 12). Connect hoses (9, 12) with bolts, washers (1) (2 used). j : 10 mm

j : 17 mm

m : 4 to 6.8 N∙m (0.4 to 0.7 kgf∙m, 3 to 5 lbf·ft)

m : 50 N∙m (5 kgf∙m, 37 lbf·ft) 28. Connect ground (19) with bolt, washer (18).

34. Install clamps (8) (2 used) with bolt, washer (7). j : 17 mm

j : 17 mm

m : 50 N∙m (5 kgf∙m, 37 lbf·ft)

m : 20 N∙m (2 kgf∙m, 15 lbf·ft) 29. Connect connectors (13, 24).

35. Install cover (10) with bolts, washers (11) (2 used). 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

7, 8, 9

14, 15, 16, 17 a-

Alternator

10, 11, 12, 13 WNDB-03-04-023

1 View B

3 2 3

4 6

18, 19, 20, 21

WNDB-03-04-022 b-

36. Connect terminals (20, 21) with washer (19) and nut (18). j : 19 mm

Starter

WNDB-03-04-024

42. Connect terminals (13) (2 used) with washers (12) (2 used) and nuts (11) (2 used). Install covers (10) (2 used). j : 8 mm

m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

m : 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)

37. Install connector (3) with bracket (4).

43. Connect terminal (9) with washer (8) and screw (7).

38. Connect connector (3).

m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

39. Install connector (5) to bracket (6).

44. Install bracket (2) with bolt, washer (1).

40. Connect connector (5). 41. Connect terminal (17) with washer (16) and nut (15). Install cover (14). j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

W3-4-1-22

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

SECTION 3 BODY Group 4 Engine

View A

2 a

3 a-

6, 7, 8

4, 5

WNDB-03-04-029

45. Connect hoses (1, 3) with clamps (2) (2 used). m : 6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft) IMPORTANT: Check the angle to install clamp (7). 46. Install clamps (5, 7) and spacer (8) with bolts, washers (4, 6). j : 17 mm m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

W3-4-1-23

30˚ WNDB-03-04-030

SECTION 3 BODY Group 4 Engine

7 a-

Radiator

6 b-

WNDB-03-04-021

Engine

IMPORTANT: Do not apply THREEBOND #1207B onto the inner connecting surface of hose (4) and the inner surface of hose (4) of engine (b). 47. Apply THREEBOND #1207B onto the outer connecting surface of hose (4) of engine (b). Connect the engine (b) side of hose (4) with clamp (5).

IMPORTANT: Do not apply THREEBOND #1207B onto the inner connecting surface of hose (7) and the inner surface of hose (7) of radiator (a). 50. Apply THREEBOND #1207B onto the outer connecting surface of hose (7) of radiator (a). Connect the radiator (a) side of hose (7) with clamps (2) (2 used).

j : 11 mm

j : 7 mm

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

m : 6 to 7.4 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.5 lbf·ft)

48. Connect the pipe (3) assembly with clamps (1) (2 used). j : 11 mm m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 49. Install bolts, washers (8) (4 used). j : 17 mm

IMPORTANT: Do not apply THREEBOND #1207B onto the inner connecting surface of hose (7) and the inner surface of hose (7) of engine (b). 51. Apply THREEBOND #1207B onto the outer connecting surface of hose (7) of engine (b). Connect the engine (b) side of hose (7) with clamp (6). j : 7 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 7.2 to 8.8 N·m (0.72 to 0.9 kgf·m, 5.3 to 6.5 lbf·ft)

W3-4-1-24

SECTION 3 BODY Group 4 Engine

2, 3

View A

13 14

5 10

WNDB-03-04-019

52. Install covers (5, 6) and rubber plates (1, 4). (Refer to W3-4-2.)

WNDB-03-04-020

55. Install the pipe (14) assembly with bolts, washers (13) (2 used).

53. Install bracket (3) with bolt, washer (2).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) 54. Connect hoses (7, 10, 11) with clips (8, 9, 12). j : 7 mm m : 3.6 to 4.4 N·m (0.36 to 0.44 kgf·m, 2.7 to 3.2 lbf·ft)

W3-4-1-25

SECTION 3 BODY Group 4 Engine

WNDB-03-04-018

56. Install the cab (4) assembly. (Refer to W3-1-1.) 57. Install hydraulic oil tank (1) and the engine cover (2) assembly. (Refer to W3-6-1.) 58. Install the air cleaner (3) assembly. (Refer to W3-4-3.)

W3-4-1-26

SECTION 3 BODY Group 4 Engine

1 6

WNDB-03-04-017

59. Connect the both ends of hose (5) with clamps (6) (2 used). j : 7 mm m : 5.5 N·m (0.6 kgf·m, 4.1 lbf·ft) 60. Install propeller shafts (3, 4). (Refer to W4-4-1.) 61. Connect hose (1) with clip (2). m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 62. Add engine oil to the engine.

fNOTE: Amount of engine oil: 25 L (6.6 US gal) 63. Add coolant to the radiator.

fNOTE: Amount of coolant: 28 L (7.4 US gal) 64. Add transmission oil to the drive unit.

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

W3-4-1-27

2 WNEE-03-04-002

SECTION 3 BODY Group 4 Engine

5 2, 3

M4GB-07-044

WNDB-03-01-001

65. Fill hydraulic oil to hydraulic oil tank (1).

69. Close the cover of battery box (6).

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

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

(37 US gal) 66. Install O-ring (3).

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

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

IMPORTANT: Check the hydraulic oil level, the transmission oil level, the coolant level, and engine oil level. Start the engine and check for any oil and coolant leaks. 72. Fill refrigerant in the air conditioner. (Refer to T5-7 in the separated volume, Technical Manual.)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 68. Connect ground (5). Tighten nut (7). j : 10 mm m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)

W3-4-1-28

SECTION 3 BODY Group 4 Engine

6 WNDB-03-07-002

73. Install rubber plate (1). (Refer to W3-4-2.) 74. Install rear cover (3). (Refer to W3-4-2.) 75. Install the following parts at the right and left sides. (Refer to W3-4-2.)  Side Cover (2)  Cover (Lower) (5)  Rear Fender (Front) (6)  Rear Fender (Rear) (4)

W3-4-1-29

4 WNDB-03-04-028

SECTION 3 BODY Group 4 Engine (Blank)

W3-4-1-30

SECTION 3 BODY Group 4 Engine Removal and Installation of Exterior Parts 1

2 10

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove the following parts.  Engine cover (1)  Rear cover (2)  Cover (lower) (3)  Side cover (front) (4)  Rear fender (rear) (5)  Front fender (6)  Rear fender (front) (7)  Deck (8) and Step (front) (9)  Rear grill (10)  Inspection cover (11)  Step (rear) (12)  Side cover (rear) (13)

W3-4-2-1

WNDB-03-04-001

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

WNDB-03-04-002

W3-4-2-2

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

06 08 09 11 12 15 16 17 23 24 25 26 29 30 31 34 35 36 37 42 43 45 46 47 48

Cover Cover Cover Bracket Bolt, Washer Rubber Plate Rubber Plate Bolt, Washer Rubber Plate Bolt, Washer Plate Bolt, Washer Cover (Lower) (Left) Cover (Lower) (Right) Bolt, Washer Engine Cover Washer Washer Bolt Rear Cover Bolt, Washer Rubber Cushion Washer Bolt, Washer Nut

1 1 1 1 16 1 1 8 1 4 1 5 1 1 10 1 7 7 7 1 3 2 4 2 2

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 17

j : 24

210

155

j : 17

j : 19 j : 19

90 90

9 9

66 66

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  Engine cover (34) weight: 45 kg (100 lb)

W3-4-2-3

Weight kg lb

100

SECTION 3 BODY Group 4 Engine Removal and Installation of Side Cover 2

3 a-

WNDB-03-04-003

Engine Cover

Without rear fender (rear)

With rear fender (rear)

4 5

9 8

10 11

WNDB-03-04-004

W3-4-2-4

WNDB-03-04-005

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

1 2 3 4 5 6 7 8 9 10 11

Side Cover (Left) Side Cover (Right) Bolt, Washer Damper Bolt Washer Nut Damper Pin Lock Pin Washer

1 1 8 2 2 4 4 4 2 2 2

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 19

j : 13

The side cover (1, 2) assembly weight: dCAUTION: 32 kg (71 lb) IMPORTANT: Attach nylon slings onto the chassis side of the side cover (1, 2) assembly.

fNOTE: Remove the rear fender (rear) before removing side covers (1, 2).

W3-4-2-5

Weight kg lb 32 71 32 71

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

WNDB-03-04-006

W3-4-2-6

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 05 06 07 10 11 14 15 16 19 20 21

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

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

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 19

j : 17

Weight kg lb

5 5 j : 17

Remove the rear fender (rear) (19, 20) dCAUTION: assemblies while holding them. Do not drop the rear fender (rear) (19, 20) assemblies. IMPORTANT: Before installing bolts, washers (16, 21), apply LOCTITE #262 onto them.

W3-4-2-7

12 12

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

WNDB-03-04-009

W3-4-2-8

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 08 10 11 12 13 19 20 22 23 24 25 30 31 32 33 34 35 39 40 43 44 51 52 53 54 55 56

Deck Bolt, Washer Tool Box Bolt, Washer Bolt, Washer Washer Nut Handrail Handrail Bolt, Washer Washer Nut Plug Handrail Handrail Bolt, Washer Washer Nut Plug Rear Fender (Front) (Left) Rear Fender (Front) (Right) Bolt, Washer Bolt, Washer Step Step Step Bolt, Washer Bolt, Washer Nut

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

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 19

j : 19 j : 19

90 90

9 9

66 66

j : 19

j : 19 j : 19

j : 19 j : 17 j : 17

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  The rear fender (front) (left) (39) assembly weight: 57 kg (130 lb)  The rear fender (front) (right) (40) assembly weight: 58 kg (130 lb)  Step (52) weight: 22 kg (49 lb)

W3-4-2-9

90 90

90 50 50

9 9

9 5 5

Weight kg lb 7 16 14

3 3

7 7

3 3

7 7

16 16

36 36

19 22 4

42 49 9

66 66

66 37 37

SECTION 3 BODY Group 4 Engine

WNDB-03-04-010 a-

Rear Fender (Front) (Left) Assembly

No.

Part Name

Q’ty

14 15 16 17 18 19 20 21 22

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

1 1 1 1 8 6 8 6 14

Rear Fender (Front) (Right) Assembly

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 17 j : 17

50 50

5 5

37 37

j : 17

W3-4-2-10

Weight kg lb

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

1, 2

5 4 3

6, 7 12, 13

5 4 5 4

8 11 10

3 4 5

9 WNDB-03-04-007

WNDB-03-04-008

Front Chassis

No.

Part Name

Q’ty

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

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

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

Wrench Size mm (in)

Tightening Torque N·m kgf·m lbf·ft

j : 19 (0.75)

3.5

j : 17 (0.67)

j : 17 (0.67) j : 17 (0.67)

W3-4-2-11

Weight kg lb 14 31 14 31

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

2 3

5 6

2 4

WNEE-03-04-054

No.

Part Name

Q’ty

1 2 3 4 5 6

Rear Grill Collar Lock Pin Pin Damper Bolt, Washer

1 3 1 1 1 4

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 17

When removing and installing the dCAUTION: following parts, hoist and hold them by using nylon slings.  The rear grill (1) assembly weight: 20 kg (45 lb)

W3-4-2-12

Weight kg lb 20 45

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

WNDB-03-04-011

No.

Part Name

Q’ty

01 04 06 35 36 37 40 41 42 43

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

2 2 16 1 1 4 1 2 2 2

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 17

j : 19

W3-4-2-13

Weight kg lb

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

WNDB-03-04-012

View A

View B

WNDB-03-04-013

W3-4-2-14

WNDB-03-04-014

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 03 11 12 13 14 18

Side Cover (Left) Side Cover (Right) Bolt, Washer Bracket Bolt, Washer Plate Plate Bolt, Washer

1 1 4 2 8 1 1 6

Wrench Size mm

Tightening Torque N·m kgf·m lbf·ft

j : 19

j : 17

W3-4-2-15

Weight kg lb 16 36 16 36

SECTION 3 BODY Group 4 Engine (Blank)

W3-4-2-16

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

1 1 6

4 4

WNDB-03-02-004

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 the left and right sides. 3. Disconnect connectors (2) (2 used). 4. Disconnect connector (3). 5. Remove clamps (4, 6). Disconnect hose (5).

W3-4-3-1

WNDB-03-04-015

SECTION 3 BODY Group 4 Engine 1

6. Remove clamps (1) (2 used). Disconnect hose (4). Remove the air cleaner (3) assembly dCAUTION: while holding it. Do not drop the air cleaner (3) assembly. 7. Remove bolts, washers (2) (4 used). Remove the air cleaner (3) assembly. j : 19 mm

W3-4-3-2

WNDB-03-04-016

SECTION 3 BODY Group 4 Engine 1

Installation 1. Install the air cleaner (3) assembly with bolts, washers (2) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 2. Connect hose (4) with clamps (1) (2 used). m : 6 to 7.4 N·m (0.6 to 0.74 kgf·m, 4.4 to 5.5 lbf·ft)

W3-4-3-3

WNDB-03-04-016

SECTION 3 BODY Group 4 Engine

3 1 1

4 4

WNDB-03-04-015

3. Connect hose (5) with clamps (4, 6). m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 4. Connect connector (3). 5. Connect connectors (2) (2 used). 6. Close side covers (1) at left and right sides.

W3-4-3-4

WNDB-03-02-004

SECTION 3 Body Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, Intercooler, Torque Converter Cooler, and Fuel Cooler

2, 3

M4GB-07-044

WNDB-03-02-004

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 until oil cools before starting any work. Do not turn the cap of hydraulic oil tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. 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 for inspection and maintenance. (Refer to W1-6-1.) Bleed air from hydraulic oil tank (1). dCAUTION: (Refer to W1-4-1.) 2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 4. Open side covers (front) (6) at the left and right sides and rear grill (7). 5. Remove rear cover (5). (Refer to W3-4-2.)

W3-5-1-1

SECTION 3 Body Group 5 Radiator Assembly

3 1 4

WNEE-03-04-003

WNDB-03-07-002

6. Bleed air from the radiator. (Refer to W1-4-1.) 7. Remove rubber plate (1). (Refer to W3-4-2.) 8. Place a container under hose (4). Loosen cock (3). Drain off coolant. Close cock (3).

fNOTE: Amount of coolant: 28 L (7.4 US gal) 9. Remove the fan motor (2) assembly. (Refer to W315-3.)

W3-5-1-2

SECTION 3 Body Group 5 Radiator Assembly

1 12

6, 7

WNDB-03-05-001

WNDB-03-05-002

15. Remove clips (12) (2 used). Disconnect hoses (13) (2 used).

10. Remove clamp (4). Disconnect hose (5). 11. Remove clip (6). Disconnect hose (7).

16. Remove bolts, washers (11) (4 used). Remove fuel cooler (10).

12. Remove clamps (8) (2 used). Disconnect hose (9).

fNOTE: THREEBOND #1207B has been applied on hose (9) connecting surface. 13. Remove clamps (2) (2 used). Disconnect the both ends of hose (1). 14. Disconnect hose (3). j : 36 mm

W3-5-1-3

j : 13 mm

SECTION 3 Body Group 5 Radiator Assembly

5 1

WNEE-03-05-031

17. Remove bolts (6) (2 used), washers (5) (2 used), rubbers (4) (2 used), tubes (3) (2 used), and spacers (2) (2 used). Remove radiator (1). j : 13 mm

W3-5-1-4

SECTION 3 Body Group 5 Radiator Assembly 1 3

3 4

4 3 A

18. Remove bolts, washers (2) (2 used). Remove oil cooler (1). j : 17 mm 19. Remove rubber seals (3) (4 used) and rubber seals (4) (2 used) from oil cooler (1). 20. Remove the adapters with oil cooler (1) attached if necessary.

W3-5-1-5

WNEE-03-05-031

SECTION 3 Body Group 5 Radiator Assembly 1

3 4

WNEE-03-05-031

21. Remove bolt (5), washer (4), tube (2), and rubber (3). Remove intercooler (1). j : 13 mm

W3-5-1-6

SECTION 3 Body Group 5 Radiator Assembly

2 WNEE-03-05-031

22. Remove bolts, washers (1) (4 used). Remove torque converter cooler (2). j : 17 mm 23. Remove the adapters with torque converter cooler (2) attached if necessary.

W3-5-1-7

SECTION 3 Body Group 5 Radiator Assembly

2 WNEE-03-05-031

Installation 1. Install all removed adapters to torque converter cooler (2). 2. Install torque converter cooler (2) with bolts, washers (1) (4 used). j : 17 mm m : 36.2 N·m (3.6 kgf·m, 26.5 lbf·ft)

W3-5-1-8

SECTION 3 Body Group 5 Radiator Assembly 1

3 4

WNEE-03-05-031

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

W3-5-1-9

SECTION 3 Body Group 5 Radiator Assembly 1 3

3 4

4 3 A

4. Install all removed adapters to oil cooler (1). 5. Install rubber seals (3) (4 used) and rubber seals (4) (2 used) to oil cooler (1). 6. Install oil cooler (1) with bolts, washers (2) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-10

WNEE-03-05-031

SECTION 3 Body Group 5 Radiator Assembly

5 1

WNEE-03-05-031

7. Install radiator (1) with spacers (2) (2 used), tubes (3) (2 used), rubbers (4) (2 used), washers (5) (2 used), and bolts (6) (2 used). j : 13 mm m : 17.6 N·m (1.8 kgf·m, 13 lbf·ft)

W3-5-1-11

SECTION 3 Body Group 5 Radiator Assembly

View A

1 a

A c

WNDB-03-15-011 b-

9 a-

6, 7

Oil cooler

15°

WNDB-03-05-001

Radiator

IMPORTANT: Check the angle to install hose (3). 8. Connect hose (3). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Connect the mark (d) side of hose (1) to the intercooler (e) side. 9. Connect both ends of hose (1) with clamps (2) (2 used).

e d-

Mark

1 e-

WNEE-03-05-030

Intercooler

m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft) 12. Connect hose (5) with clamp (4).

10. Connect hose (7) with clip (6). IMPORTANT: Do not apply THREEBOND #1207B onto the inner connecting surface and the inner surface of hose (9) of radiator (a). 11. Apply THREEBOND #1207B onto the outer connecting surface of hose (9) of radiator (a). Connect hose (9) with clamps (8) (2 used). m : 6 to 7.4 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.5 lbf·ft)

W3-5-1-12

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

SECTION 3 Body Group 5 Radiator Assembly

4, 5

6 2 M4GB-07-044

WNDB-03-07-002

13. Install the fan motor (2) assembly. (Refer to W3-153.)

18. Install the cover (5) assembly with bolts, washers (6) (6 used).

14. Add coolant to the radiator.

j : 17 mm

fNOTE: Amount of coolant: 28 L (7.4 US gal)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

15. Add transmission oil to the transmission.

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

fNOTE: Amount of transmission oil: 30 L (8 US gal) 16. Fill hydraulic oil tank (3) with hydraulic oil.

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

fNOTE: Total oil amount of hydraulic oil tank (3): 140 L

IMPORTANT: Check the hydraulic oil level, transmission oil amount, and coolant amount. Start the engine and check for any oil and coolant leaks. 21. Install rubber plate (1). (Refer to W3-4-2.)

(37 US gal) 17. Install O-ring (4).

W3-5-1-13

SECTION 3 Body Group 5 Radiator Assembly 1

WNDB-03-02-004

22. Install rear cover (1). (Refer to W3-4-2.) 23. Close side covers (front) (2) at the left and right sides and rear grill (3).

W3-5-1-14

SECTION 3 BODY Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank 1

2, 3

M4GB-07-044

Removal

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

W3-6-1-1

(37 US gal)

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 WNDB-03-04-001

4. Remove the following parts at the right and left sides. (Refer to W3-4-2.)  Rear Fender (Front) (5)  Rear Fender (Rear) (3)  Side Cover (1)  Cover (Lower) (4) 5. Remove rear cover (2). (Refer to W3-4-2.)

W3-6-1-2

SECTION 3 BODY Group 6 Hydraulic Oil Tank View A

1, 2, 3

12 10 13

9 8

WNDB-03-06-010

WNDB-03-06-011

Detail B

6. Remove the air cleaner (10) assembly. (Refer to W34-3.) 7. Remove bolt, washer (9). Remove pipe (8). j : 17 mm 8. Remove clamp (12). Disconnect tube (13). 9. Remove plugs (5) (4 used). The engine cover (4) assembly weight: dCAUTION: 87 kg (195 lb)

fNOTE: Remove engine cover (4) with the muffler (11)

assembly attached. 10. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to the plug (5) mounting holes (4 places). Attach the nylon slings onto the eyebolts (4 places). Hoist and hold the engine cover (4) assembly.

1, 2, 3

WNDB-03-06-012

11. Remove bolts (1) (7 used) and washers (2, 3) (7 used for each). j : 24 mm 12. Loosen clamp (7). Disconnect pipe (6). 13. Remove the engine cover (4) assembly.

W3-6-1-3

SECTION 3 BODY Group 6 Hydraulic Oil Tank

6, 7

14 5 2

9, 10, 11

6, 7

1 b

ab-

WNDB-03-06-006 c-

14. Remove bolts, washers (1) (3 used). Remove cover (5).

TBAP Sensor Connector Hydraulic Oil Temperature Sensor Hydraulic Oil Level Switch

6, 7

WNDB-03-06-007

17. Remove bolts, washers (6) (4 used) and clips (7) (4 used). Remove harness (8). j : 17 mm

j : 17 mm 15. Remove the harnesses from all clips of the cover (4) assembly. Remove bolt, washer (2) and bolts, washers (3) (2 used). Remove the cover (4) assembly. j : 17 mm

18. Remove bolt, washer (9), collar (10), and connector (11). j : 17 mm 19. Remove harness (8) from clips (12) (2 used).

16. Disconnect connectors (13, 14).

W3-6-1-4

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1

15, 16

13, 14

12 6

10, 11

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

j : 36 mm 27. Disconnect hose (3). j : 27 mm

j : 19 mm 22. Disconnect hoses (2) (2 used). j : 17 mm

28. Disconnect hose (5) (only with the secondary steering attached). j : 27 mm

23. Remove bolt, washer (13) and adapter (14). j : 17 mm

29. Disconnect hose (6). j : 41 mm

24. Remove bolt, washer (10), clip (11), and hose (9). j : 17 mm 25. Remove bolt, washer (7) and clip (8).

WNDB-03-06-002

26. Disconnect hose (4).

j : 17 mm 21. Disconnect hoses (1) (2 used).

7, 8

30. Remove the secondary steering pump (12) assembly (only with the secondary steering attached). (Refer to W4-7-1.)

j : 17 mm

W3-6-1-5

SECTION 3 BODY Group 6 Hydraulic Oil Tank

10 9

3, 4, 5 WNDB-03-06-003

WNDB-03-06-009

31. Remove bolt, washer (3), nut (4), and clip (5). j : 17 mm

32. Remove hoses (2) (2 used) from holders (1) (2 used). 12

33. Remove clamps (7, 8) (2 used for each). Disconnect hoses (6, 9). 34. Disconnect hose (10). 14, 15

j : 27 mm

35. Place a container under the disconnecting part of hose (13). Remove clamps (12) (2 used). Disconnect hose (13). Hydraulic oil tank (11) weight: 150 kg dCAUTION: (335 lb)

14, 15

36. Attach nylon slings onto hydraulic oil tank (11). Hoist and hold hydraulic oil tank (11).

WNDB-03-06-004

IMPORTANT: Do not contact the cab rear glass and the rear work lights when removing and installing hydraulic oil tank (11) from the machine. 37. Remove bolts (14) (6 used) and washers (15) (6 used). Hoist and remove hydraulic oil tank (11).

38. Remove the adapters with hydraulic oil tank (11) attached if necessary.

j : 24 mm

W3-6-1-6

SECTION 3 BODY Group 6 Hydraulic Oil Tank

11 12

14, 15

14, 15 10

WNDB-03-06-009

WNDB-03-06-004

Installation 1. Install all removed adapters to hydraulic oil tank (11). 1

CAUTION: Hydraulic oil tank (11) weight: 150 kg (335 lb) 2. Attach nylon slings onto hydraulic oil tank (11). Hoist hydraulic oil tank (11).

IMPORTANT: Do not contact the cab rear glass and the rear work lights when removing and installing hydraulic oil tank (11) from the machine. 3. Install hydraulic oil tank (11) with washers (15) (6 used) and bolts (14) (6 used). j : 24 mm m : 270 N·m (27 kgf·m, 200 lbf·ft)

4. Connect hose (13) with clamps (12) (2 used).

3, 4, 5 WNDB-03-06-003

m : 10 N·m (1 kgf·m, 7.4 lbf·ft) 5. Connect hose (10).

