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90Z6

93213-00810

SHOP MANUAL Disassembly & Reassembly

Printed in Japan (K) （トルコ用）

93213-00810

August 2015

SHOP MANUAL WHEEL LOADER

90Z6 Disassembly & Reassembly

93213-00810

SECTION 1 GENERAL INFORMATION SECTION AND GROUP CONTENTS

WORKSHOP MANUAL

Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Releasing Pressure Group 6 Preparation

SECTION 2 MAINTENANCE STANDARD Group 1 Body Group 2 Front Attachment

SECTION 3 BODY 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 Charging Block Group 12 Cooling Fan System Group 13 Exhaust Muffler Group 14 Ride Control Device Group 15 Battery Disconnect Switch 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.

MEMO

SECTION 4 TRAVEL SYSTEM SECTION AND GROUP CONTENTS

WORKSHOP MANUAL

Group 1 Tire Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Steering Pilot Valve Group 7 Steering Valve Group 8 Steering Cylinder Group 9 Secondary Steering Device Group 10 Stop Valve Group 11 Axle Oil Cooler

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

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.

MEMO

SECTION 1

GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling

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

Group 6 Preparation

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

Group 2 Tightening

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

Group 3 Painting

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

Group 4 Bleeding Air

Bleeding Air from Hydraulic Oil Tank.......................W1-4-1-1 Bleeding Air from Hydraulic System........................W1-4-1-2 Bleeding Air from Fuel System...................................W1-4-1-3 Bleeding Air from Radiator..........................................W1-4-1-4 Bleeding Air from Brake (Axle)...................................W1-4-1-5

Group 5 Pressure Release Procedure

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

90Z6 D&R

(Blank)

90Z6 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 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 c-

Fuzz

W162-01-01-008

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.

fNOTE:  Use penetrating oil to help loosen nut and bolts.  Make sure bolt and nut threads are clean before installing. WDAA-01-02-001

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

Wrench size mm

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

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

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

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

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

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

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

W1-2-1-1

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

Hexagon Bolt (8~11T)

Flanged Bolt (8T)

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

10 12 14 17

Socket Bolt

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.

1.4

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.

Correct

Incorrect

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

WDAA-01-02-007

Bend along edge sharply Correct

Do not bend it round

Correct

Incorrect

WDAA-01-02-008 c-

W1-2-1-3

Tighten

Loosen

SECTION 1 GENERAL Group 2 Tightening Piping Joint IMPORTANT: 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.

Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines. IMPORTANT:  Do not over-tighten union nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking the adapter. Tighten union nut (3) to the specifications.  Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting / disconnecting.

Joint Body

WDAA-01-02-009

37° 30°

b b-

Male Union Joint

c c-

Female Union Joint WDAA-01-02-010

Description 30° male

37° female

Wrench Size mm Union Nut 17 19 22 27 32 36 41 50 55 60 17 19 22 27 32 36 41

Tightening Torque N·m 25 30 40 80 140 180 200 270 380 380 25 30 40 80 140 180 200

(kgf·m) (2.5) (3) (4) (8) (14) (18) (20) (27) (38) (38) (2.5) (3) (4) (8) (14) (18) (20)

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

W1-2-1-4

(lbf·ft) (18) (22) (30) (59) (103) (133) (148) (200) (280) (280) (18) (22) (30) (59) (103) (133) (148)

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

Tightening Torque Use the specified tightening torque in the table below. Wrench Size (mm) N·m Tightening (kgf·m) Torque (lbf·ft)

25 (2.5) (18)

30 (3) (22)

40 (4) (30)

80 (8) (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-

W1-2-1-5

WDAA-01-02-011

Joint Body

Wrench Size mm Union Nut 19 22 27 32 36 41 50

Tightening Torque N·m 30 70 95 140 180 200 350

(kgf·m) (3) (7) (9.5) (14) (18) (20) (35)

(lbf·ft) (22) (52) (70) (103) (133) (148) (260)

SECTION 1 GENERAL Group 2 Tightening Quick Coupling

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

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

W1-2-1-6

M1M7-07-006

SECTION 1 GENERAL Group 2 Tightening Screw-In Connection

R 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 is used except for measurement purpose.)

Male Tapered Thread

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 and female threads so that any leaks between threads may be prevented. Therefore, apply just enough seal tape to fill up thread clearances. Avoid lap winding.  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.

a a-

Tightening Torque N·m (kgf·m, lbf·ft) FC material SS material 15 (1.5, 11) 35 (3.5, 26) 30 (3, 22) 50 (5, 37) 50 (5, 37) 95 (9.5, 70) 70 (7, 52) 160 (16, 118) 110 (11, 81) 200 (20, 148) 160 (16, 118) 330 (33, 245) 200 (20, 148) c

d cd-

Internal Thread External Thread

W105-01-01-019

Clearance

Low-Pressure-Hose Clamp Tightening Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.5 N·m (0.45 kgf·m, 3.3 lbf·ft) Worm Gear Type Band Clamp: 6 to 7 N·m (0.6 to 0.7 kgf·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-

W1-2-1-7

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 service parts. Using hoses other

Correct

Incorrect

than genuine Kawasaki 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-

W1-2-1-8

Rubbing Against Each Other

Clamp

SECTION 1 GENERAL Group 3 Painting Painting

1 5 2

WNEC-01-03-003

1 2 3 4 5

Surfaces to Be Painted Rear Console (Inner) Seat Bracket Cockpit Skirt Cockpit Side Console (Inner)

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

Paint the painted surface except the above listed in YA (Marigold Yellow).

W1-3-1-1

SECTION 1 GENERAL Group 3 Painting

3 5

7 6 90Z6W01-03-01

1 2 3 4 5 6 7 8

Surfaces to Be Painted Light Bracket Exhaust Pipe Pipe (Rain Cap) Rain Cap Grill Cover Rear Cover (Side) Articulate Lock Bar

Painting Color High Grade Black Heat-Resistant Black High Grade Black Do not paint it. High Grade Black High Grade Black High Grade Black Scarlet Red

Paint the painted surface except the above listed in YA (Marigold Yellow).

W1-3-1-2

SECTION 1 GENERAL Group 3 Painting

2 1

3 4 3

1 2 3 4 5

Surfaces to Be Painted Handrail (Front) Handrail (Rear) Step Rear Fender Deck Plate

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

Paint the painted surface except the above listed in YA (Marigold Yellow).

W1-3-1-3

90Z6W01-03-02

SECTION 1 GENERAL Group 3 Painting

90Z6W01-03-03

1 2 3

Surfaces to Be Painted Rear Axle Front Axle Guard

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

Paint the painted surface except the above listed in YA (Marigold Yellow).

W1-3-1-4

SECTION 1 GENERAL Group 3 Painting Rear Axle (1) 1

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. YA (Marigold 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 Front Axle (2) 1

View A

WNEC-01-03-012

1 2 3 4 5 6 7 8 9

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 )

Painting Color Do not paint it. YA (Marigold 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.

W1-3-1-6

WNEC-01-03-011

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

2, 5

3. Remove socket bolt (4)(4 used). Remove cap (2) and O-ring (5) of hydraulic oil tank (3). l : 6 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W1R7-01-04-001

W1-4-1-1

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 Bleed Air from the 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 (1) or replacing the fuel filter, be sure to bleed the air from the fuel system. If fuel contains high water content, check the fuel filter earlier than the normal interval and drain water if necessary. 1. Loosen drain plug (2) at lower part of fuel filter (1) to drain water. After draining water, securely tighten drain plug (2).

1 2

2. Turn the starter switch key to the START position, and turn it back to the OFF position within 15 seconds. Do not leave the key at the START position for longer than 20 seconds.

90Z6 07-61-01

3. Wait about 5 seconds until the engine stops completely, and repeat step 1. 4. If the engine does not start after repeating step 2 five times, wait for 2 minutes or longer to cool down the starter enough.

1 2

5. Repeat steps 1 through 3 until the engine starts. Make sure to have 2 minutes interval for the starter cooling. 90Z6 07-61-02

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. Lower the attachment, level, all the way to the ground or floor surface. 2. Stop the engine, and when cool, remove the radiator cap. 3. Be sure that the radiator and surge tank, if so equipped, is full of the correct coolant. 4. Install the radiator cap. 5. Run the engine and check for leaks.

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 (0.13 gal)) is drawn from each wheel (4 places) after bubbles stop.

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.

90T4GB-05-04-04a

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

2 1

3. Depress brake pedal (4) several times. Then, depress and hold brake pedal (4) to the stroke end. 3

fNOTE: Right brake pedal is optional. 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 stop in steps 3 to 5 repeatedly.

fNOTE: When bubbles do not stop after hydraulic oil

(about 0.5 liters (0.13 gal)) is drawn, repeat step 3 to step 5.

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

W1-4-1-5

T4GB-05-04-006

4 (Opt)

SECTION 1 GENERAL Group 4 Bleeding Air (Blank)

W1-4-1-6

SECTION 1 GENERAL Group 5 Pressure Release Procedure 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. 3 LOCK

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 handle (1) to the UNLOCK (2) position.

fNOTE: When the control lever lock handle is placed to

position (2), control lever lock indicator (4) goes OFF and the front control lever becomes operable.

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.

1 2 UNLOCK

90Z6T1-2-07a

5. Return front control lever lock handle (1) to the LOCK (3) position. 6. Turn the key switch OFF.

MNDB-01-008

W1-5-1-1

SECTION 1 GENERAL Group 5 Pressure Release Procedure Ride Control Accumulator Pressure Release Procedure

2 3

Release any remaining pressure as follows before removing and installing 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. 3. Bleed air from the hydraulic oil tank. (Refer to W1-41.)

4. Remove nuts (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 14 mm 90Z6W01-05-01

5. Loosen lock nut (5) of ride control valve (4). j : 13 mm IMPORTANT: Do not loosen drain plug (6) two turns or more. 6. Loosen drain plug (6) with a wrench and release any remaining pressure. Tighten drain plug (6).

4 5

l : 4 mm

7. Tighten lock nut (5). j : 13 mm m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft) 90Z6W01-05-02

W1-5-1-2

SECTION 1 GENERAL Group 5 Pressure Release Procedure 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.

MNEC-01-036

fNOTE: Right brake pedal is optional. 1

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 key switch (2) OFF.

fNOTE: The service brake primary pressure and parking brake pressure can be monitored by using the service menu of monitor (4). (Refer to TROUBLESHOOTING / Monitor in the separated volume, T/M.)

W1-5-1-3

OFF

MNEC-01-058

SECTION 1 GENERAL Group 5 Pressure Release Procedure (Blank)

W1-5-1-4

SECTION 1 GENERAL Group 6 Preparation Preparation before Inspection and Maintenance 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

LOCK

ride control switch (2) to the OFF position. Caution that an unexpected accident may occur due to the lift arm movement.

1 UNLOCK

CAUTION: If the machine is unexpectedly dmoved, a serious accident may result in. Apply the

parking brake when parking the machine.

90Z6T1-2-07a

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

UNLOCK

1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Set front control lever lock handle (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. LOCK

6. Apply the parking brake. (Parking brake switch (4): ON position)

MNEC-01-036

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 Articulation Lock

dWARNING:  Before servicing or transporting the machine, be sure to engage lock bar (1).  Before driving the machine, be sure to disengage the lock bar (1) from the front frame and fasten the lock bar to the rear frame with pin (2) and β-form lock pin (3). Articulation lock bar (1) locks the front and rear frames to prevent articulation between the front and rear frames when servicing or transporting the machine.

1 90Z6-1-108-1

90Z6-1-108-1

90Z6-1-108-2

W1-6-1-2

SECTION 1 GENERAL Group 6 Preparation Machine Position for Inspection and Maintenance (lift arm raise)

CAUTION: Support the lift arm by using a solid support for inspection and maintenance with the lift arm raised. Take care that due to lowering the lift arm may result in the accidents.

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

LOCK

4 UNLOCK

90Z6T1-2-07a

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 Pilot Valve (Two Lever Type ).......................................W2-1-2-1

Group 2 Front Attachment

Pin and Bushing...............................................................W2-2-1-1 Standard Dimensions for Lift Arm and Bucket.....W2-2-2-1 Bucket Stopper Clearance...........................................W2-2-2-2 Bucket Dump Stopper.............................................W2-2-2-2 Bucket Rollback (Tilt) Stopper..............................W2-2-2-2

90Z6 D&R

(Blank)

90Z6 D&R

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

 Lower Hinge Part (B) 3

6 2

a 90WNEC-02-01-01

A B

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

90WNEC-02-01-02

Standard (a) 90 (3.54) 90 (3.54) 95 (3.74) 95 (3.74)

W2-1-1-1

Allowable Limit (a) 89 (3.5) 91.5 (3.6) 94 (3.7) 96.5 (3.8)

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 1 Body (Blank)

W2-1-1-2

SECTION 2 MAINTENANCE STANDARD Group 1 Body Pilot Valve (Two Lever Type )

3 4

WNEC-02-01-003

123-

Cam Shaft (2 Used) Bushing (4 Used) Lever (2 Used)

456-

Screw (4 Used) Bushing (4 Used) Push Rod (3 Used)

789-

Push Rod (4 Used) Spool (4 Used) Push Rod

W2-1-2-1

SECTION 2 MAINTENANCE STANDARD Group 1 Body 1. Spool (8) diameter Difference between diameter of non-sliding part (a) and sliding part (b) a-b Unit: mm (in) Allowable Limit 0.01 (0.0004)

fNOTE: In case the value is beyond the allowable limit, replace the pilot valve assembly.

a b W4GB-02-06-016

6, 9

2. Push Rods (6, 9, and 7) length Unit: mm (in) Standard c 87.7 (3.45) d 36 (1.42)

Allowable Limit 86.7 (3.41) 36 (1.42)

W4GB-02-06-017

3. Bushing (5) inner diameter Unit: mm (in) Standard 8 (0.32)

Allowable Limit 8.5 (0.34)

fNOTE: When the bushing in the sub assembly of

W4GD-02-08-001

solenoid is worn away, replace the solenoid valve assembly.

4. Looseness in the control part When looseness on the upper end of lever (3) is 2 mm (0.08 in) or more due to the wear of screw (4), cam shaft (1) or busing (2), replace the solenoid valve assembly.

W2-1-2-2

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

WNEC-02-03-001

90W4GB-04-01-08

A B C D E F G H I

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

Standard (a) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) 130 (5.11) 130 (5.11) 115 (4.53) 115 (4.53) 115 (4.53) 115 (4.53) 115 (4.53) 115 (4.53) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94) 100 (3.94)

W2-2-1-1

Bushing

Allowable Limit (a) 99.0 (3.90) 101.5 (4.00) 99.0 (3.90) 101.5 (4.00) 129 (5.08) 131.5 (5.18) 114 (4.49) 116.5 (4.59) 114 (4.49) 116.5 (4.59) 114 (4.49) 116.5 (4.59) 99.0 (3.90) 101.5 (4.00) 99.0 (3.90) 101.5 (4.00) 99.0 (3.90) 101.5 (4.00)

WNEC-02-03-002

Unit: mm (in) Remedy Replace

SECTION 2 MAINTENANCE STANDARD Group 2 Front Attachment (Blank)

W2-2-1-2

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

d b

h g

e f

c WNEC-02-03-003

a b c d e f g h i

Bucket

Lift Arm

Unit: mm (in) Dimensions 100 (3.94) 100 (3.94) 972 (38.3) 124 (4.88) 128 (5.04) 128 (5.04) 290 (11.4) 410 (16.1) 50 (1.97)

W2-2-2-1

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

T4GB-04-04-008

90T4GB-04-04-10

Bucket Dump Stopper

Bucket Rollback (Tilt) Stopper

 Cylinder Strokes (A and B) Bucket Cylinder (A) Lift Arm Cylinder (B) mm (in) mm (in) 521±2 (20.5±0.08) 1168±2 (46±0.08)

 Cylinder Strokes (D and E) Bucket Cylinder (D) Lift Arm Cylinder (E) mm (in) mm (in) 840±2 (33.1±0.08) 260±2 (10.2±0.08)

 Bucket Dump Angle (C) C (deg.) 48 to 50

 Bucket Roll Back (Tilt) Angle (F) F (deg.) 39.5 to 41.5

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

 Height from Ground to Bucket Hinge Pin (G) G (mm) (in) 290 (11.4)

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

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

3.0 (0.12)

4.0 (0.16)

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

W2-2-2-2

SECTION 3

BODY CONTENTS Group 1 Cab

Removal and Installation of Cab...............................W3-1-1-1

Group 2 Counterweight

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

Group 3 Center Hinge

Removal and Installation of Center Hinge.............W3-3-1-1 Removal and Installation of the Hydraulic Hoses of Front Chassis Side................................................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 of Side Cover.............................................W3-4-2-2 Installation of Side Cover........................................W3-4-2-4 Removal of Engine Roof..........................................W3-4-2-6 Installation of Engine Roof.....................................W3-4-2-8 Removal and Installation of Deck and Step/Covers........................................................... W3-4-2-10 Removal and Installation of Air Cleaner.................W3-4-3-1

Group 5 Radiator Assembly

Replacement of Radiator, Oil Cooler, Air Cooler, and Torque Converter Cooler................................W3-5-1-1

Group 6 Hydraulic Oil Tank

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

Group 7 Fuel Tank

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

Group 8 Pump Device

Removal and Installation of Pump Device.............W3-8-1-1 Disassembly and Assembly of Pump Device........W3-8-2-1 Removal of Pilot Pump and Regulator...............W3-8-2-2 Installation of Pilot Pump and Regulator..........W3-8-2-3 Disassembly of Main Pump.........................................W3-8-3-1 Assembly of Main Pump...............................................W3-8-3-4

Disassembly and Assembly of Regulator...............W3-8-4-1 Disassembly and Assembly of Priority Valve.........W3-8-4-5 Removal and Installation of Accessory Pump......W3-8-5-1 Disassembly and Assembly of Accessory Pump..............................................................................W3-8-5-2

Group 9 Control Valve

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

Group 10 Pilot Valve

Removal and Installation of Pilot Valve (Two Lever Type ) .................................................. W3-10-1-1 Disassembly of Pilot Valve (Two Lever Type)...... W3-10-2-1 Assembly of Pilot Valve (Two Lever Type)........... W3-10-2-8 Removal and Installation of Pilot Valve (Multi-Function Joystick Type) .......................... W3-10-3-1 Disassembly and Assembly of Pilot Valve (Multi-Function Joystick Type)........................... W3-10-4-1

Group 11 Charging Block

Removal and Installation of Charging Block...... W3-11-1-1 Disassembly and Assembly of Charging Block............................................................................ W3-11-2-1

Group 12 Cooling Fan System

Removal and Installation of Fan Motor................ W3-12-1-1 Structure of Fan Motor............................................... W3-12-2-1 Removal and Installation of Fan Pump................ W3-12-3-1 Disassembly of Fan Pump......................................... W3-12-4-1 Assembly of Fan Pump.............................................. W3-12-4-4 Structure of Fan Pump............................................... W3-12-4-7 Removal and Installation of Fan Control Valve (Option)...................................................................... W3-12-5-1 Structure of Fan Control Valve (Option)............... W3-12-5-3 Removal and Installation of Reversing Fan Motor (Option)...................................................................... W3-12-6-1

90Z6 D&R

Group 13 Exhaust Muffler

Removal and Installation of Muffler...................... W3-13-1-1

Group 14 Ride Control Device

Removal and Installation of Ride Control Valve and Accumulator (Option)...................... W3-14-1-1 Disassembly of Ride Control Valve (Option)....... W3-14-2-1 Assembly of Ride Control Valve (Option)............ W3-14-2-4

Group 15 Battery Disconnect Switch

Removal and Installation of Battery Disconnect Switch (Option)....................................................... W3-15-1-1

90Z6 D&R

SECTION 3 BODY Group 1 Cab Removal and Installation of Cab

OFF ON

90Z6-1-106-1

90Z6-1-107-2

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.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Open the cover at battery box (1). 3. Turn battery disconnect switch (2) to OFF position. Disconnect the ground cable.

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.

W3-1-1-1

SECTION 3 BODY Group 1 Cab

4 90Z6W03-01-01

4. Open side covers (1) at the right and left sides.

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

W3-1-1-2

SECTION 3 BODY Group 1 Cab

2 4

2 3

2 4

1 2

2 3

6. Remove flanged bolts (2) (4 used). Remove cover (1).

8. Remove flanged bolts (2) (2 used). Remove covers (4) (on both sides).

j : 17 mm

7. Remove flanged bolts (2) (3 used). Remove covers (3) (on both sides). j : 17 mm

W3-1-1-3

90Z6W03-01-02

SECTION 3 BODY Group 1 Cab 14, 15 16 8, 9

12, 13

10, 11

1 90Z6W03-01-03

9. Disconnect connectors (1~7).

12. Remove bolt (12) and remove holder (13). j : 17 mm

10. Remove bolts (8) (2 used) and remove bracket (9). j : 17 mm

13. Remove nut (14) and holder (15). Disconnect window washer liquid tube (16).

11. Remove bolt (10) and remove plate (11).

j : 12 mm

j : 17 mm

W3-1-1-4

SECTION 3 BODY Group 1 Cab

1 5

13, 14, 15, 16

4 90Z6W03-01-04

fNOTE: Place a container under the disconnecting part

90Z6W03-01-05

17. Disconnect hoses (10, 11, 12).

of hoses. 14. Disconnect hoses (1, 2, 3, 4). j : 19 mm

j : 27 mm 18. Remove nut (13), spring washer (14), washer (15), cable (16), and washer (15) in this order. j : 17 mm

15. Disconnect hoses (5, 6). j : 27 mm 16. Disconnect hoses (7, 8, 9). j : 19 mm

W3-1-1-5

SECTION 3 BODY Group 1 Cab

6, 7

10, 12

6, 8

2, 3

4, 5

10, 11

90Z6W03-01-06

90Z6W03-01-07

19. Disconnect hose (1)

22. Disconnect hose (9).

j : 27 mm

20. Disconnect hoses (2, 4) with O-rings (3, 5).

23. Remove nuts (10) (2 used) and holders (11, 12).

j : 27 mm 19 mm This machine uses the refrigerant dCAUTION: R134a. Recover the entire refrigerant from the

j : 12 mm 24. Disconnect hose (13). j : 19 mm

system. IMPORTANT: Do not release refrigerant into the atmosphere, as this is illegal. Comply with refrigerant regulations. (Refer to Shop Manual Troubleshooting, Section T5-7.) 21. Remove hose bands (6) (2 used) and disconnect hoses (7, 8). j : 7 mm

W3-1-1-6

SECTION 3 BODY Group 1 Cab

a 6

Eyebolt Mounting Hole

90Z6W03-01-08

25. Remove bolts (1) (4 used) and plates (2) (4 used).

90Z6W03-01-09

27. Remove hoses (4, 5).

j : 22 mm

Cab (3) assembly weight: Approx. dCAUTION: 1000 kg (2200 lb)

28. Remove 2 each of nuts (6) indicated by bold arrows from rubber cushions (7) (4 used) on both sides.

fNOTE: The weight of cab assembly varies depending on

j : 24 mm

the equipped devices.

26. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of cab (3) assembly. Attach the nylon slings onto the eyebolts (4 places). Hoist and hold cab (3) assembly.

IMPORTANT: Do not contact the front chassis and hydraulic oil tank when removing cab (3) assembly from the machine. 29. Carefully lift up and remove cab (3) assembly, and put it on firm wooden blocks.

W3-1-1-7

SECTION 3 BODY Group 1 Cab

90Z6W03-01-08

Eyebolt Mounting Hole

Installation Cab (1) assembly weight: Approx. dCAUTION: 1000 kg (2200 lb)

fNOTE: The weight of cab assembly varies depending on the equipped devices.

1. Install eyebolts (M16, Pitch 2 mm) (4 used) to eyebolt mounting holes (a) (4 places) of cab (1) assembly. Attach the nylon slings to the eyebolts (4 places). Hoist cab (1) assembly.

W3-1-1-8

SECTION 3 BODY Group 1 Cab

6 5

a 7 a-

90Z6W03-01-10 90Z6W03-01-08

Brim

IMPORTANT: Do not contact the front chassis and hydraulic oil tank when installing cab (1) assembly onto the machine.

4. Install plates (3) (4 used) and bolts (2) (4 used) to cab (1) assembly.

2. Install 2 each of nuts (6) indicated by bold arrows to rubber cushions (7) (4 used) on both sides. j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

fNOTE: The sides with brims (a) of rubber cushion (7)

should come to the machine right/left sides (not front/ rear direction).

3. Connect hoses (5, 4). j : 22 mm m : 40 N·m (4 kgf·m, 29.5 lbf·ft)

W3-1-1-9

j : 22 mm

SECTION 3 BODY Group 1 Cab

6, 7

1 10, 12

6, 8

2, 3

10, 11

4, 5

90Z6W03-01-07

5. Connect hose (13).

j : 19 mm

Install holders (11, 12) and nuts (10) (2 used). j : 12 mm

Connect hoses (7, 8) and fix with hose bands (6) (2 used). j : 7 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 6.

90Z6W03-01-06

Install O-rings (3, 5) and connect hoses (2, 4).

fNOTE: Apply ND-OIL8 onto the O-rings at hoses (2, 4) mounting part.

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 27 mm m : 34.3 N·m (3.5 kgf·m, 25.3 lbf·ft)

7. Connect hose (9).

j : 19 mm

j : 27 mm

m : 14.7 N·m (1.5 kgf·m, 10.8 lbf·ft)

m : 80 N·m (8 kgf·m, 59 lbf·ft)

10. Connect hose (1). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-1-1-10

SECTION 3 BODY Group 1 Cab

1 13, 14, 15, 16

2 90Z6W03-01-05

11. Install washer (15), cable (16), washer (15), spring washer (14), and nut (13) in this order.

4 90Z6W03-01-04

13. Connect hoses (7, 8, 9). j : 19 mm

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 hoses (10, 11, 12).

14. Connect hoses (5, 6). j : 27 mm

j : 27 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

15. Connect hoses (1, 2, 3, 4). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-1-1-11

SECTION 3 BODY Group 1 Cab 14, 15 16 8, 9

12, 13

10, 11

1 90Z6W03-01-03

16. Connect window washer liquid tube (16). Fix with nut (14) and holder (15).

19. Install bracket (9) with bolts (8) (2 used). j : 17 mm

j : 12 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 17. Install holder (13) with bolt (12).

20. Connect connectors (1~7).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 18. Install plate (11) with bolt (10). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-12

SECTION 3 BODY Group 1 Cab

2 4

2 3

2 4

1 2

2 3

21. Install covers (4) with flanged bolts (2) (2 used) (on both sides).

90Z6W03-01-02

23. Install cover (1) with flanged bolts (2) (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) 22. Install covers (3) with flanged bolts (2) (3 used) (on both sides). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-1-1-13

SECTION 3 BODY Group 1 Cab

2 1

OFF ON

90Z6-1-106-1

24. Set battery switch (2) in battery box (1) to the ON position. 25. 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 water leaks. 26. Fill refrigerant in the air conditioner. (Refer to T5-7 in the Troubleshooting S/M.)

W3-1-1-14

90Z6-1-107-2

SECTION 3 BODY Group 1 Cab

4 90Z6W03-01-01

27. Install following parts at right and left sides. (Refer to W3-4-2.)

28. Close side covers (1) at the right and left sides.

 Deck and Rear Fender (Front) (2)  Rear Fender (Rear) (3)  Cover (Lower) (4)  Cover (Side) (5)

W3-1-1-15

SECTION 3 BODY Group 1 Cab (Blank)

W3-1-1-16

SECTION 3 BODY Group 2 Counterweight Removal and Installation of Counterweight

2 90Z6W03-02-01

Removal 1. Set the machine for inspection and maintenance. (Refer to W1-6-1.) 2. Attach slings to hooks (4) and temporarily hoist it. Counterweight (1) weight: 2540 kg dCAUTION: (5600 lb) 3. Remove bolts (2) (4 used) and washers (3) (4 used), and lift up counterweight (1) to remove it from the rear chassis. j : 46 mm

W3-2-1-1

SECTION 3 BODY Group 2 Counterweight

5 1

90Z6W03-02-01

a A

Installation X

Counterweight (1) weight: 2540 kg dCAUTION: (5600 lb)

View A-A

90Z6W03-02-02

1. Attach slings to hooks (4) of counterweight (1). Carefully hoist. 2. Install counterweight (1) onto the rear chassis and temporarily fix them with bolts (2) (4 used) and washers (3) (4 used).

5 2

j : 36 mm

X: Fit to chassis (5)

m : 1450 N·m (145 kgf·m, 1070 lbf·ft)

fNOTE: Adjust the upper surface (X) of both positioning 1

bosses (a) of counterweight (1) to touch to rear chassis (5).

90Z6W03-02-03

W3-2-1-2

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

a 90Z6W03-03-01

ab-

Stand Wire Rope

90Z6W03-03-02

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

3. Support front chassis (1) and rear chassis (2) by using stable stands (a).

2. Remove the following devices.

4. Sling rear chassis (2) using a crane (apply rope (b) to the hook) so that rear chassis (2) will not fall backward.

 Front Attachment (Refer to W5-1-1.)  Cab assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-4-1.)

When using a crane, insufficient dCAUTION: signal and sling could cause an accident resulting

 Steering Cylinder (Refer to W4-8-1.)  Hydraulic Hoses of Front Chassis Side (Refer to W33-2.)

in injury or death. To prevent such an accident, observe the following items:

 Check the sling before using it and do not use improper sling.  Use the signals as agreed upon before starting work.  Stay out of the working area while using a crane.

W3-3-1-1

SECTION 3 BODY Group 3 Center Hinge

5 a 4 6 7 8 9 1, 2

3 b 90Z6W03-03-03

5. Remove bolts (1) (5 used) and washers (2) (5 used) from bush (4).

ab-

Upper Hinge Lower Hinge

7. Remove bolt (6), washer (7), and washer (8). j : 30 mm

j : 24 mm 6. Insert M12 x 1.75 x 90 mm bolt (3) into the bottom center of bush (4). Tighten the bolt (3) to remove bush (4).

90Z6W03-03-04

8. Push out upper center hinge pin (5) and lower center hinge pin (9) respectively using a jack or “Porto-power”.

j : 19 mm

W3-3-1-2

SECTION 3 BODY Group 3 Center Hinge

1 2 3

4 6 7 5 b 9 8

90W14014

a a-

Bar

Front Chassis

8 9

Chassis separation is dangerous work. dCAUTION: To ensure your safety, be careful in doing this work. 9. Slowly turn the rear tires both the right and the left sides using a bar to separate the rear chassis.

fNOTE: While turning the rear tires, check that the

garage jack under the tank shifts back together with the rear chassis. In addition, adjust the height using the rear crane whenever the height adjustment is necessary.

90Z6W03-03-05

10. Remove sleeve (1), bolts (2) (8 used), cover (3), dust seals (4) (2 used), bearing (5), and shim (6) in front chassis (b) upper center hinge in order. j : 24 mm 11. Remove bearing retainers (7) (2 used), dust seals (8) (2 used), and bearing (9) in front chassis (b) lower center hinge.

W3-3-1-3

SECTION 3 BODY Group 3 Center Hinge

90Z6W03-03-06 a-

Rear Chassis

12. Remove rear chassis upper center hinge pin bush (1) and rear chassis lower center hinge pin bush (2) (2 used).

W3-3-1-4

SECTION 3 BODY Group 3 Center Hinge 1

Upper Hinge Section

8 Front

7 Grease nipple installation direction

10 6

Lower Hinge Section

Bearing outer ring

22.5

Front

b Split of outer bearing 20 Grease nipple installation direction

90WNEC-03-03-05

3 Top side

Bottom side

2 a-

Front Chassis

90Z6W03-03-07 b-

Dust seal installation direction 90WNEC-03-03-06

Rear Chassis

Assembly 1. Install rear chassis upper center hinge pin bush (1) and rear chassis lower center hinge pin bush (2) (2 used). 2. Install spherical bearing (3) onto the front chassis lower center hinge. Install the bearing outer ring so that the split is perpendicular to the front – rear line of the machine. 3. Install bearing retainers (4) (2 used), dust seals (5) (2 used) in the front chassis lower center hinge.

4. Temporarily install bearing (6), cover (7), and washer (8) in the front chassis upper center hinge with bolt (9).

fNOTE: When replacing bearing (6) with a new one,

adjust the clearance between the front chassis upper center pin and cover (7) to 0.1 ± 0.05 mm (0.0039 ± 0.0020 in) using shim (10). Thickness of available shim: 0.1, 0.2, 0.3, 0.5, 1.0 mm (0.004, 0.008, 0.012, 0.020, 0.040 in)

fNOTE: Install cover (7) so that the grease nipple

mounting hole is positioned at the specified angle.

fNOTE: Take care of the correct direction of dust seals (5)

j : 24 mm

as shown.

m : 210 N·m (21 kgf·m, 155 lbf·ft) 5. Install dust seals (11) (2 used) in the front chassis upper center hinge. Install sleeve (12).

fNOTE: Take care of the correct direction of dust seals (11) as shown.

W3-3-1-5

SECTION 3 BODY Group 3 Center Hinge

5 a

6 7 8 9 90W14014

a b 90Z6W03-03-04 a-

Bar

6. Be sure to support the front chassis using a stand, jack, blocks, etc. and sling the rear chassis using a crane so that the front and rear chassis do not fall down. 7. While supporting the bottom of the tank using a garage jack, slowly turn the rear tires both the right and the left sides using a bar to align the holes of the front and rear chassis upper center pins.

Upper Hinge

Lower Hinge

8. Install upper center hinge pin (5) and lower center hinge pin (9) into the rear chassis. 9. Install washer (8), washer (7), and bolt (6).

fNOTE: Take care of the grease nipple installation angle.

fNOTE: When moving the rear chassis, move the supporting stand together.

Moving the separated chassis is dWARNING: dangerous work. To ensure your safety, be careful in doing this work.

W3-3-1-6

j : 30 mm m : 400 N·m (40 kgf·m, 295 lbf·ft)

SECTION 3 BODY Group 3 Center Hinge

1, 2

90Z6W03-03-03

10. Install bush (4) in the upper center pin. 11. Install washers (2) (5 used) and bolts (1) (5 used). Apply lubrication oil to the bolt (1) thread. j : 24 mm m : 420 N·m (42 kgf·m, 310 lbf·ft)

W3-3-1-7

SECTION 3 BODY Group 3 Center Hinge

a 90Z6W03-03-01

ab-

Stand Wire Rope

90Z6W03-03-02

12. Remove stands (a) from front chassis (1) and rear chassis (2).

dCAUTION:  After reinstallation, apply grease the center hinge pins, and operate them. During operation, check the pions for abnormal noise and looseness.

13. Remove rope (b) from rear chassis (2). 14. Install the following devices.  Hydraulic Hoses of Front Chassis Side (Refer to W33-2.)  Front Attachment (Refer to W5-1-1.)  Cab assembly (Refer to W3-1-1.)  Propeller Shaft (Refer to W4-4-1.)  Steering Cylinder (Refer to W4-8-1.) Machine weight (Except the devices dCAUTION: which have been installed in step 14): Approx. 17500 kg (38580 lb)

W3-3-1-8

 No oil leakage should be found in any part.  Insufficient air bleeding in brake oil line could cause an accident resulting in injury or death. Be sure to completely bleed the brake of air. For air bleeding procedure, refer to W1-4-1.

SECTION 3 BODY Group 3 Center Hinge Removal and Installation of the Hydraulic Hoses of Front Chassis Side

1 3 5, 6, 7

90Z6W03-03-08

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.) 2. Disconnect hoses (1, 2, 3, 4).

Remove the hydraulic hoses of front chassis side before removing the center hinge. (Refer to W3-3-1.)

j : 19 mm 3. Remove bolts (7) (2 used). Disconnect and remove connectors (5, 6) from the rear chassis. j : 10 mm

W3-3-2-1

SECTION 3 BODY Group 3 Center Hinge

14 1

5, 6, 7 ,8

3, 4

17, 18

9, 10, 13

17, 19 16

11, 12 15 90Z6W03-03-09

4. Disconnect hoses (1, 2). Remove nut (3) and holder (4).

90Z6W03-03-10

7. Remove hoses (14, 15, 16). j : 19 mm

j : 36 mm

j : 17 mm

j : 50 mm j : 12 mm

8. Remove nuts (17) (2 used) and holders (18, 19).

5. Remove bolts (5) (4 used), flanges (6) (2 used), hose (7) and O-ring (8). j : 22 mm 6. Remove nuts (9) (2 used), washers (10) (2 used), plate (11), gromet (12), and bolts (13) (2 used). j : 19 mm

W3-3-2-2

j : 12 mm

SECTION 3 BODY Group 3 Center Hinge

3, 4

7 8, 9

3, 5

9. Disconnect hoses (1, 2). Remove bolts (3) (2 used) and holders (4, 5).

10. Disconnect hoses (6, 7). Remove nut (8) and holder (9).

j : 19 mm

j : 27 mm

j : 17 mm

j : 22 mm j : 12 mm

W3-3-2-3

90Z6W03-03-11

SECTION 3 BODY Group 3 Center Hinge

1, 2

90Z6W03-03-12

11. Remove nuts (1) (2 used) and holders (2) (2 used). Disconnect hose assemblies (3, 4). j : 14 mm

fNOTE: This disconnects all the hoses between the front chassis and rear chassis.

W3-3-2-4

SECTION 3 BODY Group 3 Center Hinge

1, 2

90Z6W03-03-12

Installation 1. Install hose assemblies (3, 4). Fix with holders (2) (2 used) and nuts (1) (2 used). j : 14 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-3-2-5

SECTION 3 BODY Group 3 Center Hinge

3, 4

7 8, 9

3, 5

2. Install hoses (6, 7). Fix with holder (9) and nut (8).

90Z6W03-03-11

3. Install hoses (1, 2). Fix with holders (4, 5) and bolts (3) (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)

j : 22 mm

j : 17 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W3-3-2-6

SECTION 3 BODY Group 3 Center Hinge 14 17, 18

5, 6, 7 ,8

9, 10, 13

17, 19 2

3, 4

11, 12

15 90Z6W03-03-10

90Z6W03-03-09

4 40°

Front

30° 90Z6W03-03-13

4. Install holders (18, 19) and fix with nuts (17) (2 used).

6. Install hose (7) with O-ring (8) and fix with flanges (6) (2 used) and bolts (5) (4 used).

j : 12 mm

j : 22 mm

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

m : 140 N·m (14 kgf·m, 103 lbf·ft)

5. Connect hoses (14, 15, 16).

90Z6W03-03-14

7. Install hoses (1, 2) and fix with nut (3) and holder (4).

j : 19 mm

j : 36 mm

j : 17 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft) j : 50 mm m : 270 N·m (27 kgf·m, 199 lbf·ft) j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 8. Install gromet (12) to hoses (1, 2, 7). Fix with bolts (13) (2 used), plate (11), washers (10) (2 used), and nuts (9) (2 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-3-2-7

SECTION 3 BODY Group 3 Center Hinge

1 3 5, 6, 7

90Z6W03-03-08

9. Connect connectors (5, 6) to the rear chassis and fix with bolts (7) (2 used). j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) 10. Connect hoses (1, 2, 3, 4).

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.)

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

W3-3-2-8

SECTION 3 BODY Group 4 Engine Removal and Installation of Engine

OFF ON

90Z6-1-106-1

90Z6-1-107-2

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

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

2. Open the cover at battery box (1). 3. Turn battery disconnect switch (2) to OFF position. Disconnect the ground cable.

W3-4-1-1

SECTION 3 BODY Group 4 Engine

3 4

90Z6W03-04-01

90Z6W03-01-01

4. Remove hydraulic tank (1). (Refer to W3-6.)

6. Remove muffler (7) assembly. (Refer to W3-13-1.)

5. Remove the following parts. (Refer to W3-1 and W34-2.)  Deck and rear fender (front) (2)  Rear fender (rear) (5)  Side cover (4)  Front roof (3)  Rear roof (6)

W3-4-1-2

SECTION 3 BODY Group 4 Engine 15 2, 3 13

6, 7 12 10

Cooling Unit

4, 5

Engine

1 16, 17

8, 9

90Z6W03-04-29

90Z6W03-04-02

fNOTE: Partition plates are installed between the engine

7. Loosen hose bands (2, 4, 6) and disconnect hoses (3, 5, 7).

and cooling unit. Remove bolts and the plates.

j : 10 mm Bolt (1) (6 used):

j : 11 mm

j : 17 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) Other bolts:

8. Loosen hose band (8) and disconnect hose (9). 9. Disconnect connector (10) and cables (11~15).

j : 14 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

10. Remove nut (16) and holder (17). j : 12 mm

W3-4-1-3

SECTION 3 BODY Group 4 Engine 13

2, 4 8

6 1

12 2, 3 9

2, 3

10, 11

11. Remove nuts (2) (3 used), holders (3) (2 used), and holder (4).

90Z6W03-04-03

15. Remove bolt (10). Remove bracket (11) and cable (12).

j : 12 mm

j : 24 mm

dCAUTION: Pipe bracket assy (1) weight: 33 kg (73 lbs) 12. Temporarily sling and hold pipe bracket assy (1).

13. Remove bolts (5) (4 used), nuts (6) (2 used), washers (7) (2 used), bolts (8) (2 used), and bolts (9) (2 used).

dCAUTION: Do not remove radiator cap (13) until the coolant in the radiator is cooled. Hot steam may spout out, possibly causing severe burns. After the coolant temperature lowers, slowly loosen cap (13) to release the inside air pressure before removing cap (13). 16. Remove radiator cap (13).

j : 14 mm j : 12 mm j : 17 mm 14. Remove pipe bracket assy (1).

W3-4-1-4

SECTION 3 BODY Group 4 Engine

9 14, 15 1

12, 13

8 5, 6

90Z6 07-27-02

17. Place a container under drain plug (1).

10, 11

fNOTE: Engine oil amount: Max. 37 L (9.8 US gal) 19. Place a container under drain plug (4). 20. Loosen drain plug (4) and drain coolant.

90Z6W03-04-04

21. Remove 3 each of nuts (5) and holders (6) indicated by bold arrows. Remove hose (7).

18. Loosen drain plug (1) and drain engine oil. Remove hose band (2) and hose (3). j : 24 mm

j : 12 mm 22. Loosen hose bands (8) (2 used) and disconnect hose (9) at both ends. 23. Loosen hose band (10) and disconnect hose (11). 24. Remove nut (12) and holder (13). Remove hoses (14, 15).

j : 24 mm

j : 12 mm j : 50 mm

fNOTE: Coolant amount: Max. 40 L (10.6 US gal)

W3-4-1-5

SECTION 3 BODY Group 4 Engine

1, 4

1, 5

1, 13, 14

6, 7

6, 7 8 10, 11

6, 7 3

10, 11

11, 12

90Z6W03-04-06

90Z6W03-04-05

dCAUTION: This machine uses the refrigerant

29. Remove nut (6) and holder (7).

R134a. Recover the entire refrigerant from the system. IMPORTANT: Do not release refrigerant into the atmosphere, as this is illegal. Comply with refrigerant regulations. (Refer to Shop Manual Troubleshooting, Section T5-7.) 25. Remove bolts (1) (2 used) and remove hoses (2, 3). j : 10 mm

j : 12 mm 30. Remove 3 each of nut (10) and holder (11) indicated by bold arrows. j : 12 mm 31. Remove bolts (12) (2 used) and holders (11) (2 used). j : 17 mm

26. Remove O-rings (4, 5) from hoses (2, 3). 27. Remove 4 each of nut (6) and holder (7) indicated by bold arrows.

32. Remove bolt (1) and remove hose (13) with O-ring (14). j : 10 mm

j : 12 mm 28. Disconnect connector (8) and cable (9).

W3-4-1-6

SECTION 3 BODY Group 4 Engine

14 7, 8

7, 8

11, 12 3 13

4 a a-

7, 8

90Z6W03-04-07

90Z6W03-04-08

Starter Motor

33. Disconnect connectors (1, 2).

35. Remove 4 each of nut (7) and holder (8) indicated by bold arrows.

34. Disconnect cables (3, 4, 5, 6) from starter motor (a).

j : 12 mm 36. Remove hoses (9, 10). j : 27 mm 37. Remove nut (11) and holder (12). j : 12 mm 38. Remove hoses (13, 14). j : 36 mm j : 50 mm

W3-4-1-7

SECTION 3 BODY Group 4 Engine

1 7

2, 3, 4, 5, 6

2 3 4

90Z6W03-04-09

dCAUTION: Air cooler assy (1) weight: 40 kg (88 lbs) 39. Temporarily sling and hold air cooler assy (1).

90Z6W03-04-10

42. Place a container under fuel cooler assy (7). Remove hoses (8, 9). j : 27 mm

40. Remove 2 each of nut (2), washer (3), plate (4), and bolt (5) indicated by bold arrows on both sides. Remove air cooler assy (1). j : 19 mm 41. Remove bushes (6) (4 used) from air cooler assy (1).

43. Disconnect hose (10). j : 36 mm 44. Remove bolts (11) indicated by bold arrows. Remove fuel cooler assy (7). j : 17 mm

W3-4-1-8

SECTION 3 BODY Group 4 Engine

Slide backward by 120 mm

1 13 11

14 B

14 7, 8

2 3 ABC-

4, 5 6

Flexible Plate Rear Chassis (Mounting Part) Sealing

9 90Z6W03-04-11

dCAUTION: Engine assy (1) weight: 990 kg (2183 lbs) 45. Attach nylon sling to engine assembly (1) at two positions indicated by bold arrows. Temporarily hoist and hold engine assembly (1).

49. Loosen nut (9) on both sides. j : 27 mm 50. Remove nut (10), washer (11), plate (12), bolt (13), and washer (11) on both sides. j : 27 mm

46. Remove bolts (2) (8 used) and plate (3). j : 17 mm 47. Remove 12 each of bolt (4) and washer (5) from flexible plate (a). j : 17 mm 48. Remove bolt (6). Remove 11 each of bolt (7) and boss (8). j : 14 mm

fNOTE: The rear chassis is between two blue rubber bushing (14) at (B).

51. Carefully lift and move engine assy (1) to rear side by approx. 120 mm (4.7 in) and lift up to remove engine assy (1) from the rear chassis. IMPORTANT: Place and secure engine assembly (1) onto stable stands in order not to fall down. 52. Remove all adapters from engine (1) if necessary.

fNOTE: This separates the transmission from engine assembly (1).

W3-4-1-9

SECTION 3 BODY Group 4 Engine

1 14: Blue line 15: White line

Slide forward by 120 mm to engage with transmission.

13 11

B 14 7, 8

12 90Z6-W03-04-01

2 ABC-

Flexible Plate Rear Chassis (Mounting Part) Sealing

4, 5

15 9 90Z6W03-04-11

Installation 1. Install all removed adapters to engine (1). 2. Install 2 each of blue rubber bushing (14) at (B) by sandwiching the rear chassis (on both sides).

5. Align flexible plate (a) mounting bolt holes inside engine assy, and tighten 12 each of bolt (4) with washer (5).

fNOTE: Apply lubrication oil to bolt (4).

dCAUTION: Engine assy (1) weight: 990 kg (2183 lbs) 3. Attach nylon sling to engine assembly (1) at two positions indicated by bold arrows. Lift and hold engine (1) assembly above the rear chassis.

m : 76.5 N·m (7.8 kgf·m, 56.4 lbf·ft) 6. Apply a circle of sealing agent (Loctite FMD-127 or equivalent) on the inward side of plate (3) mounting bolt holes. Install plate (3) with bolts (2) (8 used).

4. Carefully engage engine (1) to the transmission assy by sliding engine (1) forward. Put engine (1) onto the rear chassis while aligning the engine mounting position (B). Install 11 each of boss (8) with bolt (7), and bolt (6).

fNOTE: Apply lubrication oil to the bolts (6, 7) thread. j : 14 mm

j : 17 mm

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 7. Install washer (11), bolt (13), plate (12), washer (11), and nut (10) in this order on both sides. Tighten nut (9) on both sides. Apply Loctite#262 to bolt (13) and nut (9). j : 27 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 300 N·m (30 kgf·m, 221 lbf·ft)

W3-4-1-10

SECTION 3 BODY Group 4 Engine

1 7

2, 3, 4, 5, 6

5 9

90Z6W03-04-10

8. Install fuel cooler assy (7). Tighten bolts (11) indicated by bold arrows.

2 3 4

9. Connect hose (10). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 10. Connect hoses (8, 9). j : 27 mm

90Z6W03-04-09

11. Install bushes (6) (4 used) to air cooler assy (1). j : 36 mm

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

m : 140 N·m (14.3 kgf·m, 103 lbf·ft)

dCAUTION: Air cooler assy (1) weight: 40 kg (88 lbs) 12. Temporarily sling and hold air cooler assy (1) at the radiator. 13. Install air cooler assy (1). Secure with bolt (5), plate (4), washer (3), and nut (2), at 2 points indicated by bold arrows on both sides. j : 19 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-1-11

SECTION 3 BODY Group 4 Engine 9

7, 8

11, 12

C B 13

90Z6W03-04-08

7, 8 20°

15°

11 7

15°

90Z6W03-04-07

Starter Motor

7 20°

Part A

Part B

Part C 90Z6W03-04-12

Starter Motor

14. Install hoses (13, 14). j : 36 mm

17. Install 4 each of holder (8) with nut (7) indicated by bold arrows. j : 12 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 50 mm m : 270 N·m (27 kgf·m, 199 lbf·ft) 15. Install holder (12) with nut (11).