7. Install hoses (2) (2 used) to holders (1) (2 used).

j : 27 mm

8. Install clip (5) with bolt, washer (3) and nut (4).

m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm

6. Connect hoses (6, 9) with clamps (7, 8) (2 used for each).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)

W3-6-1-7

SECTION 3 BODY Group 6 Hydraulic Oil Tank 1

15, 16

13, 14

12 6

10, 11

9. Install the secondary steering pump (12) assbmly (only with the secondary steering attached). (Refer to W4-7-1.)

7, 8

15. Install hose (9) with bolt, washer (10) and clip (11). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Connect hose (6).

16. Install adapter (14) with bolt, washer (13).

j : 41 mm

j : 17 mm

m : 210 N·m (21 kgf·m, 155 lbf·ft) 11. Connect hose (5) (only with the secondary steering attached).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 17. Connect hoses (2) (2 used).

j : 27 mm

j : 17 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

12. Connect hose (3).

18. Connect hoses (1) (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)

13. Connect hose (4).

WNDB-03-06-002

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

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)

14. Install clip (8) with bolt, washer (7). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-6-1-8

SECTION 3 BODY Group 6 Hydraulic Oil Tank

1, 2

4, 5, 6

1, 2

7 8

TBAP Sensor Connector

1, 2

Hydraulic Oil Temperature Sensor

Hydraulic Oil Level Switch WNDB-03-06-007

20. Connect connectors (8, 9). 21. Install harness (3) with clips (2) (4 used) and bolts, washers (1) (4 used).

22. Install connector (6) and collar (5) with bolt, washer (4). 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) 23. Install harness (3) with clips (7) (2 used).

W3-6-1-9

SECTION 3 BODY Group 6 Hydraulic Oil Tank

View A

1, 2, 3

11 10 12

9 a

8 a-

WNDB-03-06-010

Turbocharger

WNDB-03-06-011

Detail B

The engine cover (4) assembly weight: dCAUTION: 87 kg (195 lb) 24. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to the plug (5) mounting holes (4 places). Attach nylon slings onto the eyebolts (4 places). Hoist the engine cover (4) assembly. 25. Connect exhaust pipe (6) to turbocharger (a). Temporarily install the engine cover (4) assembly with bolts (1) (7 used), washers (2, 3) (7 used for each), and clamp (7). 26. Tighten bolts (1) (7 used).

1, 2, 3

28. Tighten clamp (7).

j : 24 mm m : 210 N∙m (21 kgf∙m, 155 lbf∙ft) 27. Install plugs (5) (4 used).

WNDB-03-06-012

m : 8 to 9 N∙m (0.8 to 0.9 kgf∙m, 5.9 to 6.6 lbf∙ft) 29. Connect tube (12) with clamp (11). 30. Install pipe (8) with bolt, washer (9). 31. Install the air cleaner (10) assembly. (Refer to W3-43.)

W3-6-1-10

SECTION 3 BODY Group 6 Hydraulic Oil Tank

1 6

7, 8

5 2

9 1

M4GB-07-044

WNDB-03-06-006

32. Fill hydraulic oil tank (6) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (6): 140 L (37 US gal) 33. Install O-ring (8).

36. Install the cover (4) assembly with bolts, washers (3) (2 used) and bolt, washer (2). Install the harnesses to all clips of the cover (4) assembly. j : 17 mm

34. Install the cover (7) assembly with bolts, washers (9) (6 used).

m : 50 N·m (5 kgf·m, 37 lbf∙ft) 37. Install cover (5) with bolts, washers (1) (3 used).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf∙ft)

35. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W3-6-1-11

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 WNDB-03-04-001

38. Install rear cover (2). (Refer to W3-4-2.) 39. Install the following parts at the right and left sides. (Refer to W3-4-2.)  Cover (Lower) (4)  Side Cover (1)  Rear Fender (Rear) (3)  Rear Fender (Front) (5)

W3-6-1-12

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

WNDB-03-02-004

3, 4

5, 6

WNDB-03-07-001

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

fNOTE: Total oil amount of fuel tank (6): 235 L (62.1 US gal) 5. Remove clip (3). Disconnect hose (4).

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

W3-7-1-1

SECTION 3 BODY Group 7 Fuel Tank

2 WNDB-03-05-002

6. Remove fuel cooler (1). (Refer to W3-5-1.) 7. Remove bolts, washers (2) (3 used). Remove covers (3, 4). j : 17 mm

W3-7-1-2

WNDB-03-07-005

SECTION 3 BODY Group 7 Fuel Tank

2, 3 4, 5

2, 3

9, 10 14 1

WNDB-03-07-002

11, 12 WNDB-03-07-003

8. Remove rubber plate (1). (Refer to W3-4-2.)

12. Disconnect connector (6).

9. Remove clips (9, 11). Disconnect hoses (10, 12).

13. Remove hose (8) from guides (7) (4 used).

10. Remove bolts, washers (14) (2 used). Remove adapter (13).

14. Remove bolts, washers (2) (3 used) and clips (3) (3 used). j : 17 mm

j : 17 mm 11. Remove bolt, washer (4) and clip (5). j : 17 mm

W3-7-1-3

SECTION 3 BODY Group 7 Fuel Tank

11, 12 3

9, 10

4, 5

6, 7

15. Remove clip (9). Disconnect hose (10). 16. Remove clamp (2) and bolt, washer (8). Disconnect the oil filler port (1) assembly. j : 17 mm 17. Place a container. Remove plug (4). Open valve (5). Drain off fuel completely. j : 17 mm 18. Install a seal tape onto the thread part of plug (4). Close valve (5). Install plug (4).

WNDB-03-07-004

dCAUTION: Fuel tank (3) weight: 180 kg (400 lb) 19. Hold the bottom side of fuel tank (3) by using a hydraulic jack and the wooden blocks. 20. Remove bolts (11) (2 used) and washers (12) (2 used). j : 36 mm 21. Remove bolts (6) (2 used) and washers (7) (2 used). Remove fuel tank (3). j : 30 mm

j : 17 mm m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

W3-7-1-4

SECTION 3 BODY Group 7 Fuel Tank

9, 10 3

7, 8

4, 5

WNDB-03-07-004

Installation

dCAUTION: Fuel tank (3) weight: 180 kg (400 lb) 1. Install fuel tank (3) to rear chassis (11) by using a hydraulic jack and the wooden blocks.

4. Connect the oil filler port (1) assembly with clamp (2) and bolt, washer (6). j : 17 mm

2. Install washers (5) (2 used) and bolts (4) (2 used). j : 30 mm

m : 50 N·m (5 kgf·m) 5. Connect hose (8) with clip (7).

m : 452 N·m (45 kgf·m) 3. Install washers (10) (2 used) and bolts (9) (2 used). j : 36 mm m : 782 N·m (78 kgf·m)

W3-7-1-5

SECTION 3 BODY Group 7 Fuel Tank

1, 2 3, 4

1, 2

8, 9 13

10, 11 16

WNDB-03-07-003

WNDB-03-07-005

6. Pass hose (7) through guides (6) (4 used). 7. Connect connector (5). 8. Install clip (4) with bolt, washer (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Install adapter (12) with bolts, washers (13) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Connect hoses (9, 11) with clips (8, 10). m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 11. Install covers (15, 16) with bolts, washers (14) (3 used).

WNDB-03-05-002

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Install fuel cooler (17). (Refer to W3-5-1.)

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

W3-7-1-6

SECTION 3 BODY Group 7 Fuel Tank

1, 2

3, 4

WNDB-03-07-001

WNDB-03-07-002

14. Connect hose (2) with clip (1). m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 15. Fill fuel to fuel tank (3).

fNOTE: Total oil amount of fuel tank (3): 235 L (62.1 US gal) 16. Install cap (4).

17. Bleed air from the fuel system. (Refer to W1- 4-1.) IMPORTANT: Start the engine and check for any oil leaks. 18. Install rubber plate (5). (Refer to W3-4-2.) 19. Close rear grille (7) and the left and right sides of side covers (6). 7

W3-7-1-7

WNDB-03-02-004

SECTION 3 BODY Group 7 Fuel Tank (Blank)

W3-7-1-8

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

2, 3

M4GB-07-044

Removal

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from hydraulic oil tank (1). dCAUTION: (Refer to W1- 4-1.) 2. Remove bolts, washers (4) (6 used). Remove the cover (2) assembly and O-ring (3) from the upper part of hydraulic oil tank (1). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

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

W3-8-1-1

SECTION 3 BODY Group 8 Pump Device

3 a-

1, 2

WNDB-03-08-015

Secondary Steering Block

5. Remove bolts, washers (1) (2 used) and washers (2) (2 used). Remove and place the bracket (3) assembly outside the work area. j : 17 mm

8. Disconnect hose (5). j : 36 mm 9. Disconnect hoses (8) (2 used). j : 19 mm

fNOTE: Step 5 is only for the machine with the secondary steering attached. 6. Disconnect connector (7).

7. Disconnect hose (4) and hoses (6) (2 used). j : 17 mm

W3-8-1-2

WNDB-03-08-016

SECTION 3 BODY Group 8 Pump Device

10, 11

2 8 9 8

6, 7

WNDB-03-08-017

10. Disconnect hoses (1, 3). j : 36 mm

14. Remove socket bolts (5) (4 used). Remove suction pipe (6). Remove O-ring (7). l : 10 mm

11. Disconnect hose (2). j : 41 mm 12. Disconnect hose (4). j : 27 mm

WNDB-03-08-018

IMPORTANT: Remove nut (10) while securing socket bolt (12) by using a hexagonal wrench in order not to turn them. 15. Remove nuts (10) (2 used) and brackets (11) (2 used).

13. Place a container under the disconnecting part of rubber hose (9). Remove clamps (8) (2 used). Disconnect rubber hose (9).

j : 19 mm

j : 11 mm

W3-8-1-3

SECTION 3 BODY Group 8 Pump Device

3 2

6 7 9

8 5

WNEC-03-08-015

WNEC-03-08-017

dCAUTION: Pump device (1) weight: 94 kg (210 lb) 16. Remove reducer (2) with the bleeder valve attached of pump device (1). Install special tool (ST 0251) (a) and eyebolt (b) (M12, Pitch 1.75 mm (0.07 in)). Attach nylon slings onto eyebolt (b). Hoist and hold pump device (1).

ab-

Special Tool (ST 0251) Eyebolt

19. Remove socket bolts (5) (4 used). Remove spacer (6) from drive unit (9). l : 10 mm 20. Remove O-ring (7) from spacer (6). 21. Remove the adapters with pump device (1) attached if necessary.

j : 41 mm 17. Remove socket bolts (3, 8) (2 used for each). Remove pump device (1) from drive unit (9). l : 10 mm 18. Remove O-ring (4) from pump device (1).

W3-8-1-4

SECTION 3 BODY Group 8 Pump Device

3 2

6 7 9

8 5

WNEC-03-08-015

WNEC-03-08-017

ab-

Special Tool (ST 0251) Eyebolt

6. Install pump device (1) to drive unit (9) with socket bolts (3, 8) (2 used for each).

Installation 1. Install all removed adapters to pump device (1). 2. Install O-ring (7) to spacer (6).

l : 10 mm

3. Install spacer (6) to drive unit (9) with socket bolts (5) (4 used).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

l : 10 mm

7. Remove eyebolt (b) (M12, Pitch 1.75 mm (0.07 in)) and special tool (ST 0251) (a). Install reducer (2) with the bleeder valve attached.

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 41 mm

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

CAUTION: Pump device (1) weight: 94 kg (210 lb) 5. Install special tool (ST 0251) (a) and eyebolt (b) (M12, Pitch 1.75 mm (0.07 in)) to the mounting holes for reducer (2) with the bleeder valve attached of pump device (1). Attach nylon slings onto eyebolt (b). Hoist pump device (1). j : 41 mm

W3-8-1-5

m : 80 N·m (8 kgf·m, 59 lbf·ft)

SECTION 3 BODY Group 8 Pump Device

10, 11

2 8 9 8 B

3 A

6, 7

WNDB-03-08-018

IMPORTANT: Install nut (10) while securing socket bolt (12) by using a hexagonal wrench in order not to turn them. 8. Install brackets (11) (2 used) with nuts (10) (2 used).

View A

WNDB-03-08-017

View B

j : 19 mm 4

m : 90 N·m (9 kgf·m, 66 lbf·ft) a-

9. Install O-ring (7). Temporarily install suction pipe (6), socket bolts (5) (4 used), rubber hose (9), and clamps (8) (2 used). l : 10 mm

3 b-

20˚

j : 36 mm m : 93 N·m (9.3 kgf·m, 69 lbf·ft)

l : 10 mm

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

11. Tighten clamps (8) (2 used).

m : 210 N·m (21 kgf·m, 155 lbf·ft)

j : 11 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

WNDB-03-08-019

WNDB-03-08-020

IMPORTANT: Check the angle to install hose (3). 13. Connect hose (3).

10. Tighten socket bolts (5) (4 used).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

25˚

15. Connect hose (1). j : 36 mm

IMPORTANT: Check the angle to install hose (4). 12. Connect hose (4).

m : 180 N·m (18 kgf·m, 133 lbf·ft)

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

W3-8-1-6

SECTION 3 BODY Group 8 Pump Device

8 A

WNDB-03-08-016 a-

16. Connect hoses (8) (2 used). j : 19 mm

WNDB-03-08-015

1, 2

Secondary Steering Block

View A

View B

m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the angle to install hose (5). 17. Connect hose (5).

4 c

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hose (4). 18. Connect hose (6) (2 used) and hose (4).

WNDB-03-08-021

25˚

WNDB-03-08-022

20. Install the bracket (3) assembly with washers (2) (2 used) and bolts, washers (1) (2 used).

j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 19. Connect connector (7).

15˚

m : 50 N·m (5 kgf·m, 37 lbf·ft)

fNOTE: Step 20 is only for the machine with the secondary steering attached.

W3-8-1-7

SECTION 3 BODY Group 8 Pump Device

2, 3

M4GB-07-044

21. Install the cab assembly. (Refer to W3-1-1.) 22. Fill hydraulic oil tank (1) with hydraulic oil.

fNOTE: Total oil amount of hydraulic oil tank (1): 140 L (37 US gal) 23. Install O-ring (3).

24. Install the cover (2) assembly with bolts, washers (4) (6 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 25. Bleed air from the hydraulic system. (Refer to W14-1.) IMPORTANT: Check the hydraulic oil level. Start the engine. Check for any oil leaks.

W3-8-1-8

SECTION 3 Body Group 8 Pump Device Disassembly of Pump Device

WNDB-03-08-001

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

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

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

W3-8-2-1

SECTION 3 Body Group 8 Pump Device Disassembly of Pump Device

dCAUTION: Pump Device: 94 kg

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

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

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

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

j : 41 mm a

01A

ST 0251

01A 00

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

Eyebolt Wooden Block

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

W3-8-2-2

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

01B

06 03 WNDB-03-08-004

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

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

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

W3-8-2-3

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

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

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

01A

01B a

WNDB-03-08-005 ab-

Feedback Link Pin

cd-

Knock Pin O-Ring

W3-8-2-4

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

SECTION 3 Body Group 8 Pump Device Disassembly of Main Pump

WNDB-03-08-006

0001020304050607080911131415-

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

1718192022232425262728293031-

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

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

W3-8-3-1

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

SECTION 3 Body Group 8 Pump Device Disassembly of Main Pump

dCAUTION: Pump device weight: 74 kg (165 lb)

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

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

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

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

dCAUTION: Front casing (00) weight: 36 kg (80 lb) IMPORTANT: Inner race (02) of the drive shaft (01) assembly cannot be replaced. Do not damage it. IMPORTANT: Do not remove retaining ring (03) of the drive shaft (01) assembly. IMPORTANT: Do not remove the restrictor pin (24) assembly and knock pin (23) of front casing (00) unless necessary. 2. Hoist front casing (00) by using the special tool (ST 0250). Remove socket bolts (33) (8 used) from front casing (00). Remove the front casing (00) assembly and O-ring (17) from the pump casing (18) assembly. l : 12 mm

(00) may stay in the pump casing (18) assembly. 3. Place the front casing (00) assembly onto wooden blocks (120 mm square (4.7 in square) or more) with the rotor (50B) side up.

IMPORTANT: The valve plate (50A) side of rotor (50B) is a sliding surface. Do not damage it. 4. Remove the rotor (50B) assembly from drive shaft (01) while holding retainer (15) by hands. Place the rotor (50B) assembly with the valve plate (50A) side down. 5. Remove retainer (15) and pistons (46) (7 used) from rotor (50B). 6. Remove bushing (14) and springs (13) (7 used) from the rotor (50B) assembly. 7. Remove swash plate (09) from drive shaft (01).

ST 0250

IMPORTANT: Do not remove knock pin (11) of cam plate (49) unless necessary. 8. Remove cam plate (49) from swash plate (09).

fNOTE: When tapping the yoke part with cam plate (49) up, cam plate (49) is raised.

WNEC-03-08-010

W3-8-3-2

SECTION 3 Body Group 8 Pump Device IMPORTANT: Do not remove plugs (38) (3 used) of cradle plate (07). IMPORTANT: Do not remove knock pin (06) of the front casing (00) assembly unless necessary. 9. Remove socket bolts (08) (4 used) from cradle plate (07). Remove cradle plate (07) and O-ring (43) from the front casing (00) assembly. l : 6 mm 10. Remove the drive shaft (01) assembly from front casing (00). IMPORTANT: When removing retaining ring (05), do not damage the seal lip contacting surface of drive shaft (01). 11. Remove retaining rings (05) (2 used) from drive shaft (01). 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. IMPORTANT: When removing drive shaft (01) from roller bearing (04), do not drop drive shaft (01). 12. Place roller bearing (04) remained in drive shaft (01) in a vise. Remove shaft (01) from roller bearing (04) by using bar (a) and a hammer.

13. Remove retaining ring (45) and oil seal (44) from front casing (00). IMPORTANT: Do not remove plug (38) of pump casing (18). IMPORTANT: Do not remove knock pin (20) of valve plate (50A) unless necessary. IMPORTANT: Replace valve plate (50A) and rotor (50B) as an assembly. 14. Remove valve plate (50A) from pump casing (18). 15. Remove servo pistons (22) (3 used), O-ring (41), O-rings (42) (5 used), and spring pins (40) (2 used) from pump casing (18). IMPORTANT: Do not disassemble the feedback link (28) assembly unless necessary. 16. Remove the feedback link (28) assembly from pump casing (18). 17. Remove pressure sensor (48A) from pump casing (18). Remove O-ring (48B) from pressure sensor (48A). j : 27 mm 18. Remove plugs (35A) (2 used) from front casing (00) and pump casing (18). Remove O-rings (35B) (2 used) from plugs (35A) (2 used). l : 5 mm

19. Remove plug (36A) from pump casing (18). Remove O-ring (36B) from plug (36A).

l : 6 mm

W178-02-11-212 a-

Bar

W3-8-3-3

SECTION 3 Body Group 8 Pump Device 20. Remove plug (37A) from pump casing (18). Remove O-ring (37B) from plug (37B). l : 8 mm 21. Remove plugs (63A) (2 used) from pump casing (18). Remove O-rings (63B) (2 used) from plugs (63A) (2 used). j : 41 mm 22. Remove plug (64A) from pump casing (18). Remove O-ring (64B) from plug (64A). j : 50 mm 23. Remove plug (66A) from pump casing (18). Remove O-ring (66B) from plug (66A). j : 36 mm 24. Remove needle bearing (19) from pump casing (18).

W3-8-3-4

SECTION 3 Body Group 8 Pump Device Assembly of Main Pump A

63B

63A

31 28

35A 35B C

37A

37B

45 WNDB-03-08-007

View A

50A

50B

07 WNDB-03-08-008

W3-8-3-5

SECTION 3 Body Group 8 Pump Device View C

42 35B 35A

36A

36B

48A, 48B WNDB-03-08-009 Section B

Detail a

63A

63B 24

66A

66B

WNDB-03-08-010

64A

64B WNDB-03-08-011

0001020304050607080911131415-

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

1718192022232425262728293031-

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

W3-8-3-6

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

SECTION 3 Body Group 8 Pump Device  Assembly of the rotor (50B) assembly 6. Place rotor (50B) with the center projection part up.

Assembly of Main Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install needle bearing (19) to pump casing (18). 2. Place pump casing (18) with the regulator mounting side up. IMPORTANT: Replace valve plate (50A) and rotor (50B) as an assembly. IMPORTANT: Install valve plate (50A) of the rotor (50B) assembly with the slotted hole (opposite side of regulator mounting side) down. 3. Apply grease onto the flat surface of valve plate (50A). Fit valve plate (50A) to knock pin (20). Install valve plate (50A) to pump casing (18). 4. Install servo pistons (22) (3 used) to pump casing (18).

7. Install springs (13) (7 used) to rotor (50B). 8. Install bushing (14) to rotor (50B).

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

rotor (50B) when installing bushing (14). This makes it easy to install drive shaft (01). 9. Install the flat surface of pistons (46) (7 used) to retainer (15). Install the piston (46) assembly to rotor (50B).

IMPORTANT: Do not damage the sliding surface for oil seal (44) of drive shaft (01). 10. Install retaining ring (05) to the groove at the input side of drive shaft (01).

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

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

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

a a-

W176-02-04-016

Parallel Surface

W3-8-3-7

SECTION 3 Body Group 8 Pump Device IMPORTANT: Check the direction to install the inner race of roller bearing (04). 11. Install the inner race of roller bearing (04) to drive shaft (01) by using the special tool (ST 7904) and a hammer. 04 a

W4GB-02-04-004 ab-

Inner Race Rotor Side

16. Apply grease onto the inner surface of oil seal (44). Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

01 b

 Assembly of the front casing (00) assembly 15. Place front casing (00) with the pump casing (18) mounting side down.

such as goggles, helmets, etc in order to prevent personal injury. 17. Install oil seal (44) to front casing (00) by using the special tool (ST 7860) and a hammer. 18. Install retaining ring (45) to front casing (00).

Input Side

19. Turn over front casing (00). Place it on wooden blocks (120 mm square (4.7 in square) or more).

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

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

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

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

22. Fit the knock pin (06) position. Install cradle plate (07) to front casing (00) with socket bolts (08) (4 used). l : 6 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

23. Install O-ring (17) to front casing (00).

WNEC-03-08-009 d-

Stamped Mark

13. Install the inner ring plate of roller bearing (04) to drive shaft (01) with stamped mark (d) facing to rotor side (b). 14. Install another retaining ring (05) to drive shaft (01).

W3-8-3-8

SECTION 3 Body Group 8 Pump Device IMPORTANT: Check the direction to install the restrictor pin (24) assembly. 24. When restrictor pin (24) has been removed, install backup rings (25) (2 used) and O-rings (26) (2 used) to restrictor pin (24). Install the restrictor pin (24) assembly to front casing (00).

IMPORTANT: Take care not to drop piston (46) from the rotor (50B) assembly. 27. Install the rotor (50B) assembly to drive shaft (01). The front casing (00) assembly weight: dCAUTION: 36 kg (80 lb)

28. Raise the front casing (00) assembly almost vertically and hold it.

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

The front casing (00) assembly weight: dCAUTION: 36 kg (80 lb) c

26 ab-

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

W4GB-02-04-005

Orifice

25. Apply grease onto the knock pin (11) hole side of cam plate (49). Fit the knock pin (11) position. Install cam plate (49) to swash plate (09).

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

IMPORTANT: Install swash plate (09) with the mounting part of link pin (29) in swash plate (09) up (facing to the regulator mounting side). 26. Apply grease onto the cylindrical surface of swash plate (09). Fit the cylindrical surface of cradle plate (07) to that of swash plate (09). Install swash plate (09) to drive shaft (01).

ST 0250

WNEC-03-08-010

W176-02-04-018 d-

Mounting Part of Link Pin (29)

W3-8-3-9

SECTION 3 Body Group 8 Pump Device IMPORTANT: Install the front casing (00) assembly so that link pin (29) can be inserted into the mounting concave part for the feedback link (28) assembly in swash plate (09). 30. Install the front casing (00) assembly to pump casing (18) with socket bolts (33) (8 used) while fitting knock pin (23) and link pin (29).

35. Install O-ring (37B) to plug (37A). Install plug (37A) to pump casing (18). l : 8 mm m : 50 N·m (5.0 kgf·m, 37 lbf·ft) 36. Install O-ring (66B) to plug (66A). Install plug (66A) to pump casing (18).

l : 12 mm

j : 36 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 240 N·m (24 kgf·m, 175 lbf·ft)

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

37. Install O-ring (64B) to plug (64A). Install plug (64A) to pump casing (18). j : 50 mm

m : 550 N·m (55 kgf·m, 410 lbf·ft) 38. Install O-rings (63B) (2 used) to plugs (63A) (2 used). Install plugs (63A) (2 used) to pump casing (18). j : 41 mm W176-02-04-014

m : 450 N·m (45 kgf·m, 330 lbf·ft) 32. Install O-ring (48B) to pressure sensor (48A). Install pressure sensor (48A) to pump casing (18). j : 27 mm m : 100 N·m (10 kgf·m, 74 lbf·ft) 33. Install O-rings (35B) (2 used) to plugs (35A) (2 used). Install plugs (35A) (2 used) to pump casing (18) and front casing (00). l : 5 mm m : 15 N·m (1.5 kgf·m, 11 lbf·ft) 34. Install O-ring (36B) to plug (36A). Install plug (36A) to pump casing (18). l : 6 mm m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

W3-8-3-10

SECTION 3 Body Group 8 Pump Device Disassembly of Regulator

WNDB-03-08-012

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

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

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

W3-8-4-1

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

SECTION 3 Body Group 8 Pump Device Disassembly of Regulator IMPORTANT: As the setting changes, do not disassemble the adjusting screw part (11, 12, 14, 15, 16, 23, 24, 25, 26, 27, 33, 34) of the regulator. If they are disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, T/M.) 1. Remove socket bolts (39) (4 used) from cover (35). Remove the cover (35) assembly from casing (00).

IMPORTANT: Replace spool (18A) and sleeve (18B) as an assembly. 8. Push the end surface of spool (18A) from the hole on casing (00) by using a round bar. Remove the cylinder (20) assembly, spring (31), sleeve (18B), and spool (18A) from casing (00). 9. Remove piston (21) and O-ring (13) from cylinder (20). 10. Remove bleeder valve (132) from reducer (131).

l : 6 mm

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

j : 10 mm 11. Remove reducer (131) from casing (00). Remove O-ring (137) from reducer (131).

3. Remove socket bolts (39) (4 used) from cover (37). Remove the cover (37) assembly from casing (00). l : 6 mm

fNOTE: The stopper (24) assembly is removed with cover (37) together. 4. Remove piston (21) and O-ring (13) from the stopper (24) assembly. 5. Remove springs (29, 30) from casing (00). 6. Push the end surface of spool (03) from the hole on casing (00) by using a round bar. Remove the cylinder (05) assembly, sleeve (02), and spool (03) from casing (00). 7. Remove piston (06), O-ring (07), backup ring (08), and O-ring (09) from cylinder (05).

W3-8-4-2

j : 41 mm

SECTION 3 Body Group 8 Pump Device Assembly of Regulator 27

23 26

24 25 13

18B 18A

07 06

03 02

00 31

14 12 15

137

WNDB-03-08-013

08 39

29 131 132

WNDB-03-08-014

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

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

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

W3-8-4-3

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

SECTION 3 Body Group 8 Pump Device Assembly of Regulator IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The sleeve holes (2 places) of casing (00) are the same bores. The shapes of various parts are very similar. Assemble them while checking the illustration in order not to confuse. IMPORTANT: Check the direction to install sleeve (18B) and spool (18A). IMPORTANT: Replace spool (18A) and sleeve (18B) as an assembly. 1. Install spool (18A) to sleeve (18B). Install the sleeve (18B) assembly to casing (00) by using a round bar. 2. Install O-ring (13), piston (21), and spring (31) to cylinder (20).

8. Install O-ring (13) and springs (29, 30) to the stopper (11) assembly which has been installed to the cover (35) assembly. Install the cover (35) assembly to casing (00) with socket bolts (39) (4 used). l : 6 mm m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft) 9. Install O-ring (137) to reducer (131). Install reducer (131) to casing (00). j : 41 mm m : 80 N·m (0.8 kgf·m, 59 lbf·ft) 10. Install bleeder valve (132) to reducer (131). j : 10 mm

3. Install the cylinder (20) assembly to casing (00). IMPORTANT: Check the direction to install sleeve (02) and spool (03). 4. Install spool (03) to sleeve (02). Install the sleeve (02) assembly to casing (00) by using a round bar. 5. Install O-rings (07, 09), backup ring (08), and piston (06) to cylinder (05). 6. Install the cylinder (05) assembly to casing (00). 7. Install O-ring (13) and piston (21) to the stopper (24) assembly which has been installed to the cover (37) assembly. Install the cover (37) assembly to casing (00) with socket bolts (39) (4 used). l : 6 mm m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft)

W3-8-4-4

m : 7 to 9 N·m (0.7 to 0.9 kgf·m, 5.2 to 6.6 lbf·ft)

SECTION 3 BODY Group 8 Pump Device Structure of Pilot Pump

WNEC-03-08-005

W3-8-5-1

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

No.

Part Name

Q’ty

Flange

Oil Seal

Retaining Ring

Seal

Cover

Backup Ring

Key

O-Ring

13 14 15

Gear Gear Washer

1 1 4

Bushing

28 29 41

Knock Pin Bolt Housing

2 4 1

Wrench Size mm

N·m

Tightening Torque kgf·m lbf·ft

Remark Apply grease onto the lip when assembling. Apply grease onto the lip when assembling. Apply grease onto the lip when assembling. Apply grease onto the lip when assembling.

Apply hydraulic oil when assembling. Apply hydraulic oil when assembling. j : 17

39 to 44

W3-8-5-2

4 to 4.5

28.5 to 32.5

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

4, 5

3 2

2 WNEC-04-08-003

WNDB-05-02-001

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

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. dCAUTION: (Refer to W1-4-1.) Release any pressure in the front dCAUTION: hydraulic circuit. (Refer to W1-5-1.) 2. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm 3. Disconnect hoses (3) (2 used). j : 36 mm

W3-9-1-1

j : 19 mm

SECTION 3 BODY Group 9 Control Valve 1

5. Disconnect hoses (3) (3 used). j : 19 mm 6. Disconnect hose (1). j : 41 mm 7. Disconnect hoses (4) (2 used). j : 41 mm 8. Disconnect pipe (2). j : 36 mm

W3-9-1-2

WNDB-03-09-001

SECTION 3 BODY Group 9 Control Valve

WNDB-03-09-002

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

W3-9-1-3

SECTION 3 BODY Group 9 Control Valve

12. Disconnect hoses (1) (3 used). j : 19 mm

W3-9-1-4

WNDB-03-09-003

SECTION 3 BODY Group 9 Control Valve View A 1

2 3

2 4 WNDB-03-09-004

WNDB-03-09-005 a-

dCAUTION: Control valve (3) weight: 41 kg (89 lb)

Eyebolt Mounting Hole

15. Remove the adapters with control valve (3) attached if necessary.

13. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach the nylon slings onto the eyebolts (2 used). Hoist and hold control valve (3). 14. Remove socket bolts (1) (3 used), washers (2) (6 used), and nuts (4) (3 used). Remove control valve (3). l : 10 mm

W3-9-1-5

SECTION 3 BODY Group 9 Control Valve View A 1

2 3

2 4 WNDB-03-09-004

WNDB-03-09-005 a-

Eyebolt Mounting Hole

3. Install control valve (3) with nuts (4) (3 used), washers (2) (6 used), and socket bolts (1) (3 used).

Installation 1. Install all removed adapters to control valve (3).

dCAUTION: Control valve (3) weight: 41 kg (89 lb)

2. Install eyebolts (M10, Pitch 1.5 mm (0.06 in)) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach the nylon slings onto the eyebolts (2 used). Hoist control valve (3).

W3-9-1-6

l : 10 mm m : 133 N·m (13.3 kgf·m, 98 lbf·ft)

SECTION 3 BODY Group 9 Control Valve

4. Connect hoses (1) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-9-1-7

WNDB-03-09-003

SECTION 3 BODY Group 9 Control Valve A

4, 5

WNDB-05-02-001

WNDB-03-09-002

View A 2

IMPORTANT: Check the angle to install hose (2). 5. Connect hose (2).

j : 41 mm m : 210 N·m (21 kgf·m, 115 lbf·ft) 6. Connect hose (1). j : 27 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 7. Temporarily install pipe (3), clamp (5), and bolt, washer (4). 8. Tighten pipe (3).

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 9. Tighten bolt, washer (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-9-1-8

75 °

WNDB-03-09-006

SECTION 3 BODY Group 9 Control Valve A

5, 6

WNDB-05-02-001

WNDB-03-09-001

View A

IMPORTANT: Check the angle to install hose (1). 10. Connect hose (1).

1 a

j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 11. Connect hoses (4) (2 used). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 12. Connect hoses (3) (3 used). j : 19 mm a-

85 °

m : 30 N·m (3 kgf·m, 22 lbf·ft) 13. Temporarily install pipe (2), clamp (6), and bolt, washer (5). 14. Tighten pipe (2). 15. Tighten bolt, washer (5). 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)

W3-9-1-9

WNDB-03-09-006

SECTION 3 BODY Group 9 Control Valve 3 1 2

2 WNEC-04-08-003

WNDB-05-02-001

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

16. Connect hoses (3) (2 used). j : 36 mm

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

m : 180 N·m (18 kgf·m, 133 lbf·ft)

j : 17 mm

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

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.

W3-9-1-10

SECTION 3 Body Group 9 Control Valve Disassembly of Control Valve

f g h

j b

WNDB-03-09-007 12345678910111213-

Main Relief Valve Poppet Spring (2 Used) O-Ring (3 Used) Plug Plug Plug Poppet Poppet Plug Socket Bolt (9 Used) O-Ring (5 Used) Plug

14151617181920212223242526-

Spring Poppet Poppet Spring O-Ring Backup Ring Spring Seat (4 Used) Spring Bolt Socket Bolt (2 Used) Pilot Housing Pilot Housing Bolt

27282930313233343536373839-

Spring Pilot Housing Relief Valve Plug (2 Used) Housing O-Ring (2 Used) Spool Relief Valve Relief Valve Spool Plug Pilot Housing (2 Used) O-Ring

4041424344454647484950-

O-Ring End Plate Socket Bolt (4 Used) Poppet Spring Plug *O-Ring (3 Used) *O-Ring *O-Ring *O-Ring (3 Used) *O-Ring

ghi-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) Pump Control Valve Overload Relief Valve (Bucket: Rod Side)

fNOTE: As for the item with mark*, refer to W3-9-2-5 to W3-9-2-7.

abc-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit)

def-

Load Check Valve (Bucket Circuit) Bucket Flow Rate Control Valve Low-Pressure Relief Valve

W3-9-2-1

kl-

SECTION 3 Body Group 9 Control Valve Disassembly of Control Valve 1. Remove plug (10) from housing (31). Remove O-ring (48) from plug (10).

6. Remove socket bolts (23) (2 used) from pilot housing (24). Remove pilot housing (24) from pilot housing (28). l : 8 mm

l : 17 mm  Disassembly of Low-Pressure Relief Valve (f ) 2. Remove plug (13) from housing (31). Remove spring (14) and poppet (15) from housing (31). Remove O-ring (4) from plug (13). j : 36 mm  Disassembly of Overload Relief Valve (Bucket: Rod Side) (l) IMPORTANT: Do not disassemble the overload relief valve. If it has been disassembled, pressure should be adjusted. (Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, S/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 3. Remove relief valve (29) from housing (31). Remove O-ring (50) from relief valve (29).

7. Remove O-ring (12) from pilot housing (24). 8. Put the matching marks on the spools (33, 36) assemblies and housing (31). Remove the spools (33, 36) assemblies from housing (31).  Disassembly of Bucket Spool (h) 9. Secure the spool (36) assembly in a vise by using wooden pieces as illustrated. Remove bolt (26), spring seats (20) (2 used), and spring (27) from spool (36). j : 19 mm

j : 32 mm 4. Remove socket bolts (11) (6 used) from pilot housings (38) (2 used) and pilot housing (25). Remove pilot housings (38) (2 used) and pilot housing (25) from housing (31). l : 8 mm W4GB-02-05-002

5. Remove O-rings (12) (3 used) from pilot housings (38) (2 used) and pilot housing (25).

W3-9-2-2

SECTION 3 Body Group 9 Control Valve  Disassembly of Lift Arm Spool (g) 10. Secure the spool (33) assembly in a vise by using wooden pieces as illustrated. Remove bolt (22), O-ring (32), spring seats (20) (2 used), and spring (21) from spool (33).

 Disassembly of Pump Control Valve (k) 15. Remove plug (45), spring (44), and poppet (43) from end plate (41). Remove O-ring (49) from plug (45). l : 12 mm  Disassembly of Overload Relief Valves (Lift Arm: Bottom Side) (i) and Overload Relief Valves (Bucket: Bottom Side) (j) IMPORTANT: Do not disassemble the overload relief valve. 16. Remove relief valves (34, 35) from housing (31). Remove O-rings (49) (2 used) from relief valves (34, 35).

j : 19 mm

j : 27 mm

W4GB-02-05-002

11. Remove plug (37) from spool (33). Remove O-ring (32) from plug (37). j : 8 mm  Disassembly of Make-Up Valves (Lift Arm: Rod Side) (b) 12. Remove socket bolts (11) (3 used) from pilot housing (28). Remove pilot housing (28) from housing (31).

 Disassembly of Main Relief Valve (a) IMPORTANT: Do not disassemble the main relief valve. If it has been disassembled, pressure should be adjusted. Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, S/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 17. Remove main relief valve (1) from housing (31). Remove O-ring (47) from main relief valve (1).

l : 8 mm 13. Remove backup ring (19) and O-rings (12, 18) from pilot housing (28). 14. Remove spring (17) and poppet (16) from housing (31).

W3-9-2-3

j : 27 mm

SECTION 3 Body Group 9 Control Valve  Disassembly of Load Check Valve (Bucket Circuit) (d) and Bucket Flow Rate Control Valve (e) 18. Remove plug (7) from housing (31). Remove spring (3) and poppets (8, 9) from housing (31) by using a magnet. Remove O-ring (4) from plug (7). j : 36 mm  Disassembly of Load Check Valve (Lift Arm Circuit) (c) 19. Remove plug (5) from housing (31). Remove spring (3) and poppet (2) from housing (31) by using a magnet. Remove O-ring (4) from plug (5). j : 36 mm 20. Remove socket bolts (42) (4 used) from end plate (41). Remove end plate (41) from housing (31). Remove O-rings (39, 40) from end plate (41). l : 10 mm 21. Remove plugs (30) (2 used) and plug (6) from housing (31). Remove O-rings (46) (3 used) from plugs (30) (2 used) and plug (6). l : 10 mm

W3-9-2-4

SECTION 3 Body Group 9 Control Valve Assembly of Control Valve 11

6, 46

W3-9-2-5

WNDB-03-09-008

SECTION 3 Body Group 9 Control Valve

WNDB-03-09-009

Section A-A

19 16

5 2

WNDB-03-09-010

Section B-B c

3 4

b g

37 24

28 20 32

W3-9-2-6

49 34 32

WNDB-03-09-011

SECTION 3 Body Group 9 Control Valve

Section C-C 8

50 e

h j

20 36

Section D-D

WNDB-03-09-012

Section E-E 40

WNDB-03-09-013

41 WNDB-03-09-014

12345678910111213-

Main Relief Valve Poppet Spring (2 Used) O-Ring (3 Used) Plug Plug Plug Poppet Poppet Plug Socket Bolt (9 Used) O-Ring (5 Used) Plug

14151617181920212223242526-

Spring Poppet Poppet Spring O-Ring Backup Ring Spring Seat (4 Used) Spring Bolt Socket Bolt (2 Used) Pilot Housing Pilot Housing Bolt

27282930313233343536373839-

Spring Pilot Housing Relief Valve Plug (2 Used) Housing O-Ring (2 Used) Spool Relief Valve Relief Valve Spool Plug Pilot Housing (2 Used) O-Ring

4041424344454647484950-

O-Ring End Plate Socket Bolt (4 Used) Poppet Spring Plug O-Ring (3 Used) O-Ring O-Ring O-Ring (3 Used) O-Ring

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit)

Load Check Valve (Bucket Circuit) Bucket Flow Rate Control Valve Low-Pressure Relief Valve

ghi-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side)

Overload Relief Valve (Bucket: Bottom Side) Pump Control Valve Overload Relief Valve (Bucket: Rod Side)

ef-

W3-9-2-7

kl-

SECTION 3 Body Group 9 Control Valve Assembly of Control Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install O-rings (46) (3 used) to plugs (30) (2 used) and plug (6). Install plugs (30) (2 used) and plug (6) to housing (31). l : 10 mm m : 120 to 140 N·m (12 to 14 kgf·m, 89 to 103 lbf·ft)

 Assembly of Main Relief Valve (a) IMPORTANT: If it has been disassembled the main relief valve, pressure should be adjusted. Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, S/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 5. Install O-ring (47) to main relief valve (1). Install main relief valve (1) to housing (31). j : 27 mm

2. Install O-rings (39, 40) to end plate (41). Install end plate (41) to housing (31) with socket bolts (42) (4 used). l : 10 mm m : 90 to 95 N·m (9 to 9.5 kgf·m, 66 to 70 lbf·ft)

m : 180 to 210 N·m (18 to 21 kgf·m, 133 to 155 lbf·ft)  Assembly of Pump Control Valve (k) 6. Install poppet (43) and spring (44) to end plate (41). Install O-ring (49) to plug (45). Install plug (45) to end plate (41).

 Assembly of Load Check Valve (Lift Arm Circuit) (c) 3. Install poppet (2) and spring (3) to housing (31). Install O-ring (4) to plug (5). Install plug (5) to housing (31).

l : 12 mm m : 180 to 210 N·m (18 to 21 kgf·m, 133 to 155 lbf·ft)

j : 36 mm m : 280 to 310 N·m (28 to 31 kgf·m, 205 to 230 lbf·ft)  Assembly of Load Check Valve (Bucket Circuit) (d) and Bucket Flow Rate Control Valve (e) 4. Install poppets (9, 8) and spring (3) to housing (31). Install O-ring (4) to plug (7). Install plug (7) to housing (31).

 Assembly of Make-Up Valve (Lift Arm: Rod Side) (b) 7. Install poppet (16) and spring (17) to housing (31). 8. Install O-rings (18, 12) and backup ring (19) to pilot housing (28). Install pilot housing (28) to housing (31) with socket bolts (11) (3 used).

j : 36 mm m : 280 to 310 N·m (28 to 31 kgf·m, 205 to 230 lbf·ft)

W3-9-2-8

l : 8 mm m : 50 to 55 N·m (5 to 5.5 kgf·m, 37 to 41 lbf·ft)

SECTION 3 Body Group 9 Control Valve  Assembly of Bucket Spool (h) 9. Secure spool (36) in a vise by using wooden pieces as illustrated. Install spring seats (20) (2 used) and spring (27) to spool (36) with bolt (26). j : 19 mm

12. Fit the matching marks made when disassembling and install the spools (33, 36) assemblies to housing (31). 13. Install O-ring (12) to pilot housing (24). Install pilot housing (24) to pilot housing (28) with socket bolts (23) (2 used).

m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

l : 8 mm m : 50 to 55 N·m (5 to 5.5 kgf·m, 37 to 41 lbf·ft) 14. Install O-ring (12) to pilot housing (25). Install pilot housing (25) to housing (31) with socket bolts (11) (2 used). l : 8 mm m : 50 to 55 N·m (5 to 5.5 kgf·m, 37 to 41 lbf·ft)

W4GB-02-05-002

 Assembly of Lift Arm Spool (g) 10. Secure spool (33) in a vise by using wooden pieces as illustrated. Install spring seats (20) (2 used), spring (21), and O-ring (32) to spool (33) with bolt (22). j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

15. Install O-rings (12) (2 used) to pilot housings (38) (2 used). Install pilot housings (38) (2 used) to housing (31) with socket bolts (11) (4 used). l : 8 mm m : 50 to 55 N·m (5 to 5.5 kgf·m, 37 to 41 lbf·ft)  Assembly of Overload Relief Valve (Lift Arm: Bottom Side) (i) and Overload Relief Valve (Bucket: Bottom Side) (j) 16. Install O-rings (49) (2 used) to relief valves (34, 35). Install relief valves (34, 35) to housing (31). j : 27 mm m : 240 to 270 N·m (24 to 27 kgf·m, 175 to 200 lbf·ft)

W4GB-02-05-002

11. Install O-ring (32) to plug (37). Install plug (37) to spool (33). j : 8 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

W3-9-2-9

SECTION 3 Body Group 9 Control Valve  Assembly of Overload Relief Valve (Bucket: Rod Side) (l) IMPORTANT: If it has been disassembled the overload relief valve, pressure should be adjusted. Refer to TROUBLESHOOTING / Operational Performance Test in the separated volume, S/M.) IMPORTANT: Attach a spanner onto the hexagonal part of the relief valve case. 17. Install O-ring (50) to relief valve (29). Install relief valve (29) to housing (31). j : 32 mm m : 85 to 90 N·m (8.5 to 9 kgf·m, 63 to 66 lbf·ft)  Assembly of Low-Pressure Relief Valve (f ) 18. Install poppet (15) and spring (14) to housing (31). Install O-ring (4) to plug (13). Install plug (13) to housing (31). j : 36 mm m : 180 to 210 N·m (18 to 21 kgf·m, 133 to 155 lbf·ft) 19. Install O-ring (48) to plug (10). Install plug (10) to housing (31). l : 17 mm m : 180 to 210 N·m (18 to 21 kgf·m, 133 to 155 lbf·ft)

W3-9-2-10

SECTION 3 BODY Group 9 Control Valve Removal and Installation of Control Valve (Parallel Link) A

WNDB-03-09-101 WNDB-03-17-101

4, 5

Detail A

4, 5

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

WNDB-03-09-102

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.)

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

2. Remove bolts, washers (1) (4 used). Remove cover (2). j : 17 mm 3. Disconnect hoses (3) (2 used). j : 36 mm

W3-9-3-1

j : 19 mm

SECTION 3 BODY Group 9 Control Valve 1

5. Disconnect hoses (5) (5 used).

WNDB-03-09-103

8. Disconnect hoses (1) (3 used).

j : 19 mm

j : 41 mm

6. Disconnect hose (6).

9. Disconnect hose (2).

j : 17 mm

j : 36 mm

7. Disconnect pipe (4).

10. Disconnect hose (3).

j : 36 mm

j : 27 mm

W3-9-3-2

SECTION 3 BODY Group 9 Control Valve

5 View A A

WNDB-03-09-104

11. Disconnect pipe (5).

15. Disconnect hose (4).

j : 36 mm

j : 27 mm

12. Disconnect hose (1).

16. Disconnect hoses (7) (4 used).

j : 27 mm

j : 19 mm

13. Disconnect hose (2).

17. Disconnect hose (6).

j : 41 mm

j : 17 mm

14. Disconnect hose (3). j : 36 mm

W3-9-3-3

WNDB-03-09-105

SECTION 3 BODY Group 9 Control Valve A

View A

2 3 a

2 4 WNDB-03-09-107

WNDB-03-09-106 a-

dCAUTION: Control valve (3) weight: 71 kg (160 lb)

Eyebolt Mounting Hole

20. Remove the adapters with control valve (3) attached if necessary.

18. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach nylon slings onto the eyebolts (2 used). Hoist and hold control valve (3).

19. Remove socket bolts (1) (3 used), washers (2) (6 used), and nuts (4) (3 used). Remove control valve (3) from bracket (5). l : 10 mm

W3-9-3-4

SECTION 3 BODY Group 9 Control Valve A

View A

2 3 a

2 4 WNDB-03-09-107

WNDB-03-09-106 a-

Eyebolt Mounting Hole

3. Install control valve (3) to bracket (5) with nuts (4) (3 used), washers (2) (6 used), and socket bolts (1) (3 used).

Installation 1. Install all removed adapters to control valve (3).

dCAUTION: Control valve (3) weight: 71 kg (160 lb) 2. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to eyebolt mounting holes (a) (2 places) of control valve (3). Attach nylon slings onto the eyebolts (2 used). Hoist control valve (3).

l : 10 mm m : 133 N·m (13.3 kgf·m, 98 lbf·ft)

W3-9-3-5

SECTION 3 BODY Group 9 Control Valve B

5 View A A

WNDB-03-09-104

WNDB-03-09-105

2 a

4. Connect hose (1).

View B

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 5. Connect hoses (2) (4 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 6. Connect hose (5). j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 7. Connect hose (4). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hose (3). 8. Connect hose (3). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-9-3-6

15°

WNDB-03-09-110

SECTION 3 BODY Group 9 Control Valve

2 A

WNDB-03-09-101 WNDB-03-09-104

3, 4

9. Connect hose (1). j : 27 mm

Detail A

m : 80 N·m (8 kgf·m, 59 lbf·ft) 10. Temporarily install pipe (2), clamp (4), and bolt, washer (3). 2

11. Tighten pipe (2). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 12. Tighten bolt, washer (3).

WNDB-03-09-102

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

W3-9-3-7

SECTION 3 BODY Group 9 Control Valve A

3 View A a

5 4

5°

WNDB-03-09-111

WNDB-03-09-103

View B

13. Connect hose (3). j : 27 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 14. Connect hose (2).

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) IMPORTANT: Check the angle to install hoses (1, 4). 15. Connect hoses (1, 4). b-

j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 16. Connect hose (5). j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-9-3-8

15°

WNDB-03-09-112

SECTION 3 BODY Group 9 Control Valve

WNDB-03-09-101

WNDB-03-09-103

17. Temporarily install pipe (1), clamp (3), and bolt, washer (2).

Detail A

2, 3

18. Tighten pipe (1). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 19. Tighten bolt, washer (2).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) WNDB-03-09-102

W3-9-3-9

SECTION 3 BODY Group 9 Control Valve

1 2

20. Connect hose (2). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 21. Connect hoses (1) (5 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-9-3-10

WNDB-03-09-103

SECTION 3 BODY Group 9 Control Valve

3 A

Detail A

WNDB-03-09-102

WNDB-03-09-101

22. Connect hoses (3) (2 used). 1

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 23. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 24. 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. 25. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.)