18. Connect cables (3, 4, 5, 6) to starter motor (a). 19. Connect connectors (1, 2).

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 16. Install hoses (9, 10). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-4-1-12

SECTION 3 BODY Group 4 Engine 1, 13, 14

6, 7 9

10, 11

1, 4

1, 5

6, 7 8

B A

11, 12

10, 11

10, 11 11, 12

6, 7

90Z6W03-04-06

30°

90Z6W03-04-05

10° 15°

Part A

Part B

23. Install holder (7) with nut (6).

Part C

j : 12 mm

90Z6W03-04-13

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 20. Attach O-ring (14) to hose (13). Install hose (13) with bolt (1). j : 10 mm

24. Connect connector (8) and cable (9). 25. Install 4 each of holder (7) with nut (6) indicated by bold arrows.

m : 11 N·m (1 kgf·m, 8 lbf·ft)

j : 12 mm

fNOTE: Apply DENSO ND-OIL8.R134a or equivalent to O-ring (14).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

21. Install holders (11) (2 used) with bolts (12) (2 used). j : 17 mm

26. Attach O-rings (4, 5) to hoses (2, 3). Install hoses (2, 3) with bolts (1) (2 used). j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 11 N·m (1 kgf·m, 8 lbf·ft) 22. Install 3 each of holder (11) with nut (10) indicated by bold arrows.

fNOTE: Apply DENSO ND-OIL8.R134a or equivalent to O-rings (4, 5).

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W3-4-1-13

SECTION 3 BODY Group 4 Engine 9

14, 15

12, 13 C B

8 5, 6

10, 11 5

90Z6W03-04-04

12 90Z6 07-27-02

10°

10° 20°

Part A

Part B

Part C 90Z6W03-04-14

27. Install hoses (14, 15) and fix with holder (13) and nut (12).

31. Be sure to tighten drain plugs (1, 4). j : 24 mm

j : 12 mm

32. Install hose (3) and fix with hose band (2) .

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft)

28. Connect hose (11) and tighten hose band (10). m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 29. Connect hose (9) and hose bands (8) (2 used) at both ends. m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 30. Install hose (7) and fix with 3 each of holders (6) and nuts (5) indicated by bold arrows. j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W3-4-1-14

SECTION 3 BODY Group 4 Engine 13

2, 4

A 8

12 2, 3 9

2, 3

B 4

10, 11

90Z6W03-04-03

40°

36. Install bolts (9) (2 used), bolts (8) (2 used), washers (7) (2 used), nuts (6) (2 used), and bolts (5) (4 used).

3 2

j : 17 mm

40°

Part A

Part B

m : 50 N·m (5 kgf·m, 37 lbf·ft)

90Z6W03-04-15

j : 12 mm 33. Supply coolant and close radiator cap (13).

m : 28 N·m (2.9 kgf·m, 20.7 lbf·ft)

fNOTE: Coolant amount: 40 L (10.6 gal)

j : 14 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

34. Connect cable (12) and install bracket (11) with bolt (10).

37. Install holder (4) and holders (3) (2 used) with nuts (2) (3 used).

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

j : 12 mm

dCAUTION: Pipe bracket assy (1) weight: 33 kg (73 lbs) 35. Sling and hold pipe bracket assy (1) above the engine. Place pipe bracket assy (1) on the engine.

W3-4-1-15

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

SECTION 3 BODY Group 4 Engine 15

2, 3

6, 7 12 10

4, 5

50 mm

16, 17

8, 9

90Z6W03-04-01

90Z6W03-04-02

42. Install muffler assembly. (Refer to W3-13-1.) 2, 4, 6 3, 5, 7 Hose Band Detail

90Z6W03-04-16

38. Install holder (17) with nut (16). j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 39. Connect connector (10) and cables (11~15). 40. Connect hose (9) and fix with hose band (8). m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft) 41. Connect hoses (3, 5, 7) and fix with hose bands (2, 4, 6). j : 10 mm j : 11 mm m : 5.7 N·m (0.57 kgf·m, 4.2 lbf·ft)

W3-4-1-16

SECTION 3 BODY Group 4 Engine

3 4

90Z6W03-01-01

43. Install the following parts. (Refer to W3-1.)  Deck and rear fender (front) (2)  Rear fender (rear) (5)

ab-

Radiator Sub Tank

90Z6 07-71-02

fNOTE: After installing roof (2), supply the coolant from sub tank (b) of radiator (a). Bleed air from the cooling system. (Refer to the operation manual.)

44. Install hydraulic tank (1). (Refer to W3-6.) Install the following parts. (Refer to W3-4-2.)  Side cover (4)  Front roof (3) 45. Install rear roof (6).

W3-4-1-17

SECTION 3 BODY Group 4 Engine

OFF ON

90Z6-1-106-1

90Z6-1-107-2

46. Bleed air from the hydraulic system and fuel system. (Refer to W1-4-1.)

47. Turn battery disconnect switch (2) to ON position.

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.

48. Close the cover of battery box (1).

W3-4-1-18

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

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

10 90Z6W03-04-17

2. Remove the following parts.  Engine roof (1)  Side cover (2)  Rear roof (3) (Refer to W3-5-1.)  Rear grill (4) (Refer to W3-5-1.)  Rear fender (rear) (option) (5) (Refer to W4-1-2.)  Cover (lower) (6)  Rear fender (front) (7) (Refer to W4-1-2.)  Deck (9) and Step (8)  Front fender (10) (Refer to W4-1-1.)  Air cleaner (11) (Refer to W3-4-3.)

W3-4-2-1

SECTION 3 BODY Group 4 Engine Removal of Side Cover 1

A Detail

B Detail 4

13 8

2 5 B

7 12 A

3 a 1 90Z6W03-04-18

7 90Z6W03-04-19

3. Remove bolts (3) (2 used) from side cover.

dCAUTION:

Side cover (1) assembly weight: 30 kg (66 lb) Rear fender (rear) (a) (option) weight: 24 kg (53 lb)/side 1. Open side cover (1). In case rear fender (rear) (a) (option) is installed, remove it. (Refer to W4-1-2.) (On both sides)

j : 17 mm 4. Remove B-shape pin (4) and washers (5) (2 used) and remove rod (6). 5. Remove bolts (7) (4 used) and remove side cover (1).

IMPORTANT: Attach nylon slings onto the chassis side of the side cover (1) assembly. 2. Attach nylon slings onto the side cover (1) assembly. Temporarily lift and hold the side cover (1) assembly.

j : 19 mm 6. Remove nuts (8) (2 used), washers (9) (2 used), and bolt (10) from both ends of cylinder (2). Remove cylinder (2) and bracket (11). j : 13 mm 7. Remove bolts (12) (4 used) and bracket (13). j : 17 mm

W3-4-2-2

SECTION 3 BODY Group 4 Engine

90Z6W03-04-20

8. Remove bolts (14) (5 used) and plate (15). j : 17 mm

W3-4-2-3

SECTION 3 BODY Group 4 Engine Installation of Side Cover

A Detail

B Detail 4

13 8

2 5

11 mm (0.43 in)

8 7

11 mm (0.43 in)

Cylinder (2) Installation

8 13 90Z6W03-04-21

12 A

3 1

7 90Z6W03-04-19

dCAUTION: Side cover (1) assembly weight: 30 kg (66 lb) IMPORTANT: Attach nylon slings onto the chassis side of the side cover (1) assembly.

5. Install rod (6). Fix with B-shape pin (4) and washers (5) (2 used). 6. Install bracket (11) for cylinder (2) and side cover (1) with bolts (2) (2 used).

1. Attach nylon slings onto the side cover (1) assembly. Hoist the side cover (1) assembly. 2. Install bracket (13) with bolts (12) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect both ends of cylinder (2) to brackets (11, 13) with washers (9) (2 used), bolt (10), and nuts (8) (2 used). j : 13 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 4. Install side cover (1) with bolts (7) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-4-2-4

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

SECTION 3 BODY Group 4 Engine

15 a 90Z6W03-04-20

7. Install plate (15) with bolts (14) (5 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

90Z6W03-04-18

dCAUTION: Rear fender (rear) (a) (option) weight: 24 kg (53 lb)/side 8. Close side cover (1). Install rear fender (rear) (a) (option). (Refer to W4-12.) (On both sides)

9. Install the other side cover (1) assembly in the same manner.

W3-4-2-5

SECTION 3 BODY Group 4 Engine Removal of Engine Roof

17 5

3 1

13, 14

15, 16

11, 12

9, 10

4 19

90Z6W03-04-23

dCAUTION: Side cover assembly weight: 30 kg (66

90Z6W03-04-24

5. Prepare a container under radiator sub tank (8).

lb) 1. Remove side cover (Refer to W3-4-2.)

6. Loosen hose band (9) and disconnect hose (10).

2. Remove bolts (3) (4 used) and washers (4) (4 used) to remove precleaner (2).

7. Loosen hose bands (11, 13, 15) and disconnect hoses (12, 14, 16). Collect coolant from each hose.

j : 17 mm

fNOTE: Coolant from sub tank: Max. 7 L (1.85 gal)

3. Remove bolts (6) (4 used) and remove exhaust pipe (5). j : 17 mm

8. Loosen hose band (18) and disconnect hose (19) from air cleaner (17).

dCAUTION: Engine roof (1) assembly weight: 57

kg (126 lb) 4. Remove bolts (7) at 4 points indicated by bold arrows and install eyebolts. Attach nylon slings to the eyebolts and temporarily hoist engine roof (1) assembly. j : 17 mm (M10/8.8)

W3-4-2-6

SECTION 3 BODY Group 4 Engine

4, 5, 6

90Z6W03-04-26

90Z6W03-04-25

dCAUTION: Air cleaner (1) assembly weight: 20 kg

(44 lb) 9. Hold air cleaner (1) and remove bolts (2) (4 used). Remove air cleaner (1) and temporarily put it on the engine.

j : 17 mm 10. Remove 3 each of bolt (4), washer (5), and washer (6). j : 24 mm 9

11. Remove bolts (7) (2 used) and remove engine roof (3) assembly.

11 10

j : 17 mm

90Z6W03-04-30

fNOTE: Exhaust pipe (8) of EU Spec. machine (S/N

9001~) is directly installed to muffler (9). Loosen bolt (10) and clamp (11) to disconnect pipe (8). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-4-2-7

SECTION 3 BODY Group 4 Engine Installation of Engine Roof

4, 5, 6

90Z6W03-04-26

dCAUTION: Engine roof (3) assembly weight: 57

90Z6W03-04-25

dCAUTION: Air cleaner (1) assembly weight: 20 kg

kg (126 lb) 1. Sling and move engine roof (3) assembly over the engine mount.

(44 lb) 4. Hold air cleaner (1) and install bolts (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Tighten bolts (7) (2 used) to engine roof (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Install 3 each of bolt (4), washer (5), and washer (6) to engine roof (3). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-4-2-8

SECTION 3 BODY Group 4 Engine

13, 14

15, 16

11, 12

9, 10

3 1

90Z6W03-04-24

5. Connect hose (19) to air cleaner (17) and fix with hose band (18).

fNOTE: Insert hose (19) by 35 mm (1.38 in) into air

90Z6W03-04-23

8. Remove bolts (7) at 4 points indicated by bold arrows and install eyebolts. Attach nylon slings to the eyebolts and temporarily hoist engine roof (1) assembly.

cleaner on both ends.

j : 17 mm (M10/8.8)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 6. Connect hoses (12, 14, 16) to radiator sub tank (8) and fix with hose bands (11, 13, 15).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Install exhaust pipe (5) with bolts (6) (4 used).

m (15) : 4 N·m (0.4 kgf·m, 2.95 lbf·ft)

j : 17 mm

m (13) : 1.6 N·m (0.16 kgf·m, 1.18 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

7. Connect hose (10) to radiator sub tank (8) and fix with hose band (9).

10. Install precleaner (2) with bolts (3) (4 used) and washers (4) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Install side cover (Refer to W3-4-2). 12. Supply coolant to sub tank (8) and bleed air. (Refer to Operation & Maintenance Manual).

fNOTE: Coolant from sub tank: Max. 7 L (1.85 gal) W3-4-2-9

SECTION 3 BODY Group 4 Engine Removal and Installation of Deck and Step/Covers

5 2

16 17 18 22

6 7

15 12

22 23

9 19

8 21

21 15

W3-4-2-10

16 90Z6W03-04-22

SECTION 3 BODY Group 4 Engine No.

Part Name

Q’ty

01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Deck (Left) Deck (Right) Bolt Handrail (Left) Handrail (Right) Washer Nut Cover Bolt Stepladder (Left) Stepladder (Right) Bolt Battery Box (Left) Battery Box (Right) Washer Washer Washer, Spring Nut Cover (Left) Cover (Right) Step Bolt Step

1 1 8 1 1 8 8 2 16 1 1 8 1 1 8 8 8 8 1 1 2 10 3

Wrench Size mm

Tightening Torque N·m (kgf·m) (lbf·ft)

j : 19

j : 17

j : 19

dCAUTION: When removing and installing the following parts, hoist and hold them by using nylon slings.

Deck (Left) (1) Deck (Right) (2) Stepladder (Left) (10) Stepladder (Right) (11) Battery Box (Left) (13) Battery Box (Right) (14)

W3-4-2-11

Remark Weight: 12.5 kg (28 lb) Weight: 12.5 kg (28 lb) Weight: 5 kg (11 lb) Weight: 5 kg (11 lb) Weight: 7 kg (15 lb) Weight: 37 kg (82 lb) Weight: 37.5 kg (83 lb) Weight: 28 kg (62 lb) Weight: 28 kg (62 lb)

Weight: 2 kg (4.4 lb) Weight: 2 kg (4.4 lb) Weight: 5 kg (11 lb) Weight: 2 kg (4.4 lb)

SECTION 3 BODY Group 4 Engine (Blank)

W3-4-2-12

SECTION 3 BODY Group 4 Engine Removal and Installation of Air Cleaner 4 2

7 3

90Z6W03-04-24a

90Z6W03-04-23

4. Disconnect sensor cable (5) from air cleaner (4). 5. Loosen hose band (6) and remove air hose (7).

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Open the side covers. 3. Remove bolts (2) (4 used) and washers (3) (4 used), and remove rain cap (1) or optional precleaner when equipped. j : 17 mm

W3-4-3-1

SECTION 3 BODY Group 4 Engine

1 9

3 4

6 90Z6W03-04-25a

6. Loosen hose band (3) and disconnect air pipe (2).

90Z6W03-04-27

10. Remove bolts (9) (4 used) and bracket (8) from air cleaner (1).

j : 11 mm 7. Loosen hose band (4). Apply small amount of lubricant to the overlap width (a) of hose (2). j : 11 mm 8. Loosen 2 each of nut (6) for U-bolts (5) (2 used). Turn pipe (2) so that it will not disturb air cleaner (1) while removing. j : 19 mm 9. Hold air cleaner (1) from the bottom not to drop it. Remove bolts (7) (4 used) and take out air cleaner assembly (1) from the engine room. j : 17 mm

fNOTE:  Air cleaner (9) weight: 20 kg (44 lb)  Take out air cleaner (1) from the right side of machine.

W3-4-3-2

SECTION 3 BODY Group 4 Engine 7

9 3 4

8 5

50 mm (1.97 in)

90Z6W03-04-25

90Z6W03-04-27 Air cleaner hose

3, 4

Installation 1. Install bracket (8) to air cleaner (1) with bolts (9) (4 used). j : 17 mm

3. Install air pipe (2) and tighten hose bands (3, 4).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 2. Install air cleaner (1) in the engine room from the machine right side. Hold air cleaner (1) from the bottom and tighten bolts (7) (4 used). j : 14 mm

90Z6W03-04-16

Air hose insertion amount

j : 11 mm m : 5.7 N·m (0.57 kgf·m, 4.2 lbf·ft)

fNOTE: Insert air pipe (2) into the air cooler hoses about 50 mm (1.97 in) on both ends.

4. Secure U-bolts (5) (2 used) with 2 each of nut (6).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm

fNOTE: Air cleaner (9) weight: 20 kg (44 lb)

m : 55 N·m (5.5 kgf·m, 40.6 lbf·ft)

W3-4-3-3

SECTION 3 BODY Group 4 Engine 4

7 3

2~3 mm (0.08~0.12 in)

90Z6W03-04-24a

90Z6W03-04-23

35 mm (1.38 in)

90WNEC-03-04-26

Air hose (7) insertion amount

7. Install rain cap (1), or optional precleaner when equipped, with bolts (2) (4 used) and washers (3) (4 used). j : 17 mm

5. Install air hose (7) to air cleaner (4) and fix with hose band (6).

fNOTE: Insert air hose (7) into the air cooler hoses about 35 mm (1.38 in) on both ends.

m : 50 N·m (5 kgf·m, 37 lbf·ft) 8. Close the side covers.

6. Connect sensor cable (5) to air cleaner (4).

W3-4-3-4

SECTION 3 BODY Group 5 Radiator Assembly Replacement of Radiator, Oil Cooler, Air Cooler, and Torque Converter Cooler 1

90Z6W03-04-28

90Z6 07-27-02

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.

3. Remove bolt (2), bolts (3) (3 used), and bolt (4) on both sides. Remove rear roof (1). j : 17 mm j : 19 mm Do not remove radiator cap (5) until dWARNING: the coolant temperature in the radiator has cooled. Hot steam and coolant may spout out, possibly causing severe burns. Slowly loosen radiator cap (5) to release the inside pressure before removing the cap. 4. Make sure that the radiator is cooled enough. Remove radiator cap (5).

5. Place a container. Open plug (6) and completely drain the coolant.

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

fNOTE: Coolant amount: 40 L (10.6 gal)

2. Remove the engine roof and side covers. (Refer to W3-4-2.) Bleed air from hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

W3-5-1-1

j : 24 mm

SECTION 3 BODY Group 5 Radiator Assembly a 3, 4 8, 9

6, 7

12, 13, 15 1, 2 17, 19 10, 11

12, 14, 16

6. Loosen hose bands (2, 4) and remove hoses (1, 3).

17, 18

90Z6W03-05-01

This machine uses new refrigerant dCAUTION: R134a. Recover the entire refrigerant from the

j : 10 mm j : 11 mm 7. Prepare a container under torque converter cooler inlet (a). Remove hose (5), nut (6), and holder (7).

system. IMPORTANT: Do not release refrigerant into the atmosphere, as this is illegal. Comply with refrigerant regulations. 10. Remove bolts (12) (2 used) and remove hoses (13, 14).

j : 50 mm

j : 10 mm

j : 12 mm 11. Remove O-rings (15, 16) from hoses (13, 14). 8. Loosen hose band (8) and remove hose (9). 12. Remove nuts (17) (2 used) and holders (18, 19). 9. Remove 3 each of nut (10) and holder (11) indicated by bold arrows. j : 12 mm

W3-5-1-2

j : 12 mm

SECTION 3 BODY Group 5 Radiator Assembly

7, 8

1, 2

90Z6W03-04-05

13. Remove nuts (1) (2 used) and holders (2) (2 used).

90Z6W03-05-02

14. Disconnect hoses (3, 4).

j : 12 mm

j : 27 mm 15. Disconnect hoses (5, 6). j : 50 mm 16. Loosen hose band (7) and disconnect hose (8).

W3-5-1-3

SECTION 3 BODY Group 5 Radiator Assembly 4

2, 3

4, 5, 6

90Z6W03-05-04

90Z6W03-05-03

Rear grill assembly (1) weight: 35 kg dCAUTION: (77 lb)

20. Remove bolts (9) (8 used) and remove radiator guards (7, 8). j : 17 mm

17. Temporarily sling rear grill assembly (1).

fNOTE: Radiator guard weight: 15 kg (33 lb)/each 18. Remove bolt (3) and disconnect connector (2) for the rear working light (on both sides). j : 10 mm 19. Remove bolts (4) (8 used), nuts (5) (4 used), and washers (6) (4 used), and remove rear grill assembly (1). j : 17 mm

W3-5-1-4

SECTION 3 BODY Group 5 Radiator Assembly

11, 12

1 18

16, 17

1 2

14 10 8

4 6

11, 13

19, 20

90Z6W03-05-05

21. Disconnect hoses (1, 2, 3).

23, 24

25, 26

90Z6W03-05-06

26. Remove nuts (16) (3 used) and holders (17) (3 used) indicated by bold arrows and remove hose (18).

j : 27 mm

j : 12 mm

j : 36 mm 22. Remove bolts (4) (4 used) and remove plates (5, 6) (on both sides).

27. Remove nut (19), holder (20), and bolts (21) (2 used). Temporarily move bracket (22) and hose (1) onto the left battery box.

j : 17 mm

j : 12 mm j : 17 mm

23. Disconnect connectors (7, 8, 9).

28. Loosen hose bands (23, 25) and remove hoses (24, 26).

24. Remove bolt (10), nuts (11) (2 used), and holders (12, 13). j : 17 mm j : 12 mm 25. Remove bolts (14) (2 used). Temporarily move bracket (15) and hoses (2, 3) onto the right battery box. j : 17 mm

W3-5-1-5

SECTION 3 BODY Group 5 Radiator Assembly

4 2

5 6 3 1 7

90Z6W03-05-07

29. Remove the small square cover on the right side of rear chassis (refer to W3-4-2). Prepare a container under hose (1). 30. Loosen hose bands (2) (2 used) and disconnect hose (1). Collect torque converter oil.

90Z6W03-05-08

Radiator assembly (4) weight: 290 kg dCAUTION: (640 lb) 32. Attach a nylon slings to the radiator assembly. Hoist and hold radiator assembly (4) temporarily. 33. Remove 3 each of bolt (5), washer (6), and spacer (7) indicated by bold arrows (on both sides).

31. Remove hose bands (3) (2 used) and remove hose (1).

j : 24 mm 34. Lower radiator assembly (4) onto a level and stable surface.

W3-5-1-6

SECTION 3 BODY Group 5 Radiator Assembly

a 5

7 9

1 12 8

17 16

12 4 2

3 a-

25 24 23

19 Radiator Assembly

20 90Z6W03-05-09

35. Remove bolts (2) (4 used) on both sides and remove air conditioner condenser assy (1) and fuel cooler assy (3). j : 17 mm

22 90Z6W03-05-10

41. Remove bolts (12) (2 used), bolts (15, 16), and spacers (17) from air cooler assembly (4) on both sides. Remove plates (13, 14) and plates (18) (2 used). j : 17 mm

Air cooler assembly (4) weight: 26 kg dCAUTION: (57 lbs) 36. Temporarily sling air cooler assembly (4).

42. Remove bolts (19) (4 used) and plates (20) (2 used) from fuel cooler assembly (3). j : 17 mm

37. Remove 2 each of nut (5), washer (6), plate (7), and bolt (8) indicated by bold arrows (on both sides). Remove air cooler assembly (4). j : 19 mm

43. Remove 4 each of nut (23), washer (24), spacer (25), and bolt (26). Remove brackets (21, 22). j : 17 mm

38. Remove bush (9) (2 used) (on both sides). Hydraulic oil cooler assembly (10) dCAUTION: weight: 25 kg (55 lbs) 39. Temporarily sling hydraulic oil cooler assembly (10). 40. Remove bolts (11) (4 used) (on both sides). Remove hydraulic oil cooler assembly (10). j : 17 mm

W3-5-1-7

SECTION 3 BODY Group 5 Radiator Assembly

10 11

12, 13, 14

A A

A 15

21 17

18, 19, 20

9 6

90Z6W03-05-12

90Z6W03-05-11

44. Remove bolts (3) (4 used) and bracket (2) from radiator assembly (1).

dCAUTION: Radiator (16) weight: 30 kg (66 lbs) 48. Temporarily sling radiator (16).

j : 19 mm

CAUTION: Fan mount assembly (4) weight: 50 kg (110 lbs) 45. Temporarily sling fan mount assembly (4). 46. Remove bolt (6) from connector (5). Remove nuts (7) (4 used) and washers (8) (4 used). j : 10 mm j : 19 mm

49. Remove 2 each of bolt (12), washer (13), and rubber cushion (14) from radiator assembly (1). j : 17 mm 50. Sling up and hold radiator (16) and remove collars (15) (2 used) and cushions (17) (2 used). 51. Remove 4 each of bolt (18), washer (19), and rubber cushion (20) from radiator assembly (1). j : 19 mm

47. Remove bolts (9) (6 used), bolts (10) (2 used), and bosses (11) (2 used). Remove fan mount assembly (4).

52. Remove hydraulic oil cooler assembly (22) and remove collar (21).

j : 19 mm

W3-5-1-8

SECTION 3 BODY Group 5 Radiator Assembly

12, 13, 14

10 11

A A

A 15

4 A

21 17

18, 19, 20 9 90Z6W03-05-12

Installation 1. Install 4 each of rubber cushion (20) and collar (21) to radiator shroud assembly (1). Install hydraulic oil cooler assembly (22). 2. Install 4 each of bolt (18) and washer (19) to shroud assembly (1). j : 19 mm

90Z6W03-05-11

Fan mount assembly (4) weight: 50 kg dCAUTION: (110 lbs) 6. Temporarily sling fan mount assembly (4) and move onto radiator assembly (1). 7. Install bosses (11) (2 used), bolts (10) (2 used), and bolts (9) (2 used) to the upper part of radiator. Fix with nuts (7) (4 used) and washers (8) (4 used). j : 19 mm

m : 73.5 N·m (7.5 kgf·m, 54.2 lbf·ft) 3. Install cushions (17) (2 used), rubber cushions (14) (2 used), and collars (15) (2 used) to shroud assembly (1).

m : 90 N·m (9 kgf·m, 66 lbf·ft) 8. Install bolts (9) (4 used) to the lower part of radiator. Install connector (5) with bolt (6). j : 10 mm

dCAUTION: Radiator (16) weight: 30 kg (66 lbs)

m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

4. Temporarily sling radiator (16) and move to shroud assembly (1). Insert the protrusions on the bottom of radiator (16) into cushions (17). 5. Install 2 each of bolt (12), washer (13) to shroud assembly (1).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 9. Install bracket (2) with bolts (3) (4 used). j : 19 mm

j : 17 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

m : 37 N·m (3.8 kgf·m, 27 lbf·ft)

W3-5-1-9

SECTION 3 BODY Group 5 Radiator Assembly

12 17 16

14 21

25 24 23

19 20

22 90Z6W03-05-10

10. Install bolts (26) (4 used) to hydraulic oil cooler assembly (10). Install 4 each of spacers (25) and brackets (21, 22) with nut (23) and washer (24).

12. Install plates (18) (2 used) to air cooler assembly (4). Install spacers (17) to air cooler assembly (4) with bolts (15, 16) on both sides. 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) 11. Install plates (20) (2 used) to fuel cooler assembly (3) with bolts (19) (4 used).

13. Install plates (13, 14) to air cooler assembly (4) with bolts (12) (2 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)

W3-5-1-10

SECTION 3 BODY Group 5 Radiator Assembly

a 5

7 9

2 10

4 2

8 11 7

90Z6W03-05-13

Radiator Assembly

90Z6W03-05-09

Hydraulic oil cooler assembly (10) dCAUTION: weight: 25 kg (55 lbs)

Air cooler assembly (4) weight: 26 kg dCAUTION: (57 lbs)

14. Sling hydraulic oil cooler assembly (10) and tighten bolts (11) (4 used) (on both sides).

16. Sling air cooler assembly (4) and install to radiator assy (a). Install bolts (8) (4 used), and fix with 2 each of nut (5), washer (6), plate (7).

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 15. Install bush (9) at 2 positions indicated by bold arrows (on both sides).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 17. Install air conditioner condenser assy (1) and fuel cooler assy (3) with bolts (2) (4 used) on both sides. j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-11

SECTION 3 BODY Group 5 Radiator Assembly

4 2

5 6 3 1 7

90Z6W03-05-08

Radiator assembly (4) weight: 290 kg dCAUTION: (640 lb) 18. Sling radiator assembly (4). Carefully lift up and install onto the rear chassis.

90Z6W03-05-07

20. Install hose (1) and fix with hose bands (3) (2 used). m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 21. Close the square cover on the right side of rear chassis (refer to W3-4-2).

19. Install bolt (5), washer (6), and spacer (7) to the 3 positions indicated by bold arrows (on both sides). j : 24 mm m : 210 N·m (21 kgf·m, 155 lbf·ft)

W3-5-1-12

SECTION 3 BODY Group 5 Radiator Assembly

1 18

16, 17 C

30 mm 15°

C Detail

25 mm

40°

B A

35°

26 A Detail

19, 20

D Detail B Detail 90Z6W03-05-14

23, 24

25, 26

90Z6W03-05-06

22. Install hoses (24, 26) and fix with hose bands (23, 25).

24. Install hose (18) and fix with nuts (16) (3 used) and holders (17) (3 used) indicated by bold arrows.

m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

23. Install hose (1) and bracket (22) with bolts (21) (2 used). Install holder (20) with nut (19). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W3-5-1-13

SECTION 3 BODY Group 5 Radiator Assembly 11, 12

1 14

B 8

10°

11, 13

5 10

10°

4 6

Arrow View A

B Detail 90Z6W03-05-15

90Z6W03-05-05

25. Install hoses (2, 3) and bracket (15) and fix with bolts (14) (2 used). Install holders (12, 13) with bolt (10), nuts (11) (2 used).

Fan Motor

28. Connect hoses (1, 2, 3).

j : 17 mm

j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 36 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 180 N·m (18 kgf·m, 133 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 26. Connect connectors (7, 8, 9). 27. Install plates (5, 6) with bolts (4) (4 used) (on both sides). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-5-1-14

SECTION 3 BODY Group 5 Radiator Assembly 4

2, 3

4, 5, 6

90Z6W03-05-04

29. Install radiator guards (7, 8) with bolts (9) (8 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

fNOTE: Radiator guard weight: 15 kg (33 lb)/each

90Z6W03-05-03

Rear grill assembly (1) weight: 35 kg dCAUTION: (77 lb) 30. Sling rear grill assembly (1) and move to the rear of the radiator. 31. Secure rear grill assembly (1) with bolts (4) (8 used), washers (6) (4 used), and nuts (5) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 32. Connect connector (2) for the rear working light and fix with bolt (3) (on both sides). j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

W3-5-1-15

SECTION 3 BODY Group 5 Radiator Assembly

7, 8

1, 2

90Z6W03-05-02

33. Connect hose (8) and fix with hose band (7).

90Z6W03-04-05

36. Install holders (2) (2 used) with nuts (1) (2 used).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

34. Connect hoses (5, 6). j : 50 mm m : 270 N·m (27 kgf·m, 199 lbf·ft) 35. Connect hoses (3, 4). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-5-1-16

SECTION 3 BODY Group 5 Radiator Assembly a

3, 4 (E)

10, 11

8, 9

12, 13, 15

10, 11 10°

10°

20°

5 6, 7

17, 18

10, 11 (B)

A Detail

B Detail

1, 2

50 mm

E 10, 11 (A)

12, 14, 16

17, 18

C Detail

5 10°

D Detail

17, 19

6, 7

1, 3

2, 4 E Detail 90Z6W03-05-16

90Z6W03-05-01

37. Install O-rings (15, 16) to hoses (13, 14) and fix with bolts (12) (2 used).

41. Install hose (5), nut (6), and holder (7) to torque converter cooler inlet (a).

j : 10 mm

j : 50 mm

m : 11 N·m (1.1 kgf·m, 8 lbf·ft)

m : 270 N·m (27 kgf·m, 199 lbf·ft)

fNOTE: When connecting hoses to the refrigerant pipe,

j : 12 mm

apply DENSO ND-OIL8.R134a or equivalent to O-rings.

38. Install holders (18, 19) with nuts (17) (2 used). j : 12 mm

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 42. Install hoses (1, 3) and fix with hose bands (2, 4). j : 10 mm

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

m : 5.7 N·m (0.57 kgf·m, 4.2 lbf·ft)

39. Install nut (10) and holder (11) at 3 positions indicated by bold arrows.

j : 11 mm m : 5.7 N·m (0.57 kgf·m, 4.2 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 40. Install hose (9) and fix with hose band (8). m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

fNOTE: Insert hose (9) by 50 mm at the radiator side, and 36 mm at the engine side.

W3-5-1-17

SECTION 3 BODY Group 5 Radiator Assembly

90Z6 07-27-02

43. Tighten plug (6) and supply coolant. (Refer to Operation & Maintenance Manual.) j : 24 mm

fNOTE: Coolant amount: 40 L (10.6 gal)

90Z6W03-04-28

44. Install radiator cap (5). 45. Install rear roof (1). Fix with bolt (2), bolts (3) (3 used), and bolt (4) on both sides. j : 17 mm

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

m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 46. Install the engine roof and side covers. (Refer to W34-2.)

W3-5-1-18

SECTION 3 BODY Group 6 Hydraulic Oil Tank Removal and Installation of Hydraulic Oil Tank 2 3

5 1

90Z6W03-06-01

Removal

Bleed air from hydraulic oil tank (1). dCAUTION: (Refer to W1-4-1.) 2. Remove bolts (2) (6 used). Remove cover (3), suction filter (4), and O-ring (5). 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): 123 L (32.5 US gal)

W3-6-1-1

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 1 90Z6W03-04-17

4. Remove following parts.  Rear fender (front) (1) (Refer to W4-1-2.)  Engine roof (2) (Refer to W3-4-2.)  Side cover (3) (Refer to W3-4-2.)

W3-6-1-2

SECTION 3 BODY Group 6 Hydraulic Oil Tank 2

6, 13

14, 15

6, 7

6, 12

6, 8 16, 17

10 90Z6W03-06-02

5. Disconnect hoses (2, 3, 4, 5) from hydraulic oil tank (1).

j : 27 mm 9. Remove nuts (6) (2 used) and holders (12, 13). j : 12 mm

j : 27 mm 6. Remove nuts (6) (2 used) and holders (7, 8).

10. Remove bolt (14) and holder (15). j : 17 mm

j : 12 mm 7. Remove hoses (9, 10).

90Z6W03-06-03

8. Remove hose (11).

j : 17 mm j : 19 mm

View A

11. Loosen hose band (16) and remove hose (17). j : 11 mm

j : 36 mm j : 50 mm

W3-6-1-3

SECTION 3 BODY Group 6 Hydraulic Oil Tank

a 1 5, 6

a 2

4 11

5, 7

90Z6W03-06-05

90Z6W03-06-04

12. Disconnect hoses (2, 3, 4) from hydraulic oil tank (1). j : 50 mm j : 27 mm 13. Remove nuts (5) (3 used), holders (6) (2 used), and holder (7). j : 12 mm

Hydraulic oil tank (1) weight: 220 kg dCAUTION: (485 lb) 15. Attach nylon slings onto hydraulic oil tank (1) at hoisting points (a). Hoist and hold hydraulic oil tank (1) temporarily. 16. Remove bolts (11) (3 used) and washers (12) (3 used) (on both sides). Hoist and remove hydraulic oil tank (1).

14. Disconnect connector (8) and remove bolt (10). Remove cable (9).

j : 30 mm

j : 10 mm

W3-6-1-4

SECTION 3 BODY Group 6 Hydraulic Oil Tank

a 1 5, 6

8 2

4 11

5, 7

90Z6W03-06-05

90Z6W03-06-04

Installation Hydraulic oil tank (1) weight: 220 kg dCAUTION: (485 lb)

3. Install cable (9) and fix with bolt (10). Connect connector (8).

1. Sling hydraulic oil tank (1) and move onto the rear chassis. 2. Apply Loctite#262 or equivalent to bolts (11) (3 used). Install hydraulic oil tank (1) with bolts (11) (3 used) and washers (12) (3 used) (on both sides).

j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) 4. Install holders (6) (2 used) and holder (7) with nuts (5) (3 used). j : 12 mm

j : 30 mm

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

m : 610 N·m (61 kgf·m, 450 lbf·ft) 5. Connect hoses (2, 3, 4) to hydraulic oil tank (1). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 50 mm m : 270 N·m (27 kgf·m, 199 lbf·ft)

W3-6-1-5

SECTION 3 BODY Group 6 Hydraulic Oil Tank 2

14, 15

6, 13 2

6, 12

5 6, 7

A View A

16, 17

90Z6W03-06-03

32 mm

20°

6, 8

5 mm

90Z6W03-06-02 Machine Front

View B

90Z6W03-06-06

6. Install hose (17) and fix with hose band (16).

10. Install hoses (9, 10).

j : 11 mm

j : 36 mm

m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

m : 180 N·m (18 kgf·m, 133 lbf·ft) j : 50 mm

7. Install holder (15) with bolt (14).

m : 270 N·m (27 kgf·m, 199 lbf·ft)

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

11. Install holders (7, 8) and fix with nuts (6) (2 used). j : 12 mm

8. Install holders (12, 13) with nuts (6) (2 used).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

12. Connect hoses (2, 3, 4, 5) from hydraulic oil tank (1). j : 17 mm

9. Install hose (11).

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

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

W3-6-1-6

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 1 90Z6W03-04-17

13. Remove following parts.  Rear fender (front) (1) (Refer to W4-1-2.)  Engine roof (2) (Refer to W3-4-2.)  Side cover (3) (Refer to W3-4-2.)

W3-6-1-7

SECTION 3 BODY Group 6 Hydraulic Oil Tank

3 1

90Z6W03-06-01

14. Fill hydraulic oil tank (1) with hydraulic oil. (Refer to Operation & Maintenance Manual.)

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

fNOTE: Hydraulic tank capacity (1): 123 L (32.5 US gal)

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

15. Install O-ring (3). 16. Install breather valve (2) assembly with bolts (4) (4 used). l : 5 mm m : 11 N·m (1.1 kgf·m, 8 lbf·ft)

W3-6-1-8

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

7 6

3, 4 1

2 90Z6-1-114-1

90Z6 07-27-02

4. Place a container under drain bolt (3). Remove drain bolt (3) and washer (4) and drain fuel. j : 24 mm

fNOTE: Fuel tank (2) capacity: 396 L (104 US gal) 5. Remove nuts (5) (2 used) and adapters (6, 7) from fuel tank (2). j : 41 mm

2. Remove the radiator assembly. (Refer to W3-5-1.) 3. Remove cap (1).

W3-7-1-1

SECTION 3 BODY Group 7 Fuel Tank

6 3 1

2 7, 8

9, 10 90Z6W03-07-02

90Z6W03-07-01

6. Remove bolts (2) (2 used) and bolts (4) (2 used). Remove block assemblies (3, 5). j : 17 mm 7. Remove hose (6) from fuel tank (1).

9. Remove nut (9) and holder (10). j : 12 mm 10. Remove hose (11). j : 27 mm

j : 17 mm 8. Remove nuts (7) (3 used) and holders (8) (3 used). j : 12 mm

W3-7-1-2

SECTION 3 BODY Group 7 Fuel Tank

9, 10

3, 5

9, 10 7

3, 4

2 9, 10 6 90Z6W03-07-03

14. Disconnect hoses (6, 7, 8).

dCAUTION: Fuel tank (1) weight: 320 kg (706 lb) 11. Install eyebolt to (a) (M16 x 2) and temporarily sling and hold fuel tank (1). 12. Disconnect fuel level sensor connector (2).

j : 27 mm 15. Remove bolts (9) (4 used) and washers (10) (4 used). Remove fuel tank (1) from the rear chassis. j : 36 mm

13. Remove nuts (3) (3 used), holders (4) (2 used) and holder (5). j : 12 mm

W3-7-1-3

SECTION 3 BODY Group 7 Fuel Tank 9, 10

3, 5

a 20°

5 9, 10

3, 4 3 2

9, 10 6

A Detail

15°

B Detail 90Z6W03-07-04

90Z6W03-07-03

Installation

dCAUTION: Fuel tank (1) weight: 320 kg (706 lb) 1. Install eyebolt to (a) (M16 x 2) and move fuel tank (1) onto the rear chassis. 2. Apply Loctite#262 to bolts (9) (4 used). Install fuel tank (1) to with bolts (9) (4 used) and washers (10) (4 used). j : 36 mm m : 700 N·m (70 kgf·m, 516 lbf·ft) 3. Connect hoses (6, 7, 8). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 4. Install holders (4) (2 used) and holder (5) with nuts (3) (3 used). j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 5. Connect fuel level sensor connector (2).

W3-7-1-4

SECTION 3 BODY Group 7 Fuel Tank

5 6

A 3

2 7, 8

9, 10

90Z6W03-07-01 90Z6W03-07-02

6. Install hose (11). j : 27 mm 8

7. Install holder (10) with nut (9). j : 12 mm

8 20°

15°

A Detail

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

B Detail 90Z6W03-07-05

8. Install holders (8) (3 used) with nuts (7) (3 used). j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 9. Install hose (6) to fuel tank (1). j : 17 mm 10. Install block assemblies (3, 5) with bolts (2) (2 used) and bolts (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-7-1-5

SECTION 3 BODY Group 7 Fuel Tank

7 6

3, 4

1 90Z6 07-27-02

11. Install adapters (6, 7) to fuel tank (2) and fix with nuts (5) (2 used).

2 90Z6-1-114-1

13. Install cap (1). 14. Install the radiator assembly. (Refer to W3-5-1.)

j : 41 mm 12. Install drain bolt (3) and washer (4) to fuel tank (2). Supply fuel. (Refer to Operation & Maintenance Manual.)

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

j : 24 mm

fNOTE: Fuel tank (2) capacity: 396 L (104 US gal)

W3-7-1-6

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

3 1

d a

f 90Z6W03-08-01 abc-

Main Pump Regulators Pilot Pump

def-

Priority Valve Fan Pump (Accessory Pump) Engine

fNOTE: The pump device consists of main pump (a)

90Z6W03-06-01

assembly with the assembled units (b, c, d) and accessory pump (e).

Removal

CAUTION: Escaping fluid under pressure may penetrate the skin and eyes, and cause serious injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. Wait until oil cools before starting any work. Do not turn the cap of hydraulic tank (1) quickly. The cap may fly off by internal pressure. Release any remaining pressure and remove the cap. 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.

Bleed air from hydraulic tank (1). dCAUTION: (Refer to W1-4-1.) 2. Remove bolts (2) (6 used). Remove cover (3), suction filter (4), and O-ring (5). j : 17 mm 3. Place a container. Drain off hydraulic oil by using an oil feed pump.

fNOTE: Hydraulic tank (1) capacity: 123 L (32.5 US gal) 4. Remove the cab assembly. (Refer to W3-1-1.)

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

W3-8-1-1

SECTION 3 BODY Group 8 Pump Device

17, 18, 19

11 20, 21

3 1

2 13 6

14, 15, 16

90Z6W03-08-02

5. Disconnect hoses (2, 3, 4) and hoses (5, 6) from pump device (1).

j : 36 mm

j : 22 mm

j : 50 mm j : 27 mm

6. Disconnect hoses (7, 8). j : 19 mm

9. Disconnect connector (13).

j : 36 mm Pump device (1) weight: 110 kg (243 dCAUTION: lb)

j : 41 mm

90Z6W03-08-03

8. Disconnect hoses (9, 10) and hoses (11, 12) from pump device (1).

j : 17 mm

7. Remove plug (G1) with bleeder and install a plug with eyebolt. Temporarily sling pump device (1).

10. Remove bolts (14) (4 used), pipe (15), and O-ring (16). l : 10 mm 11. Remove bolts (17) and washers (18, 19) on both sides. Remove pilot pump (20) with O-ring (21). l : 8 mm

W3-8-1-2

SECTION 3 BODY Group 8 Pump Device

90Z6W03-08-04

12. Remove bolts (2) (4 used). Remove pump device (1) and O-ring (3). l : 10 mm 13. Remove bolts (5) (4 used), spacer (4), sleeve (6), and O-ring (7). l : 10 mm

W3-8-1-3

SECTION 3 BODY Group 8 Pump Device

G1 2

1 B

90Z6W03-08-04

Pump device (1) weight: 110 kg (243 dCAUTION: lb) IMPORTANT: Check the installation angle of each adapter. 1. Attach nylon sling to eyebolt (G1). Lift and hold main pump (1) and install adapters, if removed.

20°

View A

Installation

30°

View B

25° 55° 20°

j : 41 mm

20°

2. Install sleeve (6) and O-ring (7). Install spacer (4) with bolts (5) (4 used).

View C

l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

10° 90Z6W03-08-05

3. Install pump device (1) with O-ring (3). Tighten bolts (2) (4 used). l : 10 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-8-1-4

SECTION 3 BODY Group 8 Pump Device

17, 18, 19

11 20, 21

13 11

30°

9 14, 15, 16

90Z6W03-08-03

4. Install O-ring (21) and pilot pump (20) to pump (1). Fix with washers (18, 19) and bolts (17) on both sides.

15°

90Z6W03-08-06

7. Connect hoses (9, 10) and hoses (11, 12) to pump device (1).

l : 8 mm

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 50 mm m : 270 N·m (27 kgf·m, 199 lbf·ft)

5. Install pipe (15) and O-ring (16) to pump (1). Fix with bolts (14) (4 used)

j : 27 mm

l : 10 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft) 6. Connect connector (13).

W3-8-1-5

SECTION 3 BODY Group 8 Pump Device 8

7 2

3 1

90Z6W03-06-01

90Z6W03-08-02 55°

1 8

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

fNOTE: Hydraulic tank (1) capacity: 123 L (32.5 US gal) 90Z6W03-08-07

12. Install O-ring (5), suction filter (4), and cover (3) with bolts (2) (6 used). j : 17 mm

8. Connect hoses (7, 8).

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) j : 36 mm

13. Remove eyebolt (G1) and install bleeder plug with bolts (4) (4 used). j : 41 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 80 N·m (8 kgf·m, 59 lbf·ft) 9. Connect hoses (2, 3, 4) and hoses (5, 6) to pump device (1). j : 17 mm

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

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

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

j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft) 10. Install the cab assembly. (Refer to W3-1-1.)

W3-8-1-6

SECTION 3 BODY Group 8 Pump Device Disassembly and Assembly of Pump Device

12-

Pilot Pump Socket Bolt (2 used)

34-

Spring Washer (2 Used) Washer (2 Used)

90T4GB-03-01-03

56-

W3-8-2-1

O-Ring Regulator

78-

Socket Bolt (4 used) Main Pump

SECTION 3 BODY Group 8 Pump Device Removal of Pilot Pump and Regulator Eyebolt Eyebolt

7 6 9

1 8

8 5 a W4GB-02-04-001

dCAUTION: Pump device weight: 110 kg (243 lb) 1. Remove the plug with bleeder on regulator (6) and install a plug with eyebolt as shown. Attach a nylon sling to the eyebolt. Hoist the pump device and place it onto stable wooden blocks (a) with the regulator side up. j : 41 mm 2. Remove socket bolts (2) (2 used), spring washers (3) (2 used) and washers (4) (2 used) from pilot pump (1). Remove pilot pump (1) and O-ring (5) from main pump (8).

2 3

90W4GB-02-04-01

IMPORTANT: Put the matching marks on regulator (6) and main pump (8) before disassembling. 3. Remove socket bolts (7) (4 used) from regulator (6). l : 8 mm IMPORTANT: Do not drop O-ring (9) between regulator (6) and main pump (8). 4. Remove regulator (6) from main pump (8).

fNOTE: Pull the regulator obliquely upward when it

l : 8 mm

W3-8-2-2

moves up.

SECTION 3 BODY Group 8 Pump Device Installation of Pilot Pump and Regulator

9 11

11 6

12 8

1 4 9

5 W4GB-02-04-002

IMPORTANT: Check that O-rings (10) (5 used) are installed on the regulator (6) mounting surface. 1. Adjust the two sleeve positions and align two grooves in both sleeves on regulator (6).

2 3

90W4GB-02-04-08

5. Install regulator (6) to main pump (8) with socket bolts (7) (4 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

2. Place regulator (6) on main pump (8). 6. Install O-ring (5) to pilot pump (1). 3. Insert feedback link (11) into two grooves in both sleeves. 4. Adjust regulator (6) position so that two knock pins (12) on main pump (8) can enter regulator (6).

IMPORTANT: Place pilot pump (1) with the inlet port (the larger port diameter) facing upward. 7. Install pilot pump (1) to main pump (8) with socket bolts (2) (2 used), spring washers (3) (2 used) and washers (4) (2 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-8-2-3

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-2-4

SECTION 3 BODY Group 8 Pump Device Disassembly of Main Pump 1

9 10 43

44 45

20 13

A Detail

23 12

14 15

26 28 27

22 38

24 25

40 23

29 30 A 31

41 21

37 36 32

90W4GB-02-04-09

123456789101112-

Retaining Ring Pump Casing Valve Plate Rotor Plunger Piston (9 used) Swash Plate Knock Pin Front Casing Socket Bolt (8 used) Socket Bolt (4 used) Drive Shaft Bearing Inner Race

131415161718192021222324-

Needle Bearing Knock Pin Spring (4 used) Bushing Servo Piston (3 used) Retainer Cam Plate Knock Pin Plug (5 used) Cradle Plate Plug (2 used) Pin

252627282930313233343536-

W3-8-3-1

Spring Pin Feedback Link Spring Pin Pin Link Pin O-Ring O-Ring Retainer Ring (2 used) Plug Roller Bearing Knock Pin Oil Seal

373839404142434445-

Retaining Ring O-Ring Spring Pin (2 used) O-Ring (5 used) Plug Pressure Sensor Restriction Pin Backup Ring (2 used) O-Ring (2 used)

SECTION 3 BODY Group 8 Pump Device

34 31

Regulator

21 20

38 28 26

6 7

24 19

29 39 15

21 1

Pilot Pump

41 90Z6W03-08-14

Disassembly

dCAUTION: Pump device weight: 110 kg (243 lb)

dCAUTION: Front casing (8) weight: 48 kg (110 lb)

1. Secure the main pump assembly on a workbench with the pilot pump (a) side up.

3. Remove the front casing (8) assembly from pump casing (2). At this time, drive shaft (11), the rotor (4) assembly, and restriction pin (43) are removed with front casing (8) together.

fNOTE: Cover the workbench with a rubber mat so that

the pump is not scratched or damaged especially on the regulator mounting surface.

2. Loosen socket bolts (9) (8 used) from front casing (8). l : 14 mm

fNOTE: When removing front casing (8), raise the pump casing (2) side a little in order to prevent rotor (4) from falling off.

fNOTE: Restriction pin (43) may remain in pump casing (2). Do not remove it unless necessary.