26. Install cover (2) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) WNDB-03-17-101

W3-9-3-11

SECTION 3 BODY Group 9 Control Valve (Blank)

W3-9-3-12

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve (Parallel Link)

WNDB-03-09-116

W3-9-4-1

SECTION 3 BODY Group 9 Control Valve

75, 75A

D E D F D G

68 15

WNDB-03-09-117

W3-9-4-2

SECTION 3 BODY Group 9 Control Valve 75

75A

50A, 50B

Section A

77A 77

50C

47 50

Section B

WNDF-03-09-009

34 31

90 91

23 25

b f

27 14

19 07 28

Section C

53 53A

39A 39

WNDF-03-09-013

22 24

09 29A

g i

07 93

53A

W3-9-4-3

38A

WNDF-03-09-014

SECTION 3 BODY Group 9 Control Valve

Section D

WNDF-03-09-010 l

Section E 36

09 36A

76A

22 24 23

25 21 76

76A

36A 36

74A

74A 74 10 07

07 k

17 WNDF-03-09-012

Section F 30

09 30A

76A

22 24 23

25 21 76

76A

30A 30

74A

74A 74 10 07

07 o

17 WNDF-03-09-012

W3-9-4-4

SECTION 3 BODY Group 9 Control Valve

Section G

61 61A

58 WNDB-03-09-118

0106070809101112141516171921222324-

Housing Bolt (3 Used) Spring Seat (8 Used) Spring (3 Used) O-Ring (9 Used) Pilot Housing (3 Used) Bolt Spring Pilot Housing Socket Bolt (17 Used) Socket Bolt (2 Used) Pilot Housing (4 Used) Pilot Housing Poppet (3 Used) Poppet (3 Used) Spring (4 Used) Plug (3 Used)

25- O-Ring (5 Used) 27- Plug 28- O-Ring (2 Used) 29- Relief Valve 29A- O-Ring 30- Relief Valve (2 Used) 30A- O-Ring (2 Used) 31- Poppet 32- Spring 33- O-Ring 34- Backup Ring 36- Relief Valve (2 Used) 36A- O-Ring (2 Used) 38- Relief Valve Assembly 38A- O-Ring 39- Relief Valve Assembly 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) 55- Housing (2 Used) 58- End Plate 59- Poppet 60- Spring 61- Plug 61A- O-Ring 65- O-Ring (3 Used) 66- O-Ring (3 Used)

68- Socket Bolt (4 Used) 74- Plug (4 Used) 74A- O-Ring (4 Used) 75- Plug (2 Used) 75A- O-Ring (2 Used) 76- Plug (4 Used) 76A- O-Ring (4 Used) 77- Plug 77A- O-Ring 90- Plug 91- Poppet 92- Spool 93- Spool 94- Spool (2 Used)

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit) Load Check Valve (Bucket Circuit) and Check Valve (Bucket Flow Rate Control Valve) Low-Pressure Relief Valve

fgh-

cd-

ijk-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side) Overload Relief Valve (Bucket: Bottom Side) Overload Relief Valve (Bucket: Rod Side) Quick Coupler Spool

Check Valve (Quick Coupler Flow Rate Control Valve) and Load Check Valve (Quick Coupler) m- Overload Relief Valve (Quick Coupler: Bottom Side) n- Overload Relief Valve (Quick Coupler: Rod Side) o- Auxiliary Spool

W3-9-4-5

qr-

Check Valve (Auxiliary Flow Rate Control Valve) and Load Check Valve (Auxiliary Circuit) Overload Relief Valve (Auxiliary Circuit) Overload Relief Valve (Auxiliary Circuit)

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve IMPORTANT: The shapes of the control valve parts are similar and the directions to install the control valve parts have been determined. Put the marks for the mounting directions and positions of the parts. 1. Remove plug (77) from housing (01). Remove O-ring (77A) from plug (77). l : 17 mm  Disassembly of Low-Pressure Relief Valve (e) 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  Removal of Overload Relief Valve (Bucket: Rod Side) (j) 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: Place a spanner onto hexagonal part (z) of relief valve case (y).

Relief Valve Case

 Removal of Overload Relief Valve (Quick Coupler: Bottom Side) (m) and Overload Relief Valve (Quick Coupler: Rod Side) (n) 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: Place a spanner onto the hexagonal part (z) of the relief valve case (y). 4. Remove relief valves (36) (2 used) from housing (55). Remove O-rings (36A) (2 used) from relief valves (36) (2 used). j : 32 mm  Removal of Overload Relief Valves (Auxiliary Circuit) (q, r) 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: Place a spanner onto hexagonal part (z) of relief valve case (y). 5. Remove relief valves (30) (2 used) from housing (55). Remove O-rings (30A) (2 used) from relief valves (30) (2 used). j : 32 mm

Hexagonal Part WNDF-03-09-021

3. Remove relief valve (29) from housing (01). Remove O-ring (29A) from relief valve (29). j : 32 mm

W3-9-4-6

SECTION 3 BODY Group 9 Control Valve 6. Remove plugs (74) (4 used) from pilot housings (10, 17) (2 used for each) of housings (55) (2 used). Remove O-rings (74A) (4 used) from plugs (74) (4 used).

 Disassembly of Bucket Spool (g) 13. Secure spool (93) in a vise by using wooden pieces as illustrated. Remove bolt (06), spring seats (07) (2 used), and spring (08) from spool (93).

l : 8 mm

j : 19 mm

7. Remove socket bolts (15) (14 used) from pilot housings (17) (4 used) and pilot housings (10) (3 used). Remove pilot housings (17) (4 used) and pilot housings (10) (3 used) from housing (01) and housings (55) (2 used). l : 8 mm 8. Remove O-rings (09) (7 used) from the pilot housings (17) (4 used) and pilot housings (10) (3 used). W4GB-02-05-002

9. Remove socket bolts (16) (2 used) from pilot housing (14). Remove pilot housing (14) from pilot housing (19). l : 8 mm 10. Remove O-ring (09) from pilot housing (14). IMPORTANT: Spools (92, 93) and spools (94) (2 used) have been selected to match the port holes of housing (01) and housings (55) (2 used). Replace spools (92, 93) and spools (94) (2 used) and housing (01) and housings (55) (2 used) as an assembly. IMPORTANT: Slowly remove the spool (92, 93) assemblies and spool (94) assemblies (2 used) by turning them. 11. Put matching marks on the spool (92, 93) assemblies and housing (01). Remove the spool (92, 93) assemblies from housing (01). 12. Put matching marks on the spool (94) assemblies (2 used) and housings (55) (2 used). Remove the spool (94) assemblies (2 used) from housings (55) (2 used).

 Disassembly of Lift Arm Spool (f ) 14. Secure spool (92) in a vise by using wooden pieces as step 13. Remove bolt (11), spring seats (07) (2 used), and spring (12) from spool (92). Remove O-ring (28) from bolt (11). j : 19 mm 15. Remove plug (27) from spool (92). Remove O-ring (28) from plug (27). l : 8 mm  Disassembly of Quick Coupler Spool (k) 16. Secure spool (94) in a vise by using wooden pieces as step 13. Remove bolt (06), spring seats (07) (2 used), and spring (08) from spool (94). j : 19 mm  Disassembly of Auxiliary Spool (o) 17. Secure spool (94) in a vise by using wooden pieces as step 13. Remove bolt (06), spring seats (07) (2 used), and spring (08) from spool (94). j : 19 mm

W3-9-4-7

SECTION 3 BODY Group 9 Control Valve Disassembly of Make-Up Valve (Lift Arm: Rod Side) (b) 18. Remove socket bolts (15) (3 used) from pilot housing (19). Remove pilot housing (19) from housing (01). l : 8 mm 19. Remove backup ring (34) and O-rings (09, 33) from pilot housing (19).

 Removal 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: Place a spanner onto hexagonal part (v) of relief valve case (w).

20. Remove spring (32) and poppet (31) from housing (01).

 Disassembly of Overload Relief Valve (Lift Arm: Bottom Side) (h) and Overload Relief Valve (Bucket: Bottom Side) (i) 21. Remove plugs (38B, 39B), springs (38D, 39D), and relief valves (38C, 39C) from housing (01). Remove O-rings (38A, 39A) from plugs (38B, 39B). j : 27 mm

fNOTE: Relief valves (38C, 39C) cannot be disassembled.

Hexagonal Part

Relief Valve Case WNDF-03-09-022

22. Remove main relief valve (50) from the housing (01). Remove O-rings (50A, 50C) and backup ring (50B) from main relief valve (50).

Detail of Relief Valve Assemblies (38, 39) 38D, 39D 38A, 39A

j : 27 mm

38B, 39B

 Disassembly of Load Check Valve (Bucket Circuit) and Check Valve (Bucket Flow Rate Control Valve) (d) 23. Remove plug (24) from the 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 38C, 39C

WNDB-03-09-015

W3-9-4-8

SECTION 3 BODY Group 9 Control Valve  Disassembly of Load Check Valve (Lift Arm Circuit) (c) 24. 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). j : 36 mm  Disassembly of Check Valve (Quick Coupler Flow Rate Control Valve) and Load Check Valve (Quick Coupler) (l) 25. Remove plug (24) from the housing (55). Remove the spring (23) and poppets (21, 22) from housing (55) by using a magnet. Remove O-ring (25) from plug (24). j : 36 mm  Disassembly of Check Valve (Auxiliary Flow Rate Control Valve) and Load Check Valve (Auxiliary Circuit) (p) 26. Remove plug (24) from housing (55). Remove spring (23) and poppets (21, 22) from housing (55) by using a magnet. Remove O-ring (25) from plug (24). j : 36 mm

27. Remove socket bolts (68) (4 used) from end plate (58). Separate housing (01), housings (55) (2 used), and end plate (58). Remove O-rings (65, 66) (3 used for each) from housings (55) (2 used) and end plate (58). l : 10 mm 28. 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 29. Remove plugs (76) (4 used) from housings (55) (2 used). Remove O-rings (76A) (4 used) from plugs (76) (4 used). j : 36 mm 30. Remove plug (61) from end plate (58). Remove O-ring (61A) from plug (61). l : 12 mm 31. Remove spring (60) and poppet (59) from end plate (58).

W3-9-4-9

SECTION 3 BODY Group 9 Control Valve Assembly of Control Valve (Parallel Link)

75, 75A

D E D F D G

68 15

WNDB-03-09-117

W3-9-4-10

SECTION 3 BODY Group 9 Control Valve 75

75A

50A, 50B

Section A

77A 77

50C

47 50

Section B

WNDF-03-09-009

34 31

90 91

23 25

b f

27 14

19 07 28

Section C

53 53A

39A 39

WNDF-03-09-013

22 24

09 29A

g i

07 93

53A

W3-9-4-11

38A

WNDF-03-09-014

SECTION 3 BODY Group 9 Control Valve

Section D

WNDF-03-09-010 l

Section E 36

09 36A

76A

22 24 23

25 21 76

76A

36A 36

74A

74A 74 10 07

07 k

17 WNDF-03-09-012

Section F 30

09 30A

76A

22 24 23

25 21 76

76A

30A 30

74A

74A 74 10 07

07 o

17 WNDF-03-09-012

W3-9-4-12

SECTION 3 BODY Group 9 Control Valve

Section G

61 61A

58 WNDB-03-09-118

0106070809101112141516171921222324-

ab-

Main Relief Valve Make-Up Valve (Lift Arm: Rod Side) Load Check Valve (Lift Arm Circuit) Load Check Valve (Bucket Circuit) and Check Valve (Bucket Flow Rate Control Valve) Low-Pressure Relief Valve

fgh-

cd-

ijk-

Lift Arm Spool Bucket Spool Overload Relief Valve (Lift Arm: Bottom Side) Overload Relief Valve (Bucket: Bottom Side) Overload Relief Valve (Bucket: Rod Side) Quick Coupler Spool

W3-9-4-13

qr-

Check Valve (Auxiliary Flow Rate Control Valve) and Load Check Valve (Auxiliary Circuit) Overload Relief Valve (Auxiliary Circuit) Overload Relief Valve (Auxiliary Circuit)

SECTION 3 BODY Group 9 Control Valve Assembly of Control Valve IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. 1. Install poppet (59) and spring (60) to end plate (58). 2. Install O-ring (61A) to plug (61). Install plug (61) to end plate (58).

IMPORTANT: Check dimension (x) to install end plate (58). 5. Install O-rings (65, 66) (3 used for each) to housings (55) (2 used) and end plate (58). Secure housing (01), housings (55) (2 used), and end plate (58) with socket bolts (68) (4 used). At this time, set dimension (x) of end plate (58) to 1 mm (0.04 in).

l : 12 mm

l : 10 mm

m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)

m : 88 to 93 N·m (8.8 to 9.3 kgf·m, 65 to 69 lbf·ft)

3. Install O-rings (76A) (4 used) to plugs (76) (4 used). Install plugs (76) (4 used) to housings (55) (2 used).

58 68

j : 36 mm m : 240 to 269 N·m (24 to 26.9 kgf·m, 175 to 200 lbf·ft) 4. 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 x-

m : 118 to 138 N·m (11.8 to 13.8 kgf·m, 87 to 102 lbf·ft)

Dimension WNDB-03-09-119

W3-9-4-14

SECTION 3 BODY Group 9 Control Valve  Assembly of Check Valve (Auxiliary Flow Rate Control Valve) and Load Check Valve (Auxiliary Circuit) (p) 6. Install poppets (21, 22) and spring (23) to housing (55). Install O-ring (25) to plug (24). Install plug (24) to housing (55). j : 36 mm

 Installation 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: Place a spanner onto hexagonal part (v) of relief valve case (w).

m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)

 Assembly of Check Valve (Quick Coupler Flow Rate Control Valve) and Load Check Valve (Quick Coupler) (l) 7. Install poppets (21, 22) and spring (23) to housing (55). Install O-ring (25) to plug (24). Install plug (24) to housing (55). j : 36 mm m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)  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).

Hexagonal Part

Relief Valve Case WNDF-03-09-022

10. Install the O-rings (50A, 50C) and backup ring (50B) to main relief valve (50). Install main relief valve (50) to housing (01).

j : 36 mm

j : 27 mm

m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)  Assembly of Load Check Valve (Bucket Circuit) and Check Valve (Bucket Flow Rate Control Valve) (d) 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

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 the pilot housing (19). Install pilot housing (19) to housing (01) with socket bolts (15) (3 used).

m : 275 to 304 N·m (27.5 to 30.4 kgf·m, 205 to 225 lbf·ft)

W3-9-4-15

l : 8 mm m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft)

SECTION 3 BODY Group 9 Control Valve  Assembly of Auxiliary Spool (o) 13. Secure spool (94) in a vise by using wooden pieces as illustrated. Install spring seats (07) (2 used) and spring (08) to spool (94) with bolt (06).

 Assembly of Lift Arm Spool (f ) 16. Secure spool (92) in a vise by using wooden pieces as step 13. Install O-ring (28) to plug (27). Install plug (27) to spool (92).

j : 19 mm

l : 8 mm

m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft) 17. Install O-ring (28) to bolt (11). Install spring seats (07) (2 used) and spring (12) to spool (92) with bolt (11). 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

 Assembly of Quick Coupler Spool (k) 14. Secure spool (94) in a vise by using wooden pieces as step 13. Install spring seats (07) (2 used) and spring (08) to spool (94) with bolt (06). j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)  Assembly of Bucket Spool (g) 15. Secure spool (93) in a vise by using wooden pieces as step 13. Install spring seats (07) (2 used) and spring (08) to spool (93) with bolt (06). j : 19 mm m : 25 to 30 N·m (2.5 to 3 kgf·m, 18.5 to 22 lbf·ft)

W3-9-4-16

SECTION 3 BODY Group 9 Control Valve IMPORTANT: Spools (92, 93) and spools (94) (2 used) have been selected to match the port holes of the housing (01) and housings (55) (2 used). Replace spools (92, 93) and spools (94) (2 used) and housing (01) and housings (55) (2 used) as an assembly. IMPORTANT: Check the direction to install the spools (92, 93) and spools (94) (2 used). IMPORTANT: Slowly install the spool (92, 93) assemblies and spool (94) assemblies (2 used) to the housing (01) and housings (55) (2 used) by turning the spool (92, 93) assemblies and spool (94) assemblies (2 used). 18. Fit the matching marks made when disassembling and install the spools (92, 93) assemblies to housing (01).

 Assembly of Overload Relief Valve (Lift Arm: Bottom Side) (h) and Overload Relief Valve (Bucket: Bottom Side) (i) IMPORTANT: The set pressure of relief valves (38C, 39C) are different. Check the positions to install relief valve (38C) (identification mark (a): 1) and relief valve (39C) (identification mark (a): no mark). 24. Install O-rings (38A, 39A) to plugs (38B, 39B). Install relief valves (38C, 39C), springs (38D, 39D), and plugs (38B, 39B) to housing (01). j : 27 mm m : 235 to 264 N·m (23.5 to 26.4 kgf·m, 175 to 195 lbf·ft)

19. Fit the matching marks made when disassembling and install the spool (94) assemblies (2 used) to housings (55) (2 used).

Detail of Relief Valve Assemblies (38, 39) 38D, 39D 38A, 39A

20. Install O-ring (09) to pilot housing (14). Install pilot housing (14) to pilot housing (19) with socket bolts (16) (2 used). l : 8 mm

38B, 39B

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 (10) (3 used). Install pilot housings (10) (3 used) to housing (01) and housings (55) (2 used) with socket bolts (15) (6 used).

38C, 39C a-

l : 8 mm m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft) 22. Install O-rings (09) (4 used) to pilot housings (17) (4 used). Install pilot housings (17) (4 used) to housing (01) and housings (55) (2 used) with socket bolts (15) (8 used). l : 8 mm m : 49 to 54 N·m (4.9 to 5.4 kgf·m, 36 to 40 lbf·ft) 23. Install O-rings (74A) (4 used) to plugs (74) (4 used). Install plugs (74) (4 used) to pilot housings (10, 17) (2 used for each) of housings (55) (2 used). l : 8 mm m : 69 to 74 N·m (6.9 to 7.4 kgf·m, 51 to 55 lbf·ft)

W3-9-4-17

Identification Mark

WNDB-03-09-015

SECTION 3 BODY Group 9 Control Valve Installation of Overload Relief Valve (Bucket: Rod Side) (j) 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: Place a spanner onto hexagonal part (z) of relief valve case (y).

 Installation of Overload Relief Valves (Auxiliary Circuit) (q, r) 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: Place a spanner onto hexagonal part (z) of relief valve case (y). 27. Install O-rings (30A) (2 used) to relief valves (30) (2 used). Install relief valves (30) (2 used) to housing (55). j : 32 mm m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61.5 to 65 lbf·ft)

Relief Valve Case

Hexagonal Part WNDF-03-09-021

 Assembly of Low-Pressure Relief Valve (e) 28. Install poppet (45) and spring (46) to housing (01). Install O-ring (25) to plug (47). Install plug (47) to housing (01).

25. Install O-ring (29A) to relief valve (29). Install relief valve (29) to housing (01).

j : 36 mm m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)

j : 32 mm

29. Install O-ring (77A) to the plug (77). Install plug (77) to housing (01).

m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61.5 to 65 lbf·ft)  Installation of Overload Relief Valve (Quick Coupler: Bottom Side) (m) and Overload Relief Valve (Quick Coupler: Rod Side) (n) 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: Place a spanner onto hexagonal part (z) of relief valve case (y). 26. Install O-rings (36A) (2 used) to relief valves (36) (2 used). Install relief valves (36) (2 used) to housing (55). j : 32 mm m : 83 to 88 N·m (8.3 to 8.8 kgf·m, 61.5 to 65 lbf·ft)

W3-9-4-18

l : 17 mm m : 177 to 206 N·m (17.7 to 20.6 kgf·m, 131 to 152 lbf·ft)

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 Removal and Installation of Auxiliary Pilot Valve

1 2

WNDB-03-10-001

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove screws (1) (3 used). Remove cover (2). 3. Disconnect connectors (3, 4).

W3-10-3-1

SECTION 3 BODY Group 10 Pilot Valve 1

4. Remove screws (1) (5 used). Remove cover (2). 5. Remove rubber seals (3, 4). 6. Remove screws (5) (4 used). Remove cover (6).

W3-10-3-2

WNDB-03-10-002

SECTION 3 BODY Group 10 Pilot Valve 1

5 6 8 7 WNDB-03-10-003

7. Remove bolts, washers (3) (2 used). Remove lever (4). j : 13 mm 8. Disconnect hoses (7) (2 used). j : 19 mm 9. Disconnect hose (8). j : 17 mm 10. Disconnect hose (6). j : 19 mm 11. Remove socket bolts (2) (2 used). Remove auxiliary pilot valve (5) from frame (1). l : 8 mm 12. Remove the adapters with auxiliary pilot valve (5) attached if necessary.

W3-10-3-3

SECTION 3 BODY Group 10 Pilot Valve 1

5 6 8 7 WNDB-03-10-003

6. Install lever (4) with bolts, washers (3) (2 used).

Installation 1. Install all removed adapters to auxiliary pilot valve (5).

j : 13 mm m : 10 N·m (1 kgf·m, 7.4 lbf·ft)

2. Install auxiliary pilot valve (5) to frame (1) with socket bolts (2) (2 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hose (6). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect hose (8). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 5. Connect hoses (7) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-10-3-4

SECTION 3 BODY Group 10 Pilot Valve 1

7. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (6) with screws (5) (4 used). 9. Install rubber seals (3, 4). 10. Install cover (2) with screws (1) (5 used).

W3-10-3-5

WNDB-03-10-002

SECTION 3 BODY Group 10 Pilot Valve 1 2

WNDB-03-10-001

11. Connect connectors (3, 4). 12. Install cover (2) with screws (1) (3 used).

W3-10-3-6

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

W3-10-4-1

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).

W3-10-4-2

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.

W3-10-4-3

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

W3-10-4-4

60E- O-Ring 62- Spool 63- Spool (3 Used) 65- Spring (4 Used) 66A- Socket (3 Used) 66B- Spring (3 Used) 80- Casing

SECTION 3 BODY Group 10 Pilot Valve 3. Install pushers (53B) (3 used) and O-rings (53D) (3 used) to solenoids (53C) (3 used).

Assembly of Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The pilot valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. IMPORTANT: Casing (80) is made of aluminium. Strong force deforms it. Handle it with care. 1. Check the port hole number and install the same parts before disassembling. Install springs (66B) (3 used), sockets (66A) (3 used), springs (65) (3 used), and spools (63) (3 used) to hole (b) on port 1, hole (c) on port 3, and hole (d) on port 4 of casing (80).

4. Install the solenoid (53C) assemblies (3 used) to hole (b) on port 1, hole (c) on port 3, and hole (d) on port 4 of casing (80). 5. Install pusher (60B), retaining ring (60D), and O-ring (60E) to guide (60A). 6. Install the guide (60A) assembly and plate (60C) to hole (a) on port 2 of casing (80). 7. Fit projection (f ) on the lower surface of plate (51) to groove (e) on the side of solenoids (53C) (3 used). Place plate (51) onto casing (80).

a c

b d

WNEC-03-10-003 ab-

Hole on Port 2 Hole on Port 1

cd-

Hole on Port 3 Hole on Port 4

Groove on Side of Solenoid (53C)

f, g fg-

2. Install spring (65) and spool (62) to hole (a) on port 2 of casing (80).

W3-10-4-5

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)

W3-10-4-6

SECTION 3 BODY Group 10 Pilot Valve IMPORTANT: Install the harness of handle (1) by winding around lever (11A). At this time, adjust the harness in order not to rub. 21. Install bracket (b) of the harness of handle (1) to groove (a) on plate (51). Secure the harness.

16. Tighten nut (11C) to the specified torque. j : 19 mm m : 40±4 N·m (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).

W3-10-4-7

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-4-8

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

W3-10-5-1

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

W3-10-5-2

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).

W3-10-5-3

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).

W3-10-5-4

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).

W3-10-5-5

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.

W3-10-5-6

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

W3-10-5-7

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

W3-10-5-8

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).

W3-10-5-9

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.

W3-10-5-10

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

W3-10-5-11

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).

W3-10-5-12

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.

W3-10-5-13

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-5-14

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Auxiliary Pilot Valve

6 2 3

4 5

8 9

11 10

11 13

15 16

18 21

WNDF-03-10-001

123456-

Boot Set Screw Cam Bushing (2 Used) Shaft Socket Bolt (2 Used)

789101112-

Cover Steel Ball (2 Used) Seal (2 Used) Plug (2 Used) O-Ring (2 Used) Push Rod (2 Used)

131415161718-

Spring Seat (2 Used) Spring (2 Used) Spring (2 Used) Shim (2 Used) Washer (2 Used) Spool (2 Used)

W3-10-6-1

19- Plug 20- O-Ring 21- Casing

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Auxiliary Pilot Valve IMPORTANT: Casing (21) is made of aluminium. Strong force deforms it. Handle it with care. IMPORTANT: Spool (18) has been selected to match the hole on casing (21). Arrange the disassembled parts together with each port in order not to confuse. The port number is stamped on the outer surface of casing (21). 1. Secure the auxiliary pilot valve in a vise by using wooden pieces with the boot (1) side up. 2. Remove boot (1) from cover (7). 3. Remove set screw (2) from cam (3).

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: Bushings (4) (2 used) cannot be reused. 6. Remove bushings (4) (2 used) from cover (7) by using a hammer and special tool (ST 8187). 7. Put the matching marks on plug (10) and casing (21). Remove plug (10) and push rod (12) from casing (21). 8. Remove push rod (12) and O-ring (11) from plug (10).

l : 3 mm

fNOTE: LOCTITE #241 has been applied to set screw (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. 4. Put the matching marks on cam (3) and cover (7). Remove shaft (5) by using a round bar (less than 7 mm) and a hammer. Remove cam (3) from cover (7).

IMPORTANT: Do not damage the inner circumference of plug (10) when removing seal (9). 9. Remove seal (9) from plug (10) by using a screwdriver. 10. Remove other plug (10), push rod (12), O-ring (11), and seal (9) in the same way as step 7 to step 9.

fNOTE: Steel balls (8) (2 used) and cam (3) are an

assembly. Steel balls (8) (2 used) cannot be removed. IMPORTANT: Push rods (12) (2 used) and plugs (10) (2 used) may fly out due to the spring force of springs (15) (2 used) when removing cover (7). 5. Put the matching marks on cover (7) and casing (21). Loosen and remove socket bolts (6) (2 used) alternately. Remove cover (7) from casing (21). l : 5 mm

W3-10-6-2

SECTION 3 BODY Group 10 Pilot Valve 11. Put the matching marks on spool assembly (a), spring (15), and casing (21). Remove spool assembly (a) and spring (15) from casing (21). 13

13. Disassemble other spool assembly (a) in the same way as step 11 to step 12. 14. Remove plug (19) from casing (21). Remove O-ring (20) from plug (19).

l : 6 mm

WNDF-03-10-003 a a-

Spool Assembly

IMPORTANT: Do not damage spool (18) when removing it. IMPORTANT: Do not push spring seat (13) over 4 mm (0.157 in). IMPORTANT: The thickness of shim (16) has been determined during the performance testing at the factory. When keeping, pair shim (16) with each spool assembly (a). 12. Push spring seat (13) and compress spring (14). Move spring seat (13) to the hole (b) part. Slowly return spring seat (13). Therefore, spool assembly (a) is disassembled into spring seat (13), spring (14), shim (16), washer (17), and spool (18).

fNOTE: Shim (16) may not have been used. View A

WNDJ-04-05-013 b-

Hole

W3-10-6-3

SECTION 3 BODY Group 10 Pilot Valve Assembly of Auxiliary Pilot Valve

4 Section A-A

12 9 6 10 7 11 13 14 15 16

17 19 20 18 WNDF-03-10-002

123456-

Boot Set Screw Cam Bushing (2 Used) Shaft Socket Bolt (2 Used)

789101112-

Cover Steel Ball (2 Used) Seal (2 Used) Plug (2 Used) O-Ring (2 Used) Push Rod (2 Used)

131415161718-

Spring Seat (2 Used) Spring (2 Used) Spring (2 Used) Shim (2 Used) Washer (2 Used) Spool (2 Used)

W3-10-6-4

19- Plug 20- O-Ring 21- Casing

SECTION 3 BODY Group 10 Pilot Valve 2. Assemble other spool assembly (a) in the same way as step 1.

Assembly of Auxiliary Pilot Valve IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. IMPORTANT: Do not damage spool (18) when installing it. IMPORTANT: Do not push spring seat (13) over 4 mm (0.157 in). IMPORTANT: When using shim (16) different from the one that has been removed, the performance changes. Install shim (16) which have been kept since removing. 1. Install washer (17), shim (16), spring (14), and spring seat (13) to spool (18). Push spring seat (13) and compress spring (14). Insert the end of spool (18) into the hole (b) part of spring seat (13). Move spool (18) to the hole (c) part. Slowly return spring seat (13). 13

3. Secure casing (21) in a vise by using wooden pieces with the cover (7) mounting surface up. IMPORTANT: Do not strongly fit the bottom of spool (18) to corner (d) of casing (21) when installing spool assembly (a). 4. Fit the matching marks made when disassembling and install spring (15) and spool assembly (a) to casing (21). a

15 21

18 18

WNDF-03-10-003 a a-

Spool Assembly WNDF-03-10-004 d

View A

b a-

Spool Assembly

WNDJ-04-05-013 Hole

Corner

5. Install other spring (15) and spool assembly (a) in the same way as step 4.

Hole

fNOTE: Shim (16) may not have been used.

W3-10-6-5

SECTION 3 BODY Group 10 Pilot Valve IMPORTANT: Check the direction to install seal (9). 6. Apply grease to seal (9). Install seal (9) to plug (10) in the direction as shown in the illustration.

IMPORTANT: Cover (7) is raised by the spring force of springs (15) (2 used). Tighten socket bolts (6) (2 used) alternately and set cover (7) horizontally. 11. Fit the matching marks made when disassembling and install cover (7) to casing (21) with socket bolts (6) (2 used). l : 5 mm m : 8.8±0.8 N·m (0.88±0.08 kgf·m, 6.5±0.6 lbf·ft)

12. Fit the matching marks made when disassembling and install cam (3) to cover (7).

WNDF-03-10-005

IMPORTANT: When installing push rod (12), do not damage the lip part of seal (9). Slowly insert push rod (12). 7. Apply grease to O-ring (11). Install O-ring (11) and push rod (12) to plug (10).

IMPORTANT: Check the direction to install shaft (5). 13. Apply grease to shaft (5). Install shaft (5) to cover (7) while holding cam (3). At this time, install shaft (5) with notched part (a) up. 3

8. Fit the matching marks made when disassembling and install plug (10) and push rod (12) to casing (21).

9. Install other plug (10), push rod (12), O-ring (11), and seal (9) in the same way as step 6 to step 8. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury. IMPORTANT: When installing bushing (4), prevent the end of bushing (4) from protruding to the inside of cover (7). IMPORTANT: Replace bushings (4) (2 used) with the new ones. 10. Install bushings (4) (2 used) to cover (7) by using a hammer and special tool (ST 8187).

Notched Part

WNDF-03-10-006

14. Apply LOCTITE #241 to set screw (2). Install set screw (2) to cam (3).

W3-10-6-6

l : 3 mm m : 6.9±1 N·m (0.69±0.1 kgf·m, 5.1±0.7 lbf·ft)

SECTION 3 BODY Group 10 Pilot Valve 15. Apply grease to O-ring (20). Install O-ring (20) to plug (19). Install plug (19) to casing (21). l : 6 mm m : 29.4±2 N·m (2.94±0.2 kgf·m, 21.5±1.5 lbf·ft) IMPORTANT: When applying grease to push rod (12), do not damage push rod (12) and plug (10). When applying grease, use the one like a spatula which is made from soft material. 16. Tilt cam (3). Apply grease to the top of push rods (12) (2 used). IMPORTANT: Do not twist and install boot (1) incorrectly as dustproofness and waterproofness of the auxiliary pilot valve are reduced. 17. Spray anti-rust oil to the parts inside boot (1). Install the upper end of boot (1) to cam (3). Install the lower end of boot (1) to the groove of case (7).

W3-10-6-7

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-6-8

SECTION 3 BODY Group 11 Brake Charge Valve Removal and Installation of Brake Charge Valve (Unloader Valve)

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.) 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. Remove cover (1). (Refer to W3-4-2.)

W3-11-1-1

WNDB-03-12-001

SECTION 3 BODY Group 11 Brake Charge Valve

Detail A

WNDB-03-11-001

3. Disconnect connector (3). 4. Disconnect hoses (1) (3 used). j : 27 mm 5. Disconnect hose (2). j : 27 mm

W3-11-1-2

WNDB-03-11-002

SECTION 3 BODY Group 11 Brake Charge Valve

1 11 2 17

16 3 14

8, 9, 10

5, 6, 7

WNDB-03-11-003

6. Disconnect hose (1). j : 19 mm

WNEC-03-11-005

11. Remove bolts, washers (13, 19) (2 used for each) and washers (18) (2 used). Remove the brake charge valve (11) assembly.

7. Remove bolt, washer (5), nut (6), and clips (7) (2 used). j : 17 mm 8. Disconnect hoses (2, 3). j : 19 mm 9. Remove bolt, washer (8), nut (9), and clips (10) (2 used). j : 17 mm

j : 17 mm 12. Remove rubbers (16) (2 used) from bracket (17). 13. Remove bolt, washer (12), nut (15), and bolts, washers (14) (2 used). Remove brake charge valve (11) from the bracket (17) assembly. j : 17 mm 14. Remove the adapters with brake charge valve (11) attached if necessary.

10. Disconnect hoses (4) (2 used). j : 22 mm

W3-11-1-3

SECTION 3 BODY Group 11 Brake Charge Valve

Detail A

6 A

4 5 4

WNDB-03-11-001

Installation 1. Install all removed adapters to brake charge valve (1). 2. Install brake charge valve (1) to the bracket (7) assembly with bolt, washer (2), nut (5), and bolts, washers (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Install rubbers (6) (2 used) to bracket (7). 4. Install the brake charge valve (1) assembly with bolts, washers (3, 9) (2 used for each) and washers (8) (2 used). j : 17 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-1-4

WNEC-03-11-005

SECTION 3 BODY Group 11 Brake Charge Valve 11

1 A

3 8, 9, 10

5, 6, 7

WNDB-03-11-002

WNDB-03-11-003

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

View A

j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 6. Install clips (10) (2 used) with bolt, washer (8) and nut (9). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

IMPORTANT: Check the angle to install hoses (2, 3). 7. Connect hoses (2, 3).

j : 19 mm 2

m : 30 N·m (3 kgf·m, 22 lbf·ft)

3 WNEC-03-11-006

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

30˚

15˚

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

11. Connect hoses (11) (3 used).

9. Connect hose (1).

j : 27 mm

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

m : 80 N·m (8 kgf·m, 59 lbf·ft) 12. Connect connector (13).

10. Connect hose (12). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

W3-11-1-5

SECTION 3 BODY Group 11 Brake Charge Valve

13. Bleed air from the hydraulic system and the brake (axle). (Refer to W1-4-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 14. Install cover (1). (Refer to W3-4-2.)

W3-11-1-6

WNDB-03-12-001

SECTION 3 BODY Group 11 Brake Charge Valve Structure of Brake Charge Valve (Unloader 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

WNDB-03-12-001

Removal

CAUTION:

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.

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

 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

Detail A

6 a

2, 3, 4 b

WNDB-03-11-004

3. Remove bolt, washer (2), nut (3), and clips (4) (2 used). j : 17 mm 4. Disconnect hoses (5) (2 used). j : 19 mm IMPORTANT: Remove brake accumulator (1) while holding the assembly. Do not drop the assembly. 5. Remove bolts, washers (6) (4 used). Remove the brake accumulator (1) assembly. j : 17 mm

W3-11-3-2

Brake Charge Valve

WNDB-03-11-002

Line Filter

SECTION 3 BODY Group 11 Brake Accumulator 1

3 3 3

WNDB-03-11-005

6. Remove nuts (3) (16 used) and U-bolts (4) (4 used). Remove brake accumulators (1) (2 used) from bracket (2). j : 17 mm 7. Remove the adapters with brake accumulators (1) (2 used) attached if necessary.

W3-11-3-3

SECTION 3 BODY Group 11 Brake Accumulator 1

3 3 3

1 View A

4 2 a-

WNEC-03-11-010

0 mm (0 in)

1 View B c A b WNDB-03-11-005 B

Installation 1. Install all removed adapters to brake accumulators (1) (2 used).

WNDB-03-11-006 b-

IMPORTANT: Check the position to install brake accumulators (1) (2 used). 2. Install brake accumulators (1) (2 used) to bracket (2) with nuts (3) (16 used) and U-bolts (4) (4 used). j : 17 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

W3-11-3-4

25˚

SECTION 3 BODY Group 11 Brake Accumulator

Detail A

6 a

2, 3, 4 b

WNDB-03-11-004

3. Install the brake accumulator (1) assembly with bolts, washers (6) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 4. Connect hoses (5) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) 5. Install clips (4) (2 used) with bolt, washer (2) and nut (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-3-5

Brake Charge Valve

WNDB-03-11-002

Line Filter

SECTION 3 BODY Group 11 Brake Accumulator

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 6. Bleed air from the hydraulic system and the brake (axle). (Refer to W1-4-1.) 7. Install covers (1, 2). (Refer to W3-4-2.)

W3-11-3-6

WNDB-03-12-001

SECTION 3 BODY Group 12 Manifold Valve Removal and Installation of Manifold Valve

WNDB-03-12-001

Removal

CAUTION:

1. Set the machine position 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: hydraulic circuit. (Refer to W1-5-1.) 2. Remove following parts. (Refer to W3-4-2.) Rear Fender (Front) (2)

 Do not directly heat the accumulator. Do not weld the accumulator housing.

Deck (1)

 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.

W3-12-1-1

SECTION 3 BODY Group 12 Manifold Valve

2 10

WNEC-03-01-001

7, 8, 9 WNDB-03-12-002

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

6. Remove bolt, washer (7), brackets (8) (2 used), and tube (9). j : 17 mm

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

7. Disconnect connectors (10) (3 used).

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

W3-12-1-2

SECTION 3 BODY Group 12 Manifold Valve

WNDB-03-12-003

8. Disconnect hoses (3) (2 used). j : 19 mm 9. Disconnect hose (2). j : 17 mm 10. Disconnect hose (1). j : 27 mm

W3-12-1-3

SECTION 3 BODY Group 12 Manifold Valve

WNDB-03-12-004

11. Disconnect hose (1). j : 19 mm 12. Disconnect hoses (3) (2 used). j : 17 mm 13. Disconnect hose (2). j : 27 mm

W3-12-1-4

SECTION 3 BODY Group 12 Manifold Valve

Detail A 1

3 7 6 2

WNDB-03-12-005

14. Remove bolts, washers (5) (3 used), washers (6) (6 used), and rubber cushions (7) (3 used). Remove the manifold valve (4) assembly.

WNEC-03-12-012

17. Remove the adapters with manifold valve (4) attached if necessary.

j : 19 mm 15. Remove bolts, washers (2) (3 used). Remove manifold valve (4) from bracket (3). j : 17 mm 16. Remove accumulator (1) from manifold valve (4). j : 36 mm

W3-12-1-5

SECTION 3 BODY Group 12 Manifold Valve

Detail A 1

3 7 6 2

WNDB-03-12-005

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

WNEC-03-12-012

4. Install the manifold valve (4) assembly with rubber cushions (7) (3 used), washers (6) (6 used), and bolts, washers (5) (3 used).

2. Install accumulator (1) to manifold valve (4).

j : 19 mm

j : 36 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 (3) to manifold valve (4) with bolts, washers (2) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-6

SECTION 3 BODY Group 12 Manifold Valve

WNDB-03-12-004

5. Connect hose (2). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 6. Connect hoses (3) (2 used). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 7. Connect hose (1). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-1-7

SECTION 3 BODY Group 12 Manifold Valve

View A b

2 WNDB-03-12-007

WNDB-03-12-006

IMPORTANT: Check the angle to install hose (1). 8. Connect hose (1). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) IMPORTANT: Check the angle to install hose (2). 9. Connect hose (2). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 10. Connect hoses (3) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-12-1-8

105°

75°

SECTION 3 BODY Group 12 Manifold Valve

2 10

4 10

WNEC-03-01-001

7, 8, 9 WNDB-03-12-002

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

11. Connect connectors (10) (3 used). 12. Install tube (9) and brackets (8) (2 used) with bolt, washer (7).

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

j : 17 mm

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

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. 13. Bleed air from the hydraulic system. (Refer to W1-41.) 14. Install cover (5) with bolts, washers (6) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-12-1-9

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

SECTION 3 BODY Group 12 Manifold Valve

17. Install following parts. (Refer to W3-4-2.) Deck (1) Rear Fender (Front) (2)

W3-12-1-10

WNDB-03-12-001

SECTION 3 BODY Group 12 Manifold Valve Disassembly of Manifold Valve View A

WNDB-03-12-008

01020304050607080910-

Plug Shim (Several) Poppet Spring Shim (Several) Plunger Spring Spring Plug Sleeve

12131415161720212224-

Filter Screw Spool Stopper Filter Solenoid Spring Solenoid Body Plug (7 Used)

25262728293032333435-

Plug Plug (2 Used) Plug Socket Bolt (4 Used) Washer Nut O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring

W3-12-2-1

36- O-Ring (2 Used) 37- O-Ring (2 Used) 38- O-Ring 39- O-Ring 40- O-Ring 41- O-Ring 43A- Sleeve 43B- Spool 44- O-Ring 45- Plug

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. 1. Remove plug (01) from body (22). Remove O-ring (37) from plug (01).

8. Measure and record mounting dimension (a) before removing screw (13). Put the matching marks onto body (22) and screw (13).

j : 36 mm

IMPORTANT: The quantity and kind of shims (02, 05) have been determined for each manifold valve. Do not lose shims (02, 05). 2. Remove spring (04), shims (05, 02), and poppet (03) from body (22).

3. Remove plug (09) from body (22). Remove O-ring (34) from plug (09). l : 6 mm 4. Remove spring (07) and plunger (06) from body (22).

WNEC-03-12-005 a-

5. Remove socket bolts (28) (2 used) from solenoid (17). Remove solenoid (17) from body (22). Remove O-ring (41) from solenoid (17).

Mounting Dimension

9. Remove screw (13) from body (22). Remove O-ring (34) from screw (13).

l : 4 mm

l : 6 mm

IMPORTANT: Replace sleeve (43A) and spool (43B) as an assembly. 6. Remove the sleeve (43A) assembly and spring (20) from body (22). Remove spool (43B) and O-rings (38, 39, 40) from sleeve (43A).

10. Remove socket bolts (28) (2 used) from solenoid (21). Remove solenoid (21) from body (22). Remove O-ring (32) from solenoid (21).

IMPORTANT: Remove nut (30) while securing screw (13) by using a hexagonal wrench in order not to turn them. 7. Remove nut (30) from screw (13).

IMPORTANT: Replace the sleeve (10) assembly as the manifold valve assembly. 11. Remove the sleeve (10) assembly from body (22).

l : 4 mm

j : 17 mm l : 6 mm (0.24 in)

W3-12-2-2

SECTION 3 BODY Group 12 Manifold Valve 12. Remove spool (14) from sleeve (10).

fNOTE: Spring (08) and washer (29) cannot be

disassembled as stopper (15) has been press fitted to sleeve (10). 13. Remove plugs (24) (7 used) from body (22). Remove O-rings (33) (7 used) from plugs (24) (7 used). l : 5 mm

14. Remove plug (25) from body (22). Remove O-ring (35) from plug (25). l : 6 mm 15. Remove plug (27) from body (22). Remove O-ring (37) from plug (27). l : 12 mm 16. Remove plugs (26) (2 used) from body (22). Remove O-rings (36) (2 used) from plugs (26) (2 used). l : 8 mm

fNOTE: Filters (12, 16) cannot be disassembled as they have been press fitted to body (22). 17. Remove plug (45) from body (22). Remove O-ring (44) from plug (45). j : 22 mm

W3-12-2-3

SECTION 3 BODY Group 12 Manifold Valve Assembly of Manifold Valve

24, 33

W V

28 17

21 22

24, 33 WNDB-03-12-009

Section V

Section W

35 12

43A 43B 20 30 13

41 32 10

39 38

14 29 08 15 WNEC-03-12-003

W3-12-2-4

TNED-03-07-012

SECTION 3 BODY Group 12 Manifold Valve Section X-X

Section Y-Y

44 07

09 34

06 33 24 26 36 33 TNED-03-07-011

24 WNDB-03-12-010

Section Z-Z

27 02, 05 37 33 24 03

33 24 36 26

WNEC-03-12-004

01020304050607080910-

Plug Shim (Several) Poppet Spring Shim (Several) Plunger Spring Spring Plug Sleeve

12131415161720212224-

Filter Screw Spool Stopper Filter Solenoid Spring Solenoid Body Plug (7 Used)

25262728293032333435-

Plug Plug (2 Used) Plug Socket Bolt (4 Used) Washer Nut O-Ring O-Ring (7 Used) O-Ring (2 Used) O-Ring

W3-12-2-5

36- O-Ring (2 Used) 37- O-Ring (2 Used) 38- O-Ring 39- O-Ring 40- O-Ring 41- O-Ring 43A- Sleeve 43B- Spool 44- O-Ring 45- Plug

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-ring (44) to plug (45). Install plug (45) to body (22).

8. Install O-ring (34) to screw (13). Fit the matching marks. Install screw (13) to body (22) so that a clearance can be equal to mounting dimension (a) before disassembling. l : 6 mm

j : 22 mm m : 70 N·m (7 kgf·m, 52 lbf·ft)

2. Install O-rings (36) (2 used) to plugs (26) (2 used). Install plugs (26) (2 used) to body (22).

l : 8 mm m : 48.5±4.9 N·m (4.9±0.5 kgf·m, 36±3.6 lbf·ft) 3. Install O-ring (37) to plug (27). Install plug (27) to body (22).

l : 12 mm m : 98±9.8 N·m (10±1 kgf·m, 72±7.2 lbf·ft)

WNEC-03-12-005

4. Install O-ring (35) to plug (25). Install plug (25) to body (22).

l : 6 mm m : 26.5±2.9 N·m (2.7±0.3 kgf·m, 19.5±2.1 lbf·ft) 5. Install O-rings (33) (7 used) to plugs (24) (7 used). Install plugs (24) (7 used) to body (22).

Mounting Dimension

IMPORTANT: Install nut (30) while securing screw (13) by using a hexagonal wrench in order not to turn them. 9. Install nut (30) to screw (13).

l : 5 mm

j : 17 mm m : 19.6±2 N·m (2±0.2 kgf·m, 14.5±1.5 lbf·ft)

m : 9.8±1 N·m (1 kgf·m, 7.2±0.7 lbf·ft)

l : 6 mm

6. Install spool (14) to sleeve (10). Install the sleeve (10) assembly to body (22). 7. Install O-ring (32) to solenoid (21). Install solenoid (21) to body (22) with socket bolts (28) (2 used). l : 4 mm m : 3.92±0.4 N·m (0.4 kgf·m, 2.9±0.3 lbf·ft)

W3-12-2-6

SECTION 3 BODY Group 12 Manifold Valve IMPORTANT: Replace sleeve (43A) and spool (43B) as an assembly. 10. Install O-rings (40, 39, 38) to sleeve (43A). Install spool (43B) to sleeve (43A). 11. Install spring (20) and the sleeve (43A) assembly to body (22). 12. Install O-ring (41) to solenoid (17). Install solenoid (17) to body (22) with socket bolts (28) (2 used). l : 4 mm m : 3.92±0.4 N·m (0.4 kgf·m, 2.9±0.3 lbf·ft) 13. Install plunger (06) and spring (07) to body (22). 14. Install O-ring (34) to plug (09). Install plug (09) to body (22). l : 6 mm m : 12.0±1.2 N·m (1.2±0.1 kgf·m, 8.9±0.9 lbf·ft) IMPORTANT: Install shims (02, 05) as the same condition before disassembling. 15. Install poppet (03), shims (02, 05), and spring (04) to body (22). 16. Install O-ring (37) to plug (01). Install plug (01) to body (22). j : 36 mm m : 98±9.8 N·m (10±1 kgf·m, 72±7.2 lbf·ft)

W3-12-2-7

SECTION 3 BODY Group 12 Manifold Valve (Blank)

W3-12-2-8

SECTION 3 BODY Group 13 Solenoid Valve Removal and Installation of Parking Brake Solenoid Valve Unit

1 WNDB-03-12-001

Removal

dCAUTION:

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

Bleeding air from the hydraulic oil dCAUTION: tank. (Refer to W1- 4-1.) Release any pressure in the parking dCAUTION: brake circuit. (Refer to W1-5-1.) 2. Remove cover (1). (Refer to W3-4-2.)