4. Place front casing (8) onto a stable wooden block of larger than 30 x 30 mm with rotor (4) side facing up.

W3-8-3-2

SECTION 3 BODY Group 8 Pump Device IMPORTANT: The valve plate (3) side of rotor (4) is a sliding surface. Do not damage the sliding surface. 5. Hold retainer (18) by hand and remove rotor (4) assembly from drive shaft (11). Place rotor (4) assembly with the valve plate side down. 6. Hold the lower part of retainer (18) and remove retainer (18) together with servo piston (17) from rotor (4). 7. Remove bushing (16) and springs (15) (4 used) from rotor (4). 8. Remove plate (19) from swash plate (6).

fNOTE: Plate (19) can be raised by tapping the yoke part of swash plate (6) while positioning plate (19) upside.

9. Remove socket bolts (10) (4 used) from cradle plate (22). Remove cradle plate (22) from front casing (8). l : 6 mm 10. Remove drive shaft (11) together with roller bearing (34) from front casing (8) by hand. IMPORTANT: When removing retaining ring (32), do not damage the seal lip surface of drive shaft (11). 11. Remove retaining rings (32) (2 used) from drive shaft (11). 12. Remove the roller and the outer ring of roller bearing (34).

W3-8-3-3

SECTION 3 BODY Group 8 Pump Device Assembly of Main Pump

34 31

Regulator

21 20

38 28 26

6 7

24 19

29 39 15

4 21 1

Pilot Pump

41 90Z6W03-08-14

123456789101112-

Retaining Ring Pump Casing Valve Plate Rotor Plunger Piston (9 used) Swash Plate Knock Pin Front Casing Socket Bolt (8 used) Socket Bolt (4 used) Drive Shaft Bearing Inner Race

131415161718192021222324-

Needle Bearing Knock Pin Spring (4 used) Bushing Servo Piston (3 used) Retainer Cam Plate Knock Pin Plug (5 used) Cradle Plate Plug (2 used) Pin

252627282930313233343536-

W3-8-3-4

Spring Pin Feedback Link Spring Pin Pin Link Pin O-Ring O-Ring Retainer Ring (2 used) Plug Roller Bearing Knock Pin Oil Seal

373839404142434445-

Retaining Ring O-Ring Spring Pin (2 used) O-Ring (5 used) Plug Pressure Sensor Restriction Pin Backup Ring (2 used) O-Ring (2 used)

SECTION 3 BODY Group 8 Pump Device IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Tap and install needle bearing (13) to pump casing (2) with the stamped mark on the outer race facing up by using a special tool and a hammer. IMPORTANT: Valve plate (3) and rotor (4) must be replaced as an assembly. IMPORTANT: Install valve plate (3) of the rotor (4) assembly with the slotted hole facing down. 2. Apply grease onto the flat surface of valve plate (3). Align the position of knock pin (14) in pump casing (2) and install valve plate (3).

6. Evenly tap and install inner race (12) to drive shaft (11) by using a special tool and a hammer. 7. Install retaining ring (1) to drive shaft (11). IMPORTANT: Do not damage the sliding surface of oil seal (36) at drive shaft (11). 8. There are two ring grooves in drive shaft (11). Install retaining ring (32) to the ring groove closer to the end surface. 34 (Inner ring)

3. Install servo pistons (17) (3 used) to pump casing (2). 27

W4GB-02-04-004

9. Check the direction of the inner ring of roller bearing (34). Lightly tap and install roller bearing (34) to drive shaft (11) by using a hammer. Parallel surfaces W176-02-04-016

IMPORTANT: Check the direction to install feedback link (26). 4. Align the groove for pin (24) in pump casing (2) and install the feedback link (26) assembly. At this time, face link pin (29) to the front casing (8) side.

10. Install the roller and the outer/inner ring plates of roller bearing (34) to drive shaft (11) with the stamped mark facing out. 11. Install retaining ring (32) to drive shaft (11).

fNOTE: Fit the parallel surfaces into the groove of casing (2) when install spring pin (27).

IMPORTANT: Check the directions of spring (15) and retainer (18). 5. Assemble rotor (4) as follows: 5-1. Install spring (15) and bushing (16) in rotor (4) assembly.

fNOTE: When installing bushing (16), align the spline of bushing (16) with the spline of rotor (4) to makes shaft (11) installation easier. 5-2. Insert plunger pistons (5) (9 used) from the flat surface of retainer (18) and install them to rotor (4).

W3-8-3-5

SECTION 3 BODY Group 8 Pump Device

11 37

34 31

22 10

20 6 26 19 40

2 45

12. Assemble front casing (8) as follows.

9) Tighten socket bolts (10) (4 used).

1) Place front casing (8) with the pump casing (2) side facing down. 2) Apply grease onto the inner surface of oil seal (36). 3) Evenly tap and install oil seal (36) into front casing (8) by using a special tool and a plastic hammer. 4) Install retaining ring (37) to front casing (8). 5) Turn over front casing (8) and place onto a wooden block larger than 30 mm x 30 mm. 6) Install O-ring (31) to front casing (8). 7) Install drive shaft (11) to front casing (8). At this time, tap drive shaft (11) by using a plastic hammer to make roller bearing (34) insertion easier. 8) Install cradle plate (22) to front casing (8) by aligning with pin (35).

90Z6W03-08-14 W4GB-02-04-005

j : 6 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 10) Install O-ring (30) to front casing (8). 11) Install backup rings (44) (2 used) and O-rings (45) (2 used) to restricting pin (43) when restricting pin (43) is removed. 12) Install restricting pin (43) to front casing (8). At this time, install restricting pin (43) with the orifice hole side facing inside. 13. Apply grease onto the surface of cam plate (19) (on knock pin (20) hole side). Align the position of knock pin (20) with swash plate (6) and install cam plate (19).

W3-8-3-6

SECTION 3 BODY Group 8 Pump Device

Connecting part with link pin (29) Apply grease on surface

6 W176-02-04-014

W176-02-04-018

IMPORTANT: Install swash plate (6) so that the connecting part with link pin (29) of swash plate (6) faces upward (the regulator mounting side). 14. Apply grease onto the cylindrical surface of swash plate (6). Install swash plate (6) to front casing (8) assembly by aligning with the cylindrical surface of cradle plate (22).

19. Tighten front casing (8) to pump casing (2) with socket bolts (9) (8 used). j : 14 mm m : 210 N·m (21 kgf·m, 155 lbf·ft) 20. Install O-ring (30), O-rings (40) (5 used) and spring pins (39) (2 used) to pump casing (2).

15. Install rotor (4) assembly to the front casing (8) assembly. Do not drop plunger pistons (5) from the rotor (4) assembly. The front casing (8) assembly weight: dCAUTION: 48 kg (110 lb) 16. Stand and hold front casing (8) assembly almost to the vertical position.

fNOTE: If standing front casing (8) assembly too much or straight, swash plate (6) may come off.

17. Hoist front casing (8) assembly.

fNOTE: Do not incline front casing (8) assembly while

hoisting it as the center of gravity is on the rotor (4) side. Rotor (4) may come off if the front casing (8) assembly inclines.

IMPORTANT: Install link pin (29) by inserting it into the concave part of swash plate (6) where feedback link (26) is connected. 18. Install front casing (8) assembly to pump casing (2) by aligning with link pin (29) position.

W3-8-3-7

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-3-8

SECTION 3 BODY Group 8 Pump Device Disassembly and Assembly of Regulator

5 1

2 3 12

13 27 28

23 24 25

W4GB-02-04-006 12345678910-

Nut Cylinder Lock Nut Stopper O-Ring Piston (2 used) Sleeve Spool Casing Spring

11121314151617181920-

Cylinder Lock Nut Set Screw O-Ring Backup Ring O-Ring Piston Cylinder Spool Sleeve

21222324252627282930-

W3-8-4-1

Spring Spring Stopper O-Ring O-Ring (3 used) Stopper Lock Nut Lock Nut Socket Bolt (8 used) Cover

3132333435-

Socket Bolt (4 used) O-Ring Plug Cover

SECTION 3 BODY Group 8 Pump Device

13 12

32 34

25 23

26 24

33 22

21 7

16 15

5 1

90Z6W03-08-15

12345678910-

Nut Cylinder Lock Nut Stopper O-Ring Piston (2 used) Sleeve Spool Casing Spring

11121314151617181920-

Cylinder Lock Nut Set Screw O-Ring Backup Ring O-Ring Piston Cylinder Spool Sleeve

21222324252627282930-

W3-8-4-2

Spring Spring Stopper O-Ring O-Ring (3 used) Stopper Lock Nut Lock Nut Socket Bolt (8 used) Cover

3132333435-

Socket Bolt (4 used) Bleeder O-Ring Plug Cover

SECTION 3 BODY Group 8 Pump Device Disassembly

Assembly

IMPORTANT: Do not disassemble the lock nut assemblies (1 to 4, 12 and 13, 26 to 28) as pump performance is decreased. When disassembling is required, make sure to adjust the adjusting screws according to the performance measurement procedure after assembling.

fNOTE: Rotating set screw (13) and lock nuts (12, 27,

IMPORTANT: Before assembling, clean and apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: Check the direction to install sleeve (7) and spool (8). 1. Insert spool (8) into sleeve (7). Install sleeve (7) assembly to casing (9) by using a round bar according to the matchmarks.

28) will change the set pressure, affecting the pump performance.

1. Remove socket bolts (29) (4 used) from cover (35). Remove cover (35) from casing (9). At this time, set screw (13) and the stopper (23) assembly are removed with cover (35) together. l : 6 mm IMPORTANT: Do not rotate lock nut (3) and nut (1) as the setting changes. 2. Remove socket bolts (29) (4 used) from cover (30). Remove cover (30) from casing (9). At this time, the stopper (4) assembly is removed with cover (30) together. l : 6 mm

fNOTE: Make sure spool (8) and sleeve (7) move smoothly in the casing.

2. Install O-ring (24) to cylinder (11). 3. Insert piston (6) into cylinder (11). Install the cylinder (11) assembly to casing (9). IMPORTANT: Check the direction to install sleeve (20) and spool (19). 4. Insert spool (19) into sleeve (20). Install sleeve (20) assembly to casing (9) by using a round bar according to the matchmarks.

fNOTE: Make sure spool (19) and sleeve (20) move smoothly in the casing.

3. Remove springs (21, 22) from casing (9). IMPORTANT: Put matchmarks before removing sleeves (20, 7) from casing (9). 4. Insert a round bar into the hole on casing (9). Remove cylinder (18), sleeve (20) and spool (19) from casing (9) by pushing the end surface of spool (19). At this time, piston (17) is removed with cylinder (18) together. 5. Remove piston (17) from cylinder (18).

5. Install O-rings (14, 16) and backup ring (15) to cylinder (18). 6. Insert piston (17) into cylinder (18). Install cylinder (18) assembly to casing (9). 7. Install O-ring (5) and piston (6) to the stopper (4) assembly which is installed to cover (30). Install cover (30) assembly to casing (9) with socket bolts (29) (4 used). l : 6 mm

6. Insert a round bar into the hole on casing (9). Remove cylinder (11), sleeve (7) and spool (8) from casing (9) by pushing the end surface of spool (8). At this time, piston (6) is removed with cylinder (11) together.

m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft) 8. Install O-ring (24) and springs (21, 22) to stopper (23) assembly which is installed to cover (35). Install cover (35) assembly to casing (9) with socket bolts (29) (4 used).

7. Remove piston (6) from cylinder (11).

l : 6 mm m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft)

W3-8-4-3

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-4-4

SECTION 3 BODY Group 8 Pump Device Disassembly and Assembly of Priority Valve

A B

2 9

10 8

7 15

11 12

14 4

13 View B

3 View A

W4GB-02-04-007

1234-

Spool Plug Orifice (2 used) Plug

5678-

Spring O-Ring Orifice Poppet

9101112-

W3-8-4-5

Plug Seat Nut Spring

13141516-

Screw Nut Cap Gasket (2 used) Casing

SECTION 3 BODY Group 8 Pump Device Disassembly of Priority Valve

2 1

3 7 5

8 9 15 11

12345678910111213141516-

Spool Plug Orifice (2 used) Plug Spring O-Ring Orifice Poppet Plug Seat Nut Spring Screw Nut Cap Gasket (2 used) Casing

3 90Z6W03-08-16

The components of the priority valve dCAUTION: are easily contaminated by dirt.

6. Remove nut cap (14) from screw (13). At this time, prevent gasket (15) from falling off.

Prevent any foreign material from entering the components when disassembling and assembling.

j : 22 mm 7. Remove nut (11) from casing (16). At this time, prevent gasket (15) from falling off.

1. Remove plug (2) from casing (16). j : 41 mm

j : 22 mm

2. Remove plug (4) from casing (16). Remove O-ring (6) from plug (4).

8. Remove screw (13) from casing (16). At this time, prevent spring (12) and poppet (8) from falling off.

j : 50 mm

9. Remove spring (12) and poppet (8).

3. Remove orifice (3) [blue-white] from plug (4). l : 3 mm

10. Remove seat (10) from casing (16). j : 7 mm

4. Remove spool (1) and spring (5) from casing (16). 5. Remove orifice (3) [blue-white] and orifice (7) [red] from plug (4).

11. Remove plug (9) from casing (16).

l : 3 mm

W3-8-4-6

l : 6 mm

SECTION 3 BODY Group 8 Pump Device Assembly of Priority Valve 1. Install plug (9) to casing (16).

7. Install orifice (3) to plug (4).

l : 6 mm

l : 3 mm

m : 15 N-m (1.5 kgf-m, 11 lbf-ft)

m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)

2. Install seat (10) to casing (16).

8. Install O-ring (6) to plug (4). Install plug (4) to casing (16).

j : 7 mm

j : 50 mm

m : 15 N-m (1.5 kgf-m, 11 lbf-ft)

m : 550 N·m (56 kgf·m, 400 lbf·ft)

3. Install spring (12) and poppet (8) to screw (13). Install poppet (8) to casing (16) so that the end of poppet (8) can be inserted into the hole on seat (10).

9. Install plug (2) to casing (16). j : 41 mm m : 450 N·m (46 kgf·m, 330 lbf·ft)

4. Install nut (11) and gasket (15) to screw (13).

fNOTE: Measure, adjust the steering relief pressure, and install nut cap (14).

j : 22 mm m : 46 N·m (4.7 kgf·m, 34 lbf·ft)

10. Install nut cap (14) and gasket (15) to screw (13).

5. Install orifice (3) [blue-white] and orifice (7) [red] to spool (1). l : 3 mm m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 6. Insert spool (1) and spring (5) into casing (16). At this time, check the direction of spool (1).

W3-8-4-7

j : 22 mm m : 37 N·m (3.7 kgf·m, 27.5 lbf·ft)

SECTION 3 BODY Group 8 Pump Device (Blank)

W3-8-4-8

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

c 90Z6W03-08-01 ab-

Main Pump Fan Pump (Accessory Pump)

Engine

fNOTE: The accessory pump (fan pump) is installed on

the engine mount, and supplies pressurized oil to the fan motor and optional fan control valve. Refer to W3-15-3 for removal and installation procedures of the accessory pump.

W3-8-5-1

SECTION 3 BODY Group 8 Pump Device Disassembly and Assembly of Accessory Pump

fNOTE: The accessory pump supplies pressurized oil to the fan motor and optional fan control valve. Refer to W3-15-4 for disassembly and assembly procedures of the accessory pump.

W3-8-5-2

SECTION 3 BODY Group 9 Control Valve Removal and Installation of Control Valve 11, 12, 13 8

7, 10, 9

11, 14, 13

9 7

2 3

5 6

24 15, 16, 17

18, 19, 20 90Z6W03-09-01

21, 22, 23

90Z6W03-09-02

5. Remove bolts (7) (8 used) and remove pipe assemblies (8, 10) with O-rings (9) (2 used). l : 8 mm 6. Remove bolts (11) (8 used) and remove hose assemblies (12, 14) with O-rings (13) (2 used).

1. Set the lift arm to the raised position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.)

j : 14 mm 7. Remove bolts (15) (4 used) and remove hose assembly (16) with O-ring (17). j : 22 mm

2. Remove nuts (2) (7 used) and washers (3) (7 used). Remove cover (1). j : 17 mm

8. Remove bolts (18) (4 used) and remove hose assembly (19) with O-ring (20). j : 17 mm

3. Remove bolt (4) and clamp (5) on both sides. 9. Remove bolts (21) (4 used) and remove hose assembly (22) with O-ring (23).

j : 19 mm

l : 6 mm

4. Put a container under control valve (6) to catch any drained oil.

10. Disconnect hose (24). j : 36 mm

W3-9-1-1

SECTION 3 BODY Group 9 Control Valve

8 9

a 3 7

4 2

1 a-

Eyebolt Mounting Hole 90Z6W03-09-03

11. Disconnect hoses (2 ~ 7) from control valve (1). j : 19 mm 12. Disconnect hoses (8, 9). j : 17 mm j : 22 mm

90Z6W03-09-04

dCAUTION: Control valve weight: 65 kg (143 lbs) 14. Install M10 x 1.5 eyebolts to eyebolt mounting holes (a) (2 positions) on control valve (1). Temporarily sling and hold control valve (1). 15. Remove bolts (11) (2 used), bolt (12), and washers (13) (3 used). Carefully lift up control valve (1).

13. Disconnect connector (10).

l : 10 mm

W3-9-1-2

SECTION 3 BODY Group 9 Control Valve 11

45°

13 25° 25° 10°

a 20°

a 35°

1 45°

1 90Z6W03-09-05

90Z6W03-09-04

Eyebolt Mounting Hole

Installation IMPORTANT: Check the installation angle of each adapters. 1. Install all removed adapters to control valve (1).

3. Install control valve (1) with bolts (11) (2 used), bolt (12), and washers (13) (3 used). l : 10 mm

dCAUTION: Control valve (1) weight: 65 kg (143 lb) 2. Install M10 x 1.5 eyebolts to eyebolt mounting holes (a) (2 positions) on control valve (1). Sling and move onto the front chassis.

W3-9-1-3

m : 110 N·m (11 kgf·m, 81 lbf·ft)

SECTION 3 BODY Group 9 Control Valve

8 9

15°

4 2 1

90Z6W03-09-03

4. Connect connector (10).

90Z6W03-09-06

6. Connect hoses (2 ~ 7) to control valve (1). j : 19 mm

5. Connect hoses (8, 9).

m : 30 N·m (3 kgf·m, 22 lbf·ft)

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft) j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-9-1-4

SECTION 3 BODY Group 9 Control Valve 11, 12, 13

7, 10, 9

11, 14, 13

9 7

5°

24 15, 16, 17 14

18, 19, 20

90Z6W03-09-07

21, 22, 23

90Z6W03-09-02

IMPORTANT: Check the angle to install hose (14). 11. Install O-rings (13) (2 used) to hose assemblies (12, 14), and install with bolts (11) (8 used).

7. Connect hose (24). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

j : 14 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

8. Install O-ring (23) to hose assembly (22), and install with bolts (21) (4 used).

12. Install O-rings (9) (2 used) to pipe assemblies (8, 10), and install with bolts (7) (8 used).

l : 6 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

l : 8 mm

9. Install O-ring (20) to hose assembly (19), and install with bolts (18) (4 used). j : 17 mm m : 94 N-m (9.6 kgf-m, 69 lbf-ft) 10. Install O-ring (17) to hose assembly (16), and install with bolts (15) (4 used). j : 22 mm m : 140 N·m (14 kgf·m, 103 lbf·ft)

W3-9-1-5

m : 140 N·m (14 kgf·m, 103 lbf·ft)

SECTION 3 BODY Group 9 Control Valve

1 2 3

90Z6W03-09-01

13. Install clamp (5) with bolt (4) on both sides. j : 19 mm m : 35 N·m (3.5 kgf·m, 25.8 lbf·ft) 14. Set the lift arm to the raised position for inspection and maintenance. (Refer to W1-6-1.) 15. Install cover (1) with nuts (2) (7 used) and washers (3) (7 used). j : 17 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

W3-9-1-6

SECTION 3 BODY Group 9 Control Valve Disassembly of Control Valve

90Z6-03-02-07

19 23

90Z6-03-02-05

Cross Section A-A

12345-

Socket Bolt (4 used) Flange O-Ring Spring Poppet (Load Check Valve)

1718192021-

Overload Relief Valve O-Ring (2 used) Spring Seat (2 used) Spring Spool End

2223323435-

W3-9-2-1

Cap Socket Bolt (4 used) Housing Anti-Void Valve Spool

36374041-

Spacer Cap Restriction Valve Restriction Valve

SECTION 3 BODY Group 9 Control Valve 11 6

7 1

14 15

4 17

19 18

21 23

24 25

32 18

19 27

34 27

35 36

37 38 23 23

12345678910111213-

Socket Bolt (4 used) Flange O-Ring Spring Poppet (Load Check Valve) Socket Bolt (4 used) Flange O-Ring Spring Poppet (Load Check Valve) Socket Bolt (4 used) Body O-Ring

W4GB-02-05-005

14151617181920212223242526-

Spacer Spring Poppet (Logic Control Valve) Overload Relief Valve O-Ring (4 used) Spring Seat (4 used) Spring Spool End Cap Socket Bolt (8 used) Cap Spool End Spring

W3-9-2-2

27282930313233343536373839-

Overload Relief Valve (2 used) Relief Valve (Pump Control) Bolt (4 used) Housing O-Ring Housing Main Relief Valve Anti-Void Valve Spool Spacer (2 used) Cap (2 used) Spool Plug

SECTION 3 BODY Group 9 Control Valve Disassembly 1. Place the control valve on a clean surface with the logic control valve faces up. Put the matching marks on the spools for assembling. 2. Remove socket bolts (23) (4 used) from caps (22, 24). Remove caps (22, 24) from housing (32).

10. Remove socket bolts (1) (4 used) from flange (2). Remove flange (2), spring (4), poppet (5) and O-ring (3) from housing (32). l : 5 mm 11. Remove socket bolts (11) (4 used) from body (12). Remove body (12), spacer (14), spring (15), poppet (16) and O-rings (3, 13) from housing (32).

l : 5 mm

3. Remove O-rings (18) (2 used) from housing (1).

12. Remove socket bolts (6) (2 used) from flange (7). Remove flange (7), spring (9), poppet (10) and O-ring (8) from housing (32).

Carefully pull out spools (35, 38). dCAUTION: Do not force them out or distort. Handle the

spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve. 4. Remove the spools (35, 38) assemblies from housing (32).

fNOTE: Put the matching marks on spools (35, 38)

corresponding to the matching marks on housing (32) in order not to be confused. IMPORTANT: Do not disassemble the spool assembly (35, 38). 5. Remove relief valve (28) assembly (for pump control) from housing (30).

l : 5 mm 13. Remove socket bolts (29) (4 used) from housing (30). Remove housing (30) and O-ring (31) from housing (32). j : 12 mm 14. Remove socket bolts (23) (4 used) from caps (37) (2 used). Remove caps (37) (2 used), spacers (36) (2 used) and O-rings (18) (2 used) from housing (32). l : 5 mm

j : 38 mm 6. Remove overload relief valve (27) assemblies (2 used) from housing (32). j : 32 mm 7. Remove main relief valve (33) assembly from housing (32). j : 38 mm 8. Remove overload relief valve (17) assembly from housing (32). j : 32 mm 9. Remove the anti-void valve (34) assembly from housing (32). j : 32 mm

W3-9-2-3

SECTION 3 BODY Group 9 Control Valve

W4GB-02-05-002

Check that mating surface (a) of dCAUTION: wooden piece to the spool is free of metal chips.

Secure the spool assembly at the position to the spring. 14. Secure the spool (35) assembly in a vise by using wooden pieces as illustrated. Remove spool end (21), spring seat (19), spring (20) and spring seat (19) from spool (35). j : 10 mm 15. Secure the spool (38) assembly in a vise by using wooden pieces as illustrated. Remove spool end (25), spring seat (19), spring (26) and spring seat (19) from spool (38). j : 10 mm

IMPORTANT: Clean the disassembled parts in clean mineral oil , and dry enough with compressed air before reassembling.

W3-9-2-4

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. a

5. Install spacer (36) to spool (35). Align the protrude of spacer (36) and the hollow inside cap (37). Secure cap (37) to housing (32) with socket bolts (23) (2 used). l : 5 mm m : 39.2 to 44.1 N·m (4 to 4.45 kgf·m, 29 to 32.5 lbf·ft)

W4GB-02-05-002

6. Install poppet (5), spring (4) and O-ring (3) to housing (32). Install flange (2) to housing (32) with socket bolts (1) (4 used).

Check that mating surface (a) of dCAUTION: wooden piece to the spool is free of metal chips.

l : 5 mm m : 58 to 64 N·m (6 to 6.5 kgf·m, 43 to 47 lbf·ft)

Secure the spool assembly at the position to spring (20).

1. Clamp spool (35) in a vise by using wooden pieces as illustrated. Install spring seat (19), spring (20) and spring seat (19) to spool (35) with spool end (21). j : 10 mm

7. Install anti-void valve (34) to housing (32). j : 32 mm m : 78 to 88 N·m (8 to 9 kgf·m, 57.5 to 65 lbf·ft) 8. Install overload relief valve (17) to housing (32).

m : 9.8 to 11.8 N·m (1 to 1.2 kgf·m, 7.2 to 8.7 lbf·ft)

j : 32 mm m : 78 to 88 N·m (8 to 9 kgf·m, 57.5 to 65 lbf·ft)

2. Apply hydraulic oil onto the polishing part of spool (35) assembly. Slowly and carefully insert spool (35) assembly into the hole on housing (32).

fNOTE: Carefully insert the spool so that it is not forced

in or distorted. Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

3. Install O-ring (18) to the groove on the cap (22) mounting position in housing (32). Install cap (22) to housing (32) with socket bolts (23) (2 used). l : 5 mm m : 39.2 to 44.1 N·m (4 to 4.45 kgf·m, 29 to 32.5 lbf·ft) 4. Install O-ring (18) to the groove on the cap (37) mounting position in housing (32).

W3-9-2-5

SECTION 3 BODY Group 9 Control Valve a

W4GB-02-05-002

13. Install spacer (36) to spool (38). Align the protrude of spacer (36) and the hollow inside cap (37). Secure cap (37) to housing (32) with socket bolts (23) (2 used).

Check that mating surface (a) of dCAUTION: wooden piece to the spool is free of metal chips. Secure the spool assembly at the position to spring (26).

l : 5 mm

9. Clamp spool (38) in a vise by using wooden pieces as illustrated. Install spring seat (19), spring (26) and spring seat (19) to spool (38) with spool end (25). j : 10 mm

m : 39.2 to 44.1 N·m (4 to 4.45 kgf·m, 29 to 32.5 lbf·ft) 14. Install poppet (16), spring (15), spacer (14) and O-rings (3, 13) to housing (32). Install body (12) to housing (32) with socket bolts (11) (4 used).

m : 9.8 to 11.8 N·m (1 to 1.2 kgf·m, 7.2 to 8.7 lbf·ft)

l : 5 mm

10. Apply hydraulic oil onto the polishing part of spool (38) assembly. Slowly and carefully insert spool (38) assembly into the hole on housing (32).

fNOTE: Carefully insert the spool so that it is not forced

in or distorted. Handle the spool with extreme care, even a small nick, dent, or scratch can ruin the spool which requires replacement of the entire valve.

m : 58 to 64 N·m (6 to 6.5 kgf·m, 43 to 47 lbf·ft) 15. Install overload relief valves (27) (2 used) to housing (32).

11. Install O-ring (18) to the groove on the cap (24) mounting position in housing (32). Install cap (24) to housing (32) with socket bolts (23) (2 used). l : 5 mm m : 39.2 to 44.1 N·m (4 to 4.45 kgf·m, 29 to 32.5 lbf·ft) 12. Install O-ring (18) to the groove on the cap (37) mounting position in housing (32).

W3-9-2-6

j : 32 mm m : 78 to 88 N·m (8 to 9 kgf·m, 57.5 to 65 lbf·ft)

SECTION 3 BODY Group 9 Control Valve 39

10 9 8 7 33

Cross Section B-B

32 31 29

16. Install O-ring (31) to housing (32). Install housing (30) to housing (32) with bolts (44) (4 used). j : 12 mm m : 145 to 159 N·m (14.8 to 16.2 kgf·m, 107 to 117 lbf·ft)

W4GB-02-05-010

19. Install O-ring (8) to the groove on the flange (7) mounting position in housing (32). Install poppet (10), spring (9) and flange (7) to housing (32). Install flange (7) to housing (32) with socket bolts (6) (2 used). l : 5 mm

17. Install relief valve (for pump control) (28) to housing (30). j : 38 mm

m : 58 to 64 N·m (6 to 6.5 kgf·m, 43 to 47 lbf·ft) 20. Install plug (39) to housing (32).

m : 103 to 113 N·m (10.5 to 11.5 kgf·m, 76 to 83 lbf·ft)

l : 5 mm m : 80 to 86 N·m (8.2 to 8.8 kgf·m, 58 to 63 lbf·ft)

18. Install main relief valve (33) to housing (32). j : 38 mm m : 78 to 88 N·m (8 to 9 kgf·m, 57.5 to 65 lbf·ft)

W3-9-2-7

SECTION 3 BODY Group 9 Control Valve (Blank)

W3-9-2-8

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve (Two Lever Type ) 2

11 8

5 12

WNEC-03-10-013

WNEC-03-10-019

3. Disconnect connectors (3, 12). 4. Remove cover (5) and screws (4) (5 used). 5. Remove cover (7) and screws (6) (3 used). 6. Remove cover (11) and screws (10) (3 used).

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

7. Remove cover (9) and screws (8) (4 used) on both sides.

2. Remove cover (2) and screws (1) (3 used).

W3-10-1-1

SECTION 3 BODY Group 10 Pilot Valve

1 1

2 2

3 4 5 5

6 7

7 9

9 WNEC-03-10-015

8. Remove clips (3, 8).

11. Remove nuts (2) (2 used).

9. Disconnect connectors (4) (8 used) and connectors (9) (3 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

WNEC-03-10-017

j : 17 mm 12. Remove covers (5) (2 used). 13. Loosen nuts (7) (2 used). j : 19 mm 14. Remove levers (6) (2 used). Remove nuts (7) (2 used) from levers (6) (2 used). j : 17 mm

W3-10-1-2

SECTION 3 BODY Group 10 Pilot Valve

1 10 10

8 9

7 90Z6W03-10-03

15. Disconnect hoses (2~7) from pilot valve (1).

WNEC-03-10-016

17. Remove socket bolts (10) (4 used).

j : 19 mm 16. Disconnect connector (8) and remove pressure sensor (9). j : 24 mm

l : 8 mm 18. Remove pilot valve (1) from frame (11). 19. Remove the adapters with pilot valve (1) attached if necessary.

W3-10-1-3

SECTION 3 BODY Group 10 Pilot Valve 10 10 11

8 9

WNEC-03-10-016 30°

5°

90Z6W03-10-03

5°

25° 90Z6W03-10-04

Installation

3. Connect hoses (2~7) to pilot valve (1).

1. Install all removed adapters to pilot valve (1).

j : 19 mm

2. Install pilot valve (1) to frame (11) with bolts (10) (4 used).

m : 30 N·m (3 kgf·m, 22 lbf·ft)

l : 8 mm

4. Install pressure sensor (9) and connect connector (8).

m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

j : 24 mm m : 16 N-m (1.6 kgf-m, 11.8 lbf-ft)

W3-10-1-4

SECTION 3 BODY Group 10 Pilot Valve

1 1

2 2

4 5 5

6 7

WNEC-03-10-017

8˚

WNEC-03-10-015 Machine Front

2 6 7

5. Temporarily tighten nuts (7) (2 used) to levers (6) (2 used).

b a

j : 19 mm 6. Install levers (6) (2 used) to pilot valve (8). Tighten nuts (7) (2 used) to the specified torque.

90WNEC-03-10-20 a-

143 mm (5.6 in)

223 mm (8.8 in)

j : 19 mm m : 40 N·m (4 kgf·m, 30 lbf·ft) 7. Install covers (5) (2 used). Temporarily tighten nuts (2) (2 used). j : 17 mm

9. Connect connectors (4) (8 used) and connectors (10) (3 used). 10. Install clips (3, 9).

IMPORTANT: Check the mounting dimension to install grip (1). 8. 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.

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.

j : 17 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)

fNOTE: Install grip (1) while turning cover (5). W3-10-1-5

SECTION 3 BODY Group 10 Pilot Valve

11 8

5 12

WNEC-03-10-019

WNEC-03-10-013

12. Install cover (9) with screws (8) (4 used) on both sides. 13. Install cover (11) with screws (10) (3 used).

16. Connect connectors (3, 12). 17. Install cover (2) with screws (1) (3 used).

14. Install cover (7) with screws (6) (3 used). 15. Install cover (5) with screws (4) (5 used).

W3-10-1-6

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

43 20

22 21 22

21 22 23

24 25 26 27 28

24 25

28 29 30 31

24 25 26 27

32 a

30 28 46 30 31

31 32

52 53 d

WNEC-03-10-006

W3-10-2-1

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

W3-10-2-2

Hole on Port 4

SECTION 3 BODY Group 10 Pilot Valve Disassembly of Pilot Valve (Two Lever Type)

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).

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).

W3-10-2-3

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).

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).

20. Remove nuts (2) (2 used) and screws (3) (2 used) from lever (4).

W3-10-2-4

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

25. Remove detent rings (10) (2 used) and springs (11) (2 used) from detent bushings (15) (2 used).

W4GB-02-06-012 abc-

Dia. 10 mm (Dia. 0.39-0.012-0.016 in) 30 mm (1.18 in) 40 mm (1.58 in) -0.3-0.4

def-

24. Remove push rods (12) (2 used) from detent bushings (15) (2 used).

2 mm (0.079 in) Dia. 8-0.2-0.3 mm (Dia. 0.32-0.008-0.012 in) 30°

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).

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).

W3-10-2-5

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.

W3-10-2-6

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-2-7

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

12 19 44 51

20 21 51

53 52 50

24 25 26

46 30

29 29

Section A-A

Section B-B

d WNEC-03-10-007

W3-10-2-8

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

W3-10-2-9

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). 15

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).

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).

W3-10-2-10

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). l : 5 mm

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.

W3-10-2-11

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). 24

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

W3-10-2-12

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).

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

l : 5 mm

m : 17 N·m (1.7 kgf·m, 13 lbf·ft)

m : 9 N·m (0.9 kgf·m, 6.6 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).

W3-10-2-13

SECTION 3 BODY Group 10 Pilot Valve  Assembly of Pilot Valve Assemblies at Port 1 Side and Port 2 Side

24. Install socket bolt (52) and band (53) to casing (50).

23. Assemble the pilot valve assemblies at port 1 side and port 2 side in the same way of step 1 to step 22.

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.

W3-10-2-14

SECTION 3 BODY Group 10 Pilot Valve Removal and Installation of Pilot Valve (Multi-Function Joystick Type) 1

7 8

10 9

WNEC-03-10-010

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). 5. Remove cover (10) and screws (9) (3 used). 6. Remove cover (8) and screws (7) (4 used) on both sides.

W3-10-3-1

SECTION 3 BODY Group 10 Pilot Valve

2 8

8 10

9 11

5 6

WNEC-03-10-018

3 90Z6W03-10-01

7. Disconnect hoses (1~7). j : 19 mm

9. Disconnect connectors (9, 10, 11). 10. Remove pressure sensor (12). j : 24 mm

8. Remove clip (8).

W3-10-3-2

SECTION 3 BODY Group 10 Pilot Valve

3 2

WNEC-03-10-021

11. Remove 4 each of bolt and washers (3) from bracket (2). 12. Remove pilot valve (1) from bracket (2). 13. Remove the adapters with pilot valve (1) attached if necessary.

W3-10-3-3

SECTION 3 BODY Group 10 Pilot Valve

1 35°

3 35°

40°

View A 90Z6W03-10-02

WNEC-03-10-021

Installation 1. Install all removed adapters to pilot valve (1).

fNOTE: Take care of the installation angle of adapters.

2. Install pilot valve (1) to bracket (2) with 4 each of bolt and washers (3). j : 10 mm m : 5 N·m (0.5 kgf·m, 3.7 lbf·ft)

W3-10-3-4

SECTION 3 BODY Group 10 Pilot Valve

2 8

8 10

9 11

5 6

WNEC-03-10-018

3 90Z6W03-10-01

3. Install pressure sensor (12). j : 24 mm m : 16 N-m (1.6 kgf-m, 11.8 lbf-ft) 4. Connect hoses (1~7). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

5. Connect connectors (9, 10, 11). 6. Install clip (8). 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.

W3-10-3-5

SECTION 3 BODY Group 10 Pilot Valve

7 8

10 9

WNEC-03-10-010

8. Install cover (8) with screws (7) (4 used) on both sides. 9. Install cover (10) with screws (9) (3 used).

10. Install cover (6) with screws (5) (3 used). 11. Install cover (4) with screws (3) (5 used). 12. Install cover (2) with screws (1) (2 used).

W3-10-3-6

SECTION 3 BODY Group 10 Pilot Valve Disassembly and Assembly of Pilot Valve (Multi-Function Joystick Type) Section A

11B

11A 11C 13

35D, 35E, 35F, 35G, 35H

35A

35I

35B

60B 60C

35C 50A

50B 53B 53C

60A 60E

53D

60D

66A

66B 62 63

65 80 WNEC-03-10-002 a 1- Handle 11A- Lever 11B- Screw 11C- Nut 13- Boot 35A- Nut 35B- Washer 35C- Cam

35D- Shim (Several) 35E- Shim (Several) 35F- Shim (Several) 35G- Shim (Several) 35H- Shim (Several) 35I- Universal Joint 50A- Retaining Ring (3 Used) 50B- Armature (3 Used)

Section of Port 2

51- Plate 53B- Pusher (3 Used) 53C- Solenoid (3 Used) 53D- O-Ring (3 Used) 60A- Guide 60B- Pusher 60C- Plate 60D- Retaining Ring

Sections of Port 1, 3, and 4

W3-10-4-1

b 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

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

W3-10-4-2

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 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).

WNEC-03-10-003

4. Remove screw (11B) from handle (1) by using a star screwdriver.

ab-

Hole on Port 3 Hole on Port 4

l : 8 mm

6. Loosen nut (11C) from lever (11A).

fNOTE: LOCTITE #262 has been applied on universal

j : 19 mm

joint (35I).

fNOTE: Hold plate (51) against spring (65) when

7. Remove the lever (11A) assembly from universal joint (35I).

removing universal joint (35I).

fNOTE: LOCTITE #262 has been applied on lever (11A). 8. Remove boot (13) and nut (11C) from the lever (11A) assembly.

13. Remove plate (51) from casing (80). 14. Remove plate (60C) and the guide (60A) assembly from casing (80) by using a screwdriver.

9. Remove retaining ring (50A) and armature (50B) from pusher (53B).

15. Remove the solenoid (53C) assemblies (3 used) from casing (80) by using a screwdriver.

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).

fNOTE: LOCTITE #262 has been applied on nut (35A).

cd-

12. Remove universal joint (35I) from casing (80) by using a wrench.

5. Remove handle (1) from lever (11A).

j : 27 mm

Hole on Port 2 Hole on Port 1

16. Remove pusher (60B), retaining ring (60D), and O-ring (60E) from guide (60A). 17. Remove pushers (53B) (3 used) and O-rings (53D) (3 used) from solenoids (53C) (3 used). 18. Remove spool (62) and spring (65) from hole (a) on port 2 of casing (80) by using a pair of pliers. 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

WNEC-03-10-003 ab-

Hole on Port 2 Hole on Port 1

cd-

Hole on Port 3 Hole on Port 4

e e-

Groove on Side of Solenoid (53C)

f, g fg-

WNEC-03-10-004 Projection on Lower Surface of Plate (51) Groove on Side of Plate (60C)

Assembly 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). 2. Install spring (65) and spool (62) 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). 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)

fNOTE: Hold plate (51) against spring (65) by hand. 9. Install shims (35D, 35E, 35F, 35G, and 35H), cam (35C), and washer (35B) to universal joint (35I).

fNOTE: Insert a screwdriver into the hole on the side of cam (35C) and tighten it to the specified torque when installing nut (35A).

3. Install pushers (53B) (3 used) and O-rings (53D) (3 used) to solenoids (53C) (3 used). 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).

10. Apply LOCTITE #262 onto the thread part of universal joint (35I). Install nut (35A) to universal joint (35I). j : 27 mm m : 30±3 N·m (3±0.3 kgf·m, 22±2 lbf·ft) 11. Install armature (50B) between the end of cam (35C) and pusher (53B).

W3-10-4-4

SECTION 3 BODY Group 10 Pilot Valve

WNEC-03-10-005 a-

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. 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).

Groove

Bracket

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). 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. 22. Lower and install boot (13) to handle (51).

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).

W3-10-4-5

SECTION 3 BODY Group 10 Pilot Valve (Blank)

W3-10-4-6

SECTION 3 BODY Group 11 Charging Block Removal and Installation of Charging Block

3 90Z6W03-12-01

123-

Charging Block Parking Brake Accumulator Service Brake Accumulators

W3-11-1-1

SECTION 3 BODY Group 11 Charging Block

90Z6W03-01-01

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Bleed air from hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Operate the brake pedal more than 50 dCAUTION: times, and release any pressure in the circuit. 2. Remove cover (1) under the deck and cover (2) both on the machine left side (Refer to W3-4-2).

W3-11-1-2

SECTION 3 BODY Group 11 Charging Block

3 15 2

16 1

19 10, 11 17

90Z6W03-12-02

3. Remove hoses (1, 2) and hose (3).

j : 17 mm

j : 19 mm

j : 27 mm 7. Remove hoses (15, 16).

j : 27 mm j : 22 mm 5. Disconnect connectors (8, 9, 10, 11).

90Z6W03-12-03

6. Remove hoses (12, 13) and hose (14).

j : 17 mm

4. Remove hoses (4, 5) and hoses (6, 7).

j : 22 mm 8. Remove bolts (17) (4 used). Remove charging block (18) and plate (19). j : 17 mm

W3-11-1-3

SECTION 3 BODY Group 11 Charging Block

6 5

3 9

2 10

9 8 11

90Z6W03-12-05

9. Remove bolts (1) (2 used) from brackets (2, 3).

90Z6W03-12-06

14. Hold accumulator (16). Remove nuts (12) (4 used) and washers (13) (4 used).

j : 17 mm

10. Remove bolts (4) (6 used) and washers (5) (6 used). Remove brackets (2, 3). j : 19 mm

15. Remove U-bands (14) (2 used) and rubber sheet (15) (2 used) and remove accumulator (16). Remove another accumulator (16) in the same manner.

11. Remove 3 each of bushings (6) from brackets (2, 3). 12. Remove hoses (7, 8). j : 22 mm Brake accumulator (9) assembly dCAUTION: weight: 20 kg (44 lb) 13. Remove 2 each of bolts (10, 11) and remove accumulator (9) assembly. j : 17 mm

W3-11-1-4

SECTION 3 BODY Group 11 Charging Block

20°

1 10°

10°

40°

10°

90Z6W03-12-04

Installation IMPORTANT: Check the angle to install adapters. 1. Reinstall all the removed adapters to charging block (1) and accumulators (2).

W3-11-1-5

SECTION 3 BODY Group 11 Charging Block

6 15 12

5 14

9 16

3 1 2

90Z6W03-12-06

2. Apply adhesive to rubber sheet (15) and attach to U-bands (14).

fNOTE: Use chloroprene rubber-based adhesive

35°

90Z6W03-12-05

Brake accumulator (9) assembly dCAUTION: weight: 20 kg (44 lb)

j : 17 mm

3. Install accumulator (16) to bracket (9) and U-bands (2 used) with rubber sheet (15) attached. Fix with nuts (12) (4 used) and washers (13) (4 used).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 6. Install hoses (7, 8). j : 22 mm

j : 17 mm m : 32 N·m (3.2 kgf·m, 23.6 lbf·ft)

5. Install accumulator (9) assembly with 2 each of bolts (10, 11).

(DIABOND No. 808 or equivalent).

4. Install another accumulator (16) in the same manner.

40°

m : 40 N·m (4 kgf·m, 30 lbf·ft) 7. Install 3 each of bushings (6) to brackets (2, 3). 8. Install brackets (2, 3) to the rear chassis with bolts (4) (6 used) and washers (5) (6 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 9. Install brackets (2, 3) with bolts (1) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W3-11-1-6

SECTION 3 BODY Group 11 Charging Block

3 B

15 7

C A

16 19 17

10, 11

90Z6W03-12-02 90Z6W03-12-03

10°

1 7

20°

50°

Arrow View B Arrow View A

90Z6W03-12-08

90Z6W03-12-07

9. Install charging block (18) and plate (19) with bolts (17) (4 used). j : 17 mm

12. Connect connectors (8, 9, 10, 11). 13. Install hoses (4, 5) and hoses (6, 7). j : 27 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m (4) : 80 N·m (8 kgf·m, 59 lbf·ft)

10. Install hoses (15, 16).

m (5) : 95 N·m (9.5 kgf·m, 70 lbf·ft)

j : 22 mm

m : 40 N·m (4 kgf·m, 30 lbf·ft) 11. Install hoses (12, 13) and hose (14). j : 17 mm

Arrow View C

m : 40 N·m (4 kgf·m, 30 lbf·ft) 14. Install hoses (1, 2) and hose (3). j : 17 mm

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

j : 27 mm

j : 19 mm

m : 80 N·m (8 kgf·m, 59 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft)

W3-11-1-7

SECTION 3 BODY Group 11 Charging Block

15. Bleed air from the hydraulic system and service brake (axle) (Refer to W1-4-1). IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 16. Install cover (1) under the deck and cover (2) both on the machine left side (Refer to W3-4-2).

W3-11-1-8

90Z6W03-01-01

SECTION 3 BODY Group 11 Charging Block Disassembly and Assembly of Charging Block 13 14

7 10 11 12

7 6

13 14

3 4 15

8 3 4

7 6

5 B

41 39

16 47

48 13

35 33

4 3

22 25

A B

58 14

4 3

49 23

14 13

6 5 50

17 20

14 13

4 3 18

34 55

33 2 52 3 4 53 54

Arrow View Z

4 3 2

90Z6W03-12-09

123456789101112131415-

Plug (5 used) O-Ring (5 used) Plug (9 used) O-Ring (9 used) Plunger (3 used) Spring (4 used) O-Ring (6 used) Plug (3 used) Plug Spring Plunger Sleeve Plug (10 used) O-Ring (10 used) Filter (2 used)

161718192021222324252627282930-

Body Stopper Spring Washer Spool Sleeve O-Ring Socket Bolt (4 used) Solenoid Solenoid O-Ring Sleeve O-Ring O-Ring O-Ring

313233343536373839404142434445-

Spool Spring O-Ring (3 used) Plug (3 used) Plunger Spring Screw Nut Spring Needle Valve Body O-Ring Backup Ring O-Ring Sleeve

W3-11-2-1

464748495051525354555657585960-

Backup Ring O-Ring Piston Nut O-Ring Adjusting Screw Poppet Spring Shim Shim O-Ring Plug Orifice Plunger Connector

SECTION 3 BODY Group 11 Charging Block 13 14

7 10 11 12

7 6

13 14

3 4 15

8 3 4

7 6

5 B

41 39

16 47

48 13

35 33

4 3

4 18 3

32 20

14 13 17

22 25

23 24

90Z6W03-12-11

Disassembly IMPORTANT: Keep the disassembled parts together by each part in order not to confuse.

fNOTE: Charging block weight: 14.6 kg 1. Remove plug (9), O-ring (7), spring (10), poppet (11), and sleeve (12) from body (16). l : 6 mm

3. Remove plugs (8) (3 used), O-rings (7) (3 used), springs (6) (3 used), and poppets (5) (3 used) from body (16). l : 6 mm 4. Remove plugs (34) (3 used), O-rings (33) (3 used), spring (36), plunger (35) from body (16). l : 8 mm

2. Remove plugs (13) (10 used) and O-rings (14) (10 used), and orifice (58) from body (16). l : 5 mm

W3-11-2-2

SECTION 3 BODY Group 11 Charging Block

6 5

49 56

B 14

58 14

4 3

33 2

55 52

4 1

4 3 2

1 90Z6W03-12-12

5. Remove relief valve assembly (7, 37~48) from body (16).

11. Remove socket bolts (23) (2 used) from body (16). l : 4 mm

j : 32 mm

fNOTE: Set pressure changes if relief valve assembly

(7, 37~48) is disassembled. Do not disassemble unless necessary.

6. Remove plug (57), O-ring (56), shims (54, 55), spring (53), and poppet (52) from body (16). Record the number of shims. j : 30 mm

12. Remove solenoid (24), O-ring (22), and sleeve (21) assembly from body (16). 13. Remove spool (20) from sleeve (21).

fNOTE: As stopper (17) is pressed fit in sleeve (21), spring (18) and washer (19) cannot be disassembled.

14. Remove plugs (3) (9 used) and O-rings (4) (9 used) from body (16).

7. Remove socket bolts (23) (2 used) from body (16).

l : 3 mm

l : 4 mm 8. Remove solenoid (25), O-ring (26), sleeve (27), and O-rings (28, 29, 30) from body (16). 9. Remove spool (31) and spring (32) from body (16). 10. Remove nut (49), O-rings (50), and adjusting screw (51) from body (16).

15. Remove plugs (1) (5 used) and O-rings (2) (5 used) from body (16). l : 6 mm 16. Remove connector (60), spring (6), and plunger (59) from body (16).

j : 17 mm

W3-11-2-3

j : 13 mm

SECTION 3 BODY Group 11 Charging Block

1, 2

3, 4

1, 2

3, 4

MR 13, 14

(ACCF)

(ACCR)

P DR X PS1 PB

PS2

PP (ACCP) 13, 14

1, 2 90Z6-03-07-03

123456789101112131415-

Plug (5 used) O-Ring (5 used) Plug (9 used) O-Ring (9 used) Plunger (3 used) Spring (4 used) O-Ring (6 used) Plug (3 used) Plug Spring Plunger Sleeve Plug (10 used) O-Ring (10 used) Filter (2 used)

161718192021222324252627282930-

Body Stopper Spring Washer Spool Sleeve O-Ring Socket Bolt (4 used) Solenoid Solenoid O-Ring Sleeve O-Ring O-Ring O-Ring

313233343536373839404142434445-

W3-11-2-4

Spool Spring O-Ring (3 used) Plug (3 used) Plunger Spring Screw Nut Spring Needle Valve Body O-Ring Backup Ring O-Ring Sleeve

464748495051525354555657585960-

Backup Ring O-Ring Piston Nut O-Ring Adjusting Screw Poppet Spring Shim Shim O-Ring Plug Orifice Plunger Connector

SECTION 3 BODY Group 11 Charging Block 13 8

14 60

14 13

53 5

57 52

Cross Section V-V 3 54, 55 4

28 29 3

Cross Section Z-Z

49 3

Cross Section U-U

Cross Section Y-Y

20 19

7 10 11

14 17 23

18 Cross Section T-T 8

Cross Section X-X

2 37

40 42 43

7 6

5 Cross Section S-S

8 6

41 34

36 4

Cross Section W-W 90Z6-03-07-05

W3-11-2-5

SECTION 3 BODY Group 11 Charging Block 13 14

7 10 11 12

7 6

13 14

3 4 15

8 3 4

7 6

5 B

41 39

16 47

48 13

35 33

4 3

4 18 3

32 20

14 13 17

22 25

23 24

90Z6W03-12-11

Assembly IMPORTANT: Before assembling, apply hydraulic oil to the parts in order to prevent them from seizing. 1. Install O-rings (7) (3 used) to plugs (8) (3 used). Install poppets (5) (3 used) and springs (6) (3 used) to body (16). Install plugs (8) (3 used) to body (16). l : 6 mm m : 21.5 N·m (2.2 kgf·m, 15.5 lbf·ft)

3. Install O-ring (22) to solenoid (24). Install solenoid (24) to body (16) with socket bolts (23) (2 used). l : 4 mm m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft) 4. Install O-ring (50) to adjuster screw (51). Install adjuster screw (51) to body (16), and lock with nut (49). j : 17 mm

2. Install spool (20) to sleeve (21). Install sleeve (21) to body (16).

m : 19.6 N·m (2 kgf·m, 14.5 lbf·ft) 5. Install O-rings (28, 29, 30) to sleeve (27). Install spool (31) to sleeve (27).

W3-11-2-6

SECTION 3 BODY Group 11 Charging Block 14

6 5

49 56

B 14

58 14

4 3

33 2

55 52

4 1

6. Install spring (32), the sleeve (27) assembly, O-ring (26), and solenoid (25) to body (16) in this order. Install solenoid (25) to body (16) with socket bolts (23) (2 used).

4 3 2

90Z6W03-12-12

12. Install plunger (59), spring (6), connector (60), and plugs (13) to body (16). l : 5 mm

l : 4 mm

m : 21 N·m (2.1 kgf·m, 15.5 lbf·ft)

m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft)

j : 13 mm m : 21.5 N·m (2.2 kgf·m, 15.5 lbf·ft)

7. Install O-ring (56) to plug (57). Install poppet (52), spring (53), shims (54, 55), and plug (57) to body (16). j : 30 mm m : 98 N·m (10 kgf·m, 72 lbf·ft)

13. Apply LOCTITE #242 to the thread part of orifice (58). Install orifice (58) to body (16). Install O-rings (14) (9 used) to plugs (13) (9 used). Install plugs (13) (9 used) to body (16). l : 4 mm m : 5.9 N·m (0.6 kgf·m, 4.4 lbf·ft)

8. Install plunger (35) and spring (36) to body (16). Install plugs (34) (3 used) with installed O-rings (33) (3 used) to body (16).

l : 5 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

l : 8 mm m : 49 N·m (5 kgf·m, 36 lbf·ft)

14. Install O-ring (7) to plug (9). Install sleeve (12), poppet (11), spring (10), and plug (9) to body (16).

9. Install O-ring (47) and backup ring (46) to sleeve (45).

l : 6 mm m : 21 N·m (2.1 kgf·m, 15.5 lbf·ft)

10. Install O-rings (42, 44) and backup ring (43) to the body (41) assembly. Install piston (48), sleeve (45), and the body (41) assembly to body (16). j : 32 mm

15. Install O-rings (4) (9 used) to plugs (3) (9 used). Install O-rings (2) (5 used) to plugs (1) (5 used). Install plugs (3) (9 used) and plugs (1) (5 used) to body (16). l : 3 mm

m : 59 N·m (6 kgf·m, 43 lbf·ft)

m : 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) 11. Install O-ring (14) to plugs (13).

l : 6 mm m : 26.5 N·m (2.7 kgf·m, 19.5 lbf·ft)

W3-11-2-7

SECTION 3 BODY Group 11 Charging Block (Blank)

W3-11-2-8

SECTION 3 BODY Group 12 Cooling Fan System Removal and Installation of Reversing Fan Motor (Option)

13, 14 5

2 4 13, 14

6 10

15, 16, 17 90Z6W03-04-28

15, 16, 17

7, 8

90Z6W03-05-03

3. Open rear grill (5). Place a container under fan motor (6) to receive drain. 4. Remove bolt (7) and bracket (8). j : 17 mm

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

5. Disconnect hoses (9, 10, 11).

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

j : 27 mm j : 36 mm

2. Remove bolts (2) (2 used), bolts (3) (6 used), and bolts (4) (2 used). Remove rear roof (1). j : 17 mm j : 19 mm

Rear grill (12) assy weight: 35 kg (77 dCAUTION: lb) 6. Sling and hold rear grill (12) assembly. 7. Remove bolt (14). Disconnect connector (13) for the rear working lamp (on both sides). j : 10 mm 8. Remove bolts (15) (8 used), nuts (16) (4 used), and washers (17) (4 used). Remove rear grill (13) assembly. j : 17 mm

W3-12-1-1

SECTION 3 BODY Group 12 Cooling Fan System

3 2

4 1 2

9 6

90Z6W03-15-02

90Z6W03-15-01

9. Open radiator cover (1) (on both sides).

11. Disconnect connectors (5, 6, 7).

10. Remove bolts (2) (2 used), connector fixing bolt (3), and bracket (4) (on both sides).

12. Remove bolts (8) (4 used) and remove plates (9, 10) (on both sides).

j : 17 mm j : 10 mm

j : 17 mm Fan mount (11) assy weight: 50 kg dCAUTION: (110 lb) 13. Attach sling to holes (a) and temporarily hold fan mount assy (11).

W3-12-1-2

SECTION 3 BODY Group 12 Cooling Fan System

5 13

7 4

90Z6W03-05-11a

14. Remove bolt (4) from connector (3).

17. Remove lock nut (10) and washer (11) at the center of fan (12).

j : 10 mm

j : 21 mm

15. Remove nuts (5) (4 used) and washers (6) (4 used). j : 19 mm 16. Remove bolts (7) (6 used), bolts (8) (2 used), and bosses (9) (2 used). Remove fan mount assembly (2) from radiator assembly (1). j : 19 mm

90Z6W03-15-03

IMPORTANT: When removing fan (12), be careful not to lose key (13) attached to the taper shaft of fan motor (16). 18. Remove fan (12). 19. Remove bolts (14) (4 used) and washers (15) (4 used). Remove fan motor (16). l : 8 mm 20. Remove the adapters installed on fan motor (16), if necessary.

W3-12-1-3

SECTION 3 BODY Group 12 Cooling Fan System 2

12 8

12 13

11 a

90Z6W03-15-05

10°

90Z6W03-05-11a

90Z6W03-15-04

Installation IMPORTANT: Check the installation angle of adapters. 1. Install all removed adapters to fan motor (16).

Fan mount (2) assy weight: 50 kg (110 dCAUTION: lb) 5. Attach sling to holes (a) and temporarily hold fan mount assy (2).

2. Install fan motor (16) to fan (2) mount with bolts (14) (4 used) and washers (15) (4 used).

6. Install fan mount assembly (2) to radiator assembly (1) with bolts (8) (2 used), bosses (9) (2 used), and bolts (7) (6 used). Tighten nuts (5) (4 used) with washers (6) (4 used).

l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) IMPORTANT: Thoroughly clean and remove all oil from tapered shaft (a) of fan motor (16) and key (13). 3. Install key (13) to fan motor (16). Fit fan (12) to key (13) and install fan (12) to fan motor (16).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 7. Install connector (3) with bolt (4).

4. Apply LOCTITE #262 to lock nut (10). Tighten lock nut (10) with washer (11) to secure fan (12). j : 21 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-12-1-4

j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

SECTION 3 BODY Group 12 Cooling Fan System

a 3 2

4 1

10 9

8 1

90Z6W03-15-02

8. Install plates (9, 10) with bolts (8) (4 used) (on both sides).

90Z6W03-15-01

10. Install bracket (4) with connector fixing bolt (3) and bolts (2) (2 used) (on both sides).

j : 17 mm

j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) j : 17 mm

9. Connect connectors (5, 6, 7).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Close radiator cover (1) (on both sides).

W3-12-1-5

SECTION 3 BODY Group 12 Cooling Fan System 15

13, 14

2 4

13, 14

3 6 10 4

15, 16, 17 11

15, 16, 17

7, 8

90Z6W03-04-28

90Z6W03-05-03

14. Connect hoses (9, 10, 11) to fan motor (6). 6

j : 27 mm

10°

11 10°

m : 80 N·m (8 kgf·m, 59 lbf·ft) 6

j : 36 mm

90Z6W03-05-15

m : 180 N·m (18 kgf·m, 133 lbf·ft) Rear grill (12) assy weight: 35 kg (77 dCAUTION: lb) 12. Sling and move rear grill (12) assembly to radiator guard. Install rear grill (12) assembly with bolts (15) (8 used), nuts (16) (4 used), and washers (17) (4 used).

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

j : 17 mm

16. 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. Start the engine and check for any oil leaks.

13. Fix connector (13) for the rear working lamp with bolt (14) (on both sides). Connect the couplers.

17. Install rear roof (1) with bolts (2) (2 used), bolts (3) (6 used), and bolts (4) (2 used).

j : 10 mm

j : 17 mm

m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 18. Close rear grill (1).

W3-12-1-6

SECTION 3 BODY Group 12 Cooling Fan System Structure of Fan Motor 1

2 5

3 4

No.

Part Name

90Z6W03-15-06

Q’ty

Oil Motor

Coupling

Outrigger Bearing

Nut

Lock Washer

Woodruff Key

Motor Shaft

Nut

Woodruff Key

Bearing Shaft

Solenoid Valve

Tool Size mm

Tightening Torque N·m (kgf·m, lbf·ft)

Remark

Clean the mating surfaces of the parts before assembly. Apply grease to the bearing spline. 45~50 (4.6~5.1, 33~37)

80 (8.2, 59)

68~75 (6.9~7.6, 50~55)

W3-12-2-1

Fan speed control

SECTION 3 BODY Group 12 Cooling Fan System (Blank)

W3-12-2-2

SECTION 3 BODY Group 12 Cooling Fan System Removal and Installation of Fan Pump

d a 5 f

90Z6W03-08-01 abc-

Main Pump Regulators Pilot Pump

def-

Priority Valve Fan Pump (Accessory Pump) Engine

1 90Z6W03-08-08

2. Open the right side cover. 3. Disconnect hoses (2, 3) from fuel filter (1). j : 27 mm 4. Disconnect hoses (5, 6) from fan pump (4). j : 50 mm

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

j : 36 mm

W3-12-3-1

SECTION 3 BODY Group 12 Cooling Fan System

7, 8, 9

5 2, 3 90Z6W03-08-09

5. Remove nut (2) and holder (3).

90Z6W03-08-10

7. Remove 2 each of bolt (7) and washers (8, 9).

j : 12 mm

j : 19 mm

6. Remove bolts (4) (4 used) and remove fuel filter (1) with the gasket. j : 17 mm

8. Remove fan pump (5) and gasket (6).

fNOTE: Fan pump (5) weight: 7.5 kg (16.5 lbs) 9. Remove the adapters, if needed.

W3-12-3-2

SECTION 3 BODY Group 12 Cooling Fan System 7, 8, 9

4 5

90Z6W03-08-10

2, 3

90Z6W03-08-09

20°

30°

9 90Z6W03-08-11

Installation IMPORTANT : Check the angle to install adapters. 1. Reinstall all the removed adapters.

3. Install fuel filter (1) with the gasket with bolts (4) (4 used). j : 17 mm

2. Install gasket (6) and fan pump (5) with 2 each of bolt (7) and washers (8, 9). j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft) 4. Install holder (3) with nut (2).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 12 mm

fNOTE: Fan pump (5) weight: 7.5 kg (16.5 lbs)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W3-12-3-3

SECTION 3 BODY Group 12 Cooling Fan System

3 1 45°

[IN] 15°

[IN]

90Z6W03-08-12

25°

[IN]

5 4

15°

1 6

90Z6W03-08-08

5. Connect hoses (5, 6) to fan pump (4).

[OUT]

6. Connect hoses (2, 3) to fuel filter (1).

j : 50 mm

j : 27 mm

m : 270 N·m (27 kgf·m, 199 lbf·ft)

m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

90Z6W03-08-13

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.

W3-12-3-4

SECTION 3 BODY Group 12 Cooling Fan System Disassembly of Fan Pump

50, 52

54 90W4GB-02-04-07

0102030405-

Front Cover Body Drive Gear Driven Gear Side Plate (2 used)

0650525354-

Rear Cover Gasket (2 used) Backup Ring (2 used) Gasket Gasket

56575859-

Hex Socket Bolt (4 used) Waster (4 used) Oil Seal Stop Ring

W3-12-4-1

SECTION 3 BODY Group 12 Cooling Fan System * 02

05 50 53 01

58 59 56 57

54 52 50

90Z6W03-15-15

05 *:

Matchmark

0102030405-

Front Cover Body Drive Gear Driven Gear Side Plate (2 used)

0650525354-

Rear Cover Gasket (2 used) Backup Ring (2 used) Gasket Gasket

56575859-

Hex Socket Bolt (4 used) Waster (4 used) Oil Seal Stop Ring

W3-12-4-2

SECTION 3 BODY Group 12 Cooling Fan System

Drive gear (03) rotation direction Matchmark

[Input]

[Output]

Matchmark Driven gear (04) rotation direction

90W4GB-02-08-12

90W4GB-02-08-16

IMPORTANT: Put match marks on front cover (01), body (02), and rear cover (06) before separating them.

6. Pull out oil seal (58) using the edge of a screwdriver.

fNOTE: Take care not to scratch the oil seal hole.

1. Vise the accessory pump unit at front cover (01) with rear cover (06) up. 2. Remove hex socket bolts (56) (4 used) and washer (57) (4 used) and remove rear cover (06) from body (02). Remove gasket (54), backup ring (52), gasket (50), and side plate (05) in order.

fNOTE: Backup rings (52), gaskets (50), and side plates (05) installed to front cover (01) and rear cover (06) are identical respectively.

3. Put match marks on drive gear (03) and driven gear (04) to the gear shaft ends facing to rear side. l : 5 mm 4. Remove side plate (05), gasket (50), backup ring (52), and gasket (53). 5. Remove stop ring (59) from front cover (01).

W3-12-4-3

SECTION 3 BODY Group 12 Cooling Fan System Assembly of Fan Pump 02

Matchmark

Apply grease

03 05 50 53 01

Matchmark Apply grease

58 59 56 *

54 52 50

90Z6W03-15-15

IMPORTANT: Replace gaskets (50, 53, 54) and backup ring (52) with new ones when assembling.

W3-12-4-4

SECTION 3 BODY Group 12 Cooling Fan System 58

Dust lip Apply grease

Main lip

90W4GB-02-08-17

Pushing tool Guide

52 52

Push in the seal straight to the bottom.

58 01

90W4GB-02-08-14

90W4GB-02-08-18

IMPORTANT: Clean all parts and apply air blow enough. Assemble the parts with bare hands.

4. Install body (02).

1. Vise front cover (01) with body (02) mounting side up. 2. Install gasket (53), backup ring (52), gasket (50), and side plate (05) to front cover (01).

fNOTE:  Put backup ring (52) into the groove of gasket (50). Avoid the ring from twisting or pinching.  Take care of the direction of side plate (05). The side shown below faces to the cover side. (The flat surface faces to the gear.) 3. Install drive gear (03) and driven gear (04). Align the matchmarks.

fNOTE: Apply a thin coat of hydraulic oil to the side surfaces of drive gear (03) and driven gear (04) (see below).

5. Install side plate (05), gasket (50), backup ring (52), and gasket (54) to rear cover (06). 6. Install rear cover (06).

fNOTE: Apply a thin coat of hydraulic oil to the bushings pressed in rear cover (06) before installing the cover.

7. Align matchmarks on covers (01, 06) and body (02) and tighten hex socket bolt (56) (4 used). l : 12 mm m : 130~140 N·m (13.3~14.3 kgf·m, 96~103 lbf·ft) 8. Turn over and vise the assembled parts at rear cover (06) with front cover (01) up. 9. Apply grease between the lips of oil seal (58). 10. Push in oil seal (58) straight to the bottom of oil seal hole in front cover (01).

fNOTE: The tools as shown below can make oil seal installation easier.

W3-12-4-5

SECTION 3 BODY Group 12 Cooling Fan System

Pliers

59 01

90W4GB-02-08-19

11. Install stop ring (59).

W3-12-4-6

SECTION 3 BODY Group 12 Cooling Fan System Structure of Fan Pump 59

50, 52

01 53

90W4GB-02-04-07

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

01 02 03 04 05 06 50 52 53 54 56 57 58 59

Front Cover Body Drive Gear Driven Gear Side Plate Rear Cover Gasket Backup Ring Gasket Gasket Hex Socket Bolt Washer Oil Seal Stop Ring

1 1 1 1 1 1 2 2 1 1 4 4 1 1

Bushing

Wrench Size mm

N·m

Tightening Torque kgf·m lbf·ft

Remark

*1 *1 *1 *1 *1 *2 *2 l : 12

130 to 140

13.3 to 14.3

96 to 103 *2 *1 2 each pressed in the front and rear covers.

fNOTE: *1: Apply hydraulic oil when assembling. *2: Apply grease when assembling.

W3-12-4-7

SECTION 3 BODY Group 12 Cooling Fan System (Blank)

W3-12-4-8

SECTION 3 BODY Group 12 Cooling Fan System Removal and Installation of Fan Control Valve (Option) 11

3 10

5 8 2 10

9 90Z6W03-15-07

2. Open radiator guard cover (1) on the right side. 3. Disconnect connectors (2, 3, 4). 4. Remove hoses (5, 6, 7, 8, 9). j : 36 mm

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

j : 27 mm j : 19 mm

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

5. Remove bolts (10) (3 used) indicated by bold arrows, and remove fan control valve (11). j : 17 mm

fNOTE: Fan control valve (11) weight: 12 kg (26 lb) 6. Remove adapters, if needed.

W3-12-5-1

SECTION 3 BODY Group 12 Cooling Fan System

10°

10° B

3 10

B A

A B-B

10°

A-A

90Z6W03-15-08

90Z6W03-15-07

Installation IMPORTANT: Check the installation angle of adapters. 1. Install all removed adapters to fan control valve (11).

3. Install hoses (5, 6, 7, 8, 9). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

2. Install fan control valve (11) with bolts (10) (3 used) indicated by bold arrows.

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

j : 17 mm

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft)

fNOTE: Fan control valve (11) weight: 12 kg (26 lb)

4. Connect connectors (2, 3, 4). 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. Close radiator guard cover (1) on the right side.

W3-12-5-2

SECTION 3 BODY Group 12 Cooling Fan System Structure of Fan Control Valve (Option)

4 3 2

2 1

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

W3-12-5-3

WJBA-03-16-006

SECTION 3 BODY Group 12 Cooling Fan System No.

Part Name

Q’ty

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)

Solenoid Valve

Socket Bolt

Solenoid Valve

Plug

Relief Valve

Plug

O-Ring

Spring

Check Valve

O-Ring

Spring

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

W3-12-5-4

Remark

SECTION 3 BODY Group 12 Cooling Fan System Removal and Installation of Reversing Fan Motor (Option)

14, 15

2 4 14, 15

6 12

16, 17, 18 90Z6W03-04-28

16, 17, 18

7, 8

90Z6W03-15-09

3. Open rear grill (5). Place a container under fan motor (6) to receive drain. 4. Remove bolt (7) and bracket (8). j : 17 mm

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

5. Disconnect hoses (9, 10, 11, 12).

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

j : 27 mm j : 19 mm (0.75 in)

2. Remove bolts (2) (2 used), bolts (3) (6 used), and bolts (4) (2 used). Remove rear roof (1). j : 17 mm j : 19 mm (0.75 in)

Rear grill (12) assy weight: 35 kg (77 dCAUTION: lb) 6. Sling and hold rear grill (12) assembly. 7. Remove bolt (15). Disconnect connector (14) for the rear working lamp (on both sides). j : 10 mm 8. Remove bolts (16) (8 used), nuts (17) (4 used), and washers (18) (4 used). Remove rear grill (13) assembly. j : 17 mm

W3-12-6-1

SECTION 3 BODY Group 12 Cooling Fan System

5 1

6 2 4

90Z6W03-15-11

90Z6W03-15-10

9. Open radiator cover (1) (on both sides).

11. Disconnect connectors (5, 6, 7).

10. Remove bolts (2) (2 used), connector fixing bolt (3), and bracket (4) (on both sides).

12. Remove bolts (8) (4 used) and remove plates (9, 10) (on both sides).

j : 17 mm j : 10 mm

j : 17 mm Fan mount (11) assy weight: 45 kg dCAUTION: (100 lb) 13. Attach sling to holes (a) and temporarily hold fan mount assy (11).

W3-12-6-2

SECTION 3 BODY Group 12 Cooling Fan System

5 13

7 4

90Z6W03-05-11a

14. Remove bolt (4) from connector (3).

17. Remove lock nut (10) and washer (11) at the center of fan (12).

j : 10 mm

j : 21 mm

90Z6W03-15-03

W3-12-6-3

SECTION 3 BODY Group 12 Cooling Fan System 2

12 8

12 13

11 a

90Z6W03-15-05

7 4

90Z6W03-05-11a

10° 90Z6W03-15-12

Installation IMPORTANT: Check the installation angle of adapters. 1. Install all removed adapters to fan motor (16).

Fan mount (11) assy weight: 45 kg dCAUTION: (100 lb) 5. Attach sling to holes (a) and temporarily hold fan mount assy (2).

2. Install fan motor (16) to fan (2) mount with bolts (14) (4 used) and washers (15) (4 used).

6. Install fan mount assembly (2) to radiator assembly (1) with bolts (8) (2 used), bosses (9) (2 used), and bolts (7) (6 used). Tighten nuts (5) (4 used) with washers (6) (4 used).

j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 7. Install connector (3) with bolt (4).

4. Apply LOCTITE #262 to lock nut (10). Tighten lock nut (10) with washer (11) to secure fan (12). j : 21 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

W3-12-6-4

j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

SECTION 3 BODY Group 12 Cooling Fan System

a 2

4 5 1

9 3 6 2

90Z6W03-15-11

8. Install plates (9, 10) with bolts (8) (4 used) (on both sides).

90Z6W03-15-10

10. Install bracket (4) with connector fixing bolt (3) and bolts (2) (2 used) (on both sides).

j : 17 mm

j : 10 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) j : 17 mm

9. Connect connectors (5, 6, 7).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 11. Close radiator cover (1) (on both sides).

W3-12-6-5

SECTION 3 BODY Group 12 Cooling Fan System

14, 15 5

14, 15 11

6 12

20°

10 Arrow View A

16, 17, 18 16, 17, 18

7, 8

90Z6W03-15-13

90Z6W03-15-09

CAUTION: Rear grill (13) assy weight: 35 kg (77 lb) 12. Sling and move rear grill (13) assembly to radiator guard. Install rear grill (13) assembly with bolts (16) (8 used), nuts (17) (4 used), and washers (18) (4 used).

14. Connect hoses (9, 10, 11, 12) to fan motor (6). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

j : 17 mm

15. Install bracket (8) with bolt (7).

m : 50 N·m (5 kgf·m, 37 lbf·ft) 13. Fix connector (14) for the rear working lamp with bolt (15) (on both sides). Connect the couplers. j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

W3-12-6-6

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

SECTION 3 BODY Group 12 Cooling Fan System 2 1

2 4 3

90Z6W03-04-28

16. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 17. Install rear roof (1) with bolts (2) (2 used), bolts (3) (6 used), and bolts (4) (2 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft) 18. Close rear grill (1).

W3-12-6-7

SECTION 3 BODY Group 12 Cooling Fan System (Blank)

W3-12-6-8

SECTION 3 BODY Group 13 Exhaust Muffler Removal and Installation of Muffler 11 7, 8

2 9

10 5 6

4 90Z6W03-04-20

90Z6W03-04-23

4. Remove bolts (3) (5 used) and cover (4). j : 17 mm 5. Remove clamp (6) from pipe (5). 6. Remove nuts (7) (2 used) and washers (8) (2 used) from muffler (11) assembly. Remove bracket (9) and U-bolt (10). j : 17 mm

2. Remove bolts (1) (4 used) and exhaust pipe (2). j : 17 mm

7. Remove pipe (5) from muffler (11).

3. Open the side cover.

W3-13-1-1

SECTION 3 BODY Group 13 Exhaust Muffler

2, 3

4 90Z6W03-16-01

8. Remove nuts (2) (2 used) and holders (3) (2 used) fixing drain pipe (4).

90Z6W03-16-03

9. Remove drain pipe (4) from muffler (1). j : 22 mm

j : 12 mm

10. Remove bolts (5) (4 used) from muffler (1). j : 17 mm

W3-13-1-2

SECTION 3 BODY Group 13 Exhaust Muffler

1 2

5 4

90Z6W03-16-02

d CAUTION: Muffler (1) weight: 25 kg (55 lb)

90Z6W03-04-30

fNOTE: Exhaust pipe (2) of EU Spec. machine (S/N

9001~) is directly installed to muffler (3). Loosen bolt (4) and clamp (5) to disconnect pipe (2).

11. Take out muffler (1) from the left side of the machine.

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

W3-13-1-3

SECTION 3 BODY Group 13 Exhaust Muffler

90Z6W03-16-02

Installation

d CAUTION: Muffler (1) weight: 25 kg (55 lb) 1. Install muffler (1) from the left side of the machine.

W3-13-1-4

SECTION 3 BODY Group 13 Exhaust Muffler

2, 3

90Z6W03-16-03

2. Temporarily tighten bolts (5) (4 used) to muffler (1). j : 17 mm

90Z6W03-16-01

4. Install nuts (2) (2 used) and holders (3) (2 used) to drain pipe (4). j : 12 mm

3. Install drain pipe (4) to muffler (1).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft)

W3-13-1-5

SECTION 3 BODY Group 13 Exhaust Muffler

1 7, 8

9 10

5 6

4 90Z6W03-04-20

5. Install pipe (5) to muffler (1).

90Z6W03-16-03

8. Tighten muffler mounting bolts (2). j : 17 mm

6. Install bracket (9), U-bolt (10), nuts (7) (2 used) and washers (8) (2 used) to secure pipe (5) and muffler (1) assembly.

m : 50 N·m (5 kgf·m, 37 lbf·ft) 9. Install clamp (6) to pipe (5).

j : 17 mm

m : 8 N·m (0.8 kgf·m, 5.9 lbf·ft)

m : 40 N·m (4 kgf·m, 30 lbf·ft) 7. Adjust the position of muffler (1) so that it does not apply load to the connection part of pipe (5).

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

W3-13-1-6

SECTION 3 BODY Group 13 Exhaust Muffler

2 1

90Z6W03-04-23

11. Install exhaust pipe (2) with bolts (1) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 12. Close the side cover.

W3-13-1-7

SECTION 3 BODY Group 13 Exhaust Muffler (Blank)

W3-13-1-8

SECTION 3 BODY Group 14 Ride Control Device Removal and Installation of Ride Control Valve and Accumulator (Option)

1 2

8 4, 5, 7

4, 6, 7

90Z6W03-09-01

Removal

90Z6W03-17-01

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

dCAUTION:  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.

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 nuts (2) (7 used) and washers (3) (7 used). Remove cover (1).

 Do not directly heat the accumulator. Do not weld the accumulator housing.

j : 17 mm

 Be sure to release pressure before starting to work on the piping lines.

3. Remove bolts (4) (8 used) and remove hose assemblies (5, 6) with O-rings (7) (2 used).

j : 14 mm 4. Disconnect hose (8).

W3-14-1-1

j : 36 mm

SECTION 3 BODY Group 14 Ride Control Device

20 16

9, 11

14 15

13 13

20 1

2 3

8 7 6

7 90Z6W03-17-02

5. Remove hoses (1, 2, 3).

90Z6W03-17-03

11. Remove bolts (14) (3 used) and washers (15) (3 used) from ride control valve assembly (13). Remove bracket (16).

j : 36 mm j : 17 mm

j : 19 mm

6. Disconnect connector (4).

dCAUTION: Accumulator (7) weight: 45 kg (99 lb)

7. Remove bolts (5) (2 used) and remove bracket (6).

12. Loosen nuts (17) (8 used) and remove accumulator (7).

j : 17 mm

Accumulator (7) assy weight: 60 kg dCAUTION: (132 lb)

13. Remove nuts (17) (8 used) and washers (18) (4 used) and remove U-bolts (19) (2 used) from bracket (20).

8. Temporarily attach vinyl sling to accumulator assembly (7) and hold it.

j : 17 mm

9. Remove bolts (8) (3 used) and bolt (9). Remove accumulator assembly (7) with bosses (10) (3 used) and boss (11).

14. Remove the adapters, if necessary.

j : 19 mm 10. Remove bolts (12) (4 used) and remove ride control valve assembly (13). j : 19 mm

W3-14-1-2

SECTION 3 BODY Group 14 Ride Control Device

14 15

13 7

20 19

Machine Front

20 20°

19 18 17

90Z6W03-17-05

7 90Z6W03-17-03

Installation IMPORTANT: Check the angle to install adapters. 1. Install all the removed adapters to ride control valve (13) and accumulator (7).

dCAUTION: Accumulator (7) weight: 45 kg (99 lb) 2. Attach vinyl sling to accumulator (7) and move it to bracket (20). Fit accumulator (7) to surface (a) of bracket (20). 3. Install accumulator (7) to bracket (20) and secure with U-bolts (19) (2 used), nuts (17) (8 used), and washers (18) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 4. Install ride control valve assembly (13) to bracket (16) with bolts (14) (3 used) and washers (15) (3 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-14-1-3

SECTION 3 BODY Group 14 Ride Control Device

20 16

9, 11

5 2 3

8 7 6

90Z6W03-17-02

5. Install ride control valve assembly (13) with bolts (12) (4 used).

8. Install bracket (6) with bolts (5) (2 used). j : 17 mm

j : 19 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

9. Connect connector (4).

Accumulator (7) assy weight: 60 kg dCAUTION: (132 lb) 6. Sling accumulator (7) assembly and move it to the front chassis.

10. Install hoses (1, 2, 3). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

7. Install accumulator assembly (7) with bosses (10) (3 used) and boss (11). Tighten bolts (8) (3 used) and bolt (9). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W3-14-1-4

j : 17 mm m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

SECTION 3 BODY Group 14 Ride Control Device

8 4, 5, 7 1 2 4, 6, 7 3

90Z6W03-17-01

35°

8 5 90Z6W03-09-01

6 5°

35°

90Z6W03-17-04

11. Install hose (8).

15. Set the machine in lift arm raise position for inspection and maintenance. (Refer to W1-6-1.)

j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

16. Install cover (1) with nuts (2) (7 used) and washers (3) (7 used).

IMPORTANT: Check the angle to install hoses (3, 2). 12. Install hose assemblies (5, 6) with O-rings (7) (2 used). Tighten bolts (4) (8 used). j : 14 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft) 13. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 14. 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.

W3-14-1-5

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

SECTION 3 BODY Group 14 Ride Control Device (Blank)

W3-14-1-6

SECTION 3 BODY Group 14 Ride Control Device Disassembly of Ride Control Valve (Option)

WNDB-03-16-001 02- Spring 03- Plug 04- O-Ring (2 Used) 05- Plug 05A- O-Ring 07- Plug 08- Solenoid Valve 08A- Sleeve 08B- Spool 08C- Solenoid 08D- Spring 08E- Plate

08F- Washer 08G- Socket Bolt (2 Used) 08H- O-Ring 08I- O-Ring 08J- O-Ring 08K- O-Ring 10- Plug 13- Spring 16- O-Ring 17- Backup Ring 18- Check Valve 19- Spring

20- Plug 21- O-Ring 22- Drain Plug 23- O-Ring 24- Nut 25- Plug 25A- O-Ring 26- Plug 26A- O-Ring 27- Plug 27A- O-Ring 28- Plug

W3-14-2-1

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 14 Ride Control Device Disassembly

8. Remove plug (03) from housing (32A). Remove O-ring (04) from plug (03).

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). 6. Remove plug (07) 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). 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

W3-14-2-2

SECTION 3 BODY Group 14 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).

W3-14-2-3

SECTION 3 BODY Group 14 Ride Control Device Assembly of Ride Control Valve (Option)

A B

26, 26A 27, 27A

A TNDB-03-12-001

Section A-A a

Section B-B

32A

28A

23 24 22

02 05A 05 32B

03 04 34C

25A

WNDB-03-16-002

W3-14-2-4

34A

34B

34 T4GD-03-08-001

SECTION 3 BODY Group 14 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.

W3-14-2-5

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 14 Ride Control Device Assembly 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

j : 10 mm

m : 177 to 206 N·m (18 to 21 kgf·m, 131 to 152 lbf·ft)

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)

W4GB-02-05-002

9. Install O-ring (25A) to plug (25). Install plug (25) to housing (32A). l : 6 mm

3. Install O-ring (16) and backup ring (17) to spool (32C).

m : 34 to 39 N·m (3.5 to 4 kgf·m, 25 to 29 lbf·ft)

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).

W3-14-2-6

SECTION 3 BODY Group 14 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)

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).

11. Install O-ring (27A) to plug (27). Install plug (27) to housing (32A).

l : 4 mm m : 5 to 7 N·m (0.5 to 0.7 kgf·m, 3.7 to 5.2 lbf·ft)

l : 8 mm m : 69 to 74 N·m (7 to 7.6 kgf·m, 51 to 55 lbf·ft)

18. Install O-ring (23) to drain plug (22). Install drain plug (22) to housing (32A).

12. Install O-ring (28A) to plug (28). Install plug (28) to housing (32A).

l : 4 mm m : 7 to 9 N·m (0.7 to 0.9 kgf·m, 5.2 to 6.6 lbf·ft)

l : 12 mm 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 : 13 mm

j : 27 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).

W3-14-2-7

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

SECTION 3 BODY Group 14 Ride Control Device (Blank)

W3-14-2-8

SECTION 3 BODY Group 15 Battery Disconnect Switch Removal and Installation of Battery Disconnect Switch (Option)

View A

OFF 6

4 2 1 90Z6-1-106-1

90Z6W03-18-01

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Open battery box cover (1).

3. Turn battery disconnect switch (2) to OFF position. 4. Remove nut (3) and disconnect ground (4). j : 17 mm 5. Remove nuts (5, 6) and disconnect terminal (7). j : 17 mm j : 10 mm 6. Remove bolts (8) (2 used) and remove battery disconnect switch (2). j : 10 mm

W3-15-1-1

SECTION 3 BODY Group 15 Battery Disconnect Switch

View A

ON 6

4 2 1 90Z6-1-106-1

90Z6W03-18-01

Installation 1. Install battery disconnect switch (2) with bolts (8) (2 used). j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft)

4. Turn battery disconnect switch (2) to ON position, if necessary. 5. Close battery box cover (1).

2. Connect terminal (7) and tighten nuts (5, 6). j : 17 mm m : 21 N·m (2.1 kgf·m, 15.5 lbf·ft) j : 10 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) 3. Connect ground (4) and tighten nut (3). j : 17 mm m : 21 N·m (2.1 kgf·m, 15.5 lbf·ft)

W3-15-1-2

SECTION 4

TRAVEL SYSTEM CONTENTS Group 1 Tire

Removal and Installation of Front Tire....................W4-1-1-1 Removal and Installation of Rear Tire......................W4-1-2-1

Group 2 Drive Unit

Removal and Installation of Drive Unit...................W4-2-1-1 Structure of Drive Unit..................................................W4-2-2-1 Disassembly and Assembly of Drive Unit...............W4-2-3-1 Draining Oil and Removing Charging Pump...W4-2-3-1 Removing Control Valve.........................................W4-2-3-3 Removing Speed Sensor.........................................W4-2-3-4 Installing Charging Pump.......................................W4-2-3-5 Installing Control Valve...........................................W4-2-3-7 Installing Speed Sensor...........................................W4-2-3-8

Group 3 Axle

Removal and Installation of Front Axle...................W4-3-1-1 Removal and Installation of Rear Axle.....................W4-3-2-1 Disassembly of Axle.......................................................W4-3-3-1 Front Axle Assembly.................................................W4-3-3-1 Rear Axle Assembly..................................................W4-3-3-1 Axle Assembly............................................................W4-3-3-2 Planetary Carrier Assembly....................................W4-3-3-3 Removal of Axle Support (Rear Axle).......................W4-3-3-4 Disassembly of Axle.......................................................W4-3-3-6 Removal of Housings...............................................W4-3-3-6 Disassembly of Housings........................................W4-3-3-7 Disassembly of Planetary Carrier Assembly.....W4-3-3-9 Removal of Brake.................................................... W4-3-3-10 Removal of Differential Case Assembly.......... W4-3-3-11 Disassembly of Differential Case Assembly.. W4-3-3-12 Removal of Bearing Cage Assembly................ W4-3-3-13 Assembly of Axle.......................................................... W4-3-3-14 Adjustment of Ring Gear Backlash and Adjustment of Ring Gear Teeth Engagement.................... W4-3-3-20 Adjustment of Brake Disc Clearance............... W4-3-3-24 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment).............................................. W4-3-3-30 Installation of Axle Support (Rear Axle)............... W4-3-3-36

Disassembly of Differential..........................................W4-3-4-1 Torque Proportional Differential (TPD)..............W4-3-4-1 Limited Slip Differential (LSD)...............................W4-3-4-2 Disassembly of Bearing Cage Assembly...........W4-3-4-3 Disassembly of Differential Case Assembly (TPD)...........................................................................W4-3-4-5 Disassembly of Differential Case Assembly (LSD)............................................................................W4-3-4-6 Assembly of Differential...............................................W4-3-4-8 Torque Proportional Differential (TPD)..............W4-3-4-8 Limited Slip Differential (LSD)...............................W4-3-4-9

Group 4 Propeller Shaft

Removal and Installation of Propeller Shaft..........W4-4-1-1 Removal of Bottom Covers (Option)..................W4-4-1-1 Removal of Second Propeller Shaft....................W4-4-1-2 Removal of Third Propeller Shaft.........................W4-4-1-5 Installation of Third Propeller Shaft....................W4-4-1-6 Installation of Second Propeller Shaft...............W4-4-1-7 Installation of Bottom Covers (Option).......... W4-4-1-10

Group 5 Brake Valve

Removal and Installation of Brake Valve.................W4-5-1-1 Disassembly of Brake Valve Assembly (Option)...W4-5-2-1 Assembly of Brake Valve Assembly (Option).........W4-5-2-4 Structure of Brake Valve................................................W4-5-3-1 Disassembly of Brake Valve.........................................W4-5-3-2 Assembly of Brake Valve...............................................W4-5-3-3 Brake Valve Maintenance Standard..........................W4-5-3-4

Group 6 Steering Pilot Valve

Removal and Installation of Steering Pilot Valve...............................................................................W4-6-1-1 Disassembly of Steering Pilot Valve.........................W4-6-2-1 Assembly of Steering Pilot Valve...............................W4-6-2-4

Group 7 Steering Valve

Removal and Installation of Steering Valve...........W4-7-1-1 Disassembly and Assembly of Steering Valve......W4-7-2-1

90Z6 D&R

Group 8 Steering Cylinder

Removal and Installation of Steering Cylinder.....W4-8-1-1 Disassembly of Steering Cylinder.............................W4-8-2-1 Assembly of Steering Cylinder...................................W4-8-2-4 Removal and Installation of Steering Accumulator................................................................W4-8-3-1

Group 9 Secondary Steering Device

Removal and Installation of Secondary Steering Pump..............................................................................W4-9-1-1

Group 10 Stop Valve Removal and Installation of Stop Valve............... W4-10-1-1 Adjustment of Stop Valve Installation Position................................................................... W4-10-1-3 Disassembly of Stop Valve........................................ W4-10-2-1 Assembly of Stop Valve.............................................. W4-10-2-2 Group 11 Axle Oil Cooler Removal and Installation of Axle Oil Cooler (Option)...................................................................... W4-11-1-1 Structure of Oil Cooler Assembly (Option)......... W4-11-2-1 Structure of Oil Cooler Pump Unit (Option)....... W4-11-2-2 Structure of Check Valve Assembly (Option)..... W4-11-2-4

90Z6 D&R

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Front Tire [ A Detail ] 2 A 1

90Z6-W4-01-01-01 a-

Stand

Wheel Stopper

90Z6-W4-01-01-02

Removal 1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Remove front fender (2) while holding dCAUTION: it. Do not drop front fender (2). 4

2. Remove bolts (1) (4 used) and remove front fender (2).

j : 19 mm 3. Loosen wheel mounting bolts (3) (20 used) by one turn. j : 36 mm 90W4GB-03-01-03

d CAUTION: Machine weight: 23100 kg (50927 lb) 4. Set blocks (b) at the rear tires. Raise the machine until tire (4) slightly gets away from the ground. Securely support the machine by using stand (a). Lower the bucket onto the ground.

d CAUTION: Tire (4) weight: 670 kg (1480 lb) 5. Attach lifting tools onto tire (4). Hoist and hold tire (4). 6. Remove wheel mounting bolts (3) (20 used). Remove tire (4). j : 36 mm

W4-1-1-1

SECTION 4 TRAVEL SYSTEM Group 1 Tire

[ A Detail ] A

2 1

90Z6-W4-01-01-01 a-

Stand

Wheel Stopper

90Z6-W4-01-01-02

Installation

d CAUTION: Tire (4) weight: 670 kg (1480 lb) 1. Hoist and install tire (4) to the front axle.

IMPORTANT: Check air pressure of the tires. Check for abnormal wear and damage of the tires.

2. Temporarily tighten wheel mounting bolts (3) (20 used) to tire (4).

fNOTE: Air Pressure of Front Tires Standard Tire Size 26.5-25-20PR

j : 36 mm

d CAUTION: Machine weight: 23100 kg (50927 lb) 3. Remove stand (a) from the machine. Lower the machine and place tire (4) onto the ground.

Standard Air Pressure 422~441 kPa (4.3~4.5 kgf/cm2, 61~64 PSI)

5. Install front fender (2) with bolts (1) (4 used). j : 19 mm

4. Tighten wheel mounting bolts (3) (20 used) in the illustrated order. j : 36 mm m : 890 N·m (91 kgf·m, 655 lbf-ft)

M4GB-07-102

W4-1-1-2

m : 90 N·m (9 kgf·m, 66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Rear Tire

2 1 (RH)

1 (LH)

90Z6-W4-01-02-01

90Z6-W4-01-02-02

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

CAUTION: Weight of fender assembly Rear fender (front) (1)(RH): 53 kg (117 lb) Rear fender (front) (1)(LH): 47 kg (104 lb)

5. Remove bolts (3) (3 used) and bolts (4) (4 used). j : 19 mm 6. Remove rear fender (front) (1) assembly (RH side).

2. Attach nylon slings onto handrail (2). Hoist and hold rear fender (front) (1) (respectively on both sides). 3. Remove bolts (3) (3 used) and bolts (4) (4 used). j : 19 mm 4. Remove rear fender (front) (1) assembly (LH side).

W4-1-2-1

SECTION 4 TRAVEL SYSTEM Group 1 Tire

a [ A Detail ]

90Z6-W4-01-02-04

90Z6-W4-01-02-03 ab-

Rear fender (rear) (1) (option) weight: d24CAUTION: kg (53 lb)/side CAUTION: Remove rear fender (rear) (1) dassembly while holding not to drop it. 7. Remove bolts (2) (5 used) and remove rear fender (rear) (1) assembly on both sides. j : 19 mm

Stand Wooden Block

90Z6-W4-01-02-05

8. Insert wooden block (b) between rear chassis (6) and rear axle (7) on both right and left sides in order to prevent rear axle (7) from moving. 9. Loosen wheel bolts (5) (20 used) by one turn. j : 36 mm

d CAUTION: Machine weight: 23100 kg (50927 lb) 10. Raise the machine until tire (4) slightly gets away from the ground. Securely support the machine by using stand (a).

W4-1-2-2

SECTION 4 TRAVEL SYSTEM Group 1 Tire

90W4GB-03-01-03

d CAUTION: Tire (1) weight: 670 kg (1480 lb) 11. Attach lifting tools onto tire (1). Hoist and hold tire (1). 12. Remove wheel mounting bolts (2) (20 used). Remove tire (1). j : 36 mm

W4-1-2-3

SECTION 4 TRAVEL SYSTEM Group 1 Tire

[ A Detail ] b

90Z6-W4-01-02-04 a-

Stand

Wooden Block

90Z6-W4-01-02-05

Installation

d CAUTION: Tire (4) weight: 670 kg (1480 lb)

3. Remove wooden block (b) and stand (a) from the machine. Lower the machine and place tire (4) onto the ground.

1. Hoist and install tire (4) to rear axle (2). 2. Temporarily tighten wheel mounting bolts (5) (20 used) to tire (4).

4. Tighten wheel mounting bolts (5) (20 used) in the illustrated order.

j : 36 mm

j : 36 mm m : 890 N·m (91 kgf·m, 655 lbf·ft)

d CAUTION: Machine weight: 23100 kg (50927 lb)

M4GB-07-102

IMPORTANT: Check air pressure of the tires. Check for abnormal wear and damage of the tires.

fNOTE: Air Pressure of Rear Tires

W4-1-2-4

Standard Tire Size

Standard Air Pressure

26.5-25-20PR

324~343 kPa (3.3~3.5 kgf/cm2, 47~50 PSI)

SECTION 4 TRAVEL SYSTEM Group 1 Tire

2 1 (RH)

1 (LH)

90Z6-W4-01-02-01

90Z6-W4-01-02-02

7. Install rear fender (front) (1) assembly (RH side) with bolts (3) (3 used) and bolts (4) (4 used).

CAUTION: Weight of fender assembly dRear fender (front) (1)(RH): 53 kg (117 lb)

Rear fender (front) (1)(LH): 47 kg (104 lb) 5. Attach nylon slings onto handrail (2). Hoist and hold rear fender (front) (1) (respectively on both sides). 6. Install rear fender (front) (1) assembly (LH side) with bolts (3) (3 used) and bolts (4) (4 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-1-2-5

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

SECTION 4 TRAVEL SYSTEM Group 1 Tire

90Z6-W4-01-02-03

Rear fender (rear) (1) (option) weight: d24CAUTION: kg (53 lb)/side 8. Install rear fender (rear) (1) assembly with bolts (2) (5 used). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W4-1-2-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Drive Unit

8 2

10 11

1 7

5 12

90Z6-W4-02-01-04

90Z6-W4-02-01-07

Removal 1. Remove the following parts. (Refer to W3-1 and W34.)

2. Disconnect connectors (8~13) from the drive unit.

 Deck and rear fender (front) (2)  Cab assembly (3)  Step (4)  Hydraulic tank (1) (Refer to W3-6.)  Pump device (5) (Refer to W3-8.)  Propeller shaft (6) (Refer to W4-4.)  Rear fender (rear) (option) (7) (Refer to W4-1)

W4-2-1-1

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

8, 9 10, 11

12 13, 14

5 90Z6-W4-02-01-08

3. Loosen hose bands and remove hoses (1, 2).

90Z6-W4-02-01-09

10. Remove bolts (21) (2 used) and remove bracket (22).

j : 8 mm

j : 17 mm

4. Disconnect hoses (3, 4). j : 36 mm 5. Disconnect hose (5). j : 41 mm 6. Disconnect hose (6). j : 50 mm 7. Disconnect hose (7). j : 17 mm 8. Remove bolts (8) (4 used) and split flange (9). Remove hose (10) with O-ring (11). j : 14 mm 9. Remove bolts (12) (4 used) and remove pipe (13) with O-ring (14). j : 17 mm

W4-2-1-2

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

a a

b 7 2 7

3 8

5 4 90Z6-W4-02-01-10a

90Z6-W4-02-01-02 a-

Lifting Point

dCAUTION: Drive unit (1) weight: 900 kg (1985 lb) 11. Attach nylon slings onto drive unit (1). Hoist and hold drive unit (1).

Block

14. Remove bolts (4) (12 used) and washers (5) (12 used) from the open part of cover (3). j : 17 mm

12. Insert supporting block (b) under engine flywheel housing (7).

15. Remove bolt (8), bolts (6) (11 used), and boss (9) (11 used). j : 14 mm

13. Remove bolts (2) (8 used) and remove cover (3). j : 17 mm

W4-2-1-3

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit a

4, 7 8, 9

5 2

3, 4

90Z6-W4-02-01-10

17. Remove nuts (3) (2 used), washers (4) (2 used), washers (5) (2 used), rubber bushing (6) (4 used), bolts (7) (2 used), and washers (4) (2 used).

j : 27 mm 90Z6-W4-02-01-12

ab-

18. Remove bolts (8) (4 used) and washers (9) (4 used). Remove bracket (10) from drive unit (a).

Drive Unit Engine

j : 24 mm 16. Remove bolts (1) (4 used) and remove cover (2) on both sides.

19. Remove bracket (10) on the other side of drive unit (a) in the same manner.

j : 17 mm

W4-2-1-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Lift this side higher.

1 Slide forward by 120 mm to separate from engine.

Engine assy 90Z6-W4-02-01-11

dCAUTION: Drive unit (1) weight:

900 kg (1985 lb) 20. Hoist and move drive unit approx. 120 mm (4.7 in) to the front. Incline the unit with the torque converter side slightly up.

dCAUTION: Take special care so that the drive

unit does not interfere the parts and units around while lifting.