W3-13-1-1

SECTION 3 BODY Group 13 Solenoid Valve

Detail A

6 A

9 5

WNDB-03-11-001

3. Disconnect connectors (2, 9). 4. Remove bolt, washer (1) and connector (2).

j : 19 mm 8. Remove accumulator (4) from parking brake solenoid valve unit (5).

j : 19 mm 6. Disconnect hose (3). j : 22 mm

WNDB-03-13-001

7. Remove bolts, washers (6) (2 used) and bracket (7). Remove parking brake solenoid valve unit (5).

j : 17 mm 5. Disconnect hoses (8) (3 used).

6, 7

j : 36 mm 9. Remove the adapters with parking brake solenoid valve unit (5) attached if necessary.

W3-13-1-2

SECTION 3 BODY Group 13 Solenoid Valve Detail A A

6 A

9 5

WNDB-03-11-001

6, 7

WNDB-03-13-001

View A

Installation 1. Install all removed adapters to parking brake solenoid valve unit (5). 2. Install accumulator (4) to parking brake solenoid valve unit (5).

j : 36 mm m : 98 N·m (9.8 kgf·m, 72 lbf·ft) 3. Install parking brake solenoid valve unit (5) and bracket (7) with bolts, washers (6) (2 used).

3 a-

50˚

WNEC-03-13-006

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

6. Install connector (2) with bolt, washer (1).

IMPORTANT: Check the angle to install hose (3). 4. Connect hose (3). j : 22 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 7. Connect connectors (2, 9).

m : 40 N·m (4 kgf·m, 29.5 lbf·ft) 5. Connect hoses (8) (3 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-1-3

SECTION 3 BODY Group 13 Solenoid Valve

1 WNDB-03-12-001

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Bleeding air from the hydraulic system. (Refer to W1- 4-1.) 9. Install cover (1). (Refer to W3-4-2.)

W3-13-1-4

SECTION 3 BODY Group 13 Solenoid Valve Structure of Parking Brake Solenoid Valve Unit 1

3 3 3 3

5 6 7

WNEJ-03-13-001

No.

Part Name

Q’ty

1 2 3 4 5

Socket Bolt Solenoid Valve O-Ring Block O-Ring

4 1 4 1 2

6 7

O-Ring Filter

2 2

Wrench Size Tightening Torque (mm) N·m kgf·m 5+1 0.5+0.1 l:4

Remark lbf·ft 3.7+0.7

Apply grease onto the outer surface when assembling. l:6

25+5

W3-13-2-1

2.5+0.5

18.5+3.7

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-2-2

SECTION 3 BODY Group 13 Solenoid Valve Structure of Parking Brake Solenoid Valve

W4GB-03-10-003

No.

Part Name

Q’ty

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

Housing Spool Spring Seat Spring O-Ring Rod Stopper Plunger Spring Rod Inner Housing Coil Spacer Screw

1 1 2 2 4 1 1 1 1 1 1 1 1 1

15 16 17 18 19 20 21 24

O-Ring Spring O-Ring Washer Retaining Ring Plug Pipe Socket Bolt

2 1 1 1 1 1 1 4

16 18 19

Wrench Size (mm)

Tightening Torque N·m (kgf·m)

(lbf·ft)

j : 32

30 to 40

(3 to 4)

(22 to 30)

l : 14

30 to 40

(3 to 4)

(22 to 30)

l : 2.5

5 to 6

(0.5 to 0.6)

(3.7 to 4.4)

W3-13-3-1

Remark

Apply LOCTITE #242 or equivalent.

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-3-2

SECTION 3 BODY Group 13 Solenoid Valve Removal and Installation of Quick Coupler Solenoid Valve (Parallel Link)

WNDB-03-17-101

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

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

W3-13-4-1

j : 17 mm

SECTION 3 BODY Group 13 Solenoid Valve Detail A A

1 WNDB-03-13-101

3. Disconnect connectors (5) (2 used). 4. Disconnect hoses (1) (4 used). j : 19 mm 5. Disconnect hose (3). j : 17 mm 6. Remove tee (2). j : 19 mm 7. Disconnect hose (4). j : 19 mm

W3-13-4-2

WNDB-03-13-102

SECTION 3 BODY Group 13 Solenoid Valve

4 1

4 5

2 2

7 WNDB-03-13-103

6 WNDB-03-13-104

8. Remove bolts, washers (1) (3 used). Remove quick coupler solenoid valve (2) and bracket (6) from front chassis (3). j : 17 mm 9. Remove connectors (5) (2 used) from brackets (4) (2 used).

10. Remove bolts, washers (7) (2 used). Remove quick coupler solenoid valve (2) from bracket (6). j : 17 mm 11. Remove other adapters with quick coupler solenoid valve (2) attached if necessary.

W3-13-4-3

SECTION 3 BODY Group 13 Solenoid Valve

1 2

4 WNDB-03-13-104

Installation 1. Install the adapters which have been remove in step 11 for removal to quick coupler solenoid valve (3). 2. Install quick coupler solenoid valve (3) to bracket (4) with bolts, washers (5) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Install connectors (2) (2 used) to brackets (1) (2 used).

W3-13-4-4

SECTION 3 BODY Group 13 Solenoid Valve

Detail A

WNDB-03-13-101

1 WNDB-03-13-103

4. Install quick coupler solenoid valve (2) and bracket (4) to front chassis (3) with bolts, washers (1) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-13-4-5

SECTION 3 BODY Group 13 Solenoid Valve

View A

2 a

6 b

1 3 WNDB-03-13-105

30˚

45˚

WNDB-03-13-102

5. Connect hose (6). j : 19 mm

IMPORTANT: Check the angle to install hoses (1, 2). 9. Connect hoses (1, 2). j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

6. Install tee (4). j : 19 mm

10. Connect connectors (7) (2 used).

m : 30 N·m (3 kgf·m, 22 lbf·ft) 7. Connect hose (5). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 8. Connect hoses (3) (2 used). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-13-4-6

SECTION 3 BODY Group 13 Solenoid Valve

WNDB-03-17-101

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

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

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

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

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

W3-13-4-7

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

SECTION 3 BODY Group 13 Solenoid Valve (Blank)

W3-13-4-8

SECTION 3 BODY Group 13 Solenoid Valve Disassembly of Quick Coupler Solenoid Valve

4 5 6

5 8 6

WNDB-03-13-002

12-

Body Spring (2 Used)

34-

O-Ring (3 Used) Plug (3 Used)

56-

Spool (2 Used) O-Ring (2 Used)

W3-13-5-1

78-

Solenoid (2 Used) Socket Bolt (4 Used)

SECTION 3 BODY Group 13 Solenoid Valve Disassembly of Quick Coupler Solenoid Valve IMPORTANT: Keep the disassembled parts together by each port in order not to confuse. IMPORTANT: Push rod (a) may fall from solenoid (7) when removing solenoid (7). Do not drop push rod (a). 1. Remove socket bolts (8) (4 used). Remove solenoids (7) (2 used) from body (1). Remove O-rings (6) (2 used) from solenoids (7) (2 used). l : 4 mm

a a-

Push Rod

a WNDB-03-13-004

2. Remove plugs (4) (3 used) from body (1). Remove O-rings (3) (3 used) from plugs (4) (3 used). l : 6 mm IMPORTANT: Replace spool (5) as the quick coupler solenoid valve assembly. 3. Remove spools (5) (2 used) from body (1). Remove springs (2) (2 used) from spools (5) (2 used).

W3-13-5-2

SECTION 3 BODY Group 13 Solenoid Valve Assembly of Quick Coupler Solenoid Valve

7 8

8 6

WNDB-03-13-003

12-

Body Spring (2 Used)

34-

O-Ring (3 Used) Plug (3 Used)

56-

Spool (2 Used) O-Ring (2 Used)

W3-13-5-3

78-

Solenoid (2 Used) Socket Bolt (4 Used)

SECTION 3 BODY Group 13 Solenoid Valve Assembly of Quick Coupler Solenoid Valve IMPORTANT: Before assembling, apply hydraulic oil to parts in order to prevent them from seizing. IMPORTANT: Replace spool (5) as the quick coupler solenoid valve assembly. 1. Install springs (2) (2 used) to spools (5) (2 used). Install spools (5) (2 used) to body (1).

IMPORTANT: Check the direction to install solenoids (7) (2 used). 4. Install solenoids (7) (2 used) to body (1) in the direction as shown in the illustration with socket bolts (8) (4 used).

2. Apply grease to O-rings (3) (3 used). Install O-rings (3) (3 used) to plugs (4) (3 used). Install plugs (4) (3 used) to body (1).

l : 4 mm m : 3.92 N·m (0.39 kgf·m, 2.9 lbf·ft) 7

l : 6 mm

m : 26.5 N·m (2.65 kgf·m, 19.5 lbf·ft) 3. Check that push rods (a) (2 used) has been installed in solenoids (7) (2 used). Apply grease to O-rings (6) (2 used). Install O-rings (6) (2 used) to solenoids (7) (2 used). 8

a a-

Push Rod

a WNDB-03-13-004

W3-13-5-4

WNDB-03-13-005

SECTION 3 BODY Group 14 Priority Valve Removal and Installation of Priority Valve

WNDB-03-14-001

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils. IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach an identification tag onto the connectors, hoses, and pipes for assembling. Connect the hoses and install the clips in case the clips which secure the hoses have been removed. Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove cover (1). (Refer to W3-4-2.)

W3-14-1-1

SECTION 3 BODY Group 14 Priority Valve

Detail A

1 8 2 5, 6, 7

3 WNDB-03-14-002

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

WNDB-03-14-003

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

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

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

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

W3-14-1-2

SECTION 3 BODY Group 14 Priority Valve

Detail A

1 8 2 5, 6, 7

3 WNDB-03-14-002

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

5. Connect hose (2).

2. Install priority valve (4) with bolts (5) (2 used), washers (6) (2 used), and nuts (7) (2 used).

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

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

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

3. Connect hose (8).

m : 210 N·m (21 kgf·m, 155 lbf·ft)

j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) 4. Connect hose (3). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W3-14-1-3

WNDB-03-14-003

SECTION 3 BODY Group 14 Priority Valve

WNDB-03-14-001

7. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (1). (Refer to W3-4-2.)

W3-14-1-4

SECTION 3 BODY Group 14 Priority Valve Structure of Priority Valve 16

9 1

No. Part Name 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Wrench Size mm

Tightening Torque N·m kgf·m

5 13 12

WNDB-03-14-004

Remark lbf·ft

Diameter of Orifice: φ0.7 (0.028)

j : 24

4.5

32.5 Diameter of Orifice: φ1.2 (0.047) Diameter of Orifice: φ0.65 (0.026)

l : 14

170

17.3

125

j : 38

221

22.5

163

fNOTE: Replace the parts except for O-rings (8, 19, 21) as the priority valve assembly. W3-14-2-1

SECTION 3 BODY Group 14 Priority Valve (Blank)

W3-14-2-2

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Valve 2, 3 1

WNDB-03-02-004

WNEE-03-15-009

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

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open side cover (1). 3. Remove rubber plate (4). (Refer to W3-4-2.)

W3-15-1-1

j : 17 mm

SECTION 3 BODY Group 15 Cooling Fan System

9 4

6, 7 2 1

5. Disconnect connectors (1) (3 used).

WNDB-03-15-001

WNDB-03-15-002

10. Disconnect hose (8).

6. Disconnect hose (3). j : 36 mm 7. Disconnect hose (4).

j : 19 mm 11. Remove socket bolts (6) (3 used) and washers (7) (3 used). Remove fan valve (5). l : 8 mm

j : 36 mm 8. Disconnect hoses (2) (3 used).

12. Remove the adapters with fan valve (5) attached if necessary.

j : 27 mm 9. Disconnect hose (9). j : 17 mm

W3-15-1-2

SECTION 3 BODY Group 15 Cooling Fan System 2

9 4

6, 7 2

5 WNDB-03-15-002

WNDB-03-15-001

Installation 1. Install all removed adapters to fan valve (5). 2. Install fan valve (5) with washers (7) (3 used) and socket bolts (6) (3 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect hose (8). j : 19 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect hose (9).

4 a-

35°

WNDB-03-15-003

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 5. Connect hoses (2) (3 used).

IMPORTANT: Check the angle to install hose (4). 6. Connect hose (4).

j : 27 mm

j : 36 mm

m : 95 N·m (9.5 kgf·m, 70 lbf·ft)

m : 180 N·m (18 kgf·m, 133 lbf·ft) 7. Connect hose (3). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 8. Connect connectors (1) (3 used).

W3-15-1-3

SECTION 3 BODY Group 15 Cooling Fan System

2, 3 1

WNEE-03-15-009

9. Install clip (3) with bolt, washer (2). 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. 10. Install rubber plate (4). (Refer to W3-4-2.) 11. Close side cover (1).

W3-15-1-4

WNDB-03-02-004

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Valve

4 3 2

2 1

B A C

Section A

WNEC-03-15-001

Section C 8

9 10 11 12 7 6 5

WJBA-03-16-005

WNEC-03-15-002

Section B

Section D 20

19 18

WJBA-03-16-004

W3-15-2-1

WJBA-03-16-006

SECTION 3 BODY Group 15 Cooling Fan System No.

Part Name

Q’ty

Solenoid Valve

Socket Bolt

Solenoid Valve

Plug

Relief Valve

Plug

O-Ring

Spring

Check Valve

O-Ring

Spring

Wrench Size mm

Tightening Torque N·m

(kgf·m, lbf·ft)

l :4

(0.5, 3.7)

l :8

(7, 52)

l : 10

120

(12, 89)

Plug

j : 30

180

(18, 133)

Plug

l :6

(3.5, 26)

Orifice

Plug

l :5

(1.5, 11)

Plug

l :8

(3.5, 26)

O-Ring

W3-15-2-2

Remark

SECTION 3 Body Group 15 Cooling Fan System Removal and Installation of Fan Motor

WNDB-03-07-002

WNDB-03-02-004

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

WNEE-03-04-003

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1- 4-1.) 2. Open side covers (front) (2) at left and right sides. 3. Remove rear cover (1). (Refer to W3-4-2.)

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

4. Open rear gril (3).

7. Place a container under hose (6). Loosen cock (5). Drain off coolant. Close cock (5).

5. Remove rubber plate (4). (Refer to W3-4-2.)

fNOTE: Amount of coolant: 28 L (7.4 US gal)

W3-15-3-1

SECTION 3 Body Group 15 Cooling Fan System

2 5

6, 7

1 WNDB-03-15-005

WNDB-03-15-004

8. Disconnect connector (2).

13. Remove the harnesses from all clips of side cover (rear) (4). Remove side cover (rear) (4). (Refer to W34-2.)

9. Disconnect connectors (1) (2 used). 10. Remove the harnesses from all clips of side cover (rear) (3). Remove side cover (rear) (3). (Refer to W34-2.) 11. Disconnect connector (5). 12. Remove bolt, washer (6). Remove outdoor ambient temperature sensor (7). j : 17 mm

W3-15-3-2

SECTION 3 Body Group 15 Cooling Fan System

1, 2

3 4, 5

7, 8

12, 13

14. Disconnect connector (11). 15. Remove clip (4). Disconnect hose (5).

WNDB-03-15-006

20. Remove bolts, washers (9) (4 used). Remove bracket (6). j : 17 mm

16. Remove clamp (1). Disconnect hose (2). 17. Remove clamp (7). Disconnect hose (8). 18. Remove clamp (12). Disconnect hose (13). 19. Remove bolts, washers (10) (4 used). Remove coolant reservoir (3). j : 17 mm

W3-15-3-3

SECTION 3 Body Group 15 Cooling Fan System

View A 3, 4

5 WNDB-03-15-007

21. Remove bolt, washer (3) and bracket (4). j : 17 mm 22. Remove clamps (1) (2 used). Disconnect the radiator side of hose (2).

fNOTE: THREEBOND #1207B has been applied on hose (2) mounting surface. 23. Remove clamp (5). Disconnect the engine side of hose (2).

fNOTE: THREEBOND #1207B has been applied on mounting surface of hose (2).

W3-15-3-4

WNEE-03-15-017

SECTION 3 Body Group 15 Cooling Fan System

18 1, 2

3, 4, 5

6, 7 13, 14, 15, 16

21, 22

8, 9, 10

11, 12

WNDB-03-15-009

24. Remove bolt, washer (13), collar (14), and clips (15, 16). j : 17 mm 25. Remove bolt, washer (11) and clip (12). j : 17 mm

30. Disconnect hose (18). j : 36 mm 31. Remove clamps (19) (2 used). Disconnect the both ends of hose (20). 32. Disconnect hose (23). j : 41 mm

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

33. Remove bolt, washer (21) and clip (22). j : 17 mm

27. Remove bolt, washer (8) and clips (9, 10). j : 17 mm

WNDB-03-15-008

34. Disconnect hose (17). j : 41 mm

28. Remove bolt, washer (6) and clip (7). j : 17 mm 29. Remove bolt, washer (3) and clips (4, 5). j : 17 mm

W3-15-3-5

SECTION 3 Body Group 15 Cooling Fan System

2 3

WNEE-03-15-034 a-

WNDB-03-15-010

Support

38. Remove bolts, washers (5) (6 used). Remove the hydraulic drive fan (4) assembly. Place the hydraulic drive fan (4) assembly on a wooden block with the fan motor (1) side down.

35. Disconnect hoses (2) (2 used). j : 27 mm 36. Disconnect hose (3).

j : 19 mm

j : 17 mm The hydraulic drive fan (4) assembly dCAUTION: weight: 74 kg (165 lb)

fNOTE: Hoist the hydraulic drive fan (4) assembly so that

37. Attach the nylon slings onto the hydraulic drive fan (4) assembly. Hoist and hold the hydraulic drive fan (4) assembly.

W3-15-3-6

fan motor (1) does not come in contact with support (a). Remove the hydraulic drive fan (4) assembly from the body left side.

SECTION 3 Body Group 15 Cooling Fan System

2, 3, 4

WNEE-03-15-035

7 WNEE-03-15-025

39. Remove bolt (2), spring washer (3), and washer (4). Remove the fan (1) assembly. j : 17 mm

fNOTE: LOCTITE #262 has been applied on bolt (2). 40. Remove key (8) from fan motor (7). 41. Hoist the hydraulic drive fan (5) assembly. Place the hydraulic drive fan (5) assembly on a wooden block with the fan motor (7) side up. 42. Remove bolts, washers (9) (2 used). Remove fan motor (7). j : 19 mm 43. Remove the adapters with fan motor (7) attached if necessary.

W3-15-3-7

WNEE-03-15-026

SECTION 3 Body Group 15 Cooling Fan System

7 10

WNEE-03-15-035

WNEE-03-15-026

2, 3, 4

Installation 1. Install all removed adapters to fan motor (7). The bracket (10) assembly weight: 50 dCAUTION: kg (115 lb) 2. Attach the nylon slings onto the bracket (10) assembly. Hoist and place the bracket (10) assembly with the fan motor (7) mounting side up. 3. Install fan motor (7) with bolts, washers (9) (2 used). WNEE-03-15-025

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Hoist the hydraulic drive fan (5) assembly. Place the hydraulic drive fan (5) assembly with the fan (1) mounting side up.

7. Apply LOCTITE #262 onto bolt (2). Install washer (4), spring washer (3), and bolt (2).

5. Install key (8) to fan motor (7).

j : 17 mm m : 34.3 N·m (3.43 kgf·m, 25.5 lbf·ft)

6. Fit the fan (1) assembly to key (8). Install it.

W3-15-3-8

SECTION 3 Body Group 15 Cooling Fan System

1 6, 7

2 3

WNEE-03-15-034

1 a-

WNDB-03-15-010

Support

CAUTION: The hydraulic drive fan (4) assembly weight: 74 kg (165 lb) 8. Attach the nylon slings onto the hydraulic drive fan (4) assembly. Hoist and hold the hydraulic drive fan (4) assembly.

10. Connect hose (3). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) 11. Connect hoses (2) (2 used).

9. Install the hydraulic drive fan (4) assembly with bolts, washers (5) (6 used).

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

j : 19 mm

12. Remove plug (6). Fill hydraulic oil from port (7). Install plug (6).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE: Hoist the hydraulic drive fan (4) assembly so that fan motor (1) does not come in contact with support (a). Install the hydraulic drive fan (4) assembly from the body left side.

W3-15-3-9

l : 6 mm m : 23 N·m (2.3 kgf·m, 17 lbf·ft)

SECTION 3 Body Group 15 Cooling Fan System

3 b WNEE-03-15-036 a-

Intercooler

Mark

View A d

5, 6 c

2 7

WNDB-03-15-008

13. Connect hose (1). j : 41 mm m : 110 N·m (11 kgf·m, 81 lbf·ft) WNDB-03-15-011

14. Install clip (6) with bolt, washer (5). c-

20˚

Oil Cooler

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Connect hose (7).

IMPORTANT: Check the angle to install hose (2). 17. Connect hose (2).

j : 41 mm

j : 36 mm

m : 110 N·m (11 kgf·m, 81 lbf·ft) IMPORTANT: Connect the mark (b) side of hose (4) facing to the intercooler (a) side. 16. Connect the both ends of hose (4) with clamps (3) (2 used). m : 12 N·m (1.2 kgf·m, 8.9 lbf·ft)

W3-15-3-10

m : 180 N·m (18 kgf·m, 133 lbf·ft)

SECTION 3 Body Group 15 Cooling Fan System

1, 2

3 4, 5

7, 8

12, 13

18. Install bracket (6) with bolts, washers (9) (4 used).

WNDB-03-15-006

22. Connect hose (2) with clamp (1). m : 3.6 to 4.4 N·m (0.36 to 0.44 kgf·m, 2.7 to 3.2 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 19. Install coolant reservoir (3) with bolts, washers (10) (4 used).

23. Connect hose (5) with clip (4). 24. Connect connector (11).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 20. Connect hose (13) with clamp (12). m : 5.4 to 6.6 N·m (0.54 to 0.66 kgf·m, 4 to 4.9 lbf·ft) 21. Connect hose (8) with clamp (7). m : 3.1 to 3.7 N·m (0.31 to 0.37 kgf·m, 2.3 to 2.7 lbf·ft)

W3-15-3-11

SECTION 3 Body Group 15 Cooling Fan System

1, 2

View A 15

3, 4, 5

6, 7

13, 14, 15, 16

8, 9, 10

WNEE-03-15-030 a-

11, 12

55˚

30˚

A WNDB-03-15-009

IMPORTANT: Check the angle to install clip (5). 25. Install clips (4, 5) with bolt, washer (3).

28. Install clip (2) with bolt, washer (1). 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) 29. Install clip (12) with bolt, washer (11).

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

j : 17 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 27. Install clips (9, 10) with bolt, washer (8). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Check the angle to install clip (15). 30. Install clips (15, 16) and collar (14) with bolt, washer (13). j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-15-3-12

SECTION 3 Body Group 15 Cooling Fan System

View A

3, 4

Engine

WNDB-03-15-007 a-

Radiator

IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (2) mounting part and inner surface of hose (2) of engine (b). 31. Apply THREEBOND #1207B onto the outer surface of the hose (2) mounting part of engine (b). Connect the engine (b) side of hose (2) with clamp (5).

33. Install bracket (4) with bolt, washer (3).

m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft) IMPORTANT: Do not apply THREEBOND #1207B onto the inner surface of the hose (2) mounting part and inner surface of hose (2) of radiator (a). 32. Apply THREEBOND #1207B onto the outer surface of the hose (2) mounting part of hose (2) of radiator (a). Connect the radiator (a) side of hose (2) with clamps (1) (2 used). m : 7 N·m (0.7 kgf·m, 5.2 lbf·ft)

W3-15-3-13

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

WNEE-03-15-017

SECTION 3 Body Group 15 Cooling Fan System

2 5

6, 7

1 WNDB-03-15-005

34. Install side cover (rear) (4). (Refer to W3-4-2.) 35. Install outdoor ambient temperature sensor (7) with bolt, washer (6).

39. Connect connector (2). Install the harnesses to all clips of rear cover (rear) (3). 40. Add coolant to the radiator.

fNOTE: Amount of coolant: 28 L (7.4 US gal)

j : 17 mm

41. Add transmission oil to the transmission.

m : 50 N·m (5 kgf·m, 37 lbf·ft) 36. Connect connector (5). Install the harnesses to all clips of side cover (rear) (4). 37. Install side cover (rear) (3). (Refer to W3-4-2.)

WNDB-03-15-004

fNOTE: Amount of transmission oil: 30 L (7.9 US gal) IMPORTANT: Check the hydraulic oil level, transmission oil level, and the coolant level. Start the engine and check for any oil and coolant leaks.

38. Connect connectors (1) (2 used).

W3-15-3-14

SECTION 3 Body Group 15 Cooling Fan System

WNDB-03-07-002

42. Install rubber plate (4). (Refer to W3-4-2.) 43. Install rear cover (1). (Refer to W3-4-2.) 44. Close rear grill (3) and side covers (front) (2) at the left and right sides.