W4-2-1-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

Engine assy

a 90Z6-W4-02-01-02

90Z6-W4-02-01-06

IMPORTANT: Place drive unit (1) onto a stable stand like (a) not to fall down.

21. Remove gasket (2).

W4-2-1-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Lift this side higher.

1 Slide forward by 120 mm to separate from engine.

3 a-

90Z6-W4-02-01-11

Lifting Point

3 1

Installation

dCAUTION: Drive unit (1) weight:

900 kg (1985 lb) 1. Attach nylon slings onto drive unit (1). Hoist and hold drive unit (1). 2

2. Install gasket (2) on the joint surface between engine (3) and drive unit (1) housing.

90Z6-W4-02-01-02

W4-2-1-7

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

4, 7 8, 9 White line

7 10 6 5 90Z6-W03-04-01

3, 4

90Z6-W4-02-01-10

3. Install bracket (10) to drive unit (1). Fix with bolts (8) (4 used) and washers (9) (4 used).

fNOTE: Install bracket (10) on the other side of drive unit

j : 24 mm m : 270 N·m (27 kgf·m, 199 lbf·ft) 4. Install nuts (3) (2 used), washers (4) (2 used), washers (5) (2 used), rubber bushing (6) (4 used), bolts (7) (2 used), and washers (4) (2 used). j : 27 mm

W4-2-1-8

(a) in the same manner. Do not tighten the bolts and nuts firmly here.

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

2 1

8 9

6 90Z6-W4-02-01-02

5 Apply lubrication oil onto bolts (3) (11 used), bolt (5), and bolts (6) (12 used).

7. Install bolts (6) (12 used) and washers (7) (12 used) from the open part of cover (9). j : 17 mm

6. Install drive unit (1) to the engine assembly (2) with bolts (3) (11 used), bolt (5), and boss (4) (11 used). j : 14 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

m : 76.5 N·m (7.8 kgf·m, 56.4 lbf·ft) 8. Apply liquid gasket (Loctite FMD-127 or equivalent) onto cover (9) mounting surface. Install cover (9) with bolts (8) (8 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-2-1-9

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

5 1 90Z6-W4-02-01-12

ab-

Drive Unit Engine

9. Tighten bolts (3) (2 used) firmly.

90Z6-W4-02-01-10

11. Remove supporting block (4) under engine flywheel housing (5).

j : 27 mm m : 300 N·m (30 kgf·m, 221 lbf·ft)

12. Remove nylon slings from drive unit (6).

10. Install cover (2) with bolts (1) (4 used) on both sides. j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-2-1-10

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

8, 9 10, 11

12 21

13, 14

90Z6-W4-02-01-09

13. Install bracket (22) with bolts (21) (2 used).

90Z6-W4-02-01-08

16. Connect hose (7).

j : 17 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

14. Install pipe (13) with O-ring (14) with bolts (12) (4 used).

17. Connect hose (6). j : 50 mm

j : 17 mm

m : 270 N·m (27 kgf·m, 199 lbf·ft)

m : 23 N·m (2.3 kgf·m, 17 lbf·ft)

18. Connect hose (5).

15. Install hose (10) with O-ring (11). Fix with bolts (8) (4 used) and split flange (9).

j : 41 mm m : 200 N·m (20 kgf·m, 147.5 lbf·ft)

j : 14 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

19. Connect hoses (3, 4). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 20. Connect hoses (1, 2) and fix with hose bands. j : 8 mm m : 4 N·m (0.4 kgf·m, 2.95 lbf·ft)

W4-2-1-11

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

10 11

1 7

5 12

90Z6-W4-02-01-07

21. Connect connectors (8~13) to the drive unit.

90Z6-W4-02-01-04

22. Install the following parts. (Refer to W3-1 and W3-4.)  Deck and rear fender (front) (2)  Cab assembly (3)  Step (4)  Hydraulic tank (1) (Refer to W3-6.)  Pump device (5) (Refer to W3-8.)  Propeller shaft (6) (Refer to W4-4.)  Rear fender (rear) (option) (7) (Refer to W4-1)

W4-2-1-12

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Structure of Drive Unit 6

152, 153

157

151

150 E 3

E B

2 1 143

137, 138

179, 180

185, 174 D

170

181, 182, 183, 184

C 12

173, 174

135, 136 137, 138

137, 138

139

90Z6-W4-02-02-01 1234678910-

Pipe Distributor Cap (for Forward Suction Tube (2 used) Charging Pump Speed Sensor (4 used) Pump Spacer Distributor Cap (for Reverse Regulator Valve Control Valve

11- Pipe 12- Seal Retainer 135- Bolt (3 used) 136- Washer (3 used) 137- Bolt (5 used) 138- Washer, Spring (12 used) 139- Bolt* (19 used) 140- Bolt (7 used) 143- Bolt* (8 used)

150- Bolt* (8 used) 151- O-Ring (2 used) 152- Bolt* (2 used) 153- Washer (2 used) 157- Socket Bolt (6 used) 170- Pipe 173- Socket Bolt (8 used) 174- Washer (8 used) 179- Bolt (2 used)

fNOTE: Bolt*: Pre-assembled bolt and washer (SEMS)

W4-2-2-1

180- Washer (8 used) 181- Bolt 182- Nut 183- Washer 184- Washer 185- Bolt (2 used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 13 146, 147 130, 147

18 15

129, 147

16 24 17

120

19 21 83, 84

116 120

122 20

30 Cross Section G-G 90Z6-W4-02-02-02

13141516171819-

Torque Converter Housing Three Way Rubber Hose Pipe Distributor Cap (for 1st & 2nd) Elbow Adapter Rubber Hose

20212223242530-

Seal Retainer Elbow Adapter (2 used) Distributor Cap (for 3rd & 4th) Pipe Pipe Pipe Transmission Case

83- Drain Plug 84- O-Ring 116- Bolt (2 used) 120- Bolt* (8 used) 122- Bolt* (25 used) 129- Bolt (2 used) 130- Bolt (2 used)

fNOTE: Bolt*: Pre-assembled bolt and washer (SEMS)

W4-2-2-2

90Z6-W4-02-02-04

146- Bolt 147- Washer (5 used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

154

156

140, 138

28 148 137, 138 146 149

31 29

26272829-

Pipe Air Breather Suction Tube Strainer

139

90Z6-W4-02-02-03

30 30- Transmission Case 31- Rear Case 137- Bolt (5 used) 138- Washer, Spring (12 used)

139- Bolt* (19 used) 140- Bolt (7 used) 146- Bolt* (4 used) 148- Gasket

fNOTE: Bolt*: Pre-assembled bolt and washer (SEMS)

W4-2-2-3

149- O-Ring 154- Socket Bolt (27 used) 156- Connector (6 used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

34 32

36 38 39

124

40, 41 42

90Z6-W4-02-02-01a

43 44

125, 126

48 141 161 46 Cross Section A-A (Upper)

323334353637-

Torque Converter Assembly Ball Bearing Charging Pump Gear Charging Pump Shaft Ball Bearing Retaining Ring

383940414243-

Gear Bearing Spacer Retaining Ring Bearing Retaining Ring

444546474849-

Shaft Forward Clutch Assembly Idler Shaft Assembly Shim (2 used) Idler Cap Retainer

W4-2-2-4

90W4-02-02-06

124- Shaft 125- Bolt (9 used) 126- Washer (9 used) 141- Bolt (3 used) 161- Spacer

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

53, 54 55

90Z6-W4-02-02-01a

117

64 57

118

58 132 61 60

131

159

88 89

65 66 67 68 69

87 73

74 75

82 86

81 80 79 78 77

Cross Section A-A (Lower) 83, 84

17- Distributor Cap (for 1st & 2nd) 52- O-Ring 53- Steel Plate (Separation Disc) (EXP S/N 0101~: 7 used) (EU S/N 9001~: ? used) 54- Friction Disc (EXP S/N 0101~: 6 used) (EU S/N 9001~: ? used) 55- O-Ring 56- Piston Housing 57- Cap 58- Pin 60- Spring (22 used)

61636465666768697071727374-

Piston End Plate D-Ring D-Ring O-Ring Brake Housing Flange (2 used) O-Ring (2 used) Retainer Plate (2 used) Output Shaft Dust Cover Seal (2 used) O-Ring

75767778798081828384858687-

Bearing Spacer Gear Oil Baffle Gear Spacer Bearing Retaining Ring Drain Plug O-Ring Spacer O-Ring Bolt (8 used)

W4-2-2-5

W4GC-03-02-170a

88- Shim 89- 1st & 2nd Speed Clutch Assembly 117- Low Gear 118- Bearing 131- Disc Hub 132- Retaining Ring 159- Pin (2 used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 102 103

104

106 105

101

90W4-02-02-14

Cross Section E-E 90

90Z6-W4-02-02-01a

Cross Section B-B

90W4-02-02-09

172

93 Cross Section C-C

22- Distributor Cap (for 3rd & 4th) 90- Reverse Clutch Assembly 91- Bearing

93- 3rd&4th Clutch Assembly 101- Ball 102- Bearing

103- Reverse Gear 104- Spacer 105- Shaft

W4-2-2-6

90W4-02-02-10

106- Shim 172- High Gear

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

117

Cross Section D-D

90W4-02-02-13

90Z6-W4-02-02-01a

94 97

100 Cross Section F-F

6- Speed Sensor 94- Bracket 95- Ball

96- Spring 97- O-Ring 98- Plug

99- Spring Seat 100- Seat 117- Low Gear

W4-2-2-7

90W4-02-02-12

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit (Blank)

W4-2-2-8

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Drive Unit Draining Oil and Removing Charging Pump 1. Hoist the drive unit vertically or place it on a stand. 30

2. Remove drain plug (83) to drain oil. 83

l : 17 mm

90Z6-W4-02-02-04

Transmission Case Bottom View

dCAUTION: Drive unit weight: 900 kg (1985 lb) 3. Remove bolts (146) (4 used) from suction tube (28).

146

Remove gasket (148), ring (149), and suction strainer (29) from transmission case (30). j : 17 mm

28 148, 149

30 W4GC-03-02-007

4. Remove bolts (150) (8 used) from suction pipes (3) (2 used). Remove O-rings (151) (2 used) from suction pipes (3) (2 used).

150

j : 14 mm 5. Remove bolts (152) (2 used) and washers (153) (2 used) from charging pump (4).

150

j : 17 mm 3, 151

152, 153

145 90W4-02-02-16

W4-2-3-1

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 13

dCAUTION: Charging pump (4) weight: 11 kg (24.5 lb) 6. Remove charging pump (4) from torque converter housing (13) by tapping with a plastic hammer.

7. Remove pipes (1, 11, 16, 23, 24, 25, 26, and 170) from transmission case (30).

W4GC-03-02-009

j : 22 mm

j : 27 mm

90Z6-W4-02-02-09

W4-2-3-2

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9

Removing Control Valve

dCAUTION: Regulator valve (9) weight: 5.5 kg

154

(12.5 lb)

8. Remove pipe (107) from regulator valve (9) to housing case (13). j : 22 mm 9. Remove the upper two of socket bolts (154) (6 used) on regulator valve (9) and install the guide bolts (M8).

90W4-02-02-19

156

l : 6 mm

10. Remove regulator valve (9) from transmission case (30). 11. Remove connectors (156) (6 used) from control valve (10). j : 21 mm

d CAUTION: Control valve (10) weight: 21 kg (46.5 lb) 12. Remove the four socket bolts (154) at the corners of control valve (10) and install the guides (M8) (4 used).

W4GC-03-02-013 Guide

154 10

l : 6 mm 13. Remove the rest of socket bolts (154) (17 each). Remove control valve (10) from transmission case (30). l : 6 mm W4GC-03-02-012

W4-2-3-3

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removing Speed Sensor 14. Remove speed sensors (6) (4 used) from torque converter housing (13) and transmission case (30).

j : 27 mm 6

W4GC-03-02-014

W4-2-3-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installing Charging Pump

152, 153

f NOTE: Apply LOCTITE #5127 onto the mounting

surfaces. 1. Install charging pump (4) by aligning the charging pump (4) spline with the charging pump shaft (35) spline. 2. Install charging pump (4) to torque converter housing (13) with bolts (152) (2 used) and washers (153) (2 used). j : 17 mm

W4GC-03-02-218

m : 34 N·m (3.5 kgf·m, 25 lbf·ft) 30

3. Install oil strainer (29) to transmission case (30). Install O-ring (149) to the outer groove on transmission case (30). 29

149

90W4-02-05-11

4. Install suction tube (28) and gasket (148) to transmission case (30) with bolts (146) (4 used).

146

j : 17 mm m : 91.1 N·m (9.30 kgf·m, 67.2 lbf·ft)

30 148

5. Install O-rings (151) (2 used) to suction tubes (3) (2 used). Install suction tubes (3) (2 used) to charging pump (4) with bolts (150) (8 used).

90W4-02-05-12

4 150 13

j : 14 mm m : 19.5 N·m (2 kgf·m, 14.4 lbf·ft)

3, 151 152, 153 90W4-02-02-16

W4-2-3-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 6. Connect pipes (1, 11, 16, 23, 24, 25, 26, and 170) to transmission case (30).

j : 22 mm m : 49 N·m (5 kgf·m, 36 lbf·ft) 170

j : 27 mm

m : 93 N·m (9.5 kgf·m, 69 lbf·ft) 90W4-02-02-18

7. Install drain plug (83). j : 36 mm, or

111

l : 12.7 mm m : 140 N·m (14.3 kgf·m, 103 lbf·ft)

109 83

W4-2-3-6

90W4-02-05-14

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installing Control Valve

154

Guide

8. Install the gasket to the mating surface of control valve (10).

9. Install control valve (10) to transmission case (30) with socket bolts (154) (21 used). l : 6 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft)

f NOTE: Apply LOCTITE #572 onto the connector plug.

W4GC-03-02-012

10. Install the plug and O-ring to connectors (156) (6 used). Install connectors (156) (6 used) to control valve (10).

156

j : 21 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft)

11. Install the guide bolt to transmission case (30). Install the gasket for check valve (5), check valve (5), gasket for regulator valve (9), and regulator valve (9) to the guide bolt in order. Install socket bolts (154) to the bolt holes where no guide bolt (M8) is installed and install regulator valve (9) to transmission case (30). Remove the guide bolts (4 used) and tighten socket bolts (154) instead.

W4GC-03-02-013

154

l : 6 mm m : 9.8 N·m (1 kgf·m, 7.2 lbf·ft)

12. Install pipe (107) between regulator valve (9) and torque converter housing (13). 90W4-02-02-19

W4-2-3-7

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installing Speed Sensor 6

f NOTE: Apply LOCTITE #572 onto speed sensor (6). 13. Install speed sensors (6) (4 used) to transmission case (30). Attach speed sensor (6) to the gear and secure it at the position after 1 backward turnings. j : 27 mm

W4GC-03-02-165

W4-2-3-8

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal and Installation of Front Axle

90WNEC-04-03-02

1 90WNEC-04-03-01

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

90W4GB-03-03-102

2. Remove tires from front axle (1). (Refer to W4-1-1.) 3. Remove propeller shaft (2) from front axle (1). (Refer to W4-4-1.)

4. Remove nuts (3) (2 used) and bolts (4) (4 used). Remove guard (5). j : 12 mm j : 14 mm 5. Disconnect connector (6).

W4-3-1-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle

90Z6-W4-03-01-01

The accumulator is installed to the dCAUTION: brake circuit. Depress the brake pedal at least 50 strokes in order to release the accumulated pressure left in it.

7. Remove bolt (2) and bracket (3). j : 17 mm 8. Remove elbow adapters (4) (2 used). j : 24 mm

6. Disconnect the both ends of tubes (1) (2 used). j : 27 mm

W4-3-1-2

SECTION 4 TRAVEL SYSTEM Group 3 Axle

13 12

90W4GB-03-03-103

W4GB-03-03-104

9. Remove clip (12). Disconnect hose (13).

Front axle (1) assy weight: dCAUTION: 1330 kg (2932 lb) 10. Attach nylon slings onto the front axle (1) assembly. Hoist and hold the front axle (1) assembly.

W4-3-1-3

SECTION 4 TRAVEL SYSTEM Group 3 Axle

16 15 16

15 14 15 14 W4GB-03-03-105

11. Remove nuts (14) (8 used), washers (15) (16 used), and bolts (16) (8 used). j : 46 mm

W4GB-03-03-106

In case front axle (1) has been dCAUTION: removed for a long time, set a stand under the

axle fixed part of front chassis in order to keep the machine stable. IMPORTANT: Take care not to damage the sensor at the bottom of front axle (1). 12. Lower and remove the front axle (1) assembly. Remove the adapter if necessary.

W4-3-1-4

SECTION 4 TRAVEL SYSTEM Group 3 Axle

W4GB-03-03-106

1 W4GB-03-03-104

Installation 1. Place the front axle (1) assembly onto a stand. Set it under the mounting position of front chassis.

Front axle (1) assy weight: dCAUTION: 1330 kg (2932 lb) 2. Attach nylon slings onto the front axle (1) assembly. Hoist and hold the front axle (1) assembly.

W4-3-1-5

SECTION 4 TRAVEL SYSTEM Group 3 Axle

16 13

16 15 10 15

14 15

90W4GB-03-03-103

14 W4GB-03-03-105

3. Install the front axle (1) assembly with bolts (16) (8 used), washers (15) (16 used), and nuts (14) (8 used).

4. Connect hose (13) with clip (12).

j : 46 mm m : 1420 N·m (145 kgf·m, 1047 lbf·ft)

W4-3-1-6

m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 3 Axle

90Z6-W4-03-01-01

5. Install elbow adapters (4) (2 used).

7. Connect the both ends of tubes (1) (2 used).

j : 24 mm

j : 27 mm m : 80 N·m (8 kgf·m, 60 lbf·ft)

6. Install bracket (3) with bolt (2). j : 14 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-3-1-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle

8. Connect connector (6).

90W4GB-03-03-102

90WNEC-04-03-02

9. Install guard (5) with bolts (4) (4 used). j : 14 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 10. Fix wires from connectors (6) with nuts (3) (2 used). j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W4-3-1-8

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1 90WNEC-04-03-01

11. Install propeller shaft (2) to front axle (1). (Refer to W4-4-1.) 12. Install tires to front axle (1). (Refer to W4-1-1.) 13. Confirm that no oil leakage is observed at the brake system. Bleed air from the brake system. (Refer to T5-6 in the separated volume, T/M.)

W4-3-1-9

SECTION 4 TRAVEL SYSTEM Group 3 Axle (Blank)

W4-3-1-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal and Installation of Rear Axle

90M4GB-07-17

90Z6-W4-03-02-01

Removal The accumulator is installed to the dCAUTION: brake circuit. Depress the brake pedal at least

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

50 strokes in order to release the accumulated pressure left in it. 4. Disconnect hose (3) from rear axle (1).

2. Remove tires from rear axle (1). (Refer to W4-1-2.) 3. Remove propeller shaft (2) from rear axle (1). (Refer to W4-4-1.)

j : 27 mm 5. Remove clip (4) and disconnect hose (5).

W4-3-2-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle

90Z6-W4-03-02-02

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

W4-3-2-2

SECTION 4 TRAVEL SYSTEM Group 3 Axle

5 4 3

6 3

3 2 3 2

90W4GB-03-03-112

W4GB-03-03-111

CAUTION: Rear axle (1) assembly weight: 1540 kg (3395 lb) 7. Attach nylon slings onto the rear axle (1) assembly. Hoist and hold the rear axle (1) assembly.

8. Remove nuts (2) (10 used), washers (3) (20 used), plates (4) (2 used), plates (6) (2 used), bolts (5) (4 used), and bolts (7) (6 used).

W4-3-2-3

j : 46 mm

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1 2 3 1 3

W4GB-03-03-113

4 5

9. Lower and remove rear axle assembly (1).

fNOTE: Remove the adapters, if necessary.

90Z6-W4-03-02-03

10. Remove nuts (2) (2 used) and disconnect the both ends of tubes (3) (2 used). j : 12 mm j : 27 mm 11. Remove bolt (4). Remove bracket (5) from rear axle (1). j : 17 mm

W4-3-2-4

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1 2 3 1 3

W4GB-03-03-113

4 5

90Z6-W4-03-02-03

Installation 1. Place the rear axle (1) assembly onto a stand. Set it under the mounting position of rear chassis.

2. Install bracket (5) to rear axle (1) with bolt (4). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 3. Connect tubes (3) (2 used). Install nuts (2) (2 used) to rear axle (1). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) j : 12 mm m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

W4-3-2-5

SECTION 4 TRAVEL SYSTEM Group 3 Axle

5 4 3

6 3

3 2 3 2

90W4GB-03-03-112

W4GB-03-03-111

Rear axle (1) assembly weight: dCAUTION: 1540 kg (3395 lb) 4. Attach nylon slings onto the rear axle (1) assembly. Hoist and hold the rear axle (1) assembly.

5. Install rear axle (1) assembly with bolts (7) (6 used), bolts (5) (4 used), plates (6) (2 used), plates (4) (2 used), washers (3) (20 used), and nuts (2) (10 used). j : 46 mm m : 1420 N·m (145 kgf·m, 1047 lbf·ft)

W4-3-2-6

SECTION 4 TRAVEL SYSTEM Group 3 Axle

90Z6-W4-03-02-02

6. Connect pipes (1) (2 used). j : 17 mm

7. Apply grease. (Refer to the 90Z6 Operation & Maintenance Manual.)

m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

W4-3-2-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle

2 4

8. Connect hose (5) and fix with clip (4). m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft) 9. Connect hose (3). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft)

90M4GB-07-17 90Z6-W4-03-02-01

10. Install propeller shaft (2) to rear axle (1). (Refer to W4-4-1.) 11. Install tires to rear axle (1). (Refer to W4-1-1.) 12. Confirm that no oil leakage is observed at the brake system. Bleed air from the brake system. (Refer to the Shop Manual, Section T5-6.)

W4-3-2-8

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Axle Front Axle Assembly Differential (Front)

Housing

Housing 90Z7-W4-03-01

Rear Axle Assembly

Differential (Rear) Housing

Housing

101- Dust Seal (3 Used) 102- Bushing (2 Used) 103- Axle Support (Front) 104- Ring 105- Axle Support (Rear) 106- Bolt (6 Used) 107- Thrust Washer (2 Used)

108- Thrust Plate 109- Bolt (6 Used) 110- Cover 111- Washer (12 Used) 112- Plug (2 Used) 113- Bolt (6 Used)

90Z6-W4-03-03-01

W4-3-3-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle Axle Assembly

90WNEC-04-03-03

W4-3-3-2

SECTION 4 TRAVEL SYSTEM Group 3 Axle

123456101112131419202122232425262728-

Level Gauge Housing Pin (8 Used) Plug (4 Used) Case Air Bleeder Valve (2 Used) Drain Plug Bolt (48 Used) Washer (48 Used) Plug (2 Used) Brake Ring (2 used) Shim Bearing (2 Used) Brake Disc (4 Used) Brake Ring (2 Used) Ring Gear (2 Used) Brake Ring (2 Used) End Plate (2 Used) Pin (4 Used) D-Ring (2 Used) Brake Piston (2 Used)

293940414243444546476768697071727374759697-

D-Ring (2 Used) Spring (16 Used) Adapter (16 Used) Button Bolt (16 Used) Shaft (2 Used) Retaining Ring (4 Used) Disc Hub (2 Used) Bearing Retainer (2 Used) Bolt (24 Used) Washer (24 Used) Pin (16 Used) Lock Plate (2 Used) Adjusting Nut (2 Used) Planetary Carrier Assembly (2 Used) Bolt (2 Used) Bearing (2 Used) Axle Shaft (2 Used) Bearing (2 Used) Floating Seal (2 Used) Plug (4 Used) Temperature Sensor (Front Axle)

98- Packing (Front Axle) 113- Retainer (2 Used) 114- O-Ring (2 Used) 115- Bolt (12 Used)

Planetary Carrier Assembly (70)

90WNEC-04-03-05

85868788-

Planetary Carrier (2 Used) Retaining Ring (6 Used) Retainer Plate (2 Used) Steel Ball (6 Used)

89909192-

Thrust Washer (12 Used) Bearing (12 Used) Retaining Ring (12 Used) Planetary Gear (6 Used)

W4-3-3-3

93- Collar (6 Used) 94- Spacer (12 Used) 95- Planetary Shaft (6 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Axle Support (Rear Axle)

90Z6-W4-03-03-01

IMPORTANT: Remove plug (112) in order to drain grease. 5. Remove bolts (109) (6 used) and washers (111) (6 used). Remove cover (110).

Front Support (Front) (103) weight: dCAUTION: 100 kg (220 lb) 1. Remove bolts (106) (6 used). Take out ring (104) from support (103). 2. Attach nylon slings to support (103). Hoist and remove support (103) from the rear axle. 3. Remove bolts (106) (6 used), ring (104), dust seals (101) (2 used) and bushing (102) from support (103). 4. Attach nylon slings onto support (105). Hoist and hold support (105).

W4-3-3-4

j : 30 mm

SECTION 4 TRAVEL SYSTEM Group 3 Axle

90Z6-W4-03-03-01

6. Remove thrust washer (107) on cover (110) side. 7. Remove bolts (113) (6 used) and washers (111) (6 used). Remove thrust plate (108) and thrust washers (107) (2 used) on support (105) side. j : 30 mm

Rear Support (Rear) (105) weight: 145 dCAUTION: kg (320 lb) 8. Remove support (105) from the rear axle. 9. Remove dust seal (101) and bushing (102) from support (105).

W4-3-3-5

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Axle Removal of Housings (2) 5

11, 12 W4GB-03-03-004

Axle assembly weight: dCAUTION: TPD (Front/Rear): 1310/1240 kg (2890/2735 lb) LSD (Front/Rear): 1320/1250 kg (2910/2755 lb)

1. Place a container under case (5). Remove drain plug (magnet) (10) from case (5). Drain gear oil from case (5). l : 12.5 mm (box wrench)

fNOTE: Gear oil amount: 50 L (13 US gal)

Housing (2) assembly weight: dCAUTION: Front/Rear: 380 kg/330 kg (840 lb/730 lb) 2. Attach nylon slings onto the housing (2) assembly. Hoist and hold the housing (2) assembly. Place the housing (2) assembly on a stand. 3. Remove bolts (11)* and washers (12)* from housing (2). Amount of parts*: Front: 24 each Rear: 26 each j : Front: 24 mm j : Rear: 27 mm 4. Remove housing (2) from case (5). 5. Remove housing (2) on the opposite side in the same manner.

W4-3-3-6

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Housings (2)

73 ab-

90WNEC-04-03-14

Bolt Plate

Housing (2) assembly weight: dCAUTION: Front/Rear: 380 kg/330 kg (840 lb/730 lb) 6. Place the housing (2) assembly with the differential gear mounting side up. Secure axle shaft (73) with a firm plates and bolts. j : 36 mm

73 90WNEC-04-03-15

Housing (2) assembly weight: dCAUTION: Front/Rear: 300 kg/250 kg (660 lb/550 lb) 9. Remove axle shaft (73) from housing (2) by using a press.

fNOTE: You may sling housing (2) and remove axle shaft (73) by dropping it.

W4GB-03-03-007

Planetary carrier assembly (70) dCAUTION: weight: 82.5 kg (182 lb) 7. Attach nylon slings onto planetary carrier assembly (70). Remove bolt (71) from axle shaft (73). j : 41 mm 8. Hoist and remove planetary carrier assembly (70) from axle shaft (73) by using a pry bar. Remove shim (19) if any installed.

W4-3-3-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle 3

1 2

73 75 113

114 115 90Z7-W4-03-03

10. Remove floating seals (75) from housing (2) and retainer (113).

W4GB-03-03-011

dCAUTION: Ring gear (23) weight: 22 kg (49 lb) 14. When replacing ring gear (23), remove it from housing (2) by using a gear puller. Insert a plate into housing (2) and support the shaft of gear puller. At this time, take care not to lose pins (3) (4 used).

W4GB-03-03-010

11. Remove the inner race of bearing (74) from axle shaft (73) by using a bearing separator. 12. Remove socket bolts (115) (6 used) and remove retainer (113) from axle shaft (73). Remove O-ring (114) from retainer (113). l : 8 mm 13. Remove the outer race of bearings (72, 74) from housing (2) both at the differential gear side and wheel side. Remove the outer race of bearing by tapping the outer surface evenly.

W4-3-3-8

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Planetary Carrier Assembly (70) 90

86 85

W4GB-03-03-014

W4GB-03-03-012

15. Remove retaining ring (86) from planetary carrier (85).

18. Remove bearings (90) (2 used) and collar (93) from planetary gear (92). Remove retaining rings (91) (2 used).

16. Tap and remove planetary shaft (95) and steel ball (88) from the opposite side of planetary carrier (85).

19. Disassemble other planetary gears (92) (2 used) in the same way.

87 89 85 92

W4GB-03-03-013

W4GB-03-03-015

17. Remove the planetary gear (92) assembly, spacer (94), and thrust washer (89).

20. Remove retainer plate (87) from planetary carrier (85).

fNOTE: If spacer (94) and/or thrust washer (89) is reused,

fNOTE: If shim(s) (19) are used, remove them

put a match mark on it for assembling.

W4-3-3-9

beforehand.

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Brake

5 B 28

42 W4GB-03-03-017

W4GB-03-03-005

21. Remove end plate (25). Remove brake ring (24), brake disc (21), brake ring (22), brake disc (21), and brake ring (14) from case (5) in order. Remove pins (67) (8 used) from case (5).

24. Install the special tool (piston stopper) (B) with bolts (M16) (2 used) by using the housing (2) mounting surface of case (5). 25. Apply compressed air through the hydraulic pressure port slowly and remove brake piston (28) from case (5).

22. Remove shaft (42) assembly from side gear (38).

26. Remove D-rings (27, 29) from brake piston (28). 27. Remove the brake parts on the other side in the same manner.

43 44

28 W4GB-03-03-016

23. Remove 8 each of button bolts (41), adapters (40), and springs (39) from brake piston (28). l : 6 mm

W4GB-03-03-006

28. Remove retaining ring (43) from shaft (42) assembly. Remove disc hub (44) from the spline part of shaft (42).

W4-3-3-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Differential Case Assembly 5

46 26

67 45

W4GB-03-03-022

90Z7-W4-03-04

31. Install two of bolts (46), which removed at the previous step, to the screw holes for puller of bearing retainer (45). Tighten them evenly. Remove bearing retainer (45).

Differential case assembly weight: dCAUTION: TPD/LSD: 91 kg/98 kg (205 lb/220 lb) 29. Attach the nylon slings onto the differential case assembly. Hoist and hold the differential case assembly.

j : 19 mm

30. Remove 12 each of bolts (46) and washers (47), and lock plate (68) from bearing retainer (45). j : 19 mm

32. Remove adjusting nut (69) from bearing retainer (45). Remove the outer race of bearing (20) at the opposite side. 33. Remove bearing retainer (45) at the opposite side in the same manner.

W4GB-03-03-023

When removing and installing the dCAUTION: differential case assembly, take care not to touch the inner race of bearing (20) with case (5).

34. Remove the differential assembly from case (5).

W4-3-3-11

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Case Assembly Refer to the following section W4-3-4 for the disassembly of the differential assembly.

W4-3-3-12

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Bearing Cage Assembly

17, 18

8, 9

Arrow View A

F: 8, 9 R: 99,100

90Z7-W4-03-05

35. Remove 28 each of bolts (17) and washers (18). Remove cover (16) from case (5).

Thread part for pullers

W4GB-03-03-018

39. Install bolts (8, front axle) (99, rear axle), removed in the previous step, to the thread part (C) for pullers of bearing cage (62). Tighten bolts (8) evenly and remove bearing cage (62), pinion gear (57), and shim (64).

j : 19 mm 36. Record gear teeth contact condition and backlash of ring gear (33). The bearing cage (62) assembly dCAUTION: weight: Front/rear: 45 kg/49 kg (99 lb/108 lb)

j : 24 mm

Disassembly of Bearing Cage (62) Assembly

37. Attach nylon slings onto the bearing cage (62) assembly. Hoist and hold the bearing cage (62) assembly.

Refer to the following section W4-3-4 for the assembly of the differential case assembly.

38. Remove bolts (8) (14 used) and washers (9) (14 used) from bearing cage (62) in case of the front axle. Remove bolts (99) (16 used) and washers (100) (16 used) from bearing cage (62) in case of the rear axle. j : 24 mm

W4-3-3-13

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Axle 4 1

11, 12 13

97, 98

8, 9

15 16 17, 18

Arrow View A 90WNEC-04-03-06 1234568-

Level Gauge Housing Pin (8 Used) Plug (4 Used) Case Air Bleeder Valve (2 Used) Bolt (Front Axle) (14 Used) Bolt (Rear Axle) (16 Used)

9101112131516-

Washer (Front Axle) (14 Used) Washer (Rear Axle) (16 Used) Drain Plug Bolt (48 Used) Washer (48 Used) Plug (2 Used) Plug Cover

W4-3-3-14

1718969798-

Bolt (28 Used) Washer (28 Used) Plug (4 Used) Temperature Sensor (Front Axle Only) Packing (Front Axle Only)

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Axle equipped with TPD Differential Assembly

71 23 25 26 27 113

87 44

115

114

73 72

69 67 24

46, 47

fNOTE: Refer to the following section W4-3-4 for the detail of the differential assembly.

141920212223242526272829-

Brake Ring (2 Used) Shim Bearing (2 Used) Brake Disc (4 Used) Brake Ring (2 Used) Ring Gear (2 Used) Brake Ring (2 Used) End Plate (2 Used) Pin (4 Used) D-Ring (2 Used) Brake Piston (2 Used) D-Ring (2 Used)

90W4GB-03-03-83

394041424344454647676869-

Spring (16 Used) Adapter (16 Used) Button Bolt (16 Used) Shaft (2 Used) Retaining Ring (4 Used) Disc Hub (2 Used) Bearing Retainer (2 Used) Bolt (24 Used) Washer (24 Used) Pin (16 Used) Lock Plate (2 Used) Adjusting Nut (2 Used)

W4-3-3-15

70- Planetary Carrier Assembly (2 Used) 71- Bolt (2 Used) 72- Bearing (2 Used) 73- Axle Shaft (2 Used) 74- Bearing (2 Used) 75- Floating Seal (2 Used) 87- Retainer Plate (2 Used) 113- Retainer (2 Used) 114- O-Ring (2 Used) 115- Bolt (12 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Axle equipped with LSD Differential Assembly

23 19

25 26

27 28 29

75 74

44 73

67 24

46, 47

fNOTE: Refer to the following section W4-3-4 for the detail of the differential assembly.

1920212223242526272829-

Shim Bearing (2 Used) Brake Disc (4 Used) Brake Ring (2 Used) Ring Gear (2 Used) Brake Ring (2 Used) End Plate (2 Used) Pin (4 Used) D-Ring (2 Used) Brake Piston (2 Used) D-Ring (2 Used)

92W4GB-03-03-002 3940414243444546476768-

Spring (16 Used( Adapter (16 Used) Button Bolt (16 Used) Shaft (2 Used) Retaining Ring (4 Used) Disc Hub (2 Used) Bearing Retainer (2 Used) Bolt (24 Used) Washer (24 Used) Pin (16 Used) Lock Plate (2 Used)

W4-3-3-16

6970717273747587-

Adjusting Nut (2 Used) Planetary Carrier Assembly (2 Used) Bolt (2 Used) Bearing (2 Used) Axle Shaft (2 Used) Bearing (2 Used) Floating Seal (2 Used) Retainer Plate (2 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Planetary Carrier Assembly (70)

90 91

89 95

90W4GB-03-03-03

85868788-

Planetary Carrier (2 Used) Retaining Ring (6 Used) Retainer Plate (2 Used) Steel Ball (6 Used)

89909192-

Thrust Washer (12 Used) Bearing (12 Used) Retaining Ring (12 Used) Planetary Gear (6 Used)

W4-3-3-17

93- Collar (6 Used) 94- Spacer (12 Used) 95- Planetary Shaft (6 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Differential Case

Installation of Bearing Cage Assembly

Refer to the following section W4-3-4 for the assembly of the differential case assembly.

9 8

Assembly of Bearing Cage Assembly Refer to the following section W4-3-4 for the assembly of bearing cage (62) assembly.

W4GB-03-03-050

1. Install shim (64) between case (5) and bearing cage (62). The bearing cage (62) assembly dCAUTION: weight: Front/rear: 45 kg/49 kg (99 lb/108 lb) 2. Attach nylon slings onto the bearing cage (62) assembly. Hoist and hold the bearing cage (62) assembly. 3. Temporarily install bearing cage (62) assembly to case (5) with 4 each of bolts (8) and washers (9). j : 24 mm m : 225 N·m (23 kgf·m, 166 lbf·ft)

fNOTE: Secure bearing cage (62) assembly after installing the differential assembly.

W4-3-3-18

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Differential Case

33 5

W4GB-03-03-047

4. Install the outer races (2 used) of bearing (20) to bearing retainers (45) (2 used). 5. Turn adjusting nut (69) until it touches the outer race of bearing (20).

W4GB-03-03-048

Differential case assembly weight: dCAUTION: TPD/LSD: 91 kg/98 kg (205 lb/220 lb) IMPORTANT: When removing and installing the differential case assembly, take care not to touch the inner race of bearing (20) with case (5). 6. Attach nylon slings onto the differential case assembly. Hoist and hold the differential case assembly. 7. Fit the differential case assembly to the notch of ring gear (33). Install it to case (5). 8. Apply LOCTITE #262 onto bolts (46) (12 used).

W4-3-3-19

SECTION 4 TRAVEL SYSTEM Group 3 Axle

Adjustment of Ring Gear Backlash and Adjustment of Ring Gear Teeth Engagement

46 45 W4GB-03-03-049

9. Support the differential case assembly and install bearing retainers (45) (2 used) to case (5) with bolts (46) (12 used) and washers (47) (12 used).

W4GB-03-03-053

11. Install a dial gauge to the tooth outer end of ring gear (33).

j : 19 mm m : 98 N·m (10 kgf·m, 72 lbf·ft)

W4GB-03-03-052

10. Secure adjusting nuts (69) (2 used) with lock plates (68) (2 used), bolts (46) (2 used), and washers (47) (2 used).

fNOTE: Go to step 11 for the adjustment of ring gear backlash and teeth engagement.

W4GB-03-03-054

12. Secure pinion gear (57), turn ring gear (33) forward and backward, and measure backlash. 13. If backlash is bigger than the standard value, loosen adjusting nut (69) at the differential case B (36) side, tighten adjusting nut (69) at the differential case A (32) side, and move ring gear (33) to pinion gear (57). If backlash is small, adjust it in the contrary way.

fNOTE: Ring gear (33) backlash: 0.31 to 0.40 mm (0.012 to 0.016 in)

W4-3-3-20

SECTION 4 TRAVEL SYSTEM Group 3 Axle A. Normal Engagement Normal engagement of the tooth surface is 40 % or more around the center of the tooth. The adjustments of (B) to (E) are the checking method for the convexity of the teeth. Be careful as the engagement is reverse for the concave side.

a d

b c

W4GB-03-03-055 ab-

Tow Part (Small End) Face

cd-

Flank Heel Part (Big End)

14. Apply a film of red lead primer onto 3 to 4 teeth of ring gear (33). Turn ring gear (33) forward and backward by hand and check engagement of teeth. 15. For adjustment of engagement of teeth, refer to (A) to (E) in the following. After adjusting engagement of teeth, check backlash again.

W4GB-03-03-056

B. Contact of Tow Part For adjustment, loosen adjusting nut (69) at the differential case A (32) side, tighten adjusting nut (69) at the differential case B (36) side, and move ring gear (33) away from pinion gear (57). Next, reduce the thickness of shim (64) of bearing cage (62) and move pinion gear (57) close to ring gear (33).

W4GB-03-03-057

W4-3-3-21

SECTION 4 TRAVEL SYSTEM Group 3 Axle C. Contact of Heel Part

E. Contact of Flank Part

For adjustment, loosen adjusting nut (69) at the differential case B (36) side, tighten adjusting nut (69) at the differential case A (32) side, and move ring gear (33) close to pinion gear (57). Next, increase the thickness of shim (64) of bearing cage (62) and move pinion gear (57) away from ring gear (33).

For adjustment, increase the thickness of shim (64) of bearing cage (62) and move pinion gear (57) away from ring gear (33). Next, loosen adjusting nut (69) at the differential case B (36) side, tighten adjusting nut (69) at the differential case A (32) side, and move ring gear (33) close to pinion gear (57).

57 57

W4GB-03-03-058

D. Contact of Face Part For adjustment, reduce the thickness of shim (64) of bearing cage (62) and move pinion gear (57) close to ring gear (33). Next, loosen adjusting nut (69) at the differential case A (32) side, tighten adjusting nut (69) at the differential case B (36) side, and move ring gear (33) away from pinion gear (57).

W4GB-03-03-059

W4-3-3-22

W4GB-03-03-060

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Bearing Cage Assembly

9 8

62 ST 7791

W4GB-03-03-051

W4GB-03-03-050

16. Remove 4 each of bolts (8) with which bearing cage (62) assembly was temporarily installed (at step 3). Apply LOCTITE #262 to bolts (8). Install bearing cage (62) assembly to case (5) with bolts (8)* and washers (9)*.

17. Tighten adjusting nuts (69) on both sides by using the special tool (ST 7791).

Amount of parts*: Front axle: 14 each Rear axle: 16 each j : 24 mm m : 225 N·m (23 kgf·m, 166 lbf·ft)

W4-3-3-23

m : 120 N·m (12 kgf·m, 88.5 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Adjustment of Brake Disc Clearance If the clearance of brake disc is not dCAUTION: correct, the performance of service brake may be reduced and the service brake may be broken.

 Large clearance: The performance of service brake is reduced.  Small clearance: The early wear and seizure of brake disc may occur.

28 x c

WNEC-04-03-016

Detail of A

WNEC-04-03-017

For adjustment of clearance (x) of brake disc, measure dimensions (a, b, and c) inside the axle and combine twotype brake ring (14, 24) on the thickness.

fNOTE: Reference value (x): 1.3 ~ 1.8 mm (0.05 ~ 0.07 in) fNOTE: Thickness of brake ring (24): 6.5 mm (026 in) Thickness of brake ring (14): 6.9 mm (0.27 in)

fNOTE: Either combine one each of these two different brake rings, or use two each of the same brake ring.

W4-3-3-24

SECTION 4 TRAVEL SYSTEM Group 3 Axle 5 ST 7880

WNEC-04-03-020

WNEC-04-03-018

dCAUTION: Special tool (ST 7880) weight: 20 kg 15. Measure dimension (b) (1 place) between the brake piston (28) mounting part and the housing (2) end surface of case (5). Record it.

17. Set end plate (25), brake rings (24) (6.5 mm, 6.9 mm, 0.26 in, 0.27 in), brake discs (21) (2 used), brake ring (22), and brake piston (28). Place the special tool (ST 7880) onto the piled parts including the brake disc. Measure dimension (c) (1 place). Record it. 18. Calculate clearance (x) of the brake disc in the following formula.

Clearance (x) (calculated value) of brake disc = a + b - c (unit: mm, in) 19. If clearance (x) (calculated value) of the brake disc is not within the standard, change combination of brake rings (24) (2 used).

(1) If clearance (x) (calculated value) of the brake disc is 1.3 mm (0.051 in) or more and 1.8 mm (0.071 in) or less, select the original combination of brake rings (24) (2 used).

23 WNEC-04-03-019

16. Measure dimension (a) (4 place toward circumference of a circle) between the housing (2) end surface and the ring gear (23) end surface with ring gear (23) attached to housing (2). Calculate the mean value and record it.

(2) If clearance (x) (calculated value) of the brake disc is less than 1.3 mm (0.051 in), change the combination and select brake rings (24) (6.5 mm, 0.26 in) (2 used). (3) If clearance (x) (calculated value) of the brake disc is over 1.8 mm (0.071 in), change the combination and select brake rings (24) (6.9 mm, 0.27 in) (2 used).

fNOTE: Refer to W4-3-3-30 for installation of ring gear (23).

fNOTE: Clearance (x) (standard) of brake disc: 1.3 mm (0.051 in) (lower limit), 1.8 mm (0.071 in) (upper limit)

20. Record clearance (x) (calculated value) of the brake disc and the combination of brake rings (24) (2 used). 21. Adjust the clearances (4 places) of all brake discs for front and rear axles.

W4-3-3-25

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Brake

ST 7790

5 (7)

27, 29 28 a-

W4GB-03-03-061

Thrust Bolt (M16, Pitch 2.0 mm (0.08 in), Thread part length: 50 mm (1.97 in) or more)

W4GB-03-03-016

24. Apply LOCTITE #262 onto button bolt (41). Install 8 each of springs (39), adapters (40), and button bolts (41) to case (5) through the piston hole of brake piston (28).

Use the parts which are used dCAUTION: for adjustment of brake disc clearance when

installing the brake. 22. Install D-rings (27, 29) to the groove of the outer surface of brake piston (28). Apply grease onto D-rings (27, 29).

l : 6 mm m : 49 N·m (5 kgf·m, 36 lbf·ft)

23. Install brake piston (28) to case (5) (brake housing (7)) by using the special tool (ST 7790).

25. Install retaining ring (43), disc hub (44), and retaining ring (43) to shaft (42) in sequence. At this time, install disc hub (44) with the side with lug directed to small spline.

W4-3-3-26

SECTION 4 TRAVEL SYSTEM Group 3 Axle 5

67 21 24 W4GB-03-03-062

W4GB-03-03-063

26. Install shaft (42) to the spline of side gear (38) in case (5).

31. Install other pins (67) (6 used) by using a plastic hammer.

Select the thickness of brake ring (24) dCAUTION: which has been selected for adjustment of brake

32. Install the brake at opposite side in the same way.

disc clearance.

27. Install two pieces of pins (67) (8 used) to the bottom of case (5). Then, install brake ring (24). 28. Install brake disc (21) to the spline of disc hub (44). Install brake ring (22). 29. Install second brake disc (21) so that the open hole fits to that of first brake disc (21). Select the thickness of brake ring (24) dCAUTION: which has been selected for adjustment of brake disc clearance. 30. Install brake ring (24) and end plate (25) to case (5).

W4-3-3-27

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Housings (2) 3

1 2

113 Tool (K)

75 113

90W4GB-03-03-64

114 115 90Z7-W4-03-03

Housing (2) weight: dCAUTION: Front/Rear: 190 kg/150 kg (420 lb/335 lb) dCAUTION: Ring gear (23) weight: 21 kg (49 lb)

Tool (K)

33. When ring gear (23) has been replaced, install ring gear (23) to housing (2) by using a press or a plastic hammer. Install pins (3) (4 used). 34. Install O-ring (114) in the groove of retainer (113). Apply grease to socket bolts (115) (6 used). Install retainer (113) to axle shaft (73) with socket bolts (115) (6 used). l : 8 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

73 92W4GB-03-03-64

35. Place axle shaft (73) with the wheel mounting side down. Install floating seal (75) to retainer (113) by using the special tool (K) 36. Place housing (2) with the wheel mounting side up. Install the outer race of bearing (74) to housing (2).

W4-3-3-28

SECTION 4 TRAVEL SYSTEM Group 3 Axle

Tool (H)

Tool (L)

73 2

90W4GB-03-03-65

W4GB-03-03-065

38. Install the inner race of bearing (74) to axle shaft (73) by using the special tool (H).

Tool (L)

Housing (2) assembly weight: dCAUTION: Front/Rear: 215 kg/170 kg (475 lb/375 lb) 39. Sling housing (2) with the differential mounting side up, and install it onto the standing axle shaft (73) as shown.

75 2

92W4GB-03-03-65

37. Install floating seal (75) to housing (2) by using the special tool (L). IMPORTANT: When installing the O-ring of floating seal (75), apply a highly-volatile detergent and do not use grease. After installing floating seal (75), apply gear oil to the seal sliding surface.

73 WNEC-04-03-022

40. Turn over housing (2). Hoist housing (2) with the differential gear side up. Install housing (2) to axle shaft (73) by using a press. 41. Install the outer race of bearing (72) to housing (2). 42. Assemble the opposite side housing (2) in the same manner. Housing (2) assembly weight: dCAUTION: Front/Rear: 380 kg/330 kg (840 lb/730 lb)

W4-3-3-29

SECTION 4 TRAVEL SYSTEM Group 3 Axle Preload Adjustment of Axle Shaft Bearing (Shim Adjustment)

W4GB-03-03-067 W4GB-03-03-066

Planetary carrier (85) weight: 47 kg dCAUTION: (104 lb) 43. Install the inner race of bearing (72) to axle shaft (73). Attach nylon slings onto planetary carrier (85). Hoist and hold planetary carrier (85). In order to adjust preload, install planetary carrier (85) without installing the gear to axle shaft (73).

Y-

Level Difference

45. Loosen bolt (71) and remove retainer plate (87). Measure level difference (Y) between the axle shaft (73) end surface and planetary carrier (85). Select a shim (19) which is 0.03 to 0.10 mm (0.001 to 0.004 in) thicker than level difference (Y). j : 41 mm 71

44. Install retainer plate (87) to planetary carrier (85). Tighten bolt (71) and push the inner race of bearing (72) in axle shaft (73). At this time, turn housing (2).

87 19

85 72

j : 41 mm m : 320 N·m (32 kgf·m, 236 lbf·ft)

115

2 73

90Z7-W4-03-07

46. Install selected shim (19) and retainer plate (87) to the end of axle shaft (73) with bolt (71). j : 41 mm m : 320 N·m (32 kgf·m, 236 lbf·ft)

W4-3-3-30

SECTION 4 TRAVEL SYSTEM Group 3 Axle

W4GB-03-03-068

47. Attach a spring balance onto pin (26) of housing (2). Measure rotation resistance of the bearing by pulling the top of mounting pitch circle. If measured value is out of 20 to 39 N (2 to 4 kgf, 4.5 to 8.8 lbf ), adjust with shim (19) again. If the value is small, reduce the thickness of shim (19). If the value is big, increase the thickness. Planetary carrier (85) weight: 47 kg dCAUTION: (104 lb) 48. Attach nylon slings onto planetary carrier (85). Hoist and hold planetary carrier (85). Remove bolt (71). Remove retainer plate (87), shim (19), and planetary carrier (85). j : 41 mm

W4-3-3-31

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly and Installation of Planetary Carrier Assembly (70) 88

94 91 92

W4GB-03-03-069

90W4GB-03-03-71

52. Install planetary gear (92) between spacers (94) and thrust washer (89).

85 95 W4GB-03-03-070

49. Install retaining rings (91) (2 used) to planetary gear (92). IMPORTANT: When installing the outer race of bearing (90), do not push it to retaining ring (91) too strongly. 50. Install the outer race of bearings (90) (2 used) to both sides of planetary gear (92). Install collar (93) into the center of planetary gear (92). Install the inner race of bearing (90) to both sides.

W4GB-03-03-072

53. Install steel ball (88) to planetary shaft (95). Install planetary shaft (95) to planetary carrier (85).

51. Install thrust washers (89) (2 used) to planetary carrier (85). At this time, install stoppers of thrust washer (89) to the groove of the outer surface of planetary carrier (85).

W4-3-3-32

SECTION 4 TRAVEL SYSTEM Group 3 Axle

W4GB-03-03-073

W4GB-03-03-075

Planetary carrier assembly (70) dCAUTION: weight: 82.5 kg (182 lb) 56. Attach nylon slings onto planetary carrier assembly (70). Hoist and hold planetary carrier assembly (70). 57. Install shim (19) to axle shaft (73).

fNOTE: Use shim (19) which has been selected during

Arrow View S a-

Steel Ball Mounting Groove

"Preload Adjustment of Axle Shaft Bearing (Shim Adjustment)".

W4GB-03-03-074

IMPORTANT: Fit the notch of retaining ring (86) to the mounting groove for steel ball (88). 54. Install retaining ring (86) to planetary carrier (85). 55. Install retainer plate (87) to planetary carrier (85). Install other planetary gears (92) (2 used) to planetary carrier (85) in the same way.

58. Install planetary carrier assembly (70) to housing (2). 59. Apply LOCTITE #262 onto bolt (71). Install planetary carrier assembly (70) to axle shaft (73) with bolt (71). Install the planetary carrier assembly at the opposite side in the same way. j : 41 mm

fNOTE: After installing one piece of planetary gears (92) (3 used), install retainer plate (87). If installing two or more pieces of planetary gears (92), retainer plate (87) can not be installed.

m : 1590 N·m (162 kgf·m, 1170 lbf·ft) 60. Install planetary carrier assembly (70) to the opposite side of housing (2).

fNOTE: Align pin (3) to the groove of end plate (25) when installing end plate (25) to housing (2) of the rear axle.

W4-3-3-33

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Housing (2) 5 5

11, 12 42 2

W4GB-03-03-076

61. Apply LOCTITE #5127 onto the mating surface of case (5) and housing (2). Apply LOCTITE so that there is no bead missed on the inside of bolt-hole lines

W4GB-03-03-077

63. Apply LOCTITE #262 onto bolts (11). Install housing (2) to case (5) with bolts (11)* and washers (12)*. Amount of parts* and bolt tightening torque:

fNOTE: Bead width: 2 to 3 mm (0.079 to 0.12 in)

Front axle (24 each used) j : 24 mm

Housing (2) assembly weight: dCAUTION: Front/Rear: 380 kg/330 kg (840 lb/730 lb)

m : 225 N·m (23 kgf·m, 166 lbf·ft)

62. Attach nylon slings onto housing (2). Hoist and hold housing (2) assembly. Fit housing (2) to shaft (42), and align the bolt holes.

Rear axle (26 each used) j : 27 mm m : 490 N·m (50 kgf·m, 361 lbf·ft) 64. Install housing (2) at the opposite side in the same way.

W4-3-3-34

SECTION 4 TRAVEL SYSTEM Group 3 Axle

17,18

W4GB-03-03-079

65. Apply LOCTITE #572 onto drain plug (10). Install drain plug (10) to case (5).

W4GB-03-03-080

68. Install cover (16) to case (5) with 28 each of bolts (17) and washers (18).

j : 36 mm

j : 19 mm

66. Add oil to case (5). Verify that properly supplied at the level gauge.

fNOTE: Gear oil amount: 50 L (13 US gal)

W4GB-03-03-078

67. Apply LOCTITE #5127 onto the cover (16) mounting surface of case (5). Apply LOCTITE so that there is no bead missed on the inside of bolt-hole lines

W4-3-3-35

m : 90 N·m (9.2 kgf·m, 66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Axle Support (Rear Axle)

b a

111 113 112 105 101

107

102

105

108

Direction to Install

107 110

90WNEC-04-03-11 a-

109

111 90WNEC-04-03-12

Groove

IMPORTANT: Check the direction to install dust seal (101) and bushing (102). Insert bushing (102) till it touches to the stopper of axle support (105). 69. Apply grease onto the inner surface of bushing (102). Install bushing (102) and dust seal (101) to axle support (rear) (105).

fNOTE: Be careful of the installation direction of dust seal (101).

Axle Support (Rear) (105) weight: 140 dCAUTION: kg (310 lb)

71. Apply LOCTITE #262 onto bolts (109) (6 used). Install thrust washer (107) at the support (105) side. Install thrust plate (108) with bolts (113) (6 used) and washers (111) (6 used). Install thrust washer (107) at the cover (110) side. j : 30 mm m : 608 N·m (62 kgf·m, 448 lbf·ft) 72. Apply LOCTITE #262 onto bolts (109) (6 used). Install cover (110) with washers (111) (6 used) and bolts (109) (6 used). j : 30 mm

70. Attach nylon slings onto support (105). Hoist and hold support (105). Install axle support (rear) (105) to the rear axle.

m : 608 N·m (62 kgf·m, 448 lbf·ft) 73. Install plug (112).

W4-3-3-36

SECTION 4 TRAVEL SYSTEM Group 3 Axle

101 102 106 104

101 103 90WNEC-04-03-13

Dust Seal Installation Direction

IMPORTANT: Check the direction to install dust seals (101) (2 used) and bushing (102). Insert bushing (102) until it touches to the stopper of axle support (103). 74. Apply grease onto the inner surface of bushing (102). Install bushing (102), dust seal (101) on the support side to axle support (front) (103).

76. Apply grease onto the inner surface of bushing (102). Install ring (104) and dust seals (101) to axle support (front) (103) with bolts (106) (6 used).

fNOTE: Be careful of the installation direction of dust

seal (101).

j : 14 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

seal (101).

Axle Support (Front) (103) weight: 93 dCAUTION: kg (205 lb) 75. Attach nylon slings onto support (103). Hoist and hold support (103). Install axle support (front) (103) to the rear axle.

W4-3-3-37

SECTION 4 TRAVEL SYSTEM Group 3 Axle (Blank)

W4-3-3-38

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Torque Proportional Differential (TPD)

90WNEC-04-03-04 4589151617183031-

Plug (4 Used) Case Bolt (Front Axle) (13 Used) Washer (Front Axle) (13 Used) Plug Cover Bolt (28 Used) Washer (28 Used) Bolt (20 Used) Washer (20 Used)

32333435363738484950-

Differential Case A Ring Gear Bolt (12 Used) Washer (12 Used) Differential Case B Thrust Washer (2 Used) Side Gear (2 Used) Dowel Pin (4 Used) Spider Bearing

51525354555657585960-

Spacer Spacer Bearing Dust Cover Oil Seal O-Ring Pinion Gear Shim Bolt Washer

W4-3-4-1

61- Flange 62- Bearing Cage 63- O-Ring 64- Shim 65- Pinion (4 Used) 66- Thrust Washer (4 Used) 99- Bolt (Rear Axle) (14 Used) 100- Washer (Rear Axle) (14 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Limited Slip Differential (LSD)

90WNEC-04-03-23 893031335051525354-

Bolt (Front Axle) (13 Used) Washer (Front Axle) (13 Used) Bolt (20 Used) Washer (20 Used) Ring Gear Bearing Spacer Spacer Bearing Dust Cover

55565758596061636476-

Oil Seal O-Ring Pinion Gear Shim Bolt Washer Flange O-Ring Shim Differential Case A

W4-3-4-2

7778798081828384-

Differential Case B Pressure Ring (2 Used) Side Gear (2 Used) Plate (4 Used) Disc (4 Used) Plate (2 Used) Spider Pinion (4 Used)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Bearing Cage Assembly

fNOTE: Refer to the previous section W4-3-3 for the removal of bearing cage (62) assembly.

90Z7-W4-03-06

1. Place bearing cage (62) onto a stand with the flange (61) side up. 2. Remove bolt (59) and washer (60) from flange (61).

4. Remove flange (61) from pinion gear (57). 5. Remove dust cover (54) and shim (58) from flange (61).

j : 30 mm 3. Remove O-ring (56).

W4-3-4-3

SECTION 4 TRAVEL SYSTEM Group 3 Axle

57 62

W4GB-03-03-019

W4GB-03-03-020

6. Remove pinion gear (57) from bearing cage (62) by using a press.

8. Remove the inner race of bearing (50) from pinion gear (57) by using a separator.

7. Remove spacers (51, 52) from pinion gear (57).

9. Remove oil seal (55) from bearing cage (62). 10. Remove the inner race of bearing (53) from bearing cage (62). 11. Remove the outer races of bearings (50, 53) from bearing cage (62) by tapping each outer surface evenly. 12. Remove O-ring (63) from bearing cage (62).

W4-3-4-4

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Case Assembly (TPD)

fNOTE: Refer to the previous section W4-3-3 for the removal of differential case assembly.

30, 31 33

49 W4GB-03-03-026

W4GB-03-03-024

Differential case (TPD) weight: dCAUTION: A (32): 30 kg (66 lb), B (36): 13 kg (29 lb)

dCAUTION: Ring gear (33) weight: 23 kg (51 lb) dCAUTION: Do not drop ring gear (33).

5. Tap the center of spider (49) and remove differential case A (32) from differential case B (36).

1. Remove bolts (30) (24 used) and washers (31) (24 used) from differential case A (32). j : 24 mm 2. Remove ring gear (33) from differential case A (32).

6. Remove side gears (38) (2 used), spider (49), pinions (65) (4 used), thrust washers (37) (2 used), and thrust washers (66) (4 used) from differential case B (36) and differential case A (32).

34, 35 20

36 36

32 W4GB-03-03-025

W4GB-03-03-027

3. Put the matching marks at the jointed part between differential case B (36) and differential case A (32).

7. Remove the inner race of bearing (20) from differential case B (36) and differential case A (32) by using a bearing puller.

4. Remove 12 each of bolts (34) and washers (35) from differential case B (36). j : 22 mm

W4-3-4-5

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Case Assembly (LSD)

fNOTE: Refer to the previous section W4-3-3 for the removal of differential case assembly.

76 33 30, 31

76 77

E-

Pulling-Out Bolt Hole

W4GB-03-03-029

W4GB-03-03-028

3. Put the matching marks at the jointed part between differential case A (76) and differential case B (77).

dCAUTION: Ring gear (33) weight: 23 kg (51 lb) dCAUTION: Do not drop ring gear (33).

Differential case (LSD) weight: dCAUTION: A (76): 15 kg (33 lb), B (77): 27 kg (60 lb)

1. Remove bolts (30) (24 used) and washers (31) (24 used) from differential case A (76). 2. Remove ring gear (33) from differential case A (76). j : 24 mm

4. Install bolts (M10, Pitch 1.5 mm) (2 used) to pullingout bolt holes (E) (2 places) of differential case A (76). Tighten them evenly and remove differential case A (76) from differential case B (77). j : 17 mm

W4GB-03-03-030

5. Remove plate (82), plates (80) (2 used), discs (81) (2 used), pressure ring (78), and side gear (79) from differential case B (77).

W4-3-4-6

SECTION 4 TRAVEL SYSTEM Group 3 Axle

84 20

W4GB-03-03-032 W4GB-03-03-031

6. Remove spider (83) and pinions (84) (4 used) from differential case B (77). 7. Remove the rest of gear (79), pressure ring (78), discs (81) (2 used), plates (80) (2 used), and plate (82).

W4GB-03-03-040

8. Remove the inner race of bearing (20) from differential case B (77)and from differential case A (76) by using a bearing puller.

W4-3-4-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Differential Torque Proportional Differential (TPD) 30, 31

32 36 65 66 38 37

34, 35

48 49 57 64 52 62 53 54 56

63 51 55

303132333435363738484950-

Bolt (20 Used) Washer (20 Used) Differential Case A Ring Gear Bolt (12 Used) Washer (12 Used) Differential Case B Thrust Washer (2 Used) Side Gear (2 Used) Dowel Pin (4 Used) Spider Bearing

515253545556575859606162-

Spacer Spacer Bearing Dust Cover Oil Seal O-Ring Pinion Gear Shim Bolt Washer Flange Bearing Cage

W4-3-4-8

60 63646566-

O-Ring Shim Pinion (4 Used) Thrust Washer (4 Used)

90W4GB-03-03-83

SECTION 4 TRAVEL SYSTEM Group 3 Axle Limited Slip Differential (LSD)

30, 31 76 33

77 78 79 81 80

50 51 52 53

64 63 62 54

Bolt (20 Used) Washer (20 Used) Ring Gear Bearing Spacer Spacer Bearing Dust Cover Oil Seal O-Ring

5758596061626364-

61 60

30313350515253545556-

Pinion Gear Shim Bolt Washer Flange Bearing Cage O-Ring Shim

W4-3-4-9

58 57

767778798081828384-

Differential Case A Differential Case B Pressure Ring (2 Used) Side Gear (2 Used) Plate (4 Used) Disc (4 Used) Plate (2 Used) Spider Pinion (4 Used)

92W4GB-03-03-002

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Differential Case Assembly (TPD) Differential case A (32) weight: 30 kg dCAUTION: (66 lb) 1. Install the inner race of bearing (20) to differential case A (32) by using a press or a plastic hammer.

37 32 32 36 W4GB-03-03-035

W4GB-03-03-033

2. Turn over differential case A (32). After checking dowel pins (48) (2 used), fit the hole positions (2 places) of thrust washer (37) to dowel pin (48). Install thrust washer (37) to differential case A (32). 3. Install side gear (38) to differential case A (32).

Differential case B (36) weight: 13 kg dCAUTION: (29 lb) 5. Install the inner race of bearing (20) to differential case B (36) by using a press or a plastic hammer. 6. Turn over differential case B (36). After checking dowel pins (48) (2 used), apply grease onto thrust washer (37). Install thrust washer (37) to differential case B (36). 7. Fit side gear (38) to pinion (65) of differential case A (32). Align the matching marks put while disassembling and install differential case B (36) to differential case A (32). Tap differential case B (36) and differential case A (32) by using a plastic hammer so that each case surface contacts each other. 8. Apply LOCTITE #262 onto the thread part of bolts (34).

W4GB-03-03-034

4. Engage side gear (38) with spider (49) with pinions (65) (4 used) and thrust washers (66) (4 used) attached.

9. Install differential case B (36) to differential case A (32) in diagonal order with 12 each of bolts (34) and washers (35). j : 22 mm m : 150 N·m (15 kgf·m, 111 lbf·ft)

fNOTE: Fit spider (49) to the mounting hole of

differential case A (32) by using a plastic hammer.

W4-3-4-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle

32 30, 31 32

33 W4GB-03-03-037

W4GB-03-03-036

dCAUTION: Ring gear (33) weight: 23 kg (51 lb) Differential case A (32) weight: 30 kg dCAUTION: (66 lb) 10. Install ring gear (33) to differential case A (32) with the gear surface up. Fit ring gear (33) to the flange surface of differential case A (32) by using a plastic hammer. Temporary tighten bolts (30) (2 used) and washers (31) (2 used) from the bottom side of differential case A (32).

11. Turn over the differential case A (32) assembly. Apply LOCTITE #262 onto the thread part of bolts (30) (24 used). Install ring gear (33) with bolts (30) (24 used) and washers (31) (24 used). j : 24 mm m : 225 N·m (23 kgf·m, 166 lbf·ft)

fNOTE: Refer to the previous section W4-3-3 for the installation of differential case assembly.

j : 24 mm

W4-3-4-11

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Differential Case (LSD)

dCAUTION: Differential case A (76) weight: 15 kg (33 lb) Differential case B (77) weight: 27 kg (60 lb)

1. Install the inner race of bearing (20) to differential case A (76) and differential case B (77) by using a press or a plastic hammer.

84 83

W4GB-03-03-030

6. 77

Install pressure ring (78) to differential case B (77). Install disc (81), plate (80), disc (81), and plate (80) in order. Install discs (81) to side gear (79) by fitting the spline part.

fNOTE: Align the groove on the inner peripheral of two discs (81) in phase.

W4GB-03-03-031

2. Install plate (82), plate (80), disc (81), plate (80), disc (81), and pressure ring (78) to differential case B (77) in order.

fNOTE: Install the grooved surface of plate (82) to the side gear (79) side.

fNOTE: Align the groove on the inner peripheral of two discs (81) in phase.

3. Install side gear (79) to disc (81) by fitting the spline part. W4GB-03-03-039

4. Fit the spider (83) assembly with pinions (84) (4 used) attached to side gear (79), and install the spider (83) assembly to differential case B (77).

NOTE: Engage pinion (84) with side gear (79) by using a plastic hammer.

7. Apply grease onto plate (82). Install plate (82) to differential case A (76).

fNOTE: Install the grooved surface of plate (82) to the side gear (79) side.

5. Install side gear (79) being engaged with pinion gear (84).

W4-3-4-12

SECTION 4 TRAVEL SYSTEM Group 3 Axle

76 33 30, 31 77

F-

Bolt for Temporary Installation

8. Turn over differential case A (76). Align the matching marks put while disassembling and temporarily install differential case A (76) to differential case B (77) with bolts (F) (M10, Pitch 1.5 mm) (2 used). j : 17 mm

11. Turn over the differential case assembly. 12. Remove bolts (F) (M10, Pitch 1.5 mm) (2 used) installed in step 8. 13. Apply LOCTITE #262 onto the thread part of bolts (30) (24 used). Install ring gear (33) with bolts (30) (24 used) and washers (31) (24 used).

30, 31

W4GB-03-03-042

W4GB-03-03-040

j : 24 mm m : 225 N·m (23 kgf·m, 166 lbf·ft)

30, 31

fNOTE: Tighten bolts (30) diagonally. 33

fNOTE: Refer to the previous section W4-3-3 for the installation of differential case assembly.

W4GB-03-03-041

9. Turn over the temporarily assembled differential case B (77). 10. Install ring gear (33) to differential case B (77) with the gear surface up. Fit ring gear (33) to the flange surface of differential case B (77) by using a plastic hammer. Temporary tighten bolts (30) (2 used) and washers (31) (2 used) from the differential case A (76) side.

W4-3-4-13

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Bearing Cage

90Z7-W4-03-06

1. Install the outer races of bearings (50, 53) to bearing cage (62) by using a press. 2. Apply grease onto O-ring (63). Install O-ring (63) to bearing cage (62).

51 62

50 57

W4GB-03-03-043

3. Install the inner race of bearing (50) to pinion gear (57).

W4GB-03-03-044

5. Install bearing cage (62) to pinion gear (57). Install the inner race of bearing (53) to pinion gear (57).

4. Install spacers (51, 52) to pinion gear (57).

W4-3-4-14

SECTION 4 TRAVEL SYSTEM Group 3 Axle

61 54 C

W4GB-03-03-046

W4GB-03-03-045

6. Apply load to the inner race of bearing (53) by using a press. Measure the rotation resistance by using a spring balance. Use thread part (C) for pullers for measurement. j : 24 mm

fNOTE: Use a press which can provide at approx. 93 kN

10. Apply LOCTITE #262 onto the inner surface of dust cover (54). Install dust cover (54) to flange (61). Fit flange (61) to the spline of pinion gear (57). Install it. Turn flange (61) and fix any deformations on the seal-lip part of oil seal (55).

(9500 kgf, 21000 lbf).

fNOTE: Instead of loading by using a press, rotation

resistance can be also measured by temporary installing flange (61) and washer (60) with bolt (59). j : 30 mm m : 324 N·m (33 kgf·m, 240 lbf·ft)

7. If rotation resistance is lower than the standard value, remove pinion gear (57) and grind spacer (52) for adjustment.

fNOTE: Rotational resistance standard value: 14.7 to 26.5 N (1.5 to 2.7 kgf, 3.3 lbf to 6 lbf)

8. Apply LOCTITE #262 onto the outer surface of oil seal (55). Install oil seal (55) to bearing cage (62). 9. Apply grease onto the lip part of oil seal (55).

W4-3-4-15

SECTION 4 TRAVEL SYSTEM Group 3 Axle

57 61 x

W4GB-03-03-081 x-

Level Difference

11. Measure distance (x) between flange (61) and the end of pinion gear (57). Adjust shim (58) so that level difference (x) is 0.05 to 0.1 mm (0.002 to 0.004 in).

fNOTE: Refer to the previous section W4-3-3 for the

12. Insert O-ring (56) to the groove between flange (61) and pinion gear (57). Install washer (60) to flange (61). 13. Apply LOCTITE #262 onto the thread part of bolt (59). Install flange (61) to pinion gear (57) with bolt (59) and washer (60). Check that pinion gear (57) rotates smoothly. j : 30 mm m : 680 N·m (68 kgf·m, 500 lbf·ft)

W4-3-4-16

installation of bearing cage (62) assembly.

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Removal and Installation of Propeller Shaft Removal of Bottom Covers (Option)

10 11 12 8 4 5 6 1

2 3

90Z6-W4-04-01-01

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

dCAUTION: Belly guard (7) weight: 93 kg (205 lb)

IMPORTANT: Remove belly guards (1, 7) (option) while holding them. Be careful not to drop them.

dCAUTION: Belly guard (1) weight: 96 kg (212 lb) 2. Set a stand and a jack under belly guard (1) and hold it.

4. Set a stand and a jack under belly guard (7) and hold it. 5. Remove bolts (9) (8 used), washers (8, 10) (8 each used), rubber sheet (11) (8 used), and rings (12) (8 used). Remove belly guard (7). j : 19 mm

3. Remove bolts (3) (8 used), washers (2, 4) (8 each used), rubber sheet (5) (8 used), and rings (6) (8 used). Remove belly guard (1). j : 19 mm

W4-4-1-1

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Removal of Second Propeller Shaft

1 90Z6-W4-04-01-02

6. Disconnect pipe (1) at both ends. j : 17 mm

W4-4-1-2

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

2 5

1 3

abc-

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly 90Z6-W4-04-01-03

Second propeller shaft assembly (1,2) dCAUTION: weight: 69 kg (152 lb) IMPORTANT: Remove grease fitting (6) in order to drain grease. 7. Remove grease fitting (6).

IMPORTANT: Remove propeller shaft (1) while holding it. Do not drop propeller shaft (1). 8. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1). IMPORTANT: Remove propeller shaft (1) as an assembly. Do not disassemble propeller shaft (1) when removing it. Spline seal (7) is damaged if removed after disassembling propeller shaft (1) assembly.

9. Put the matching marks at the jointed part between propeller shaft (1) and propeller shaft (2). 10. Remove bolts (3) (4 used) and washers (4) (4 used). j : 19 mm 6

11. Remove bolts (5) (4 used). Remove propeller shaft (1) from transmission assembly (b). 90Z6-W4-04-01-04

W4-4-1-3

j : 19 mm

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1 b 8 3 2

4 5

abc-

7 6

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly 90Z6-W4-04-01-03

IMPORTANT: Remove propeller shaft (1) while holding it. Do not drop propeller shaft (1). 12. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1).

14. Remove bolts (4) (2 used), washers (5) (2 used), nuts (6) (2 used), and washers (7) from support bearing (8). Remove propeller shaft (1) from front axle assembly (a).

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

W4-4-1-4

j : 30 mm

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Removal of Third Propeller Shaft

1 2 abc-

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly 90Z6-W4-04-01-03

Third propeller shaft assembly (1) dCAUTION: weight: 21.5 kg (47 lb) IMPORTANT: Remove grease nipple (4) in order to drain grease. 15. Remove grease nipple (4). IMPORTANT: Remove propeller shaft (1) while holding it. Do not drop propeller shaft (1). IMPORTANT: Remove propeller shaft (1) as an assembly. Do not disassemble propeller shaft (1) when removing it. Spline seal (5) is damaged if removed after disassembling propeller shaft (1) assembly. 16. Remove bolts (2) (8 used) and washers (3) (8 used). j : 19 mm 17. Remove propeller shaft (1) from transmission (b) and rear axle assembly (c).

W4-4-1-5

90M4GB-07-17

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Installation of Third Propeller Shaft

1 2 abc-

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly

90Z6-W4-04-01-03

IMPORTANT: Align the direction of the flange yokes of all propeller shafts. Difference in the yoke phase will cause the propeller shaft damage and "knocking" during a turn. 1. Apply LOCTITE #262 onto bolts (2) (8 used). IMPORTANT: Install propeller shaft (1) with the spline shaft side facing to rear axle (c) side.

2. Install propeller shaft (1) to transmission (b) side with bolts (2) (4 used) and washers (3) (4 used). j : 19 mm m : 142 N·m (14.5 kgf·m, 105 lbf·ft) 3. Install propeller shaft (1) to rear axle (c) side with bolts (2) (4 used) and washers (3) (4 used).

90M4GB-07-17

IMPORTANT: Install grease nipple (4) so that all the greasing ports face to the same direction. 4. Install grease nipple (4) and apply grease.

j : 19 mm m : 142 N·m (14.5 kgf·m, 105 lbf·ft)

W4-4-1-6

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Installation of Second Propeller Shaft

1 b 8 3 2

4 5

abc-

7 6

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly 90Z6-W4-04-01-03

IMPORTANT: Align the direction of the flange yokes of all propeller shafts. Difference in the yoke phase will cause the propeller shaft damage and "knocking" during a turn. 5. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1).

7. Apply LOCTITE #262 onto bolts (2) (4 used). 8. Install propeller shaft (1) to front axle assembly (a) with bolts (2) (4 used) and washers (3) (4 used).

6. Install support bearing (7) with bolts (4) (2 used), washers (5) (2 used), nuts (6) (2 used), and washers (8) (2 used). j : 30 mm m : 400 N·m (40 kgf·m, 295 lbf·ft)

W4-4-1-7

j : 19 mm m : 142 N·m (14.5 kgf·m, 105 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

2 5

1 3

abc-

Front Axle Assembly Transmission Assembly (Drive Unit) Rear Axle Assembly 90Z6-W4-04-01-03

9. Set a stand and a jack under propeller shaft (1, 2) and hold them. Second propeller shaft assembly (1, 2) dCAUTION: weight: 69 kg (152 lb) 10. Apply LOCTITE #262 onto bolts (5) (4 used). Fit the matching marks and install propeller shaft (2) to propeller shaft (5) with bolts (5) (4 used). j : 19 mm m : 162 N·m (16.5 kgf·m, 119 lbf·ft)

11. Apply LOCTITE #262 onto bolts (3) (4 used). 12. Install propeller shaft (1) to transmission (b) side with bolts (3) (4 used) and washers (4) (4 used). j : 19 mm m : 142 N·m (14.5 kgf·m, 105 lbf·ft)

90Z6-W4-04-01-04

IMPORTANT: Install grease nipple (6) so that all the greasing ports face to the same direction. 13. Install grease fitting (6) and apply grease.

W4-4-1-8

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1 90Z6-W4-04-01-02

14. Connect the both ends of pipe (1).

15. Apply grease.

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

W4-4-1-9

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Installation of Bottom Covers (Option)

10 11 12 8 4 5 6 1

2 3

90Z6-W4-04-01-01

dCAUTION: Belly guard (7) weight: 93 kg (205 lb)

dCAUTION: Belly guard (1) weight: 96 kg (212 lb)

16. Set a stand and a jack under belly guard (7) and hold it.

18. Set a stand and a jack under belly guard (1) and hold it.

17. Install belly guard (7) with bolts (9) (8 used), washers (8, 10) (8 each used), rubber sheet (11) (8 used), and rings (12) (8 used).

19. Install belly guard (1) with bolts (3) (6 used) and washers (2) (6 each used). j : 19 mm

j : 19 mm

m : 90 N·m (9.2 kgf·m, 66 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

20. Install belly guard (5) with bolts (3) (8 used), washers (2, 4) (8 each used), rubber sheet (5) (8 used), and rings (6) (8 used). j : 19 mm m : 90 N·m (9.2 kgf·m, 66 lbf·ft)

W4-4-1-10

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Removal and Installation of Brake Valve

12 4

1 2

3 9

8 90Z6-W4-05-01-01

90WNEC-04-05-08

3. Place a container under brake valve (12). 4. Disconnect hoses (6~10), pressure switch (11), and pressure sensor (15) from brake valve (12). j : 22 mm j : 27 mm

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the brake pedal more than dCAUTION: fifty times until the pedal can be depressed lightly to release any pressure in the circuit.

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts (2) (4 used) and cover (1). Remove bolts (4) (3 used) and remove cover (3). j : 17 mm

W4-5-1-1

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

13 11

15 12 12 14

90Z6-W4-05-02-01

5. Remove bolts (13) (3 used) and remove brake valve (12) from floor board (14).

90Z6-W4-05-01-02

fNOTE: When the optional right side pedal is used,

j : 17 mm

W4-5-1-2

remove 6 each of bolt (13).

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

13 11 15

90Z6-W4-05-02-01

90Z6-W4-05-01-01

Installation 1. Install brake valve (12) to floor board (14) with bolts (13) (3 used).

2. Connect hoses (6~10), pressure switch (11), and pressure sensor (15) to brake valve (12).

j : 17 mm

j : 22 mm

m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

m : 39 N·m (4 kgf·m, 28.5 lbf·ft) j : 27 mm

fNOTE: When the optional right side pedal is used,

m : 93 N·m (9.5 kgf·m, 68.5 lbf·ft)

tighten 6 each of bolt (13).

W4-5-1-3

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

3°~6°

4 1 2

16 90WNEC-04-05-11

3. Adjust declutch position switch (15) as follows:

90WNEC-04-05-08

4. Bleed air from brake (axle). (Refer to W1-4-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

3-1) Remove socket bolt (16). l : 4 mm 3-2) Manually depress the brake pedal slightly (3°~6°), and adjust the angle of switch arm (17) so that switch (15) turns OFF.

5. Install covers (3) to floor board (14) with bolts (4) (3 used). Install cover (1) with bolts (2) (4 used).

3-3) Tighten socket bolt (16).

j : 17 mm m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

W4-5-1-4

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Disassembly of Brake Valve Assembly (Option) 23

24 8 [ Right Pedal ]

23 22

8 17 24

1 22

128-

Bracket R Bracket L Roller (2 used)

90Z6-W4-05-02-04

15- Link-Rod Assy 17- Switch Plate 20- Bolt

21- Nut 22- Socket Bolt (6 used) 23- Pedal Pad (2 used)

fNOTE: The right side pedal assembly and link rod assembly (15) are optional.

W4-5-2-1

24- Pedal Plate (2 used) 25- Brake Valve

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve [ Left Pedal Assembly ] 6

5 A

22 A

11 13

View A-A

[ Right Pedal Assembly ] 15

View B

1. Remove snap pin (3), washer (4), L pin (6), pin (5), and remove collars (7) (2 used), roller (8) from the left brake pedal. 2. Remove bolt (9), nut (10), and washer (11), and remove link-rod assy (15) and collars (13) (2 used) from the left brake pedal.

90Z7BW04-05-02

3. Remove bolt (18) and nut (19) from the left brake pedal. j : 12 mm 4. Remove socket bolts (22) (3 used) and remove bracket L (2) from the left brake pedal. l : 6 mm

j : 14 mm

j : 17 mm

W4-5-2-2

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

[ Right Pedal Assembly ]

14 20 17

17 13

18 View B

5. Remove snap pin (3), washer (4), L pin (6), pin (5), and remove collar (7) (2 used), and roller (8) from the right brake pedal.

90Z7BW04-05-03

8. Remove bolts (9), nut (10), and washer (11) from the right brake pedal, and remove switch plate (17) and washer (4).

6. Remove snap pin (3) and washer (4) from the right brake pedal.

j : 14 mm 9. Remove bolt (18) and nut (19). j : 12 mm

7. Remove link-rod assy (15) and remove washer (4), collars (13) (2 used), and spring (14).

10. Remove bolt (20) and nut (21) from the right brake pedal. j : 19 mm

W4-5-2-3

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Assembly of Brake Valve Assembly (Option) [ Left Pedal Assembly ] 11 9 A

10 19

B 15

a A

View A-A

[ Right Pedal Assembly ]

25 14

17 1 19 a-

Apply grease

View B

1. Install bracket L (2) to brake valve (25) with socket bolts (22) (3 used).

3. Temporarily install right pedal plate (24) and switch plate (17) with bolt (9), washer (11), and nut (10).

l : 6 mm

j : 14 mm

m : 26 N·m (2.6 kgf·m, 19.2 lbf·ft) 2. Temporarily install bolt (18) and nut (19) to bracket (1). j : 12 mm

90Z7BW04-05-02

4. Install collars (13) (2 used) and spring (14) to bracket R (1). 5. Apply grease to the inserted portion of link-rod assy (15) on both ends.

fNOTE: Use molybdenum disulfide grease.

W4-5-2-4

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

[ Left Pedal Assembly ] 6

3 9

8 24

24 10

View A-A

3 1

[ Right Pedal Assembly ]

View B

6. Align the holes of right pedal plate (24), washer (4), and bracket R (1), and insert link-rod assy (15). Install washer (4) and snap pin (3) and tighten bolt (9).

8. Align the holes of left pedal plate (24) and bracket L (2), and insert link-rod assy (15). Install washer (11) and nut (10) and tighten bolt (9). j : 14 mm

j : 14 mm

m : 35 N·m (3.5 kgf·m, 25.8 lbf·ft)

m : 35 N·m (3.5 kgf·m, 25.8 lbf·ft) 7. Install collars (13) (2 used) to bracket L (2).

90Z7BW04-05-02

9. Install collars (7) (2 each), roller (8) and fix them with pin (5), L pin (6), washer (4), and snap pin (3) respectively to both right and left brake pedals.

W4-5-2-5

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

[ Left Pedal ]

[ Right Pedal ]

19 90WNEC-04-05-13

10. Adjust the play of the left brake valve with bolt (18) and tighten nut (19). j : 12 mm

90WNEC-04-05-14

11. Adjust so that switch plate (17) and the end plate of link-rod assy (15) fit as shown above with socket bolt (18) and tighten nut (19). j : 12 mm

m : 12 N-m (1.2 kgf-m, 8.6 lbf-ft)

fNOTE: The appropriate play of brake pedal is 0~0.5

mm. Refer to the Operation Manual, Maintenance - I. Brake System.

12. Temporarily install bolt (20) and nut (21) to the right brake pedal. j : 19 mm 13. Fully depress the right brake pedal while fully depressing the left brake pedal. Adjust the clearance between roller (7) and bolt (20) to 3~3.5 mm and tighten nut (21). j : 19 mm m : 59 N·m (5.9 kgf·m, 43.5 lbf·ft)

W4-5-2-6

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Structure of Brake Valve 29 30 16 15

17 18

19 24 25

21 20

23 22 26

5 14

11 3

6 5 7 10

A-A

A A

90Z7BW04-05-04

12345678-

Flange Cylinder Cylinder Spring Seat (2 used) Snap Ring (2 used) Plunger (2 used) Spring Plug

910111213141516-

O-Ring Snap Ring Orifice Orifice O-Ring (2 used) Spring Oil Seal Plate

1718192021222324-

Ring Spool Spring Seat Spring Spring Retainer Holder Roller

W4-5-3-1

252627282930-

Bolt Spacer Spring Socket Bolt (2 used) Seat Boot

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Disassembly of Brake Valve 1 21 20 23 22 26 12 6 29

5 14 11

6 5 7 10

8 16 15

4 19

3 90Z7BW04-05-05

IMPORTANT: Put the matching marks on flange (1), cylinder (2), and cylinder (3) before disassembling. 1. Remove seat (29) and boot (30) from flange (1). IMPORTANT: Strong force deforms flange (1). Handle it with care. 2. Vise the brake valve at flange (1) with cylinder (3) side up.

7. Remove spring (14) and spool (6) assembly from cylinder (2). 8. Remove snap ring (5) and spring seat (4) from spool (6) assembly. 9. Remove cylinder (2) and O-ring (13) from flange (1) assembly.

IMPORTANT: Keep the disassembled parts together by each cylinder in order not to confuse.

10. Remove spacer (26), spool (18) assembly, and spring (27) from flange (1) assembly.

3. Remove snap ring (10), plug (8), O-ring (9), spring (7), and spool (6) assembly from cylinder (3).

11. Remove socket bolt (25) from spool (18) assembly. l : 4 mm

4. Remove snap ring (5) and spring seat (4) from spool (6). IMPORTANT: The reaction force of spring (27) is applied to socket bolt (28). Slowly remove socket bolt (28) while holding cylinders (2, 3). 5. Remove socket bolts (28) (2 used) from cylinder (3).

12. Remove holder (23), roller (24), retainer (22), springs (20, 21), and spring seat (19). 13. Remove ring (17), plate (16), and oil seal (15) from flange (1) assembly.

l : 6 mm 6. Remove cylinder (3) and O-ring (13) from cylinder (2) assembly.

W4-5-3-2

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Assembly of Brake Valve 1 21 20 23 22 26 12 6 29

5 14 11

6 5 7 10

8 16 15

4 19

3 90Z7BW04-05-05

IMPORTANT:  Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.  The brake valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. 1. Install oil seal (15), plate (16), and ring (17) to flange (1) assembly. 2. Install springs (20, 21), retainer (22), holder (23), roller (24) to spring seat (19). Insert socket bolt (25). 3. Tighten socket bolt (25) to spool (18) assembly.

6. Install spring seat (4) to spool (6) assembly. Fix with snap ring (5). 7. Install spool (6) assembly and spring (14) to cylinder (2). 8. Install O-ring (13) to cylinder (3). Install cylinder (3) to cylinder (2). IMPORTANT: Tighten socket bolts (28) slowly and evenly while depressing cylinders (2, 3). 9. Install socket bolts (28) (2 used) to cylinder (3). l : 6 mm

l : 4 mm

m : 26 N·m (2.6 kgf·m, 19.2 lbf·ft)

m : 70 N·m (7 kgf·m, 51.6 lbf·ft) IMPORTANT: Strong force deforms flange (1). Handle it with care. 4. Secure flange (1) in a vise. Install spool (18) assembly, spring (27), and spacer (26) to flange (1) assembly.

fNOTE: Apply grease onto the sliding surface of spool

10. Install spring seat (4) to spool (6). Fix with snap ring (5). 11. Install spool (6) assembly and spring (7) to cylinder (3). 12. Install O-ring (9) to plug (8). Install plug (8) and fix with snap ring (10).

(18). Fill grease into (a).

5. Install O-ring (13) to cylinder (2). Install cylinder (2) to flange (1).

13. Install seat (29) and boot (30) to flange (1).

W4-5-3-3

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Brake Valve Maintenance Standard

14 1

16 17 18

90WNEC-04-05-15

1. Clearance between piston (14) and flange (1)

Standard 0.016 to 0.086 (0.0006 to 0.0034)

Unit: mm (in)

Allowable Limit 0.150 (0.0059)

2. Free length of springs (7, 16, 17, 18, 23)

No. 7 16 17 18 23

Standard 11 (0.43) 123 (4.84) 52.8 (2.08) 34.5 (1.36) 24.8 (0.98)

Unit: mm (in)

Allowable Limit 10.5 (0.41) 117 (4.61) 50.8 (2.00) 33.5 (1.32) 22.3 (0.88)

W4-5-3-4

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve Removal and Installation of Steering Pilot Valve

3 1

9 7

4 6 90Z6-W4-06-01-02

90Z6-W4-06-01-01

4. Remove screws (6) (2 used) and screws (9) (4 used) from cover (7) by using a screwdriver. Remove cover (7) from steering column (8).

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) Operate the steering wheel right and dCAUTION: left several times, and release any pressure in the circuit.

2. Place a container under steering pilot valve (5). Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 3. Disconnect hoses (1, 2, 3, and 4) from steering pilot valve (5). j : 27 mm j : 19 mm

W4-6-1-1

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

5 90Z6-W4-06-01-03

fNOTE: The right brake pedal is optional. 5. Remove bolts (10) (4 used) from steering pilot valve (5). Remove steering pilot valve (5) from floor board (11). j : 17 mm 6. Remove the adapters attached to steering pilot valve (5), if necessary.

W4-6-1-2

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

3 1

5 90Z6-W4-06-01-03

fNOTE: The right brake pedal is optional.

90Z6-W4-06-01-01

Installation 1. Install all the removed adapters to steering pilot valve (5).

3. Connect hoses (1, 2, 3, and 4) to steering pilot valve (5). j : 27 mm

2. Install steering pilot valve (5) to floor board (11) with bolts (10) (4 used).

m : 80 N·m (8 kgf·m, 59 lbf·ft)

j : 17 mm

j : 19 mm

m : 53 N·m (5.4 kgf·m, 39 lbf·ft)

m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. 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.

W4-6-1-3

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

9 7

6 90Z6-W4-06-01-02

5. Install cover (7) to steering column (8) with screws (6) (2 used) and screws (9) (4 used) by using a screwdriver.

W4-6-1-4

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve Disassembly of Steering Pilot Valve 1 2 13 3 14 4

5 16 6 7

6 18 19

16 10

22 23

9 25

24 25

11 12

11 WNEC-04-06-005

1234567-

Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 Used) Thrust Needle

891011121314-

Housing Sleeve Pin Centering Spring (4 used) Flat Springs (2 used) Spool O-Ring

15161718192021-

Plate O-Ring (2 Used) Drive Rotor Star Spacer Cap

W4-6-2-1

22232425-

Ball Adapter Screw Spring Pin Screw (7 Used)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

21 a

W202-02-14-002 a-

W202-02-14-006

Vise

Disassembly IMPORTANT: Strong force deforms housing (8). Handle it with care. 1. Secure housing (8) in a vise (a) with cap (21) side up. 2. Remove screws (25) (7 used) from cap (21). Remove cap (21) from housing (8). Remove O-ring (16) from cap (21). j : 8 mm IMPORTANT: When removing rotor (18), do not drop star (19). 3. Remove rotor (18) and star (19) from housing (8). Remove spacer (20) from rotor (18). 4. Remove drive (17), plate (15), and O-rings (16, 14) from housing (8). Remove adapter screw (23) from housing (8) by using a screwdriver.

IMPORTANT: As retaining ring (2) may fly out from housing (8), always wear safety glasses. IMPORTANT: Do not drop or lose ball (22). IMPORTANT: Check the position of the holes where the ball was placed. 5. Remove housing (8) from vise (a). Turn over housing (8). Remove ball (22) and spring pin (24). Place housing (8) on a clean cloth in order not to damage the finished side. Remove retaining ring (2) from housing (8) by using a screwdriver. 6. Turn spool (13) and sleeve (9) to set pin (10) horizontally. Push spool (13) and sleeve (9) from the cap (21) side and remove bushing (3) from the housing (8).

W4-6-2-2

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

12 13

10 11

a a-

W202-02-14-021

Matching Mark

13 9

IMPORTANT: When removing seal (5), do not damage bushing (3). 7. Remove seal (5) and dust seal (1) from bushing (3). 8. Remove bearing races (6) (2 used) and thrust needle (7) from spool (13). 9. Remove spool (13) and sleeve (9) from housing (8).

fNOTE: Turn slowly and remove sleeve (9) from housing

W4GB-03-07-002

IMPORTANT: As centering spring (11) and flat spring (12) may fly out, always wear safety glasses. 11. Push spool (13) forward. Remove centering springs (11) (4 used) and flat springs (12) (2 used) from spool (13). 12. Slowly turn and remove spool (13) from sleeve (9). 13. Remove O-ring (4) from housing (8).

(8) so that sleeve (9) assembly does not stick to housing (8).

IMPORTANT: Put the matching marks (a) on sleeve (9) and spool (13) before disassembling. 10. Remove pin (10) from sleeve (9) assembly.

W4-6-2-3

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve Assembly of Steering Pilot Valve

22 24

21 6 25

17 1 25 16

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Dust Seal Retaining Ring Bushing O-Ring Seal Bearing Race (2 used) Thrust Needle

891011121314-

7 12 11 10

Housing Sleeve Pin Centering Spring (4 Used) Flat Spring (2 used) Spool O-Ring

15161718192021-

Plate O-Ring (2 Used) Drive Rotor Star Spacer Cap

W4-6-2-4

T1F3-03-07-002

22232425-

Ball Adapter Screw Spring Pin Screw (7 Used)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve 13 ST2497

13 b

11 12 a ab-

W202-02-14-019

W4GB-03-07-003

Matching Mark Spring Grooves

13 10

W202-02-14-021

Assembly IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. 1. Install spool (13) into sleeve (9) while turning. Align matching marks (a) on spool (13) and sleeve (9). IMPORTANT: As the centering spring (11) and flat spring (12) may fly out, always wear safety glasses. 2. Align spring groove (b) positions of spool (13) and sleeve (9), and place them on a flat plate. Align two centering springs (11) back to back, and two flat springs (12) in the center, and install them to a special tool (ST 2497). Install centering springs (11) (4 used) and flat springs (12) (2 used) to the spring grooves (b) of spool (13) and sleeve (9) by using a special tool.

3. Install pins (10) in the holes of spool (13) and sleeve (9). Align the ends of the pins (10) and the outer diameter surface of sleeve (9). 4. Install sleeve (9) assembly from cap (21) side of housing (8).

fNOTE: When installing sleeve (9) assembly, prevent

W4-6-2-5

binding. Keeping the pin horizontal, turn the pin right and left little by little. Insert the pin until the ends behind sleeve (9) assembly and housing (8) come to the same position.

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve

1 6

8 5

W212-02-14-002

W202-02-14-023 a-

5. Install O-ring (4), bearing races (6) (2 used), and thrust needle (7) to housing (8).

Screwdriver

6. Install dust seal (1) and seal (5) to bushing (3). IMPORTANT: Check that bushing (3) and bearing race (6) is contacting each other horizontally. 7. Tap slightly with a plastic hammer and install bushing (3) to spool (13). IMPORTANT: As retaining ring (2) may fly out from housing (8), always wear safety glasses. 8. Install retaining ring (2) to cover (8).

fNOTE: After installing retaining ring (2), extend the bore of retaining ring (2) with a screwdriver so that it enters the groove on housing (8) correctly.

IMPORTANT: Strong force deforms housing (8). Handle it with care. 9. Secure housing (8) in a vise.

W4-6-2-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve d

23 24 22 g

8 10 8

b W487-03-08-007

a b WNEC-04-06-006

c abcd-

IMPORTANT: Do not drop or lose ball (22) and spring pin (24). 10. Install O-ring (14) to housing (8). Install ball (22), adapter screw (23), and spring pin (24) to housing (8) at the position as illustrated below. Place plate (15) on housing (8).

Line at the Spline Side End Line on the York Yoke Part Port Side

efg-

W487-03-08-006 Port L Port T Line Connecting the Centers of Port L and Port T

11. Turn the sleeve (9) assembly and set pin (10) and port side (d) of housing (8) in parallel. Draw a line (a) onto the spline side end so that line (a) is parallel to line (b) on yoke part (c) of drive (17). Install drive (17). Assemble yoke part (c) of drive (17) and pin (10). Set line (a) of the spline side edge of drive (17) and port side (d) of housing (8) in parallel position. 12. Install O-ring (16) to rotor (18).

W4-6-2-7

SECTION 4 TRAVEL SYSTEM Group 6 Steering Pilot Valve 18

19 a k b

ijk-

Concave Part Line Connecting the Concave Parts Bolt Holes

13. Face O-ring (16) side of rotor (18) to plate (15) side. Install star (19) while aligning the splines of star (19) and drive (17) so that line (j) connecting concave parts (i) of star (19) is parallel to line (a) on the spline side end of drive (17). Check that line (j) connecting concave parts (i) of star (19), line (a) on the spline side end, line (b) on yoke part (c) of drive (17) and line (g) connecting the centers of port L and port T, are parallel.

W202-02-14-031

15. Install spacer (20) to rotor (18). Install O-ring (16) to cap (21). Place cap (21) on rotor (18). 16. Install cap (21) to housing (8) with screws (25) (7 used). j : 8 mm m : 23 N·m (2.3 kgf·m, 17 lbf·ft)

14. Fit the bolt holes (k) on rotor (18) to holes on plate (15) while mating drive (17) and star (19).

W4-6-2-8

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve Removal and Installation of Steering Valve

5 1

6 7 2

90Z6-W4-07-01-01

3. Disconnect hoses (2, 3, 4) from steering valve (1). j : 36 mm 4. Disconnect hose (5) from steering valve (1). j : 27 mm 5. Disconnect hoses (6, 7, 8) from steering valve (1).

Before disconnecting each hose, dCAUTION: operate the steering wheel right and left several times, and release any pressure in the circuit.

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Place a container under steering valve (1).

W4-7-1-1

j : 19 mm

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve

1 9 9 11

90Z6-W4-07-01-04

CAUTION: Steering valve (1) weight: 22 kg (49 lb) 6. Remove bolts (9) (2 used) and bolt (10) from steering valve (1). Remove steering valve (1) from bracket (11) assembly.