W3-15-3-15

WNDB-03-02-004

SECTION 3 Body Group 15 Cooling Fan System (Blank)

W3-15-3-16

SECTION 3 BODY Group 15 Cooling Fan System Structure of Fan Motor 1

22 21

20 19 18

17 16

12 11

10 WJBA-03-17-001

W3-15-4-1

SECTION 3 BODY Group 15 Cooling Fan System

No.

Part Name

Q’ty

Roller Bearing

O-Ring

Plunger

Swash Plate

Roller Bearing

Key

Shaft

Retaining Ring

Oil Seal

Housing

Holder

Retainer

Spring seat

Rotor

Spring

Washer

Retaining Ring

Valve Plate

Socket Bolt

Rear Cover

Wrench Size mm

l : 10

W3-15-4-2

Tightening Torque N·m

(kgf·m, lbf·ft)

(9, 66)

Remark

SECTION 3 BODY Group 15 Cooling Fan System Removal and Installation of Fan Pump

WNDB-03-14-001

IMPORTANT: The hose and pipe contain hydraulic oil. When removing the hose and pipe, receive oils with a container in order to avoid spilling oils.

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1- 4-1.) 2. Open side cover (front) (1).

3. Remove cover (lower) (2). (Refer to W3-4-2.)

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

W3-15-5-1

SECTION 3 BODY Group 15 Cooling Fan System

1 a-

WNDB-03-15-012

Washer Fluid Tank

4. Disconnect connectors (1) (4 used). 5. Disconnect hoses (2) (2 used). 6. Remove bolts, washers (4) (2 used) and bracket (5). Remove and place the fuel filter (3) assembly outside the work area. j : 17 mm

W3-15-5-2

WNDB-03-15-013

SECTION 3 BODY Group 15 Cooling Fan System

3 WNEE-03-04-014

4 WNEE-03-15-040

7. Disconnect hose (1). j : 41 mm 8. Disconnect hose (2). j : 27 mm 9. Remove bolts, washers (5) (2 used). Remove fan pump (4) and gasket (3). j : 17 mm 10. Remove the adapters with fan pump (4) attached if necessary.

W3-15-5-3

SECTION 3 BODY Group 15 Cooling Fan System

3 WNEE-03-04-014

4 WNEE-03-15-040

1 4

Installation 1. Install all removed adapters to fan pump (4).

2. Install gasket (3) and fan pump (4) with bolts, washers (5) (2 used). a-

j : 17 mm m : 50 N∙m (5 kgf∙m, 37 lbf∙ft) 3. Connect hose (2). j : 27 mm m : 95 N∙m (9.5 kgf∙m, 70 lbf∙ft) IMPORTANT: Check the angle to install hose (1). 4. Connect hose (1). j : 41 mm m : 210 N∙m (21 kgf∙m, 155 lbf∙ft)

W3-15-5-4

35˚

WNEE-03-04-034

SECTION 3 BODY Group 15 Cooling Fan System

WNDB-03-15-013 a-

5. Install the fuel filter (3) assembly and bracket (5) with bolts, washers (4) (2 used). j : 17 mm m : 50 N∙m (5 kgf∙m, 37 lbf∙ft) 6. Connect hoses (2) (2 used). 7. Connect connectors (1) (4 used).

W3-15-5-5

Washer Fluid Tank

WNDB-03-15-012

SECTION 3 BODY Group 15 Cooling Fan System

WNDB-03-14-001

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 8. Install cover (lower) (2). (Refer to W3-4-2.) 9. Close side cover (front) (1).

W3-15-5-6

SECTION 3 BODY Group 15 Cooling Fan System Disassembly of Fan Pump 8 7 6 5 4 3 2 1

6 14 13

10 12 4 5 6 7 11 WNEC-03-15-010

1234-

Retaining Ring Oil Seal Front Cover Gasket (2 Used)

5678-

Gasket (2 Used) Bushing (4 Used) Side Plate (2 Used) Body

10111213-

Drive Gear Driven Gear Rear Cover Washer (4 Used)

W3-15-6-1

14- Bolt (4 Used)

SECTION 3 BODY Group 15 Cooling Fan System 5. Remove drive gear (10) from body (8).

Disassembly of Fan Pump IMPORTANT: Put the matching marks on front cover (3), body (8), and rear cover (12) before disassembling. 1. Secure the front cover (3) mounting part in a vise with the rear cover (12) side up. 2. Remove bolts (14) (4 used) and washers (13) (4 used) from rear cover (12). Remove rear cover (12) from body (8). l : 10 mm IMPORTANT: Check the position and direction of side plate (7) and gaskets (4, 5) for assembling. 3. Remove gaskets (4, 5) from rear cover (12). Remove side plate (7) from the body (8) assembly.

6. Remove body (8) from front cover (3). IMPORTANT: Check the position and direction of side plate (7) and gaskets (4, 5) for assembling. 7. Remove gaskets (4, 5) and side plate (7) from front cover (3). 8. Remove retaining ring (1) from front cover (3). IMPORTANT: Do not damage the oil seal hole of front cover (3). 9. Remove oil seal (2) from front cover (3) by using a screwdriver. 2

IMPORTANT: The front and rear shapes of driven gear (11) are symmetrical. Put the matching marks for assembling. 4. Remove driven gear (11) from body (8).

W4GB-02-08-012

W3-15-6-2

SECTION 3 BODY Group 15 Cooling Fan System Assembly of Fan Pump

WNEC-03-15-011

1234-

Retaining Ring Oil Seal Front Cover Gasket (2 Used)

5678-

Gasket (2 Used) Bushing (4 Used) Side Plate (2 Used) Body

10111213-

Drive Gear Driven Gear Rear Cover Washer (4 Used)

W3-15-6-3

14- Bolt (4 Used)

SECTION 3 BODY Group 15 Cooling Fan System 4. Fit the matching marks and install body (8) to front cover (3).

Assembly of Fan Pump IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Secure front cover (3) in a vise with the body (8) mounting surface up. IMPORTANT: Check the direction to install gaskets (4, 5). 2. Apply grease onto oil gaskets (4, 5). Install gaskets (4, 5) to front cover (3). 3

IMPORTANT: Check the direction to install driven gear (11). IMPORTANT: Drive gear (10) and driven gear (11) have asymmetrical tooth shape. Mesh the gears with the small notch and install them. 5. Install drive gear (10) and driven gear (11) to the body (8) assembly.

l j

W4GB-02-08-014

3. Install side plate (7) to front cover (3) so that the yellow surface faces the gear side and long hole (a) faces the suction side. 7

hij-

Delivery Side Suction Side Large Notch (Non-Mesh Side)

e W4GB-02-08-015

Delivery Side Suction Side

de-

Small Notch (Non-Mesh Side) Rotation Direction of Drive Gear (10)

6. Install side plate (7) to drive gear (10) and driven gear (11) so that the yellow surface faces the gear side and long hole (a) faces the suction side.

Short Hole Long Hole

3 f g

fg-

kl-

bc-

WNEC-03-15-012

WNEC-03-15-005

Delivery Side Suction Side

W3-15-6-4

SECTION 3 BODY Group 15 Cooling Fan System IMPORTANT: Check the direction to install gaskets (4, 5). 7. Apply grease onto oil gaskets (4, 5). Install gaskets (4, 5) to rear cover (12). 12

11. Install oil seal (2) to front cover (3) with oil seal guide (e).

5 e

3 W4GB-02-08-014

8. Fit the matching marks and install rear cover (12) to the body (8) assembly with washers (13) (4 used) and bolts (14) (4 used).

W4GB-02-08-018 e-

l : 10 mm m : 90 to 95 N·m (9.0 to 9.5 kgf·m, 66 to 70 lbf·ft)

Oil Seal Guide

12. Install retaining ring (1) to front cover (3).

9. Turn over the body (8) assembly. Secure front cover (3) in a vise. 10. Apply grease between main lip (b) and dust lip (c) of oil seal (2). c

d b W4GB-02-08-017 bc-

Main Lip Dust Lip

Apply grease.

W4GB-02-08-019

W3-15-6-5

SECTION 3 BODY Group 15 Cooling Fan System (Blank)

W3-15-6-6

SECTION 3 BODY Group 16 Ride Control Device Removal and Installation of Ride Control Valve 1 2

2 8

3, 4, 5

2 WNEC-04-08-003

WNDB-03-16-005

3. Disconnect hose (8). j : 27 mm 4. Disconnect hose (7). j : 36 mm 5. Remove socket bolts (3) (4 used) and flanges (4) (2 used). Disconnect hose (6). Remove O-ring (5). l : 8 mm

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Release any pressure in the hydraulic dCAUTION: circuit and the ride control accumulator. (Refer to W1-5-1.) 2. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm

W3-16-1-1

SECTION 3 BODY Group 16 Ride Control Device

1, 2, 3

4 7

9 10

5 8

WNDB-03-16-007

WNDB-03-16-006

6. Remove socket bolts (1) (4 used) and flanges (2) (2 used). Disconnect hose (4). Remove O-ring (3).

10. Remove bolts, washers (10) (3 used). Remove ride control valve (7) from bracket (9). j : 19 mm

l : 8 mm

11. Remove the adapters with ride control valve (7) attached if necessary.

7. Disconnect hoses (6) (2 used). j : 17 mm 8. Disconnect connector (5). 9. Remove bolts, washers (8) (4 used). Remove the ride control valve (7) assembly. j : 19 mm

W3-16-1-2

SECTION 3 BODY Group 16 Ride Control Device

1, 2, 3 7

9 10

5 8

WNDB-03-16-007

WNDB-03-16-006

View A

Installation 1. Install all removed adapters to ride control valve (7). 2. Install ride control valve (7) to bracket (9) with bolts, washers (10) (3 used).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 3. Install the ride control valve (7) assembly with bolts, washers (8) (4 used). j : 19 mm

4 a-

10 °

WNDB-03-16-008

m : 90 N·m (9 kgf·m, 66 lbf·ft) 4. Connect connector (5). 5. Connect hoses (6) (2 used).

IMPORTANT: Check the angle to install hose (4). 6. Install O-ring (3). Install hose (4) with flanges (2) (2 used) and socket bolts (1) (4 used).

j : 17 mm

l : 8 mm

m : 25 N·m (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 7 8

1, 2, 3 A

8 WNEC-04-08-003

WNDB-03-16-005 View A

IMPORTANT: Check the angle to install hose (4). 7. Install O-ring (3). Install hose (4) with flanges (2) (2 used) and socket bolts (1) (4 used). l : 8 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 8. Connect hose (5). 4

j : 36 mm

30 °

WNDB-03-16-008

m : 180 N·m (18 kgf·m, 133 lbf·ft) 9. Connect hose (6). 13. Install cover (7) with bolts, washers (8) (4 used).

j : 27 mm

j : 17 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

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.) 11. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 12. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.)

W3-16-1-4

SECTION 3 BODY Group 16 Ride Control Device Disassembly of Ride Control Valve

WNDB-03-16-001

02- Spring 03- Plug 04- O-Ring (2 Used) 05- Plug 05A- O-Ring 07- Plug 08- Solenoid Valve 08A- Sleeve 08B- Spool 08C- Solenoid 08D- Spring 08E- Plate

08F- Washer 08G- Socket Bolt (2 Used) 08H- O-Ring 08I- O-Ring 08J- O-Ring 08K- O-Ring 10- Plug 13- Spring 16- O-Ring 17- Backup Ring 18- Check Valve 19- Spring

20- Plug 21- O-Ring 22- Drain Plug 23- O-Ring 24- Nut 25- Plug 25A- O-Ring 26- Plug 26A- O-Ring 27- Plug 27A- O-Ring 28- Plug

W3-16-2-1

28A- O-Ring 32A- Housing 32B- Spool 32C- Spool 34- Relief Valve 34A- O-Ring 34B- Backup Ring 34C- O-Ring 36- Orifice

SECTION 3 BODY Group 16 Ride Control Device 8. Remove plug (03) from housing (32A). Remove O-ring (04) from plug (03).

Disassembly of Ride Control Valve 1. 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

A B

26, 26A A

27, 27A

TNDB-03-12-001

Section A-A a

Section B-B

32A

28A

23 24 22

02 05A 05 32B

03 04 34C

25A

WNDB-03-16-002

W3-16-2-4

34A

34B

T4GD-03-08-001

SECTION 3 BODY Group 16 Ride Control Device Detail a (Solenoid Valve (08) Assembly)

08H

Detail b

08K

32C

08J 08I 08E 08F

08C

10 08G

08A

08B

WNDB-03-16-003

02- Spring 03- Plug 04- O-Ring (2 Used) 05- Plug 05A- O-Ring 07- Plug 08- Solenoid Valve 08A- Sleeve 08B- Spool 08C- Solenoid 08D*- Spring 08E- Plate

08F- Washer 08G- Socket Bolt (2 Used) 08H- O-Ring 08I- O-Ring 08J- O-Ring 08K- O-Ring 10- Plug 13- Spring 16- O-Ring 17- Backup Ring 18- Check Valve 19- Spring

WNDB-03-16-004

20- Plug 21- O-Ring 22- Drain Plug 23- O-Ring 24- Nut 25- Plug 25A- O-Ring 26- Plug 26A- O-Ring 27- Plug 27A- O-Ring 28- Plug

fNOTE: As for the item with mark*, refer to W3-16-2-1.

W3-16-2-5

28A- O-Ring 32A- Housing 32B- Spool 32C- Spool 34- Relief Valve 34A- O-Ring 34B- Backup Ring 34C- O-Ring 36- Orifice

SECTION 3 BODY Group 16 Ride Control Device Assembly of Ride Control Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: After installing orifice (36), wait for 60 minutes or more in order to let it dry. 1. Apply THREEBOND #1324 onto the thread part of orifice (36). Install orifice (36) to housing (32A). l : 5 mm m : 10 to 13 N·m (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 1 2

3 WNEC-04-08-003

WNDB-03-16-009

Removal

dCAUTION:

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 hydraulic dCAUTION: circuit and the ride control accumulator. (Refer to W1-5-1.) 2. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm

 Be sure to release pressure before starting to work on the piping lines.

3. Disconnect hose (3).

W3-16-3-1

j : 36 mm

SECTION 3 BODY Group 16 Ride Control Device

WNDB-03-16-010

4. Remove bolts, washers (4) (4 used), clip (5), clamps (1) (2 used), and rubbers stoppers (2) (2 used). Remove ride control accumulator (3). j : 19 mm 5. Remove the adapters with ride control accumulator (3) attached if necessary.

W3-16-3-2

SECTION 3 BODY Group 16 Ride Control Device

View A

WNDB-03-16-010 a-

Installation

View B

1. Install all removed adapters to ride control accumulator (3).

IMPORTANT: Check the position to install ride control accumulator (3). 2. Install ride control accumulator (3) with rubber stoppers (2) (2 used), clamps (1) (2 used), clip (5), and bolts, washers (4) (4 used). j : 19 mm

WNDB-03-16-011

0 mm

3 b-

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-16-3-3

90°

WNDB-03-16-012

SECTION 3 BODY Group 16 Ride Control Device

1 2

2 3

WNEC-04-08-003

A WNDB-03-16-009

View A

IMPORTANT: Check the angle to install hose (3). 3. Connect hose (3).

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) a

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.) 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.)

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

W3-16-3-4

45°

WNDB-03-16-013

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Removal and Installation of Bucket Regenerative Valve 1 3

WNDB-03-17-117

WNDB-03-17-101

3. Disconnect hoses (3) (4 used). j : 41 mm

fNOTE: The work space can be secured by disconnecting

1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) Bleed air (release pressure) from the dCAUTION: hydraulic oil tank. (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 : 17 mm

W3-17-1-1

hoses (3) (4 used).

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

View A

3, 4, 5

WNDB-03-17-115

4. Disconnect hoses (1) (2 used). j : 36 mm 5. Remove bolts, washers (3) (2 used), clamps (4) (4 used), and rubbers (5) (2 used). j : 17 mm 6. Disconnect pipes (2) (2 used). j : 36 mm

W3-17-1-2

WNDB-03-17-116

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

WNEC-03-01-001

7. Remove bolts, washers (2) (4 used). Remove cover (1). j : 17 mm 8. Remove bolts, washers (4) (3 used). Remove cover (3). j : 17 mm

W3-17-1-3

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

Detail A

3 4

WNDB-03-17-110

WNDB-03-17-109 B

View B

9. Disconnect hose (1). j : 22 mm 10. Disconnect hoses (3, 4). j : 36 mm 11. Disconnect hose (2). j : 22 mm 12. Remove bolts, washers (5) (4 used). j : 19 mm 5

W3-17-1-4

WNDB-03-17-111

SECTION 3 BODY Group 17 Parallel Link (Special Parts) a

WNDB-03-17-112

Freno-Linkbolt Mounting Hole

Machine Rear

13. Move bucket regenerative valve (1) toward the machine rear until bucket regenerative valve (1) reaches the position where bucket regenerative valve (1) can be hoisted. Bucket regenerative valve (1) weight: dCAUTION: 33 kg (73 lb) IMPORTANT: Protect bucket regenerative valve (1) by using cloth in order to prevent the front chassis and cab from damage. 14. Install Freno-Linkbolts (A-10: M10, Pitch: 1.5 mm) (2 used) to Freno-Linkbolt mounting holes (a) (2 places) of bucket regenerative valve (1). Attach nylon slings onto the Freno-Linkbolts (2 used). Hoist and remove bucket regenerative valve (1) from bracket (2). 15. Remove the adapters with bucket regenerative valve (1) attached if necessary.

W3-17-1-5

SECTION 3 BODY Group 17 Parallel Link (Special Parts) a

View A

WNDB-03-17-111

WNDB-03-17-112 A a-

Freno-Linkbolt Mounting Hole

Installation 1. Install all removed adapters to bucket regenerative valve (1).

3. Install bucket regenerative valve (1) to bracket (2) with bolts, washers (3) (4 used).

Bucket regenerative valve (1) weight: dCAUTION: 33 kg (73 lb) IMPORTANT: Protect bucket regenerative valve (1) by using cloth in order to prevent the front chassis and cab from damage. 2. Install Freno-Linkbolts (A-10: M10, Pitch: 1.5 mm) (2 used) to Freno-Linkbolt mounting holes (a) (2 places) of bucket regenerative valve (1). Attach nylon slings onto the Freno-Linkbolts (2 used). Hoist bucket regenerative valve (1).

W3-17-1-6

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

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

Detail A

3 4 B WNDB-03-17-110

WNDB-03-17-109

View B 3

4. Connect hose (2). j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft)

IMPORTANT: Check the angle to install hoses (3, 4). 5. Connect hoses (3, 4).

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 6. Connect hose (1).

j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-17-1-7

15°

WNDB-03-17-118

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

View A

3, 4, 5

WNDB-03-17-115

7. Temporarily install pipes (2) (2 used), rubbers (5) (2 used), clamps (4) (4 used), and bolts, washers (3) (2 used).

10. Connect hoses (1) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

8. Tighten pipes (2) (2 used). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 9. Tighten bolts, washers (3) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-17-1-8

WNDB-03-17-116

SECTION 3 BODY Group 17 Parallel Link (Special Parts) A

View A

1 2 2 3 4

WNDB-03-09-110 a-

WNDB-03-17-117

15°

View A

IMPORTANT: Check the angle to install hoses (1, 2). 11. Connect hoses (1, 2, 3, 4).

j : 41 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

WNDB-03-09-111 b-

W3-17-1-9

5°

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

3 5

WNEC-03-01-001

WNDB-03-17-101

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

16. Install cover (6) with bolts, washers (5) (4 used).

IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 13. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) 14. Install cover (3) with bolts, washers (4) (3 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Install cover (1) with bolts, washers (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-17-1-10

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

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Structure of Bucket Regenerative Valve 1, 2

4, 5

11, 12 WNDF-03-18-007

Detail of Logic Valve (3)

3a 3b

7, 8

Detail of Check Valve (6)

Detail of Pilot Check Valve (13)

13a 13b

13c

13d

WNDF-03-18-012

13e 13f WNDF-03-18-013

W3-17-2-1

13e

WNDF-03-18-014

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

No. 1 2 3 3a 3b 3c 3d 3e 3f 4 5 6 6a 6b 6c 6d 7 8 9 10 11 12 13 13a 13b 13c 13d 13e 13f

Part Name Plug O-Ring Logic Valve Backup Ring O-Ring O-Ring Backup Ring Backup Ring O-Ring Plug O-Ring Check Valve O-Ring Backup Ring Backup Ring O-Ring Plug O-Ring Orifice Casing Plug O-Ring Pilot Check Valve Backup Ring O-Ring O-Ring Backup Ring Backup Ring O-Ring

Q’ty 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1

Wrench Size (mm) l : 17

Tightening Torque N·m kgf·m 221 22.1

lbf·ft 163

j : 31.8

207.5±7.5

20.8±0.8

153±5.5

l : 12

162

16.2

119

j : 41.1

482.5±17.5

48.2±1.8

360±13

l:6

36.3

3.6

l : 10

108

10.8

j : 41.1

482.5±17.5

48.3±1.8

360±13

W3-17-2-2

Remark

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Removal and Installation of Bucket Regenerative Selector Valve 1

WNDB-03-17-101

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).

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

W3-17-3-1

j : 17 mm

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Detail A 6 A

1 4

WNDB-03-17-103

3. Disconnect hose (1). j : 19 mm

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

WNDB-03-17-104

6. Remove bolts, washers (3) (2 used). Remove the bucket regenerative selector valve (2) assembly from front chassis (6).

4. Disconnect hose (5). j : 22 mm

j : 17 mm 7. Remove the adapters with the bucket regenerative selector valve (2) assembly attached if necessary.

j : 22 mm

W3-17-3-2

SECTION 3 BODY Group 17 Parallel Link (Special Parts) 1

4 WNDF-03-18-003

8. Remove socket bolts (4) (4 used). Remove bucket regenerative selector valve (3) from valve plate (1). l : 4 mm 9. Remove O-rings (2) (4 used) from bucket regenerative selector valve (3).

W3-17-3-3

SECTION 3 BODY Group 17 Parallel Link (Special Parts) 1

4 WNDF-03-18-003

Installation 1. Install O-rings (2) (4 used) to bucket regenerative selector valve (3). 2. Install bucket regenerative selector valve (3) to valve plate (1) with socket bolts (4) (4 used). l : 4 mm m : 6.9 ±1 N·m (0.69 ±0.1 kgf·m, 5.1±0.7 lbf·ft) 3. Install all removed adapters to the bucket regenerative selector valve (3) assembly.

W3-17-3-4

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Detail A 7 A

6 5

WNDB-03-17-103

4. Install the bucket regenerative selector valve (2) assembly to front chassis (7) with bolts, washers (3) (2 used).

WNDB-03-17-104

2 5

View B a

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 6

IMPORTANT: Check the angle to install hose (5). 5. Connect hoses (4, 5). j : 22 mm

ab-

90° 45°

m : 40 N·m (4 kgf·m, 29.5 lbf·ft) IMPORTANT: Check the angle to install hose (6). 6. Connect hose (6).

7. Connect hose (1).

j : 22 mm

j : 19 mm

m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-17-3-5

WNDB-03-17-106

SECTION 3 BODY Group 17 Parallel Link (Special Parts)

WNDB-03-17-101

8. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 9. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-6-1.) 10. Install cover (2) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-17-3-6

SECTION 3 BODY Group 17 Parallel Link (Special Parts) Structure of Bucket Regenerative Selector Valve

6 7 7 8 8

16 WNDF-03-18-011

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part Name Spring O-Ring Casing Plug Spring Socket Bolt Plug O-Ring Cover Spring Seat Piston Spool Spring Seat Piston Cover Socket Bolt

Q'ty 1 2 1 1 1 4 2 2 1 1 1 1 1 1 1 4

Wrench Size (mm)

Tightening Torque N·m kgf·m

lbf·ft

l:6

2.2

l:3 l : 10

2.7 117

0.3 11.7

2 86

l:3

2.7

0.3

Remark

fNOTE: Replacement parts except plugs (4, 7), springs (1, 5), O-rings (2, 8), and socket bolts (6, 16) shall be replaced as the bucket regenerative selector valve assembly.