7. Remove the adapters attached to steering valve (1), if necessary.

l : 10 mm

W4-7-1-2

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve

1 9 9

25° 10°

2 10

90Z6-W4-07-01-04

Installation 1. Install all removed adapters to steering valve (1).

dCAUTION: Steering valve (1) weight: 22 kg (49 lb)

90Z6-W4-07-01-03

IMPORTANT: Take care of the installation angle of each hose. 3. Connect hoses (6, 7, 8) to steering valve (1). j : 19 mm

2. Install steering valve (1) to the bracket (11) assembly with bolts (9) (2 used) and bolt (10). l : 10 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft) 4. Connect hose (5) to steering valve (1).

m : 110 N·m (11 kgf·m, 81 lbf·ft)

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

W4-7-1-3

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve

8 40°

15° 30°

IMPORTANT: Take care of the installation angle of each hose. 5. Connect hoses (2, 3, 4) to steering valve (1). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft)

90Z6-W4-07-01-02

6. Set the machine for inspection and maintenance. (Refer to W1-6-1.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks. 7. Bleed air from the hydraulic system. (Refer to W1-41.)

W4-7-1-4

SECTION 4 TRAVEL SYSTEM Disassembly and Assembly of Steering Valve

D 7 B

6 17 12

5 10

9 16 15

Cross Section A

4 1

Cross Section C

Cross Section D

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Relief Valve (2 used) Plug O-Ring O-Ring (2 used) Sleeve Assembly

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14 15 16 Cross Section B

Socket Bolt (4 used) Cap Assembly O-Ring (2 used) O-Ring (2 used) Spring (2 used)

1112131415-

Spring Seat (2 used) Capscrew (2 used) Backup Ring (2 used) O-Ring (2 used) Spring (2 used)

W4-7-2-1

12 W4GB-03-08-003

16171819-

Poppet (2 used) Valve Housing Cap Spool

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve

6 7

3 10

17 14 19

13 18

12 11

10 9 4

12345-

Relief Valve (2 used) Plug O-Ring O-Ring (2 used) Sleeve Assembly

678910-

Socket Bolt (4 used) Cap Assembly O-Ring (2 used) O-Ring (2 used) Spring (2 used)

W4GB-03-08-001

1112131415-

Spring Seat (2 used) Capscrew (2 used) Backup Ring (2 used) O-Ring (2 used) Spring (2 used)

W4-7-2-2

16171819-

Poppet (2 used) Valve Housing Cap Spool

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve Disassembly IMPORTANT: Do not disassemble the overload relief valve. If disassembled, pressure should be adjusted. (Refer to Troubleshooting Shop Manual, Section T4 Operational Performance Test.)

30~40 mm 10.5~12 mm

1. Put matchmarks and remove overload relief valves (1) (2 used) from valve housing (17). 70~100 mm

j : 32 mm 2. Remove plug (2) and O-ring (3) from valve housing (17).

W4GB-03-08-002

j : 36 mm IMPORTANT: Spring (10) may jump out due to the spring force when removing cap (18) and cap assembly (7). 3. Remove socket bolts (6) (4 used) from cap (18) and cap assembly (7). l : 6 mm

7. Secure spool (19) assembly in a vise by using wooden pieces as shown. 8. Remove cap screws (12) (2 used), springs (15) (2 used), and poppets (16) (2 used) from spool (19) assembly. j : 17 mm

4. Remove springs (10) (2 used) and spring seats (11) (2 used) from valve housing (17).

9. Remove O-rings (14) (2 used) and backup rings (13) (2 used) from capscrews (12) (2 used).

5. Remove O-rings (9, 8, 4) from cap (18). Remove O-rings (9, 8, 4) and sleeve assembly (5) from cap assembly (7). IMPORTANT: Put the matching marks on valve housing (17) and spool (19) before disassembling. Do not dent, scratch, or crack spool (19) when removing. Handle spool (19) with special care. 6. Turn and remove spool (19) assembly from valve housing (17).

W4-7-2-3

SECTION 4 TRAVEL SYSTEM Group 7 Steering Valve Assembly IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing. IMPORTANT: The steering valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling. IMPORTANT: Replace O-rings with new ones. Apply grease or hydraulic oil before assembling. 1. Install backup rings (13) (2 used) and O-rings (14) (2 used) to capscrews (12) (2 used). 2. Secure spool (19) assembly in a vise by using wooden pieces (refer to the previous page). Install poppets (16) (2 used) and springs (15) (2 used) to spool (19), and install capscrews (12) (2 used) (both ends).

IMPORTANT: Check the direction to install spool (19) assembly. 5. Insert spool (19) assembly in valve housing (17). Slowly turn spool (19) and check for smooth rotation. 6. Install O-ring (4) to sleeve (5) assembly and install sleeve (5) to cap (7) assembly. 7. Install 2 each of O-rings (9, 8, 4) to cap (18) and cap (7) assembly. 8. Install cap (18) and cap (7) assembly to valve housing (1) with springs (10) (2 used) and spring seats (11) (2 used). Tighten socket bolts (9) (4 used).

j : 17 mm m : 39 to 41 N·m (4 to 4.2 kgf·m, 29 to 31 lbf·ft) 3. Attach O-ring (3) to plug (2) and install plug (2) to valve housing (17). j : 36 mm m : 205 to 225 N·m (21 to 23 kgf·m, 152 to 167 lbf·ft) 4. Install overload relief valves (1) (2 used) to valve housing (17). j : 32 mm m : 78 to 88 N·m (8 to 9 kgf·m, 58 to 65 lbf·ft)

W4-7-2-4

l : 6 mm m : 39 to 44 N·m (4 to 4.5 kgf·m, 29 to 33 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder Removal and Installation of Steering Cylinder

2 4 8 8

8 6 7

6 1

7 90Z6-W4-08-01-01

90Z6-W4-08-01-07

3. Disconnect hoses (2, 3, 4, 5) with O-rings (8) (6 used), and hoses (6, 7) from steering cylinder (1).

1. Set the machine in the position for inspection and maintenance. (Refer to W1-6-1.) 2. Place a container under steering cylinder (1). Operate the steering wheel right and dCAUTION: left several times, and release any pressure in the circuit.

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

W4-8-1-1

j : 27 mm j : 19 mm

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder

13 14 15

13 14 15 13 14 15 12

13 14 15 12

1 18 90Z6-W4-08-01-02

4. Remove grease pipes (11) (2 used).

8. Remove steering cylinder (1) and shim (18) from front and rear chassis (16, 17).

j : 17 mm Steering cylinder (1) weight: 27 kg (60 dCAUTION: lb) 5. Attach nylon slings onto steering cylinder (1). Hoist and hold steering cylinder (1).

9. Remove the other steering cylinder (1) in the same way. 10. Remove the attached adapters to steering cylinder (1), if necessary.

6. Remove bolt (13) and washers (14, 15) from pin (12). j : 24 mm 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. 7. Remove pin (12) from front and rear chassis (16, 17) by using a bar and a hammer.

W4-8-1-2

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder 13 14 15

13 14 15 13 14 15 12

13 14 15 12

1 14, 15

90Z6-W4-08-01-02

a a

Installation Steering cylinder (1) weight: 27 kg (60 dCAUTION: lb) IMPORTANT: Check the installation angle of adapters. (Refer to the next page.) 1. Install all the removed adapters to steering cylinder (1). 2. Attach nylon slings onto steering cylinder (1). Hoist steering cylinder (1). Align the bottom side hole of steering cylinder (1) and the mounting hole in rear chassis (16).

Clearance

90Z6-W4-08-01-03

4. Install shim(s) (18) so that the clearance (a) is adjusted within 1.2 mm (0.0479 in).

fNOTE: Shim (7) thickness : 1mm (0.039 in) 5. Install bolt (13) and washer (14, 15) to pin (12). j : 24 mm

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

m : 210 N·m (21 kgf·m, 155 lbf·ft)

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

6. Install grease pipes (11) (2 used). j : 17 mm

3. Install pin (12) to front and rear chassis (16, 17) by using a hammer.

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft)

W4-8-1-3

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder 5

4 5

2 4

8 8

6 7

1 90Z6-W4-08-01-01

7 90Z6-W4-08-01-07

20°

7. Connect hoses (2, 3, 4, 5) with O-rings (8) (6 used), and hoses (6, 7) to steering cylinder (1). j : 27 mm m : 95 N·m (9.5 kgf·m, 70 lbf·ft) j : 19 mm

90°

A Detail

90Z6-W4-08-01-04

m : 30 N·m (3 kgf·m, 22 lbf·ft) 8. Set the machine position for inspection and maintenance. 9. Bleed air from the hydraulic system. (Refer to W1-41.)

3 90Z6-W4-08-01-05

IMPORTANT: After completing the work, operate the steering cylinder several times to the stroke end and bleed air from the circuit.

C Detail

W4-8-1-4

B Detail

30°

90°

90Z6-W4-08-01-06

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder Disassembly of Steering Cylinder

18 17 16

10 8 6

1 WNEC-04-08-002 12345-

Cylinder Rod Dust Seal U-Ring Buffer Seal Cylinder Head

678910-

Washer O-Ring O-Ring Backup Ring Bushing

1112131415-

Retaining Ring Backup Ring (2 Used) O-Ring Dust Seal Seal Ring

W4-8-2-1

1617181920-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder

18 17 16

10 8 6

1 WNEC-04-08-002

W4-8-2-2

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder

1 1 Special Tool for Cylinder: ST 5908 W102-04-02-027

W158-04-02-022

Disassembly 6. Remove nut (18) from cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool (ST 3394) for nut.

fNOTE: The procedure starts from the step after the pipes and the bands securing the pipes have been removed.

ST 3394: 58 mm (2.3 in) Steering cylinder (1) weight: 27 kg (60 dCAUTION: lb) 1. Hoist cylinder (1). Secure cylinder (1) horizontally on a workbench. Drain hydraulic oil from the cylinder.

7. Remove the piston (16) assembly from cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool (ST 3395) for piston. ST 3395: 52 mm (2 in)

2. Pull out cylinder rod (1) about 50 mm from cylinder tube (20). Install a protective cover to cylinder rod (1). Extend washer (6) by using a chisel and a hammer. IMPORTANT: Pull out cylinder rod (1) straightly in order not to damage the sliding surface. 3. Loosen cylinder head (5) by using a hook wrench. Remove the cylinder rod (1) assembly from cylinder tube (20). j : Cylinder Head (5) Diameter: 84 mm (3.3 in) 4. Secure cylinder rod (1) on the special tool (ST 5908). Put the matching marks on the ends of cylinder rod (1), piston (16), and nut (18).

8. Remove wear ring (17), dust seal (14), seal ring (15), backup rings (12) (2 used), and O-ring (13) from piston (16). 9. Remove the cylinder head (5) assembly from cylinder rod (1). IMPORTANT: Do not remove bushing (10) unless necessary. 10. Remove dust seal (2), U-ring (3), buffer seal (4), retaining ring (11), busing (10), O-ring (8), backup ring (9), O-ring (7), and washer (6) from cylinder head (5).

5. Cut away the crimped part by using a hand drill. Remove set screw (19).

fNOTE: Set screw (19) has been crimped by using a punch at two places after installing. l : 4 mm

W4-8-2-3

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder Assembly of Steering Cylinder

7 3 4 10 8, 9 11 5

14 15 17 12, 13, 12 18

WNEC-04-08-001

12345-

Cylinder Rod Dust Seal U-Ring Buffer Seal Cylinder Head

678910-

Washer O-Ring O-Ring Backup Ring Bushing

1112131415-

W4-8-2-4

Retaining Ring Backup Ring (2 Used) O-Ring Dust Seal Seal Ring

1617181920-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder Assembly 1. Install bushing (10) to cylinder head (5) using the special tool (ST 3398) for bushing. ST 3398: 45 mm IMPORTANT: Check the installation direction. 2. Install U-ring (3) and buffer seal (4) to cylinder head (5).

Special Tool for Cylinder: ST 5908

3. Install dust seal (2) to cylinder head (5) by using the special tool (ST 3394) and a plastic hammer.

W158-04-02-022

ST 3399: 45 mm 4. Install washer (6), O-rings (7, 8), backup ring (9), and retaining ring (11) to cylinder head (5).

10. Install set screw (19) to nut (18). Crimp set screw (19) by using a punch (2 places). l : 4 mm

5. Install seal ring (15) to piston (16) by using special tool A (ST 3396). ST 3396: 70 mm After installing seal ring (15), adjust seal ring (15) by using special tool B (ST 3397). ST 3397: 70 mm 6. Install dust seal (14), wear ring (17), O-ring (13), and backup rings (12) (2 used) to piston (16).

m : 15±1.5 N·m (1.5±0.15 kgf·m, 11±1.1 lbf·ft) CAUTION: Fit the cylinder rod (1) assembly to the dcenter of cylinder tube (20) and install it straightly in order not to damage the rings.

11. Secure cylinder tube (20) on a workbench horizontally. Tighten cylinder head (5) to cylinder tube (20) by using a hook wrench. Cylinder Head (5) Diameter: 84 mm

7. Install the cylinder head (5) assembly to cylinder rod (1) using the special tool (ST 3400). ST 3400: 45 mm

m : 491±49 N·m (50±5 kgf·m, 362±36 lbf·ft) 12. Bend washer (6) in order not to loosen.

8. Fit the matching marks before disassembling and install the piston (16) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool (ST 3395) for piston. ST 3395: 52 mm m : 491±49 N·m (50±5 kgf·m, 362±36 lbf·ft) 9. Fit the matching marks before disassembling and install nut (18) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool (ST 3394) for nut. ST 3394: 58 mm m : 491±49 N·m (50±5 kgf·m, 362±36 lbf·ft)

W4-8-2-5

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder (Blank)

W4-8-2-6

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder Removal and Installation of Steering Accumulator

4 5, 6

3 90Z6-W4-08-03-01

2. Remove hose (2) from steering accumulator (1). j : 19 mm 3. Remove bolts (3) (4 used), bands (5) (2 used), and rubber sheet (6) (2 used). Remove steering accumulator (1) from front chassis (7).

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

j : 17 mm

Bleed air from the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) Operate the steering wheel right and dCAUTION: left several times, and release any pressure in the

4. Remove accumulator (4) in the same manner.

circuit.

W4-8-3-1

SECTION 4 TRAVEL SYSTEM Group 8 Steering Cylinder

4 5, 6

3 90Z6-W4-08-03-01

Installation 1. Install steering accumulator (1) to front chassis (7) with bands (5) (2 used), rubber sheet (6) (2 used), and bolts (3) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

3. Install accumulator (4) in the same manner. 4. 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.

2. Connect hose (2) to steering accumulator (1). j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft)

W4-8-3-1

SECTION 4 TRAVEL SYSTEM Group 9 Secondary Steering Device Removal and Installation of Secondary Steering Pump 4

1 3

2 90Z6-W4-09-01-02

90Z6-W4-09-01-01

fNOTE: The secondary steering is an optional equipment for the EXP Spec. machines (S/N 0101~).

Removal 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 the hydraulic oil tank. dCAUTION: (Refer to W1-4-1.) 2. Remove bolts (2) (5 used) and cover (1) from the rear chassis. j : 17 mm 3. Disconnect connectors (4) from secondary steering pump (3).

W4-9-1-1

SECTION 4 TRAVEL SYSTEM Group 9 Secondary Steering Device

+24V

6 3 7

5 7

90Z6-W4-09-01-03

4. Remove hoses (5, 6) from secondary steering pump (3).

90Z6T1-2-16

6. Remove bolts (10) (4 used) and remove secondary steering pump (3).

j : 27 mm

j : 17 mm

IMPORTANT: Remove negative cable (9) first. 5. Remove nuts (7) (2 used), negative cable (9), and positive cable (8) from secondary steering pump (3). j : 17 mm

W4-9-1-2

SECTION 4 TRAVEL SYSTEM Group 9 Secondary Steering Device

6 3 7

5 7

90Z6-W4-09-01-03

Installation 1. Install secondary steering pump (3) with bolts (10) (4 used).

3. Connect hoses (5, 6).

j : 17 mm

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

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

2. Connect positive cable (8) first and tighten nut (7), then connect negative cable (9) and tighten nut (7) to secondary steering pump (3). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-9-1-3

SECTION 4 TRAVEL SYSTEM Group 9 Secondary Steering Device

2 90Z6-W4-09-01-02

4. Connect connectors (4) to secondary steering pump (3).

90Z6-W4-09-01-01

5. Install cover (1) with bolts (2) (5 used).

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

W4-9-1-4

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

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve Removal and Installation of Stop Valve 1

9 3

4 5

90Z6-W4-11-01-01

3. Remove bolts (3) (6 used) and remove stop valves (1, 2). j : 13 mm 4. Remove adapters attached to stop valves (1, 2), if necessary.

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Disconnect hoses (4~9) from stop valves (1, 2). j : 17 mm j : 19 mm

W4-10-1-1

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve 6

10°

8 1 9

3 15°

15°

4 4

90Z6-W4-11-01-02

5 90Z6-W4-11-01-01

Installation IMPORTANT: Take care of the installation angle of each adapter. 1. Install all the adapters to stop valves (1, 2).

2. Install stop valves (1, 2) with bolts (3) (6 used). j : 13 mm m : 10 N·m (1.0 kgf·m, 7.4 lbf·ft) IMPORTANT: Adjust the stop valve installation position by referring to the following page. 3. Connect hoses (4~9) to stop valves (1, 2). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft) j : 19 mm m : 30 N·m (3 kgf·m, 22 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W4-10-1-2

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve Adjustment of Stop Valve Installation Position

Front chassis Front chassis (Stop valve)

Stopper (bolt)

Rear chassis (Plate)

Articulation angle 3 mm Clearance between chassis and stopper

Rear chassis

Stopper length 90Z6-W4-11-01-03

The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure. 1. Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension shown in the following table.

90Z6-W4-11-01-04

2. After adjustment, turn the steering wheel slowly at a rate of 5 seconds or more per turn, and confirm the clearance between the machine body and the stopper. 3. When adjustment is completed, tighten the lock nut of the stopper (bolt). j : 35 N·m (3.6 kgf·m, 25.8 lbf·ft)

Reference dimension Articulation angle

38º

37º

36º

Clearance between machine body and stopper (mm)

18.5

23.3

Stopper (bolt) length (mm)

23.7

28.5

30.9

fNOTE: The target articulation angle should be "37º".

W4-10-1-3

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve (Blank)

W4-10-1-4

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve Disassembly of Stop Valve

15 13 12 11 10 1

5 6 2

7 8

Spool Assembly 90WNEC-04-11-05 12345-

Boot Plug Spring Spool Plug

678910-

Washer Spring Poppet Screw Flange

1112131415-

Dust Seal Spacer U-Packing O-Ring Housing

Disassembly The inner spring may spring out dWARNING: causing injury. Do not point the spring toward

3. Vise spool assembly (4) at the bottom side and remove plug (5) using a screwdriver.

your face. 1. Remove boot (1), and plug (2) with O-ring (14).

4. Remove washer (6), spring (7) and poppet (8) from the spool.

j : 38 mm 2. Remove spring (3) and pull out spool assembly (4).

5. Remove screw (9) and remove flange (10), dust seal (11), spacer (12), and U-packing (13).

W4-10-2-1

SECTION 4 TRAVEL SYSTEM Group 10 Stop Valve Assembly of Stop Valve 16±0.5 mm (0.63±0.02 in)

Air vent hole

9, 10

A-A 12345-

Boot Plug Spring Spool Plug

678910-

Washer Spring Poppet Screw Flange

1112131415-

90WNEC-04-11-06

Dust Seal Spacer U-Packing O-Ring Housing

Assembly IMPORTANT: Before assembling, apply a thin coat of hydraulic oil to the parts in order to prevent them from seizing. 1. U-packing (13), spacer (12), dust seal (11), and flange (10) to housing (15) with screws (9) (2 used).

3. Install spool (4) assembly and spring (3) to housing (15). 4. Install O-ring (14) and plug (2) to housing (15). j : 38 mm m : 186.3 N·m (18.9 kgf·m, 137.4 lbf·ft)

m : 0.4 N·m (0.04 kgf·m, 0.3 lbf·ft) 2. Vise spool (4) at the bottom side and install poppet (8), spring (7), washer (6), and plug (5). m : 3.92 N·m (0.4 kgf·m, 2.9 lbf·ft)

IMPORTANT: Install boot (1) so that the air vent hole comes down. 5. Install boot (1) to housing (15).

W4-10-2-2

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler Removal and Installation of Axle Oil Cooler (Option)

6 7 2

3 90Z6W04-11-15

12-

Oil Cooler Assembly Pump Unit

34-

Flow Control Valve Front Axle Check Valve

56-

Rear Axle Check Valve Oil Filter Assembly

Fan Pump (Accessory Pump)

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

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

injury. Release the pressure before disconnecting the hydraulic pipings or removing other equipment. Hot hydraulic oil just after operation may spout out and cause severe burns. 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.

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

W4-11-1-1

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler

12 6 1

12 7 8 2

11 Drain port

90Z6W04-11-01

2. Prepare a container under the front axle housing. Remove the magnet plug on the bottom of case to drain gear oil. (Refer to W4-3-3.)

90Z6W04-11-02

6. Remove bolts (12) (10 used) and remove plates (9, 10, 11).

fNOTE: Gear oil amount: 50 L (13 gal) 3. Remove hoses (1, 2, 3). j : 36 mm 4. Remove hoses (4, 5, 6). j : 27 mm 5. Remove bolts (7) (2 used) and remove check valve (8). j : 19 mm

W4-11-1-2

j : 19 mm

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 1

3 17 18

11 2

8 6

View A 13

8. Remove hoses (5, 6, 7). j : 27 mm 9. Remove hoses (8, 9). j : 19 mm

90Z6W04-11-03

7. Remove bolts (3) (2 used) and bolts (4) (2 used) to remove plates (1, 2). j : 17 mm

90Z6W04-11-14

11. Remove bolts (14) (4 used) and remove oil filter (15 for rear oil cooler) and oil filter (16 for front oil cooler). j : 17 mm 12. Remove bolts (17) (2 used) and remove bracket (18). j : 19 mm 13. Remove bolts (19) (4 used) and remove pump unit (20).

j : 22 mm

j : 19 mm

10. Remove hoses (10, 11, 12, 13). j : 36 mm

W4-11-1-3

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 10

13, 14

3 2

5, 6 1 9 5, 6

5, 6 8 Drain port

90Z6W04-11-04

14. Prepare a container under the rear axle housing. Remove the magnet plug on the bottom of case to drain gear oil. (Refer to W4-3-3.)

90Z6W04-11-05

18. Remove nuts (5) (3 used) and holders (6) (3 used). Remove hoses (7, 8, 9). j : 12 mm

NOTE: Gear oil amount: 50 L (13 gal)

j : 36 mm

15. Remove bolts (1) (2 used) and remove grommet assembly (2).

19. Remove hose (10) and pipes (11, 12). j : 27 mm

j : 13 mm

20. Remove bolts (13) (2 used) and remove check valve (14).

16. Remove hoses (3, 4). j : 36 mm

j : 17 mm

j : 27 mm 17. Remove the rear axle assembly. (Refer to W4-3-3.)

W4-11-1-4

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 5

7 11 1 3, 4

3, 4

9, 10

90Z6W04-11-06

21. Remove bolts (2) (4 used) and plate (1).

22. Remove nuts (3) (2 used) and holders (4) (2 used). Remove hoses (5, 6, 7, 8).

j : 27 mm

90Z6W04-11-07

23. Disconnect connectors (9, 10).

j : 17 mm

j : 12 mm

24. Remove bolts (11) (5 used) and oil cooler assembly (12). j : 17 mm 25. Remove the adapters if necessary.

W4-11-1-5

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler

20°

1 15° 23°

20°

5°

10° 35°

10°

90Z6W04-11-11 20°

20°

40° 90Z6W04-11-10

10° 20°

60°

5 90Z6W04-11-08 35° 10°

5° 90Z6W04-11-09

35°

Installation IMPORTANT: Take care of the installation angle of each adapter. 1. Install the removed adapters.

90Z6W04-11-17

123-

Oil Cooler Assembly Check Valve Oil Filter

45-

Pump Unit Chekc Valve

W4-11-1-6

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 5

12 7

1 11 3, 4

9, 10

3, 4

90Z6W04-11-06

90Z6W04-11-07 10°

3, 4 90Z6W04-11-16

2. Sling oil cooler assy (12) and move onto the rear fender (RH).

5. Install hoses (5, 6, 7, 8). Fix with nuts (3) (2 used) and holders (4) (2 used). j : 12 mm

3. Install oil cooler assembly (12) with bolts (11) (5 used).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

j : 17 mm

j : 27 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 80 N·m (8 kgf·m, 59 lbf·ft)

4. Connect connectors (9, 10).

6. Install plate (1) with bolts (2) (4 used). j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

W4-11-1-7

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler

13, 14

10 A

5, 6

10 10°

35°

9 5, 6

40°

12 5, 6

9 60° 60°

View A

View B

View C

View D 90Z6W04-11-13

8 7 90Z6W04-11-05

7. Install check valve (14) with bolts (13) (2 used). j : 17 mm

9. Install hoses (7, 8, 9) and fix with nuts (5) (3 used) and holders (6) (3 used). j : 12 mm

m : 50 N·m (5 kgf·m, 37 lbf·ft)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft)

8. Install hose (10) and pipes (11, 12).

j : 36 mm

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

m : 180 N·m (18 kgf·m, 133 lbf·ft) 10. Install the rear axle assembly. (Refer to W4-3-3.)

W4-11-1-8

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 17 18 3 2

19 1

Drain port

90Z6W04-11-14

10 mm (0.39 in)

90Z6W04-11-04

Fill with oil

90Z6W04-11-18

14. Install pump unit (20) with bolts (19) (4 used).

11. Install hoses (3, 4). j : 36 mm

j : 19 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 27 mm

15. Install bracket (18) with bolts (17) (2 used).

m : 80 N·m (8 kgf·m, 59 lbf·ft)

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

12. Insert hoses (3, 4) through grommet assembly (2). Fix grommet (2) with bolts (1) (2 used) j : 13 mm

16. Install oil filter (15 for rear oil cooler) and oil filter (16 for front oil cooler) with bolts (14) (4 used).

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 13. Supply the rear axle with gear oil. (Refer to the Operator's Manual.)

fNOTE: Gear oil amount: 50 L (13 gal)

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

fNOTE: Before installing new filters, fill with clean gear oil.

W4-11-1-9

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler 1

11 2

35°

8 6

30°

20°

A 10 90Z6W04-11-12

View A 13

17. Install hoses (10, 11, 12, 13).

90Z6W04-11-03

19. Install hoses (5, 6, 7).

j : 36 mm

j : 27 mm

m : 180 N·m (18 kgf·m, 133 lbf·ft)

m : 80 N·m (8 kgf·m, 59 lbf·ft)

18. Install hoses (8, 9). j : 19 mm

20. Install plates (1, 2) with bolts (3) (2 used) and bolts (4) (2 used). j : 17 mm

m : 30 N·m (3 kgf·m, 22 lbf·ft)

m : 50 N·m (5 kgf·m, 37 lbf·ft)

j : 22 mm m : 40 N·m (4 kgf·m, 30 lbf·ft)

W4-11-1-10

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler

4 6

12 7 8 2

11 12

90Z6W04-11-02

21. Install plates (9, 10, 11) with bolts (12) (10 used).

Drain port

90Z6W04-11-01

22. Install check valve (8) with bolts (7) (2 used).

j : 19 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

m : 90 N·m (9 kgf·m, 66 lbf·ft) 23. Install hoses (4, 5, 6). j : 27 mm m : 80 N·m (8 kgf·m, 59 lbf·ft) 24. Install hoses (1, 2, 3). j : 36 mm m : 180 N·m (18 kgf·m, 133 lbf·ft) 25. Supply the front axle with gear oil. (Refer to the Operator's Manual.)

fNOTE: Gear oil amount: 50 L (13 gal)

W4-11-1-11

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler (Blank)

W4-11-1-12

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler Structure of Oil Cooler Assembly (Option) 9 3

7 1

4 9

7 9

8 9 90Z6W04-11-19

No.

Part Name

Q’ty

Cover

Oil Cooler

Plate

Bracket

Bolt

Washer

Rubber Cushion

Washer

Nut

Wrench Size j

Tightening Torque N·m

(kgf·m, lbf·ft)

(2.9, 20.7)

13 mm

12 mm

W4-11-2-1

Remark

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler Structure of Oil Cooler Pump Unit (Option)

12 11 6

25 3

7 10 1

17 16 21

2 12 5

4 28 29

33 29

26 19

A 14 13

30 30

90Z6W04-11-20

W4-11-2-2

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler No.

Part Name

Q’ty

Tightening Torque

Wrench Size j

N·m

(kgf·m, lbf·ft)

Oil Pump

Bracket

Spring Washer

Nut

19 mm

Tee Adapter

26 mm

O-Ring

Washer

Adapter

26 mm

Elbow Adapter

22 mm

(5, 37)

O-Ring

Washer

Elbow Adapter

22 mm

(5, 37)

Washer

Elbow Adapter

O-Ring

Washer

Plug

O-Ring

Reducing Valve

22.3 mm

(4.5, 33)

Seal Kit

Flow Control Valve

22.3 mm

(4.5, 33)

Seal Kit

Flared Pipe

27 mm

(8, 59)

Flared Pipe

27 mm

(8, 59)

Block

Elbow Adapter

O-Ring

Washer

Bleed Screw

19 mm

Elbow Adapter

26 mm

O-Ring

Washer

Bolt

17 mm

(5, 37)

Bolt

19 mm

(9, 66)

22 mm

32 mm

W4-11-2-3

Remark

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler Structure of Check Valve Assembly (Option) Front Axle Side 11

9 9

19 18

8 16

14 20 6 7

3 4

2 90Z6W04-11-21

Rear Axle Side

25 3 2

29 27

9 22 12

13 6 11

7 5

30 90Z6W04-11-22

W4-11-2-4

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler No.

Part Name

Q’ty

Tightening Torque

Wrench Size j

N·m

(kgf·m, lbf·ft)

32 mm

(8, 59)

32 mm

(8, 59)

22 mm

(5, 37)

22 mm

(5, 37)

Block

Elbow Adapter

O-Ring

Washer

Elbow Adapter

O-Ring

Washer

Adapter

O-Ring

Washer

Elbow Adapter

Washer

Check Valve

Adapter

22 mm

(5, 37)

Adapter

27 mm

(6, 44)

O-Ring

Elbow Adapter

27 mm

(6, 44)

O-Ring

Washer

Flared Pipe

27 mm

(8, 59)

Tee Adapter

32 mm

(8, 59)

O-Ring

Washer

Tee Adapter

27 mm

(6, 44)

O-Ring

Washer

Elbow Adapter

27 mm

(6, 44)

O-Ring

Washer

Flared Pipe

27 mm

(8, 59)

Block

W4-11-2-5

Remark

SECTION 4 TRAVEL SYSTEM Group 11 Axle Oil Cooler (Blank)

W4-11-2-6

SECTION 5

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment

Removal and Installation of Front Attachment....W5-1-1-1 Installation Position (Lift Arm)..............................W5-1-1-6 Installation Position (Bucket Cylinder)...............W5-1-1-7 Removal and Installation of Lever (Bell Crank).....W5-1-2-1 Installation Position (Lever (Bell Crank))............W5-1-2-6 Installation Position (Bucket Link).......................W5-1-2-7 Installation Position (Bucket Cylinder)...............W5-1-2-8 Removal and Installation of Bucket..........................W5-1-3-1 Installation Position (Lift Arm)..............................W5-1-3-3 Direction of Install (Bucket Link)..........................W5-1-3-4

Group 2 Cylinder

Removal and Installation of Lift Arm Cylinder......W5-2-1-1 Installation Position (Lift Arm Cylinder)............W5-2-1-3 Removal and Installation of Bucket Cylinder........W5-2-2-1 Installation Position (Bucket Cylinder)...............W5-2-2-5 Disassembly of Lift Arm Cylinder..............................W5-2-3-1 Assembly of Lift Arm Cylinder....................................W5-2-3-6 Disassembly of Bucket Cylinder................................W5-2-4-1 Assembly of Bucket Cylinder......................................W5-2-4-6

90Z6 D&R

(Blank)

90Z6 D&R

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Front Attachment 4

1 < EXP Spec. (S/N 0101~) > 6 5

90Z6-W5-01-01-01

Removal

< EU Spec. (S/N 9001~) >

6 3

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Disconnect connectors (1, 2, 3) from front chassis main cable (4). 3. Remove bolts (5) (4 used). Remove head light (6) assembly.

5 1, 2

j : 19 mm

fNOTE: Head light (6) assy weight: S/N 0101~ : 12 kg (27 lb) S/N 9001~ : 14 kg (31 lb)

4. Remove another head light assembly in the same way.

W5-1-1-1

4 90Z6W05-01-01

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

8 4

12 10

5 1 2 3 11 6

7 90Z6-W5-01-01-02

5. Remove 4 each of bolt (1), washer (2), and washer (3). Remove guard (5) and shim (6) from bucket cylinder (4).

90Z6-W5-01-01-03

7. Disconnect connector (8). 8. Remove bolts (9) (2 used) and plate (10). j : 17 mm

j : 19 mm 6. Disconnect connector (7).

9. Remove bolts (11) (2 used). Remove lift arm kick out switch (12) assembly. j : 17 mm

W5-1-1-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

90Z6-W5-01-01-05

dCAUTION: Bucket cylinder (3) weight: 195 kg

13. Remove spacers (7) (2 used) from bucket cylinder (3).

11. Remove grease nipple (4).

14. Start the engine. Retract the rod of bucket cylinder (3). Remove the rod side of bucket cylinder (3) from lever (bell crank) (5).

(430 lb) 10. Attach nylon slings onto bucket cylinder (3). Hoist and hold bucket cylinder (3).

j : 10 mm

dCAUTION: Pin (6) weight: 27 kg (60 lb) dCAUTION: Metal fragments may fly off when

15. Stop the engine. In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube.

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 12. Remove bolt (1) and washers (2, 8). Remove pin (6) from lever (bell crank) (5) using a bar and a hammer.

16. Hoist bucket cylinder (3). Tilt bucket cylinder (3) to the cab side. Secure bucket cylinder (3) by using a rope.

fNOTE: Insert a wooden block between the chassis and

j : 30 mm

W5-1-1-3

cylinder bottom side.

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment a

[ A Detail ]

3, 4, 8, 9 A

5 a-

Wooden block

90WNEC-05-01-14

90Z6-W5-01-01-06

17. Start the engine. Raise lift arm (1) and set lift arm cylinder in the horizontal position.

dCAUTION: Take care that lift arm (1) may lower.

Set the front control lever lock switch to the lock position securely before removing wooden blocks. 18. Stop the engine. Place wooden blocks under the left and right sides of lift arm cylinder (2).

a, b- Wooden block

dCAUTION: Front attachment assembly weight:

90Z6-W5-01-01-09

Approx. 2100 kg (4630 lb) 19. Attach nylon slings onto the front attachment assembly. Hoist and hold the front attachment assembly.

23. Start the engine. Retract the rod side of lift arm cylinder (2). Remove the rod side of lift arm cylinder (2) from lift arm (1).

20. Remove grease fitting (5).

24. Stop the engine. In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube.

j : 10 mm

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 21. Remove bolt (3) and washers (4, 8). Remove pin (6) from lift arm cylinder (2) using a bar and a hammer. j : 24 mm

25. Remove dust seals (7) (2 used) from lift arm (1). 26. Remove another dust seals (7) (2 used) in the same way. 27. Place a wooden block (b) to support the end of lift arm (1) as shown above.

22. Remove pin (6) on the other side in the same way.

W5-1-1-4

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

10 [ A Detail ]

4, 5, 6

10 9

90Z6-W5-01-01-08

90Z6-W5-01-01-07

28. Disconnect the both ends of pipe (8) and remove fitting (7).

30. Remove spacers (10) (2 used) from lift arm (1). 31. Remove another pin (3) in the same way.

j : 17 mm

dCAUTION: Pin (3) weight: 29 kg (64 lb) dCAUTION: Metal fragments may fly off when

IMPORTANT: Move the machine back slowly. At this time, do not contact the front attachment assembly with the front chassis mounting part.

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 29. Remove bolt (4) and washers (5, 6). Remove pin (3) from front chassis (2) using a bar and a hammer. j : 30 mm

32. Start the engine. Move the machine back. Remove the front attachment assembly from front chassis (2). Stop the engine. 33. Place the front attachment assembly on wooden blocks. 34. Remove dust seals (9) (2 used) from lift arm (1). 35. Remove another dust seal (9) (2 used) in the same way.

W5-1-1-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Lift Arm)

1 a

90WNEC-05-01-24

12-

Bushing Lift Arm

ab-

7 mm (0.28 in) 8 mm (0.31 in)

cd-

115 mm (4.53 in) 130 mm (5.12 in)

Installation Direction (Lift Arm)

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installation. Replace them if there are some troubles. (Refer to W2-3-1.) IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin. IMPORTANT: Refer to the illustration when installing the bushing of lift arm.

WNEC-05-01-028 e-

W5-1-1-6

2.5 mm (0.10 in)

15°

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Bucket Cylinder) 2 1 a

90Z6-W5-01-01-10

12-

Bushing Bucket Cylinder

ab-

8.5 mm (0.33 in) 130 mm (5.12 in)

Installation Direction (Bucket Cylinder)

IMPORTANT: Refer to the illustration when installing the bushing of bucket cylinder. IMPORTANT: For handling of bushing for the front attachment, check the followings.

Precautions for installing of bushing: If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. Precautions when reinforcing lift arm: The heat when welding in order to reinforce the lift arm may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

WNEC-05-01-028 c-

W5-1-1-7

2.5 mm (0.10 in)

15°

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment [ A Detail ]

1 10

90Z6-W5-01-01-08

9 2

4, 5, 6

2 1 90Z6-W5-01-01-07

2 a

Installation 1. Install dust seals (9) (2 used) to mounting holes of lift arm (1). Install dust seals (9) (2 used) in opposite side in the same way.

dCAUTION: Front attachment assembly weight: Approx. 2100 kg (4630 lb) 2. Attach nylon slings onto the front attachment assembly. Hoist and hold the front attachment assembly.

Clearance

90Z6-W5-01-01-11

4. Insert spacers (10) to lift arm (1) mounting holes so that clearance (a) between lift arm (1) and front chassis (2) falls within 0.3~1.2 mm (0.01~0.05 in). Install pin (3) to front chassis (2) using a hammer.

fNOTE: Spacer (10) Thickness: 1.2 mm (0.047 in)

3. Start the engine. Move the machine forward. Fit the lift arm (1) holes to front chassis (2). Stop the engine.

dCAUTION: Pin (3) weight: 29 kg (64 lb) dCAUTION: Metal fragments may fly off when

5. Install washers (5, 6) and bolt (4). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft) 6. Attach fitting (7). Connect the both ends of pipe (8) and apply grease. j : 17 mm

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury.

m : 25 N·m (2.5 kgf·m, 18.4 lbf·ft) 7. Install another pin (3) in the same way.

W5-1-1-8

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

2 3, 4, 8, 9

7 90WNEC-05-01-14

5 a-

Wooden block

90Z6-W5-01-01-06

8. Install dust seals (7) (2 used) to mounting holes of lift arm (1). Install dust seal (7) in opposite side in same way. 9. Remove the wires from the rod holes of lift arm cylinder (2). Start the engine. Extend the rod of lift arm cylinder (2). Fit the rod to the mounting holes of lift arm (1). Stop the engine.

dCAUTION: Metal fragments may fly off when

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 10. Install pin (7) to lift arm cylinder (2) using a hammer. 11. Install washers (4, 8), spacer (9), and bolt (3). j : 24 mm m : 270 N·m (27 kgf·m, 199 lbf·ft)

90WNEC-05-01-17

13. Install another pin (6) in the same way.

dCAUTION: Front attachment assembly weight: Approx. 2100 kg (4630 lb) 14. Start the engine. Raise lift arm (1).

dCAUTION: Take care that lift arm (1) may lower.

Set the front control lever lock switch to the lock position securely before removing wooden blocks. 15. Stop the engine. Remove wooden blocks under lift arm (1).

12. Install grease fitting (5). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W5-1-1-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 3

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

90Z6-W5-01-01-05

dCAUTION: Pin (6) weight: 27 kg (60 lb) dCAUTION: Metal fragments may fly off when

a 5 a-

Clearance

90Z6-W5-01-01-12

dCAUTION: Bucket cylinder (3) weight: 195 kg (430 lb) 16. Attach nylon slings onto bucket cylinder (3). Hoist and hold bucket cylinder (3).

a hammer is used. Wear necessary protection, such as goggles, helmets, etc in order to prevent personal injury. 18. Insert spacers (7) to the mounting holes of bucket cylinder (3) so that clearance (a) between bucket cylinder (3) rod and the boss of lever (5) falls within 0.3~1.2 mm (0.01~0.05 in). Install pin (6) to lever (bell crank) (5) using a hammer.

fNOTE: Spacer (7) Thickness: 1.2 mm (0.047 in)

17. Remove the wires from the rod holes of bucket cylinder (3). Start the engine. Extend the rod of bucket cylinder (3). Fit the rod to the mounting holes of lever (bell crank) (5). Stop the engine.

19. Install washers (2, 8) and bolt (1). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft) 20. Install grease fitting (4). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W5-1-1-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

12 10

5 1 2 3

11 6 9

7 90Z6-W5-01-01-03

21. Install lift arm kick out switch (12) assembly with bolts (11) (2 used). . j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft)

90Z6-W5-01-01-02

24. Connect connector (7). 25. Install guard (5) and shim (6) to bucket cylinder (4) with 4 each of bolt (1), washer (2), and washer (3). j : 19 mm

22. Install plate (10) with bolt (9).

m : 90 N·m (9 kgf·m, 66 lbf·ft)

j : 17 mm m : 50 N·m (5 kgf·m, 37 lbf·ft) 23. Connect connector (8).

W5-1-1-11

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

1 < EXP Spec. (S/N 0101~) > 6 5

90Z6-W5-01-01-01

< EU Spec. (S/N 9001~) >

26. Install head light (6) assembly with bolts (5) (4 used). j : 19 mm 6

m : 90 N·m (9 kgf·m, 66 lbf·ft)

fNOTE: Head light (6) assy weight: S/N 0101~ : 12 kg (27 lb) S/N 9001~ : 14 kg (31 lb)

27. Connect connectors (1, 2, 3) to cable (4). 28. Install another head light (6) assembly in the same way.

5 1, 2

4 90Z6W05-01-01

W5-1-1-12

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Lever (Bell Crank))

5 1 2 3

7 90Z6-W5-01-01-02

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove 4 each of bolt (1), washer (2), and washer (3). Remove guard (5) and shim (6) from bucket cylinder (4). j : 19 mm 3. Disconnect connector (7).

W5-1-2-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

2 5

3, 4, 6

8 7

90Z6-W5-01-02-01

CAUTION: Bucket link (2) weight: 79 kg (174 lb) 4. Attach nylon slings onto bucket link (2). Hoist and hold bucket link (2).

dCAUTION: Pin (1) weight: 21 kg (47 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

90WNEC-05-01-10

6. Remove spacers (7) (2 used) from bucket link (2). 7. Lower and remove bucket link (2) from lever (bell crank) (5). 8. Remove dust seals (8) (2 used) from bucket link (2).

such as goggles, helmets, etc in order to prevent personal injury. 5. Remove bolt (3) and washers (4, 6). Remove pin (1) from lever (bell crank) (5) using a bar and a hammer. j : 30 mm

W5-1-2-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

12. Remove spacers (7) (2 used) from bucket cylinder (3).

CAUTION: Bucket cylinder (3) weight: 195 kg (430 lb) 9. Attach nylon slings onto bucket cylinder (3). Hoist and hold bucket cylinder (3).

13. Start the engine. Retract the rod of bucket cylinder (3). Remove the rod side of bucket cylinder (3) from lever (bell crank) (5).

10. Remove grease nipple (4).

14. Stop the engine. In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube.

j : 10 mm

dCAUTION: Pin (6) weight: 27 kg (60 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

90Z6-W5-01-01-05

such as goggles, helmets, etc in order to prevent personal injury. 11. Remove bolt (1) and washers (2, 8). Remove pin (6) from lever (bell crank) (5) using a bar and a hammer.

15. Hoist bucket cylinder (3). Tilt bucket cylinder (3) to the cab side. Secure bucket cylinder (3) by using a rope.

fNOTE: Insert a wooden block between the chassis and

j : 30 mm

W5-1-2-3

cylinder bottom side.

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

[ A Detail ]

3, 4, 10 90Z6-W5-01-02-02

dCAUTION: Pin (8) weight: 27 kg (60 lb) 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. 16. Install pin (8) to lever (bell crank) (1) using a hammer. Install washers (7, 9) and bolt (6).

90Z6-W5-01-02-03

dCAUTION: Pin (5) weight: 50 kg (110 lb) 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. 18. Remove bolt (3) and washers (4, 10). Remove pin (5) from lift arm (2) using a hammer.

j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft) Lever (bell crank) (1) weight: 405 kg dCAUTION: (893 lb) 17. Attach nylon slings onto pin (8) which has been installed in the previous step. Hoist and hold lever (bell crank) (1).

W5-1-2-4

j : 30 mm

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

[ A Detail ]

5 A

4 3 90Z6-W5-01-02-02

19. Remove spacers (3) (2 used) from lever (bell crank) (1). 20. Hoist and remove lever (bell crank) (1) from lift arm (2). 21. Place lever (bell crank) (1) on wooden blocks.

90Z6-W5-01-02-03

dCAUTION: Pin (7) weight: 27 kg (60 lb) 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. 22. Remove bolt (5) and washers (6, 8). Remove pin (7) from lever (bell crank) (1) with using a bar and a hammer. j : 30 mm 23. Remove dust seals (4) (2 used) from lever (bell crank) (1).

W5-1-2-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Lever (Bell Crank)) 1

12-

Lever (bell crank) Bushing

ab-

b 90WNEC-05-01-27

10 mm (0.39 in) 150 mm (5.9 in)

Installation Direction (Lever (Bell Crank))

WNEC-05-01-028 b-

W5-1-2-6

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Bucket Link)

90WNEC-05-01-26 12-

Bucket Link Bushing

ab-

7 mm (0.28 in) 100 mm (3.94 in)

IMPORTANT: Refer to the illustration when installing the bushing of bucket link.

Installation Direction (Bucket Link) b

WNEC-05-01-028 b-

W5-1-2-7

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Bucket Cylinder) 2 1 a

90Z6-W5-01-01-10

12-

Bushing Bucket Cylinder

ab-

8.5 mm (0.33 in) 130 mm (5.12 in)

Installation Direction (Bucket Cylinder)

IMPORTANT: Refer to the illustration when installing the bushing of bucket cylinder. IMPORTANT: For handling of bushing for the front attachment, check the followings.

WNEC-05-01-028 c-

W5-1-2-8

2.5 mm (0.10 in)

15°

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

[ A Detail ]

5 A

4 3 90Z6-W5-01-02-02

90Z6-W5-01-02-03

Lever (bell crank) (1) weight: 405 kg dCAUTION: (893 lb) 3. Attach nylon slings onto pin (7) which has been installed in the previous step. Hoist and hold lever (bell crank) (1). Fit lever (bell crank) (1) mounting holes to lift arm (2).

90WNEC-05-01-21 a-

Clearance

1. Install dust seals (4) (2 used) to lever (bell crank) (1) mounting holes.

dCAUTION: Pin (7) weight: 27 kg (60 lb) 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. 2. Install pin (7) to lever (bell crank) (1) using a hammer. Install washers (6, 8) and bolt (5).

dCAUTION: Pin (8) weight: 50 kg (110 lb) 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. 4. Insert spacers (3) to lever (bell crank) (1) mounting holes so that the clearance (a) falls within 0.3~1.2 mm (0.01~0.05 in). Install pin (8) to lift arm (2) using a hammer.

fNOTE: Spacer (3) Thickness: 1.0 mm (0.039 in)

j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

W5-1-2-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

[ A Detail ]

3, 4, 10 90Z6-W5-01-02-02

5. Install washers (4, 10) and bolt (3) to pin (5). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

90Z6-W5-01-02-03

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. Remove bolt (6) and washers (7, 9). Remove pin (8) from lever (bell crank) (1) using a bar and a hammer. j : 30 mm

W5-1-2-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 3

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

90Z6-W5-01-01-05

dCAUTION: Pin (6) weight: 27 kg (60 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

a 5 a-

Clearance

90Z6-W5-01-01-12

Bucket cylinder (3) weight: 195 kg dCAUTION: (430 lb) 7. Attach nylon slings onto bucket cylinder (3). Hoist and hold bucket cylinder (3). 8. Remove the wires from the rod holes of bucket cylinder (3). Start the engine. Extend the rod of bucket cylinder (3). Fit the rod of bucket cylinder (3) to lever (bell crank) (5) mounting holes. Stop the engine.

such as goggles, helmets, etc in order to prevent personal injury. 9. Insert spacers (7) to the mounting holes of bucket cylinder (3) so that clearance (a) between bucket cylinder (3) rod and the boss of lever (5) falls within 0.3~1.2 mm (0.01~0.05 in). Install pin (6) to lever (bell crank) (5) using a hammer.

fNOTE: Spacer (7) Thickness: 1.2 mm (0.047 in) 10. Install washers (2, 8) and bolt (1). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft) 11. Install grease fitting (4). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W5-1-2-11

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment [ A Detail ]

2 5

3, 4, 6

8 7

dCAUTION: Pin (1) weight: 21 kg (47 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, 90WNEC-05-01-23

90WNEC-05-01-10

90Z6-W5-01-02-01

Clearance

such as goggles, helmets, etc in order to prevent personal injury. 14. Insert spacers (7) to the mounting holes of bucket link (2) so that clearance (a) between bucket link (2) and the boss of lever (5) falls within 0.3~1.2 mm (0.01~0.05 in). Install pin (1) to lever (bell crank) (5) using a hammer.

fNOTE: Spacer (7) Thickness: 1.2 mm (0.047 in)

12. Install dust seals (8) (2 used) to bucket link (2) mounting holes.

15. Install washers (4, 6) and bolt (3).

dCAUTION: Bucket link (2) weight: 79 kg (174 lb)

j : 30 mm

13. Attach nylon slings onto bucket link (2). Hoist and hold bucket link (2). Fit bucket link (2) mounting holes to lever (bell crank) (5).

m : 550 N·m (55 kgf·m, 406 lfb·ft)

W5-1-2-12

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

5 1 2 3

7 90Z6-W5-01-01-02

16. Connect connector (7). 17. Install guard (5) and shim (6) to bucket cylinder (4) with 4 each of bolt (1), washer (2), and washer (3). j : 19 mm m : 90 N·m (9 kgf·m, 66 lbf·ft)

W5-1-2-13

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment (Blank)

W5-1-2-14

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bucket Detail A

3 A

90Z6-W5-01-03-01

7 6

90WNEC-05-01-10

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

5. Remove O-rings (9) (2 used) and spacer (8) from bucket link (6).

2. Starts the engine. Operate lift arm (2). Set bucket (1) horizontally and place it on wooden blocks. Stop the engine.

6. Lower and remove the bucket (1) side of bucket link (6) from bucket (1). 7. Remove dust seals (7) (2 used) from bucket link (6).

dCAUTION: Bucket link (6) weight: 79 kg (174 lb) 3. Attach nylon slings onto bucket link (6). Hoist and hold bucket link (6).

dCAUTION: Pin (3) weight: 21 kg (47 lb) 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. 4. Remove bolt (4) and washers (5, 10). Remove pin (3) from bucket (1) using a bar and a hammer. j : 30 mm

W5-1-3-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

1 7 8 A

CAUTION: (3990 lb)

90Z6-W5-01-03-01

10. Remove O-rings (8) (2 used) and spacers (7) (4 used) from lift arm (2).

Bucket (1) weight (GSN): 1810 kg

fNOTE: The weight differs depending on the bucket type. 8. Attach nylon slings onto bucket (1). Hoist and hold bucket (1).

dCAUTION: Pin (3) weight: 20 kg (45 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

90Z6-W5-01-03-02

11. Remove another pin (3) in the same way. 12. Hoist and remove bucket (1) from lift arm (2). 13. Place bucket (1) on wooden blocks. 14. Remove dust seals (6) (2 used) from lift arm (2).

such as goggles, helmets, etc in order to prevent personal injury. 9. Remove bolt (4) and washers (5, 9). Remove pin (3) from bucket (1) using a bar and a hammer.