W3-17-4-1

SECTION 3 BODY Group 17 Parallel Link (Special Parts) (Blank)

W3-17-4-2

INDEX A Adjustment Brake Disc Clearance.................................................. W4-3-3-32 Parking brake ..................................................................W4-2-6-5 Ring Gear Backlash ..................................................... W4-3-3-29 Ring Gear Teeth Engagement ................................ W4-3-3-29 Air Cleaner, Removal and Installation ..........................W3-4-3-1 Applicable Tire Size ........................................ W4-1-1-3, W4-1-2-5 Articulation Lock..................................................................W1-6-1-2 Assembly of Auxiliary Pilot Valve .................................................... W3-10-6-4 Axle .................................................................................. W4-3-3-18 Bearing Cage ................................................................ W4-3-3-25 Brake Valve .......................................................................W4-5-2-3 Bucket Cylinder.......................................... W5-2-3-6, W5-4-5-5 Control Valve....................................................................W3-9-3-5 Control Valve (Parallel Link) ..................................... W3-9-4-10 Fan Pump ....................................................................... W3-15-6-3 Lift Arm Cylinder ....................................... W5-2-3-6, W5-4-4-5 Main Pump .......................................................................W3-8-3-5 Manifold Valve.............................................................. W3-12-2-4 Pilot Valve....................................................................... W3-10-4-4 Pilot Valve (Two Lever Type) .................................... W3-10-5-7 Pump Device ...................................................................W3-8-2-3 Quick Coupler Cylinder ................................................W5-4-6-4 Quick Coupler Solenoid Valve ................................ W3-13-5-3 Regulator ..........................................................................W3-8-4-3 Ride Control Valve....................................................... W3-16-2-4 Steering Cylinder ...........................................................W4-6-4-5 Steering Valve..................................................................W4-6-2-4 Auxiliary Pilot Valve, Assembly .................................... W3-10-6-4 Auxiliary Pilot Valve, Disassembly .............................. W3-10-6-1 Auxiliary Pilot Valve, Removal and Installation ...... W3-10-3-1 Axle, Assembly .................................................................. W4-3-3-18 Axle, Disassembly ........................................... W4-3-3-1, W4-3-3-7 Axle, Maintenance Standard ...........................................W2-2-1-1 Axle Shaft Bearing (Shim Adjustment), Preload Adjustment ................................................... W4-3-3-37 Axle Support, Installation .............................................. W4-3-3-42 Axle Support, Removal ......................................................W4-3-3-6 Axle equipped with LSD ....... W2-2-1-1, W4-3-3-3, W4-3-3-19 Axle equipped with TPD ....... W2-2-1-1, W4-3-3-2, W4-3-3-18 B 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 Bearing Cage Assembly Disassembly.............................................. W4-3-3-13 Installation..................................................................... W4-3-3-28 Removal.......................................................................... W4-3-3-12 Assembly ........................................................................ W4-3-3-25 Bell Crank (Lever), Removal and Installation .............W5-1-3-1

Bell Crank Stopper Clearance..........................................W2-3-2-2 Bleeding Air ...........................................................................W1-4-1-1 Brake (Axle) ......................................................................W1-4-1-5 Fuel System ......................................................................W1-4-1-3 Hydraulic Oil Tank ..........................................................W1-4-1-1 Hydraulic System ...........................................................W1-4-1-2 Radiator .............................................................................W1-4-1-4 Bolts, Tightening ..................................................................W1-2-1-1 Brake, Installation ............................................................. W4-3-3-34 Brake, Removal .................................................................. W4-3-3-11 Brake (Axle) Bleeding Air from ........................................W1-4-1-5 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 Disc Clearance, Adjustment ............................. W4-3-3-32 Brake Valve, Assembly .......................................................W4-5-2-3 Brake Valve, Disassembly ..................................................W4-5-2-1 Brake Valve, Removal and Installation .........................W4-5-1-1 Bucket, Removal and Installation ..................................W5-1-4-1 Bucket, Standard Dimensions .................... W2-3-2-1, W2-4-2-1 Bucket Cylinder Assembly ........................... W5-2-3-6, W5-4-5-5 Disassembly ................................................ W5-2-3-1, W5-4-5-1 Removal and Installation ....................... W5-2-2-1, W5-4-2-1 Bucket Regenerative Selector Valve Removal and Installation ......................................... W3-17-3-1 Structure ........................................................................ W3-17-4-1 Bucket Regenerative Valve Removal and Installation ......................................... W3-17-1-1 Structure ........................................................................ W3-17-2-1 Bucket Stopper Clearance ................................................W2-3-2-2 Bucket Dump Stopper..................................................W2-3-2-2 Bucket Tilt (Roll Back) Stopper ..................................W2-3-2-2 Bushing, Maintenance Standard............... W2-3-1-1, W2-4-1-1 C Cab, Removal and Installation of ...................................W3-1-1-1 Cab (Parallel Link), Removal and Installation ............W3-1-2-1 Center Hinge (Center Pin)............................ W2-1-1-1, W3-3-1-1 Maintenance Standard ................................................W2-1-1-1 Removal and Installation of .......................................W3-3-1-1 Center Hinge (Parallel Link), Removal and Installation........................................................................W3-3-2-1 Chassis, Lock..........................................................................W1-6-1-2 Clutch, Disassembly and Assembly ........................... W4-2-4-24 Clutch, Removal and Installation ...................................W4-2-4-9 Connecting Hose .................................................................W1-2-1-9 Control Valve, Multiple Assembly ...........................................................................W3-9-3-5 Disassembly .....................................................................W3-9-3-1 Removal and Installation ............................................W3-9-1-1 Control Valve (Parallel Link) Assembly ........................................................................ W3-9-4-10 Disassembly .....................................................................W3-9-4-1 Removal and Installation ............................................W3-9-2-1 Cooling Fan System ......................................................... W3-15-1-1 Counterweight, Removal and Installation .................W3-2-1-1

70Z7/70TM7 D&R

INDEX Cover (Lower), Removal and Installation ....................W3-4-2-2 Cylinder .............................................................. W2-3-3-1, W2-4-3-1 Cylinder (Parallel Link) .......................................................W5-4-1-1 D Deck, Removal and Installation ......................................W3-4-2-8 Differential Case (LSD), Assembly ............................... W4-3-3-23 Differential Case (LSD), Disassembly ......................... W4-3-3-16 Differential Case (TPD), Disassembly......................... W4-3-3-15 Differential Case Assembly, Removal ........................ W4-3-3-14 Differential Case Assembly, Installation ................... W4-3-3-27 Disassembly and Assembly Clutch .............................................................................. W4-2-4-24 Drive Unit ..........................................................................W4-2-2-1 Hydraulic Pump Drive ..................................................W4-2-4-1 Transmission ...................................................................W4-2-4-1 Transmission Control Valve ........................................W4-2-5-1 Disassembly Auxiliary Pilot Valve .................................................... W3-10-6-1 Axle ................................................................ W4-3-3-1, W4-3-3-7 Bearing Cage Assembly ............................................ W4-3-3-13 Brake Valve .......................................................................W4-5-2-1 Bucket Cylinder.......................................... W5-2-3-1, W5-4-5-1 Control Valve, Multiple .................................................W3-9-3-1 Control Valve (Parallel Link) ........................................W3-9-4-1 Differential Case (LSD)............................................... W4-3-3-16 Differential Case (TPD) .............................................. W4-3-3-15 Fan Pump ....................................................................... W3-15-6-1 Fast-Speed Forward Clutch (K4) ............................ W4-2-4-43 Lift Arm Cylinder ....................................... W5-2-3-1, W5-4-4-1 Main Pump .......................................................................W3-8-3-1 Manifold Valve.............................................................. W3-12-2-1 Pilot Valve....................................................................... W3-10-4-1 Pilot Valve (Two Lever Type) .................................... W3-10-5-1 Planetary Carrier Assembly ..................................... W4-3-3-10 Pump Device ...................................................................W3-8-2-1 Quick Coupler Cylinder ................................................W5-4-6-1 Quick Coupler Solenoid Valve ................................ W3-13-5-1 Regulator ..........................................................................W3-8-4-1 Reverse Clutch (KR) .................................................... W4-2-4-36 Ride Control Valve....................................................... W3-16-2-1 Slow-Speed Forward Clutch (KV) .......................... W4-2-4-36 Speed Clutch (K1), (K2), and (K3) ........................... W4-2-4-27 Steering Cylinder ...........................................................W4-6-4-1 Steering Valve..................................................................W4-6-2-1 Drive Unit (Torque Converter, Transmission).............W4-2-4-1 Disassembly and Assembly ........................................W4-2-2-1 Removal and Installation ............................................W4-2-1-1 Duct Plate, Removal and Installation ...........................W4-2-5-4 Dump Stopper, Bucket ......................................................W2-3-2-2 E Engine Cover, Removal and Installation......................W3-4-2-2 Engine, Removal and Installation ..................................W3-4-1-1 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 Pump, Assembly ....................................................... W3-15-6-3 Fan Pump, Disassembly.................................................. W3-15-6-1 Fan Pump, Removal and Installation ......................... W3-15-5-1 Fan System, Cooling ........................................................ W3-15-1-1 Fan Valve, Removal and Installation .......................... W3-15-1-1 Fan Valve, Structure ......................................................... W3-15-2-1 Fast-Speed Forward Clutch (K4) .................................. W4-2-4-42 Assembly ........................................................................ W4-2-4-45 Disassembly .................................................................. W4-2-4-43 First Speed Clutch (K1) ................................................... W4-2-4-24 Flange at Output Shaft Side, Removal and Installation........................................................................W4-2-6-7 Floating Seal, Precautions for Using .............................W1-1-1-2 Front Attachment ........................................... W2-3-1-1, W5-1-1-1 Hydraulic Circuit Pressure Release Procedure .....W1-5-1-1 Maintenance Standard ................................................W2-3-1-1 Removal and Installation ............................................W5-3-1-1 Front Attachment (Parallel Link) ....................................W5-3-1-1 Maintenance Standard ................................................W2-4-1-1 Front Attachment (With Lift Arm Auto Leveler), Removal and Installation ............................................W5-1-2-1 Front Attachment (With Lift Arm Kickout), Removal and Installation ............................................W5-1-1-1 Front Axle, Removal and Installation............................W4-3-1-1 Front Fender, Removal and Installation ................... W3-4-2-11 Front Tire, Removal and Installation .............................W4-1-1-1 Fuel Cooler, Replacement.................................................W3-5-1-1 Fuel System, Bleeding Air from ......................................W1-4-1-3 Fuel Tank, Removal and Installation .............................W3-7-1-1 H Hydraulic Oil Tank, Bleeding Air .....................................W1-4-1-1 Hydraulic Oil Tank, Removal and Installation ............W3-6-1-1 Hydraulic Pump Drive, Disassembly and Assembly ...........................................................................W4-2-4-1 Hydraulic System, Bleeding Air ......................................W1-4-1-2 I Inspection Cover, Removal and Installation ........... W3-4-2-13 Installation Bearing Cage Assembly ............................................ W4-3-3-28 Brake (Axle) ................................................................... W4-3-3-34 Differential Case .......................................................... W4-3-3-27 Support (Rear Axle) .................................................... W4-3-3-42 Intercooler, Replacement of ............................................W3-5-1-1 L LSD................................................ W2-2-1-1, W4-3-3-3, W4-3-3-19 Lever, Removal and Installation .....................................W5-1-3-1 Lever Stopper Clearance...................................................W2-3-2-2 Lift Arm, Standard Dimensions ......................................W2-3-2-1 Lift Arm Cylinder, Assembly........................ W5-2-3-6, W5-4-4-5 Lift Arm Cylinder, Disassembly .................. W5-2-3-1, W5-4-4-1

70Z7/70TM7 D&R

INDEX Lift Arm Cylinder, Removal and Installation................................................... W5-2-1-1, W5-4-1-1 Lock of Chassis .....................................................................W1-6-1-2 Low-Pressure-Hose Clamp Tightening ........................W1-2-1-8 M Machine Position for Inspection and Maintenance (lift arm raise)...................................................................W1-6-1-3 Main Pump, Assembly .......................................................W3-8-3-5 Main Pump, Disassembly..................................................W3-8-3-1 Manifold Valve, Assembly .............................................. W3-12-2-4 Manifold Valve, Disassembly ........................................ W3-12-2-1 Manifold Valve, Removal and Installation ............... W3-12-1-1 Manual Release, Parking Brake .......................................W4-2-6-6 Multiple Control Valve Assembly ...........................................................................W3-9-3-5 Disassembly .....................................................................W3-9-3-1 Removal and Installation ............................................W3-9-1-1 Multiple Control Valve (Parallel Link) Assembly ........................................................................ W3-9-4-10 Disassembly .....................................................................W3-9-4-1 Removal and Installation ............................................W3-9-2-1 N Nuts, Tightening ..................................................................W1-2-1-1 Nylon Sling, Precautions for Using ................................W1-1-1-3 O Oil Cooler, Replacement ...................................................W3-5-1-1 Oscillation Stopper .............................................................W4-1-2-6 P Painting ...................................................................................W1-3-1-1 Painting (Parallel Link) .......................................................W1-3-2-1 Parallel Link (Special Parts)............................................ W3-17-1-1 Parking Brake Adjustment ......................................................................W4-2-6-5 Manual Release ...............................................................W4-2-6-6 Removal and installation.............................................W4-2-6-1 Replace Brake Friction Pad .........................................W4-2-6-1 Parking Brake Accumulator Pressure Release Procedure .........................................................................W1-5-1-3 Parking Brake Solenoid Valve, Structure .................. W3-13-3-1 Parking Brake Solenoid Valve Unit Removal and Installation ......................................... W3-13-1-1 Structure ........................................................................ W3-13-2-1 Pilot Pump, Structure .........................................................W3-8-5-1 Pilot Valve ............................................................................ W3-10-1-1 Assembly ........................................................................ W3-10-4-4 Disassembly .................................................................. W3-10-4-1 Removal and Installation ......................................... W3-10-1-1 Pilot Valve (Two Lever Type) Assembly ........................................................................ W3-10-5-7 Disassembly .................................................................. W3-10-5-1 Removal and Installation ......................................... W3-10-2-1 Pin, Maintenance Standard......................... W2-3-1-1, W2-4-1-1 Piping Joint ............................................................................W1-2-1-4 Planetary Carrier, Assembly .............................................W4-3-3-4

Planetary Carrier, Disassembly .................................... W4-3-3-10 Precautions for Disassembling and Assembling ...............................W1-1-1-1 Spilt Flange.......................................................................W1-2-1-3 Using Floating Seal ........................................................W1-1-1-2 Using Nylon Sling ..........................................................W1-1-1-3 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment) .................................................................. W4-3-3-37 Preparation before Inspection and Maintenance....W1-6-1-1 Pressure Release Procedure .............................................W1-5-1-1 Front Attachment Hydraulic Circuit ........................W1-5-1-1 Parking Brake Accumulator ........................................W1-5-1-3 Ride Control Accumulator ..........................................W1-5-1-2 Priority Valve, Removal and Installation ................... W3-14-1-1 Priority Valve, Structure .................................................. W3-14-2-1 Propeller Shaft, Removal and Installation ..................W4-4-1-1 Pump Device, Assembly....................................................W3-8-2-3 Pump Device, Disassembly ..............................................W3-8-2-1 Pump Device, Removal and Installation .....................W3-8-1-1 Q Quick Coupler Cylinder, Assembly ................................W5-4-6-4 Quick Coupler Cylinder, Disassembly...........................W5-4-6-1 Quick Coupler Cylinder, Removal and Installation ..W5-4-3-1 Quick Coupler Solenoid Valve (Parallel Link), Removal and Installation ......................................... W3-13-4-1 Quick Coupler Solenoid Valve, Assembly ................ W3-13-5-3 Quick Coupler Solenoid Valve, Disassembly........... W3-13-5-1 Quick Coupler, Removal and Installation....................W5-3-2-1 Quick Coupler, Standard Dimensions ..........................W2-4-2-1 R Radiator Assembly ..............................................................W3-5-1-1 Radiator Bleeding Air from ..............................................W1-4-1-4 Radiator, Replacement ......................................................W3-5-1-1 Rear Axle, Removal and Installation of ........................W4-3-2-1 Rear Cover, Removal and Installation of .....................W3-4-2-2 Rear Fender (Front), Removal and Installation .........W3-4-2-8 Rear Fender (Rear), Removal and Installation ...........W3-4-2-6 Rear Grill, Removal and Installation ........................... W3-4-2-12 Rear Tire, Removal and Installation ...............................W4-1-2-1 Regulator, Pump, Assembly .............................................W3-8-4-3 Regulator, Pump, Disassembly .......................................W3-8-4-1 Releasing Pressure ..............................................................W1-5-1-1 Removal Bearing Cage Assembly ............................................ W4-3-3-12 Brake (Axle) ................................................................... W4-3-3-11 Differential Case Assembly ...................................... W4-3-3-14 Support (Rear Axle) .......................................................W4-3-3-6 Removal and Installation Air Cleaner ........................................................................W3-4-3-1 Auxiliary Pilot Valve .................................................... W3-10-3-1 Battery Box (With Battery Disconnect Switch) ....W3-2-3-1 Battery Box (Without Battery Disconnect Switch) .........................................................................................W3-2-2-1 Battery Disconnect Switch .........................................W3-2-4-1 Bell Crank ..........................................................................W5-1-3-1 70Z7/70TM7 D&R

INDEX Removal and Installation Brake Accumulator ..................................................... W3-11-3-1 Brake Charge Valve ..................................................... W3-11-1-1 Brake Valve .......................................................................W4-5-1-1 Bucket ................................................................................W5-1-4-1 Bucket Cylinder.......................................... W5-2-2-1, W5-4-2-1 Bucket Regenerative Selector Valve ..................... W3-17-3-1 Bucket Regenerative Valve ...................................... W3-17-1-1 Cab ......................................................................................W3-1-1-1 Cab (Parallel Link)...........................................................W3-1-2-1 Center Hinge....................................................................W3-3-1-1 Center Hinge (Parallel Link) ........................................W3-3-2-1 Clutch .................................................................................W4-2-4-9 Control Valve....................................................................W3-9-1-1 Control Valve (Parallel Link) ........................................W3-9-2-1 Counterweight................................................................W3-2-1-1 Cover (Lower) ..................................................................W3-4-2-2 Deck ....................................................................................W3-4-2-8 Drive Unit ..........................................................................W4-2-1-1 Engine ................................................................................W3-4-1-1 Engine Cover ...................................................................W3-4-2-2 Exterior Parts ...................................................................W3-4-2-1 Fan Motor....................................................................... W3-15-3-1 Fan Pump ....................................................................... W3-15-5-1 Fan Valve ........................................................................ W3-15-1-1 Flange at Output Shaft Side .......................................W4-2-6-7 Front Attachment ..........................................................W5-3-1-1 Front Attachment (With Lift Arm Auto Leveler)..W5-1-2-1 Front Attachment (With Lift Arm Kickout)............W5-1-1-1 Front Axle..........................................................................W4-3-1-1 Front Fender ................................................................. W3-4-2-11 Front Tire ...........................................................................W4-1-1-1 Fuel Tank ...........................................................................W3-7-1-1 Hydraulic Oil Tank ..........................................................W3-6-1-1 Inspection Cover ......................................................... W3-4-2-13 Lever ...................................................................................W5-1-3-1 Lift Arm Cylinder ....................................... W5-2-1-1, W5-4-1-1 Manifold Valve.............................................................. W3-12-1-1 Parking Brake (Replace Brake Friction Pad) ..........W4-2-6-1 Parking Brake Solenoid Valve Unit........................ W3-13-1-1 Pilot Valve....................................................................... W3-10-1-1 Pilot Valve (Two Lever Type) .................................... W3-10-2-1 Priority Valve ................................................................. W3-14-1-1 Propeller Shaft ................................................................W4-4-1-1 Pump Device ...................................................................W3-8-1-1 Quick Coupler..................................................................W5-3-2-1 Quick Coupler Cylinder ................................................W5-4-3-1 Quick Coupler Solenoid Valve (Parallel Link) .... W3-13-4-1 Rear Axle ...........................................................................W4-3-2-1 Rear Cover ........................................................................W3-4-2-2 Rear Fender (Front)........................................................W3-4-2-8 Rear Fender (Rear) .........................................................W3-4-2-6 Rear Grill ......................................................................... W3-4-2-12 Rear Tire .............................................................................W4-1-2-1 Ride Control Accumulator ....................................... W3-16-3-1 Ride Control Valve....................................................... W3-16-1-1

Removal and Installation Secondary Steering Pump ..........................................W4-7-1-1 Side Cover .........................................................................W3-4-2-4 Side Cover (Rear) ......................................................... W3-4-2-14 Steering Accumulator ..................................................W4-6-5-1 Steering Cylinder ...........................................................W4-6-3-1 Steering Valve..................................................................W4-6-1-1 Step (Front).......................................................................W3-4-2-8 Step (Rear) ..................................................................... W3-4-2-13 Torque Converter ...........................................................W4-2-3-1 Replace Brake Friction Pad, Parking..............................W4-2-6-1 Replacement Fuel Cooler .......................................................................W3-5-1-1 Intercooler ........................................................................W3-5-1-1 Oil Cooler ..........................................................................W3-5-1-1 Radiator .............................................................................W3-5-1-1 Torque Converter Cooler .............................................W3-5-1-1 Reverse Clutch (KR), Assembly .................................... W4-2-4-38 Reverse Clutch (KR), Disassembly ............................... W4-2-4-36 Ride Control Accumulator Pressure Release Procedure .......................................W1-5-1-2 Removal and Installation ......................................... W3-16-3-1 Ride Control Device ......................................................... W3-16-1-1 Ride Control Valve, Assembly ....................................... W3-16-2-4 Ride Control Valve, Disassembly ................................. W3-16-2-1 Ride Control Valve, Removal and Installation ........ W3-16-1-1 Ring Gear Backlash, Adjustment................................. W4-3-3-29 Ring Gear Teeth Engagement, Adjustment ............ W4-3-3-29 S Screw-In Connection..........................................................W1-2-1-8 Seal Tape Application.........................................................W1-2-1-8 Second Speed Clutch (K2) ............................................. W4-2-4-25 Secondary Steering Device..............................................W4-7-1-1 Secondary Steering Pump, Removal and Installation........................................................................W4-7-1-1 Side Cover, Removal and Installation ...........................W3-4-2-4 Side Cover (Rear), Removal and Installation ........... W3-4-2-14 Slow-Speed Forward Clutch (KV), Assembly .......... W4-2-4-38 Disassembly of ............................................................. W4-2-4-36 Solenoid Valve ................................................................... W3-13-1-1 Specified Tightening Torque Chart ...............................W1-2-1-1 Speed Clutch (K1), (K2), and (K3), Assembly ........... W4-2-4-31 Speed Clutch (K1), (K2), and (K3), Disassembly ..... W4-2-4-27 Spilt Flange, Precautions ..................................................W1-2-1-3 Standard Dimensions for Bucket .............. W2-3-2-1, W2-4-2-1 Standard Dimensions for Lift Arm .................................W2-3-2-1 Standard Dimensions for Quick Coupler ....................W2-4-2-1 Steering Accumulator, Removal and Installation ....W4-6-5-1 Steering Cylinder, Assembly ............................................W4-6-4-5 Steering Cylinder, Disassembly ......................................W4-6-4-1 Steering Cylinder, Removal and Installation..............W4-6-3-1 Steering Device ....................................................................W4-6-1-1 Steering Valve, Assembly ..................................................W4-6-2-4 Steering Valve, Disassembly ............................................W4-6-2-1 Steering Valve, Removal and Installation....................W4-6-1-1

70Z7/70TM7 D&R

INDEX Step (Front), Removal and Installation ........................W3-4-2-8 Step (Rear), Removal and Installation ....................... W3-4-2-13 Stopper, Bucket ....................................................................W2-3-2-2 Structure Brake Charge Valve ..................................................... W3-11-2-1 Bucket Regenerative Selector Valve ..................... W3-17-4-1 Bucket Regenerative Valve ...................................... W3-17-2-1 Fan Motor....................................................................... W3-15-4-1 Fan Valve ........................................................................ W3-15-2-1 Parking Brake Solenoid Valve ................................. W3-13-3-1 Parking Brake Solenoid Valve Unit........................ W3-13-2-1 Pilot Pump ........................................................................W3-8-5-1 Priority Valve ................................................................. W3-14-2-1 Support (Rear Axle), Installation ................................. W4-3-3-42 Support (Rear Axle), Removal .........................................W4-3-3-6 T T/M Oil Filter, Removal and Installation.......................W4-2-2-4 Third Speed Clutch (K3) ................................................. W4-2-4-26 Tightening Bolts and Nuts ...............................................W1-2-1-1 Tire ............................................................................................W4-1-1-1 Tire Size, Applicable....................................... W4-1-1-3, W4-1-2-5 Torque Converter, Removal and Installation .............W4-2-3-1 Torque Converter Cooler, Replacement ......................W3-5-1-1 TPD, Axle ..................................... W2-2-1-1, W4-3-3-2, W4-3-3-18 Transmission, Disassembly and Assembly .................W4-2-4-1 Transmission Control Valve, Disassembly and Assembly ...................................................... W4-2-5-1, W4-2-5-7 Travel System, Maintenance Standard.........................W2-2-1-1 U Unloader Valve, Removal and Installation of.......... W3-11-1-1 Unloader Valve, Structure of......................................... W3-11-2-1

70Z7/70TM7 D&R

INDEX (Blank)

70Z7/70TM7 D&R