15. Remove dust seals (6) (2 used) in opposite side in the same way.

j : 30 mm

W5-1-3-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Installation Position (Lift Arm)

1 a

90WNEC-05-01-24

12-

Bushing Lift Arm

ab-

7 mm (0.28 in) 8 mm (0.31 in)

cd-

115 mm (4.53 in) 130 mm (5.12 in)

Installation Direction (Lift Arm)

WNEC-05-01-028 e-

W5-1-3-3

2.5 mm (0.10 in)

15°

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Direction of Install (Bucket Link)

90WNEC-05-01-26 12-

Bucket Link Bushing

ab-

7 mm (0.28 in) 100 mm (3.94 in)

Direction to Install (Bucket Link)

IMPORTANT: Refer to the illustration when installing the bushing of bucket link. IMPORTANT: For handling of HN bushing for the front attachment, check the followings.

Precautions for installing of bushing: If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing. Precautions when reinforcing lift arm and bucket link: The heat when welding in order to reinforce the lift arm and bucket link may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

WNEC-05-01-028 b-

W5-1-3-4

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

1 7 8 A

90Z6-W5-01-03-01 a

dCAUTION: Pin (3) weight: 20 kg (45 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

90WNEC-05-01-22 a-

90Z6-W5-01-03-02

Clearance

such as goggles, helmets, etc in order to prevent personal injury. 3. Insert spacers (7) (2 used) to lift arm (2) mounting holes so that clearance (a) between lift arm (2) and the boss of bucket (1) falls within 0.3~1.2 mm (0.01~0.05 in). Install O-rings (8) (2 used). Install pin (3) to bucket (1) using a hammer.

fNOTE: Spacer (7) Thickness: 1.0 mm (0.039 in) 1. Install dust seals (6) (2 used) to lift arm (2) mounting holes. Install dust seals (6) (2 used) in opposite side in the same way.

CAUTION: (3990 lb)

4. Install washers (5, 9) and bolt (4). j : 30 mm

Bucket (1) weight (GSN): 1810 kg

m : 550 N·m (55 kgf·m, 406 lfb·ft)

fNOTE: The weight differs depending on the bucket type. 2. Attach nylon slings onto bucket (1). Hoist and hold bucket (1). Fit bucket (1) mounting holes to lift arm (2).

5. Install another pin (3) in the opposite side in the same way.

W5-1-3-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

[ A Detail ]

3 A

9 2

90Z6-W5-01-03-01

90WNEC-05-01-10

dCAUTION: Pin (3) weight: 21 kg (47 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, 90WNEC-05-01-19 a-

Clearance

6. Install dust seals (7) (2 used) to bucket link (6) mounting holes.

fNOTE: Spacer (8) Thickness: 1.0 mm (0.039 in)

dCAUTION: Bucket link (6) weight: 79 kg (174 lb) 7. Attach nylon slings onto bucket link (6). Hoist and hold bucket link (6).

such as goggles, helmets, etc in order to prevent personal injury. 9. Insert spacers (8) (2 used) to bucket link (6) mounting holes so that clearance (a) between bucket link (6) and the boss of bucket (1) falls within 0.3~1.2 mm (0.01~0.05 in). Install O-rings (9) (2 used). Install pin (3) to bucket (1) using a hammer.

10. Install washers (5, 10) and bolt (4). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

8. Start the engine. Operate the bucket cylinder. Fit bucket link (6) mounting holes to bucket (1). Stop the engine.

W5-1-3-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Lift Arm Cylinder a 1

[ A Detail ]

1 2 3, 4, 8, 9 6 7 7

90WNEC-05-01-14

5 a-

90Z6-W5-02-01-01

Wooden block

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. 5. Remove bolt (3), washers (4, 8), and spacer (9). Remove pin (6) from lift arm cylinder (2) using a bar and a hammer. j : 24 mm

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Start the engine. Raise lift arm (1). Set lift arm cylinder (2) in the horizontal position. Operate the bucket cylinder. Dump and place the bucket on wooden blocks. Stop the engine. Lift arm cylinder (2) weight: 185 kg dCAUTION: (407 lb) 3. Attach nylon slings onto lift arm cylinder (2). Hoist and hold lift arm cylinder (2).

6. Start the engine. Retract lift arm cylinder (2). Remove lift arm cylinder (2) from lift arm (1). 7. Stop the engine. In order not to extend the rod, pass the wires through the rod hole of lift arm cylinder (2) and secure the rod to the cylinder tube. 8. Remove dust seals (7) (2 used) from lift arm (1).

4. Remove grease nipple (5). j : 10 mm

W5-2-1-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

3, 4

7, 8

5 1 9 90Z6-W5-02-01-03

90Z6-W5-02-01-02

d Release any pressure in the front dCAUTION: hydraulic circuit. (Refer to W1-5-1.)

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

9. Place containers under the disconnecting part of hoses (1) (2 used). Remove bolts (2) (8 used) and flanges (3) (4 used). Disconnect hoses (1) (2 used). Remove O-rings (4) (2 used). l : 8 mm

10. Remove grease nipple (5). j : 10 mm

dCAUTION: Pin (9) weight: 22 kg (48.5 lb) 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. 11. Remove bolt (7) and washer (8). Remove pin (9) from front chassis (6) using a bar and a hammer. j : 30 mm 12. Hoist and remove lift arm cylinder (10). 13. Remove another lift arm cylinder (10) in the same manner.

W5-2-1-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation Position (Lift Arm Cylinder) 2

90WNEC-05-01-38 12-

Lift Arm Cylinder Bushing

ab-

6.5 mm (0.26 in) 115 mm (4.53 in)

Installation Direction (Lift Arm Cylinder)

IMPORTANT: For handling of HN bushing for the front attachment, check the followings. Precautions for installing bushing: If a hammer is used to install the bushing, the bushing may be damaged. Use a press for installing bushing.

WNEC-05-01-028 b-

Precautions when reinforcing lift arm: The heat when welding in order to reinforce the lift arm may cause oil leakage and decrease lubrication performance. When lubrication oil leaks, replace the bushing.

W5-2-1-3

2.5 mm (0.098 in)

15 °

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

3, 4

7, 8

1 9 90Z6-W5-02-01-03

CAUTION: Lift arm cylinder (10) weight: 185 kg (407 lb) 1. Attach nylon slings onto lift arm cylinder (10). Hoist and hold lift arm cylinder (10). Fit mounting holes on the bottom side of lift arm cylinder (10) to front chassis (6).

90Z6-W5-02-01-02

5. Install O-rings (4) (2 used). Install hoses (1) (2 used) with flanges (3) (4 used) and bolts (2) (8 used).

dCAUTION: Pin (9) weight: 22 kg (48.5 lb) 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. 2. Install pin (9) to front chassis (6) using a hammer. 3. Install bolt (7) and washer (8). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft) 4. Install grease fitting (5). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W5-2-1-4

l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

a 1

[ A Detail ]

1 2 3, 4, 8, 9 6 7 7

90WNEC-05-01-14

5 a-

90Z6-W5-02-01-01

Wooden block

6. Remove the wires from the rod holes of lift arm cylinder (2).

10. Install grease fitting (5). Apply grease. j : 10 mm

7. Start the engine. Extend lift arm cylinder (2). Fit the rod to the lift arm (1) mounting holes. Stop the engine. Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection,

such as goggles, helmets, etc in order to prevent personal injury. 8. Install dust cylinders (7) (2 used) to lift arm cylinder (2). Install pin (6) using a hammer.

m : 4 N·m (0.4 kgf·m, 3 lbf·ft) 11. Install another lift arm cylinder (2) in the same manner. 12. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

9. Install washer (4) and bolt (3). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

W5-2-1-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-1-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder

5, 6 2 1 8 9

4 90Z6-W5-01-01-02

90Z6-W5-02-02-01

4. Remove nut (5) and clip (6). j : 12 mm 5. Disconnect the both ends of pipe (7).

1. Set the machine position for inspection and maintenance. (Refer to W1-6-1.) 2. Remove 4 each of bolt (1), washer (8), and washer (9). Remove guard (2) and shim (10) from bucket cylinder (3). j : 19 mm 3. Disconnect connector (4).

W5-2-2-1

j : 17 mm

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

CAUTION: Bucket cylinder (3) weight: 195 kg (430 lb) 6. Attach nylon slings onto bucket cylinder (3). Hoist and hold bucket cylinder (3). 7. Remove grease nipple (4). j : 10 mm

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

90Z6-W5-01-01-05

9. Remove spacers (7) (4 used) from bucket cylinder (3). 10. Start the engine. Retract the rod of bucket cylinder (3). Remove the rod side of bucket cylinder (3) from lever (bell crank) (5). 11. Stop the engine. In order not to extend the rod, pass a wire through the rod hole and secure the rod to the cylinder tube.

Pin (6) weight: 27 kg (60 lb)

such as goggles, helmets, etc in order to prevent personal injury. 8. Remove bolt (1) and washers (2, 8). Remove pin (6) from lever (bell crank) (5) using a bar and a hammer. j : 30 mm

W5-2-2-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

2, 3, 4 5, 6, 7

90Z6-W5-02-02-02

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.) 12. Place a container under the disconnecting part of hose (1). 13. Remove bolts (2) (4 used) and flanges (3) (2 used). Disconnect hose (1). Remove O-ring (4). l : 8 mm 14. Place a container under the disconnecting part of hose (8). 15. Remove bolts (5) (4 used) and flanges (6) (2 used). Disconnect hose (8). Remove O-ring (7). l : 8 mm

W5-2-2-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

[ A Detail ]

9 2

4, 5, 6 90Z6-W5-02-02-03

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. 16. Remove bolt (4) and washer (5). Remove pin (1) from front chassis (3) using a bar and a hammer.

90Z6-W5-02-02-04

17. Remove spacers (9) (2 used) from bucket cylinder (2). 18. Remove bucket cylinder (2) from front chassis (3). 19. Hoist and remove bucket cylinder (2).

j : 30 mm

W5-2-2-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Installation Position (Bucket Cylinder) 2 1 a

90Z6-W5-01-01-10

12-

Bushing Bucket Cylinder

ab-

8.5 mm (0.33 in) 130 mm (5.12 in)

Installation Direction (Bucket Cylinder)

IMPORTANT: Refer to the illustration when installing the bushing of bucket cylinder. IMPORTANT: For handling of bushing for the front attachment, check the followings.

WNEC-05-01-028 c-

W5-2-2-5

2.5 mm (0.10 in)

15°

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

[ A Detail ]

9 2

4, 5, 6 90Z6-W5-02-02-04

90Z6-W5-02-02-03

Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, 3 a

5 a-

Clearance

90WNEC-05-02-32

such as goggles, helmets, etc in order to prevent personal injury. 2. Insert spacers (9) (2 used) to the mounting holes of bucket cylinder (2) so that clearance (a) between bucket cylinder (3) and the boss of front chassis (3) falls within 0.3~1.2 mm (0.01~0.05 in).

fNOTE: Spacer (7) Thickness: 1.2 mm (0.047 in)

Bucket cylinder (3) weight: 195 kg dCAUTION: (430 lb)

3. Install pin (1) to front chassis (3).

1. Attach nylon slings onto bucket cylinder (2). Hoist and hold bucket cylinder (2). Fit bucket cylinder (2) mounting holes to front chassis (3).

4. Install washers (5, 6) and bolt (4). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

W5-2-2-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

2, 3, 4 5, 6, 7

1 15°

90Z6-W5-02-02-02

5. Install O-ring (7). Connect hose (8) with flanges (6) (2 used) and bolts (5) (4 used). l : 8 mm

90Z6-W5-02-02-05

IMPORTANT: Check the installation angle of hose (1). 6. Install O-ring (4). Connect hose (1) with flanges (3) (2 used) and bolts (2) (4 used).

m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

l : 8 mm m : 65 N·m (6.5 kgf·m, 48 lbf·ft)

W5-2-2-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 3

[ A Detail ]

3 1, 2, 8 5 6

90Z6-W5-01-01-04

90Z6-W5-01-01-05

9. Insert spacers (7) (2 used) to the mounting holes of bucket cylinder (3) so that clearance (a) between bucket cylinder (3) and the boss of lever (bell crank) (5) falls within 0.3~1.2 mm (0.01~0.05 in).

fNOTE: Spacer (7) thickness: 1.2 mm (0.047 in) 5

a 90WNEC-05-01-18

Clearance

dCAUTION: Pin (6) weight: 27 kg (60 lb) 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. 10. Install pin (6) to lever (bell crank) (5) using a hammer.

7. Remove the wires from the rod holes of bucket cylinder (3). 8. Start the engine. Extend bucket cylinder (3). Fit the rod to lever (bell crank) (5) mounting holes.

11. Install washers (2) and bolt (1). j : 30 mm m : 550 N·m (55 kgf·m, 406 lfb·ft)

Stop the engine.

12. Install grease nipple (4). Apply grease. j : 10 mm m : 4 N·m (0.4 kgf·m, 3 lbf·ft)

W5-2-2-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

5, 6

2 1 8 9

4 90Z6-W5-02-02-01

13. Connect the both ends of pipe (7). j : 17 mm m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft)

90Z6-W5-01-01-02

15. Connect connector (4). 16. Install guard (2) and shims (10) (4 used) to bucket cylinder (3) with 4 each of bolt (1), washer (8), and washer (9).

14. Install clip (6) with nut (5). Apply grease.

j : 19 mm

j : 12 mm

m : 90 N·m (9 kgf·m, 66 lbf·ft)

m : 20 N·m (2 kgf·m, 14.8 lbf·ft) 17. Bleed air from the hydraulic system. (Refer to W1-41.) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

W5-2-2-9

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-2-10

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Lift Arm Cylinder

3 6 7 5

43 37

27 25

24 34

45 46

9 11 10

2 29

1 20 23

16 13

W4GB-04-02-022

123456789101112-

Socket Bolt (12 Used) Set Screw Pin Wiper (2 Used) Pin Bushing (2 Used) Pipe Band Socket Bolt (2 Used) Spring Washer (2 Used) Pipe Band Pipe Clamp Socket Bolt Spring Washer Dust Seal

131415161718192021222324-

Retaining Ring U-Packing Buffer Seal Rod Cover O-Ring O-Ring Backup Ring Rod Bushing Retaining Ring Cylinder Tube Rod Piston

252627282930313233343536-

Dust Ring Packing Wear Ring O-Ring Backup Ring (2 Used) Piston Nut Set Screw Spring Washer (4 Used) Socket Bolt (4 Used) Pipe O-Ring Pipe

W5-2-3-1

37383940414243444546-

O-Ring Spring Washer (2 Used) Socket Bolt (2 Used) Pipe Band Spring Washer (4 Used) Socket Bolt (4 Used) Pipe Band Pipe Clamp Spring Washer Socket Bolt

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Head cover (tail end) part

High pressure hose

Apply low pressure air

Oil container

W4GB-04-02-024

W4GB-04-02-023

Disassembly CAUTION: Lift arm cylinder weight: 185 kg (408 dlb) IMPORTANT: Do not secure cylinder tube (22) or pipes (34, 36). Use a wooden block with the V-groove. 1. Secure the cylinder assembly on a workbench. Secure the parallel surface of the cylinder assembly at the head cover (tail end) part of cylinder tube (22) in order not to move.

4. Remove 4 each of socket bolts (33, 42) (4 each used) from pipes (34, 36). Remove bolts (46, 10) and spring washers (45, 11) from clamps (44, 9). Remove clamps (44, 9) and disconnect pipes (34, 36) from cylinder tube (22). l : 8 mm j : 19 mm j : 17 mm

Apply low-pressure air slowly and dCAUTION: adjust the extension speed of piston rod (23).

Prevent personal injury by making sure all area is clear and co-workers are out of the extension direction of piston rod (23). 2. Temporary connect a high-pressure hose to the port of the piston rod (23) side, and put the other end in an oil container of 10 L (3 gal) capacity or more. Apply low-pressure air from pipe (36) and drain oil from the rod cover (16) side. 3. Adjust the extended piston rod (23) position by using a crane or a wooden block in order to align piston rod (23) and cylinder tube (22).

5. Remove socket bolts (1) (12 used) from rod cover (16). l : 14 mm IMPORTANT: Be careful not to damage the surface of piston rod (30) by covering with a cloth. 6. Install set screw (2) in the flange of rod cover (16) to make clearance between the mating surface of the flange. Insert a screwdriver in the clearance. Pry it and remove rod cover (16) from cylinder tube (22). l : 6 mm 7. Attach a nylon sling onto piston rod (23). Hoist and hold piston rod (23). Slowly remove piston rod (23) assembly from cylinder tube (22) by moving around.

W5-2-3-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Hammer

Spatula

24 Screwdriver

Seal ring

Back ring

24 W4GB-04-02-004

IMPORTANT: Do not secure the chromium plated surface of piston rod (23). Secure at the rod head part. 8. Secure the parallel surface of the piston rod (23) assembly in order not to move.

W4GB-04-02-005

14. Remove the backup ring on both sides of packing (26) from piston (24). IMPORTANT: When cutting packing (26), place piston (24) on a stable V-block. Do not damage the seal groove by a cut-off tool. 15. Cut and remove center packing (26) (seal ring and back ring) as shown above.

9. Remove set screw (31) from piston nut (30). l : 4 mm

fNOTE: As set screw (31) is crimped at the piston nut (30) side, remove set screw (31) slowly by applying oil onto the thread part and repeating "loosening and screwing."

16. Remove O-ring (28) and backup rings (29) (2 used) from piston (24) bore part by using a spatula.

10. Remove piston nut (M75, P2, D106) (30) from piston rod (23). 11. Remove piston (M90, P3) (24) from piston rod (23) while holding the cylinder. 12. Remove rod cover (16) from piston rod (23). 13. Remove wear ring (27) and dust ring (25) from piston (24).

W5-2-3-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

3 6 7 5

43 37

27 25

24 34

45 46

9 11 10

2 29

1 20 23

16 13

W4GB-04-02-022

W5-2-3-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Spatula

18 Screwdriver

Spatula

W4GB-04-02-006

W4GB-04-02-008

20. Remove retaining ring (13) from rod cover (16).

17. Place rod cover (16) on a workbench which is covered with a rag for slip resistance. 18. Remove O-ring (18) and backup ring (19) from the outer periphery of rod cover (16).

Screwdriver Hammer

Awl

14 15

Vise

W4GB-04-02-007

19. Puncture and remove U-packing (14) and buffer seal (15) from rod cover (16) by using an awl.

W4GB-04-02-009

21. Remove dust seal (12) from rod cover (16). 22. As rod bushing (20) has been installed in rod cover (16) tightly, it is difficult to remove rod bushing (20) from rod cover (16). Replace damaged or worn rod bushing (20) as follows. 1) Remove retaining ring (21) from rod cover (16). 2) Install rod cover (16) to a lathe. Do the centering correctly. 3) Cut rod bushing (20) until the thickness is thin enough. Deform and remove rod bushing (20) by using a needle-nosed screwdriver.

W5-2-3-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Lift Arm Cylinder 1

A 6, 7

8 16

23 D

32, 33

34, 35

38, 39

41, 42

36, 37

25 26 27 28, 29

14 15 17 18, 19

10, 11 View A-A

30, 31

24 12, 13

45, 46 20

C Detail

D Detail

View B-B W4GB-04-02-026

123456789101112-

Socket Bolt (12 Used) Set Screw Pin Wiper (2 Used) Pin Bushing (2 Used) Pipe Band Socket Bolt (2 Used) Spring Washer (2 Used) Pipe Band Pipe Clamp Socket Bolt Spring Washer Dust Seal

131415161718192021222324-

Retaining Ring U-Packing Buffer Seal Rod Cover O-Ring O-Ring Backup Ring Rod Bushing Retaining Ring Cylinder Tube Rod Piston

252627282930313233343536-

Dust Ring Packing Wear Ring O-Ring Backup Ring (2 Used) Piston Nut Set Screw Spring Washer (4 Used) Socket Bolt (4 Used) Pipe O-Ring Pipe

W5-2-3-6

37383940414243444546-

O-Ring Spring Washer (2 Used) Socket Bolt (2 Used) Pipe Band Spring Washer (4 Used) Socket Bolt (4 Used) Pipe Band Pipe Clamp Spring Washer Socket Bolt

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Hammer

Pressing tool

Press Fitting tool

16 20

W4GB-04-02-013

16 Pressing tool Metal part W4GB-04-02-012

12 W4GB-04-02-014

Assembly 1. Install rod bushing (20) into rod cover (16) by using a press and a fitting tool. IMPORTANT: Align rod bushing (20) with the center of the mounting hole and place vertically. Apply oil onto the inner surface of the mounting hole. Install rod bushing (20). After installation, clean again and remove metal powder.

3. Install dust seal (12) by using a hammer.

fNOTE: • Align dust seal (12) with the mounting hole and place vertically. • A tool as shown above makes the seal installation easier. Evenly contact the special tool with the metal part of dust seal (12). • Before installation, apply oil onto the inner surface of the hole. After installation, clean again and remove metal powder.

2. Install retaining ring (21) to rod cover (16). IMPORTANT: Check that rod bushing (20) and retaining ring (21) are installed completely.

4. Install retaining ring (13). IMPORTANT: Check that dust seal (12) and retaining ring (13) are installed completely.

W5-2-3-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Piston Seal Tool

Insert seal into the groove from this side.

Slide ring Back ring of packing (26)

Seal Deformation

W4GB-04-02-015

24 17

W4GB-04-02-018

8. Install the back ring of packing (26) to piston (24). • A tool with slope as shown above makes the ring installation easier.

W4GB-04-02-016

R part

Heat the seal ring of packing (26) with dCAUTION: oil heated by an electric heater. Avoid direct heat by using fire. 9. Warm up the seal ring of packing (26) to 150 to 180°C (302 to 365 °F). Quickly install the seal ring to the seal groove of piston (24).

Pressing tool

Buffer seal installation direction W4GB-04-02-017

5. Install U-packing (14) and buffer seal (15) to the inside of rod cover (16).

W4GB-04-02-019

6. Install O-ring (18) and backup ring (19) to the outer periphery of rod cover (16).

10. Adjust the stretched seal ring to the previous shape.

fNOTE: A flat pressing tool may help to fit the seal.

7. Install O-ring (17) to the flange part of rod cover (16).

W5-2-3-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

IMPORTANT: Apply a thin coat of hydraulic oil onto O-ring (28) and the thread part on the inner part of piston (24). 15. Install a bolt to the screw hole at the end of piston (24). Install piston (M90, P3) (24) to rod (23). After tightening piston (24), remove the bolt.

Backup ring

Bolt size: M10 x 20 mm (2 used)

Seal ring

W4GB-04-02-020

m Piston (24): 981±98 N·m (100±10 kgf·m, 720±72 lbf·ft)

11. Install backup rings to both sides of the seal ring on packing (26).

IMPORTANT: Apply a thin coat of hydraulic oil onto the thread part of piston nut (30). 16. Install piston nut (M75, P2, D106) (30).

m : 1865±186 N·m (190±19 kgf·m, 1375±137 lbf·ft)

17. Apply LOCTITE #242 onto the thread part of set screw (31). Install set screw (31) to piston nut (30). 29

l : 4 mm m : 14.7 N·m (1.5 kgf·m, 11 lbf·ft)

fNOTE: Wipe out extruded LOCTITE. Caulk screw holes (2 places) diagonally by using a center punch.

W4GB-04-02-021

12. Install O-ring (28) and backup rings (29) (2 used) to the inner side of piston (24). IMPORTANT: Wear ring (27) and dust ring (25) are not used until the installation to the cylinder tube (22). The figure above shows the final assembly of piston (24). 13. Secure piston rod (23) on a workbench.

18. Place cylinder tube (22) on a workbench horizontally. Secure the parallel surface of the head cover. IMPORTANT: Prevent wear ring (27) and dust seal (25) from falling off. 19. Install wear ring (27) and dust ring (25) in the outer periphery of piston (24). Apply oil. 20. Hoist at the center of gravity part of rod (23). Insert piston (24) into cylinder tube (22) by moving around.

IMPORTANT: Apply a thin coat of hydraulic oil onto the special tool and the surface of rod (23) in order to protect the seals. 14. Install rod cover (16) to rod (23).

W5-2-3-9

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

A 6, 7

8 16

23 D

32, 33

34, 35

38, 39

41, 42

36, 37

25 26 27 28, 29

14 15 17 18, 19

10, 11 View A-A

30, 31

24 12, 13

45, 46 20

C Detail

D Detail

View B-B W4GB-04-02-026

W5-2-3-10

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 21. Align rod cover (16) with the screw hole of the flange part in cylinder tube (11). Tighten with socket bolts (1) (12 used). l : 14 mm m : 422 to 441 N·m (48 to 50 kgf·m, 311 to 325 lbf·ft)

fNOTE: Apply LOCTITE #242 onto the thread part of socket bolt (1).

IMPORTANT: Cover rod (23) with a cloth in order to prevent its surface from being damaged. 15. Apply low-pressure air to the port in the rod side of cylinder tube (22). Retract rod (23). 16. Install pipes (34, 36) with socket bolts (33, 42), spring washers (32, 41), bolts (6, 39) and spring washers (7, 38). l : 8 mm m： 110 to 120 N·m (11 to 12 kgf·m, 80 to 85 lbf·ft) j : 17 mm j : 19 mm m： 55 to 60 N·m (5.5 to 6 kgf·m, 40 to 45 lbf·ft)

W5-2-3-11

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-3-12

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Bucket Cylinder

7 1

6 30

28 27 24 21

23 22

29 13 32 17 15

20 33

1 90Z6-W5-02-04-01

12345678910-

Wiper (4 used) Bushing (2 used) Bushing (2 used) Socket Bolt Spring Washer Pipe Socket Bolt (4 used) Spring Washer (4 used) Retaining Ring Dust Seal

11121314151617181920-

U-Packing Buffer Seal Rod Cover O-Ring O-Ring Backup Ring Rod Bushing Retaining Ring Cylinder Tube Rod

21222324252627282930-

Piston O-Ring Packing Wear Ring O-Ring Backup Ring (2 used) O-Ring Piston Nut Set Screw O-Ring

W5-2-4-1

31- Set Screw 32- Socket Bolt (18 used) 33- Socket Bolt (4 used)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly CAUTION: Bucket cylinder weight: 195 kg (430 dlb) 19

Head cover (tail end) part

W4GB-04-02-003

IMPORTANT: Do not secure at cylinder tube (19). Use a wooden block with the V-groove. 1. Secure the cylinder assembly on a workbench. Secure the parallel surface of the cylinder assembly at the head cover (tail end) part of cylinder tube (19) in order not to move.

IMPORTANT: Be careful not to damage the surface of piston rod (20) by covering with a cloth. 4. Adjust the extended piston rod (20) position by using a crane or a wooden block in order to align piston rod (20) and cylinder tube (19). 5. Remove socket bolts (7) (4 used) and socket bolt (4) from pipe (6). Disconnect pipe (6) from cylinder tube (19). l : 10 mm

High pressure hose

l : 19 mm 6. Remove socket bolts (32) (18 used) from rod cover (13). Apply low pressure air

Oil container

l : 14 mm

W4GB-04-02-003

2. Temporary connect a high-pressure hose to the port of the piston rod (20) side, and put the other end in an oil container of 10 L (3 gal) capacity or more. CAUTION: Apply low-pressure air slowly and dadjust the extension speed of piston rod (20).

Prevent personal injury by making sure all area is clear and co-workers are out of the extension direction of piston rod (20). 3. Apply low-pressure air from pipe (6) and drain oil from the rod cover (13) side.

7. Install set screw (31) in the flange part of rod cover (13) to make clearance between the mating surface of the flange. 8. Insert a screwdriver in the clearance. Pry it and remove rod cover (13) from cylinder tube (9). 9. Attach a nylon sling onto piston rod (20). Hoist and hold piston rod (20). Remove piston rod (20) slowly from cylinder tube (19) by moving around.

W5-2-4-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Hammer

Spatula Screwdriver

Seal ring

Back ring

21 W4GB-04-02-005

W4GB-04-02-004

IMPORTANT: Do not secure the chromium plated surface of piston rod (20). Secure at the rod head part. 10. Secure the parallel surface of the piston rod (20) assembly in order not to move.

16. Remove the backup ring on both sides of packing (23) from piston (21).

11. Remove set screw (29) from piston nut (28).

fNOTE: As set screw (29) is crimped at the piston nut (28) side, remove set screw (29) slowly by applying oil onto the thread part and repeating "loosening and screwing."

IMPORTANT: When cutting packing (23), place piston (21) on a stable V-block. Do not damage the seal groove by a cut-off tool. 17. Cut and remove center packing (23) (seal ring and back ring) as shown above. 18. Remove O-ring (25) and backup rings (26) (2 used) from piston (21) bore part by using a spatula.

12. Remove piston nut (M90, P2, D127) (28) from piston rod (20). 13. Remove piston (M105, P3) (21) from piston rod (20) while holding the cylinder. 14. Remove rod cover (13) from piston rod (20). 15. Remove wear ring (24) and O-ring (27) from piston (21).

W5-2-4-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

7 1

6 30

28 27 24 21

23 22

29 13 32 17 15

12 31

20 33

1 90Z6-W5-02-04-01

W5-2-4-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Spatula

15 Screwdriver

Spatula

W4GB-04-02-008

W4GB-04-02-006

19. Place rod cover (13) on a workbench which is covered with a rag for slip resistance.

22. Remove retaining ring (9) from rod cover (13).

20. Remove O-ring (15) and backup ring (16) from the outer periphery of rod cover (13).

Screwdriver Hammer

Awl

11 12

Vise

W4GB-04-02-007

21. Puncture and remove U-packing (11) and buffer seal (12) from rod cover (13) by using an awl.

W4GB-04-02-009

23. Remove dust seal (10) from rod cover (13). 24. As rod bushing (17) has been installed in rod cover (13) tightly, it is difficult to remove rod bushing (17) from rod cover (13). Replace damaged or worn rod bushing (17) as follows. 1) Remove retaining ring (18) from rod cover (13). 2) Install rod cover (13) to a lathe. Do the centering correctly. 3) Cut rod bushing (17) until the thickness is thin enough. Deform and remove rod bushing (17) by using a needle-nose screwdriver.

W5-2-4-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Bucket Cylinder 1

4, 5 13

7, 8

6 19

30 C

A 33 15, 16 10 11 12

23 24 27 28

18 21

View A

25, 26

B Detail

C Detail 90Z6-W5-02-04-02

12345678910-

Wiper (4 used) Bushing (2 used) Bushing (2 used) Socket Bolt Spring Washer Pipe Socket Bolt (4 used) Spring Washer (4 used) Retaining Ring Dust Seal

11121314151617181920-

U-Packing Buffer Seal Rod Cover O-Ring O-Ring Backup Ring Rod Bushing Retaining Ring Cylinder Tube Rod

21222324252627282930-

Piston O-Ring Packing Wear Ring O-Ring Backup Ring (2 used) O-Ring Piston Nut Set Screw O-Ring

W5-2-4-6

31- Set Screw 32- Socket Bolt (18 used) 33- Socket Bolt (4 used)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Hammer

Pressing tool Press

Fitting tool

13 13

W4GB-04-02-013 Pressing tool Metal part

W4GB-04-02-012

10 W4GB-04-02-014

Assembly 1. Install rod bushing (17) into rod cover (13) by using a press and a fitting tool. IMPORTANT: Align rod bushing (17) with the center of the mounting hole and place vertically. Apply oil onto the inner surface of the mounting hole. Install rod bushing (17). After installation, clean again and remove metal powder.

3. Install dust seal (10) by using a hammer.

fNOTE: • Align dust seal (10) with the mounting hole and place vertically. • A tool as shown above makes the seal installation easier. Evenly contact the tool with the metal part of dust seal (10). • Before installation, apply oil onto the inner surface of the hole. After installation, clean again and remove metal powder.

2. Install retaining ring (18) to rod cover (13). IMPORTANT: Check that rod bushing (17) and retaining ring (18) are installed completely.

4. Install retaining ring (9). IMPORTANT: Check that dust seal (10) and retaining ring (9) are installed completely.

W5-2-4-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Piston Seal Insert seal into the groove from this side.

Tool

Slide ring Back ring of packing (23)

Seal Deformation W4GB-04-02-015

W4GB-04-02-018

8. Install the back ring of packing (23) to piston (21). • A tool with slope as shown above makes the ring installation easier. Heat the seal ring of packing (23) with dCAUTION: oil heated by an electric heater. Avoid direct heat 11

W4GB-04-02-016

R part

by using fire. 9. Warm up the seal ring of packing (23) to 150 to 180°C (302 to 365 °F). Quickly install the seal ring to the seal groove of piston (21).

Pressing tool

Buffer seal installation direction W4GB-04-02-017

5. Install U-packing (11) and buffer seal (12) to the inside of rod cover (13).

W4GB-04-02-019

6. Install O-ring (15) and backup ring (16) to the outer periphery of rod cover (13). 7. Install O-ring (14) to the flange part of rod cover (13).

10. Adjust the stretched seal ring to the previous shape.

fNOTE: A flat pressing tool may help to fit the seal.

W5-2-4-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

IMPORTANT: Apply a thin coat of hydraulic oil onto O-ring (25) and the thread part on the inner part of piston (21). 15. Install a bolt to the screw hole at the end of piston (21). Install piston (M105, P3) (21) to rod (20). After tightening piston (21), remove the bolt.

Backup ring

Bolt size: M12 x 25 mm (2 used)

Seal ring

W4GB-04-02-020

m : 981±98 N·m (100±10 kgf·m, 720±72 lbf·ft)

11. Install backup rings to both sides of the seal ring on packing (23).

IMPORTANT: Apply a thin coat of hydraulic oil onto the thread part of piston nut (28). 16. Install piston nut (M90, P2, D127) (28).

m : 1865±186 N·m (190±19 kgf·m, 1375±137 lbf·ft)

17. Apply LOCTITE #242 onto the thread part of set screw (29). Install set screw (29) to piston nut (28).

l : 4 mm m : 14.7 N·m (1.5 kgf·m, 11 lbf·ft)

fNOTE: Wipe out extruded LOCTITE. Caulk screw holes (2 places) diagonally by using a center punch.

W4GB-04-02-021

12. Install O-ring (25) and backup rings (26) to the inner side of piston (21). IMPORTANT: Wear ring (24) and O-rings (22, 27) are not used until the installation to the cylinder tube (19). The figure above shows the final assembly of piston (21).

18. Place cylinder tube (19) on a workbench horizontally. Secure the parallel surface of the head cover. IMPORTANT: Prevent wear ring (24) and O-rings (22, 27) from falling off. 19. Install wear ring (24) and O-rings (22, 27) in the outer periphery of piston (21). Apply oil. 20. Hoist at the center of gravity part of rod (20). Insert piston (21) into cylinder tube (19) by moving around.

13. Secure piston rod (20) on a workbench. IMPORTANT: Apply a thin coat of hydraulic oil onto the surface of rod (20) in order to protect the seals. 14. Install rod cover (13) to rod (20).

W5-2-4-9

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

4, 5 13

7, 8

6 19

30 C

A 33 15, 16 10 11 12

23 24 27 28

18 21

32 View A

17 B Detail

25, 26 C Detail 90Z6-W5-02-04-02

W5-2-4-10

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 21. Align rod cover (13) with the screw hole of the flange part in cylinder tube (19). Tighten with socket bolt (32) (18 used). l : 14 mm m : 471 to 491 N·m (48 to 50 kgf·m, 347 to 361 lbf·ft)

fNOTE: Apply LOCTITE #242 onto the thread part of socket bolt (32).

IMPORTANT: Cover rod (20) with a cloth in order to prevent its surface from being damaged. 22. Apply low-pressure air to the port in the rod side of cylinder tube (19). Retract rod (20). 23. Connect pipe (6) with socket bolt (7), spring washer (8). j : 10 mm m : 108 to 116 N·m (11 to 12 kgf·m, 80 to 85 lbf·ft) 24. Tighten socket bolt (4) with washer (5). j : 10 mm m : 49 to 54 N·m (5 to 5.5 kgf·m, 36 to 40 lbf·ft)

fNOTE: Apply LOCTITE #262 onto the thread part of socket bolt (4).

W5-2-4-11

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder (Blank)

W5-2-4-12

INDEX A Accessory Pump, Disassembly and Assembly...........W3-8-5-2 Accessory Pump, Removal and Installation................W3-8-5-1 Adjustment of Brake Disc Clearance.......................... W4-3-3-24 Adjustment of Ring Gear Backlash.............................. W4-3-3-20 Adjustment of Ring Gear Teeth Engagement......... W4-3-3-20 Adjustment of Stop Valve Installation Position...... W4-10-1-3 Air Cleaner, Removal and Installation...........................W3-4-3-1 Air Cooler, Replacement....................................................W3-5-1-1 Articulation Lock..................................................................W1-6-1-2 Assembly Axle................................................................................... W4-3-3-14 Brake Valve........................................................................W4-5-3-3 Brake Valve Assembly (Option)..................................W4-5-2-4 Bucket Cylinder................................................................W5-2-4-6 Control Valve, Multiple..................................................W3-9-2-5 Differential.........................................................................W4-3-4-8 Fan Pump........................................................................ W3-12-4-4 Lift Arm Cylinder.............................................................W5-2-3-6 Main Pump........................................................................W3-8-3-4 Pilot Valve (Two Lever Type)..................................... W3-10-2-8 Ride Control Valve (Option)...................................... W3-14-2-4 Steering Cylinder............................................................W4-8-2-4 Steering Pilot Valve (Orbitrol).....................................W4-6-2-4 Stop Valve....................................................................... W4-10-2-2 Axle............................................................................................W4-3-1-1 Assembly......................................................................... W4-3-3-14 Disassembly................................................. W4-3-3-1, W4-3-3-6 Axle Assembly.......................................................................W4-3-3-2 Axle Oil Cooler (Option), Removal and Installation.......................................... W4-11-1-1 Axle Oil Cooler Assembly (Option), Structure......... W4-11-2-1 Axle Oil Cooler Pump Unit (Option), Structure....... W4-11-2-2 Axle Support (Rear Axle), Installation........................ W4-3-3-36 Axle Support (Rear Axle), Removal................................W4-3-3-4 B Battery Disconnect Switch (Option), Removal and Installation.......................................... W3-15-1-1 Bearing Cage Assembly, Disassembly...........................W4-3-4-3 Bearing Cage Assembly, Removal............................... W4-3-3-13 Bell Crank, Removal and Installation.............................W5-1-2-1 Bleeding Air from Brake (Axle).........................................W1-4-1-5 Bleeding Air from Fuel System........................................W1-4-1-3 Bleeding Air from Hydraulic Oil Tank............................W1-4-1-1 Bleeding Air from Hydraulic System..............................W1-4-1-2 Bleeding Air from Radiator...............................................W1-4-1-4 Bolt Locking............................................................................W1-2-1-3 Bottom Covers (Option), Installation.......................... W4-4-1-10 Bottom Covers (Option), Removal.................................W4-4-1-1 Brake, Removal................................................................... W4-3-3-10 Brake (Axle), Bleeding Air..................................................W1-4-1-5 Brake Disc Clearance, Adjustment.............................. W4-3-3-24 Brake Valve Assembly............................................................................W4-5-3-3 Disassembly......................................................................W4-5-3-2

Maintenance Standard.................................................W4-5-3-4 Removal and Installation.............................................W4-5-1-1 Structure............................................................................W4-5-3-1 Brake Valve Assembly (Option), Assembly..................W4-5-2-4 Brake Valve Assembly (Option), Disassembly............W4-5-2-1 Bucket, Removal and Installation...................................W5-1-3-1 Bucket, Standard Dimensions..........................................W2-2-2-1 Bucket Cylinder Assembly............................................................................W5-2-4-6 Disassembly......................................................................W5-2-4-1 Removal and Installation.............................................W5-2-2-1 Bucket Dump Stopper Clearance...................................W2-2-2-2 Bucket Rollback (Tilt) Stopper Clearance.....................W2-2-2-2 Bucket Stopper Clearance.................................................W2-2-2-2 Bushing, Standard................................................................W2-2-1-1 C Cab, Removal and Installation.........................................W3-1-1-1 Center Hinge..........................................................................W2-1-1-1 Removal and Installation.............................................W3-3-1-1 Center Pin................................................................................W2-1-1-1 Charging Block, Disassembly and Assembly........... W3-11-2-1 Charging Block, Removal and Installation............... W3-11-1-1 Charging Pump, Installing.................................................W4-2-3-5 Charging Pump, Removing...............................................W4-2-3-1 Check Valve Assembly (Option), Structure............... W4-11-2-4 Connecting Hose..................................................................W1-2-1-8 Control Valve, Multiple Assembly............................................................................W3-9-2-5 Disassembly......................................................................W3-9-2-1 Removal and Installation.............................................W3-9-1-1 Control Valve, Transmission Installing.............................................................................W4-2-3-7 Removing..........................................................................W4-2-3-3 Cooling Fan System.......................................................... W3-12-1-1 Counterweight, Removal and Installation..................W3-2-1-1 Covers, Removal and Installation................................ W3-4-2-10 Cylinder....................................................................................W5-2-1-1 D Deck, Removal and Installation.................................... W3-4-2-10 Differential, Assembly.........................................................W4-3-4-8 Differential, Disassembly...................................................W4-3-4-1 Differential Case Assembly (LSD), Disassembly.........W4-3-4-6 Differential Case Assembly (TPD), Disassembly........W4-3-4-5 Differential Case Assembly, Disassembly................. W4-3-3-12 Differential Case Assembly, Removal......................... W4-3-3-11 Direction of Install (Bucket Link).....................................W5-1-3-4 Disassembly and Assembly Accessory Pump..............................................................W3-8-5-2 Charging Block.............................................................. W3-11-2-1 Drive Unit...........................................................................W4-2-3-1 Pilot Valve (Multi-Function Joystick Type)........... W3-10-4-1 Priority Valve.....................................................................W3-8-4-5 Pump Device....................................................................W3-8-2-1 90Z6 D&R

INDEX Disassembly and Assembly Regulator...........................................................................W3-8-4-1 Steering Valve...................................................................W4-7-2-1 Disassembly of Axle........................................ W4-3-3-1, W4-3-3-6 Disassembly of Bearing Cage Assembly......................W4-3-4-3 Disassembly Brake Valve........................................................................W4-5-3-2 Brake Valve Assembly (Option)..................................W4-5-2-1 Bucket Cylinder................................................................W5-2-4-1 Control Valve, Multiple..................................................W3-9-2-1 Differential.........................................................................W4-3-4-1 Differential Case Assembly....................................... W4-3-3-12 Differential Case Assembly (LSD)..............................W4-3-4-6 Differential Case Assembly (TPD)..............................W4-3-4-5 Fan Pump........................................................................ W3-12-4-1 Housings............................................................................W4-3-3-7 Lift Arm Cylinder.............................................................W5-2-3-1 Main Pump........................................................................W3-8-3-1 Pilot Valve (Two Lever Type)..................................... W3-10-2-1 Planetary Carrier Assembly.........................................W4-3-3-9 Ride Control Valve (Option)...................................... W3-14-2-1 Steering Cylinder............................................................W4-8-2-1 Steering Pilot Valve.........................................................W4-6-2-1 Stop Valve....................................................................... W4-10-2-1 Draining Transmission Oil..................................................W4-2-3-1 Drive Unit................................................................................W4-2-1-1 Disassembly and Assembly.........................................W4-2-3-1 Removal and Installation.............................................W4-2-1-1 Structure............................................................................W4-2-2-1 E Engine, Removal and Installation...................................W3-4-1-1 Engine Roof, Installation....................................................W3-4-2-8 Engine Roof, Removal.........................................................W3-4-2-6 Exhaust Muffler.................................................................. W3-13-1-1 Exterior Parts, Removal and Installation......................W3-4-2-1 F Fan Control Valve (Option) Removal and Installation.......................................... W3-12-5-1 Structure......................................................................... W3-12-5-3 Fan Motor, Removal and Installation.......................... W3-12-1-1 Fan Motor, Structure......................................................... W3-12-2-1 Fan Motor, Reversing, (Option), Removal and Installation.......................................... W3-12-6-1 Fan Pump Assembly......................................................................... W3-12-4-4 Disassembly................................................................... W3-12-4-1 Removal and Installation.......................................... W3-12-3-1 Structure......................................................................... W3-12-4-7 Floating Seal, Precautions for Using..............................W1-1-1-2 Front Attachment, Removal and Installation.............W5-1-1-1 Front Attachment, Standard.............................................W2-2-1-1 Front Attachment Hydraulic Circuit Pressure Release Procedure..........................................................................W1-5-1-1

Front Axle Assembly............................................................W4-3-3-1 Front Axle, Removal and Installation............................W4-3-1-1 Front Tire, Removal and Installation..............................W4-1-1-1 Fuel System, Bleeding Air..................................................W1-4-1-3 Fuel Tank, Removal and Installation..............................W3-7-1-1 H Housings, Disassembly.......................................................W4-3-3-7 Housings, Removal..............................................................W4-3-3-6 Hydraulic Hoses of Front Chassis Side, Removal and Installation.........................................................................W3-3-2-1 Hydraulic Oil Tank, Bleeding Air......................................W1-4-1-1 Hydraulic Oil Tank, Removal and Installation.............W3-6-1-1 Hydraulic System, Bleeding Air.......................................W1-4-1-2 I Installation Position Bucket Cylinder.......................W5-1-1-7, W5-1-2-8, W5-2-2-5 Bucket Link........................................................................W5-1-2-7 Lever (Bell Crank)............................................................W5-1-2-6 Lift Arm Cylinder.............................................................W5-2-1-3 Lift Arm.......................................................... W5-1-1-6, W5-1-3-3 Installation Axle Support (Rear Axle)........................................... W4-3-3-36 Bottom Covers (Option)............................................ W4-4-1-10 Engine Roof.......................................................................W3-4-2-8 Pilot Pump.........................................................................W3-8-2-3 Regulator...........................................................................W3-8-2-3 Second Propeller Shaft.................................................W4-4-1-7 Side Cover..........................................................................W3-4-2-4 Third Propeller Shaft......................................................W4-4-1-6 Installing Charging Pump.................................................W4-2-3-5 Installing Control Valve, Transmission...........................W4-2-3-7 Installing Speed Sensor......................................................W4-2-3-8 J Joint, Piping............................................................................W1-2-1-4 L Lever, Removal and Installation......................................W5-1-2-1 Lift Arm, Standard Dimensions.......................................W2-2-2-1 Lift Arm Cylinder Assembly............................................................................W5-2-3-6 Disassembly......................................................................W5-2-3-1 Removal and Installation.............................................W5-2-1-1 Limited Slip Differential (LSD)..................... W4-3-4-2, W4-3-4-9 Loading Pilot Valve..............................................................W2-1-2-1 Locking, Nut and Bolt.........................................................W1-2-1-3 Low-Pressure-Hose Clamp Tightening.........................W1-2-1-7 LSD........................................................................ W4-3-4-2, W4-3-4-9 LSD, Disassembly..................................................................W4-3-4-6

90Z6 D&R

INDEX M Machine Position for Inspection and Maintenance (lift arm raise)....................................................................W1-6-1-3 Main Pump, Assembly........................................................W3-8-3-4 Main Pump, Disassembly...................................................W3-8-3-1 Muffler, Removal and Installation................................ W3-13-1-1 N Nut Locking............................................................................W1-2-1-3 Nylon Sling, Precautions for Using.................................W1-1-1-3 O O-Ring Seal Joint..................................................................W1-2-1-5 Oil Cooler, Replacement....................................................W3-5-1-1 Orbitrol Assembly............................................................................W4-6-2-4 Disassembly......................................................................W4-6-2-1 Removal and Installation.............................................W4-6-1-1 P Painting....................................................................................W1-3-1-1 Parking Brake Accumulator Pressure Release Procedure..........................................................................W1-5-1-3 Pilot Pump, Installation......................................................W3-8-2-3 Pilot Pump, Removal...........................................................W3-8-2-2 Pilot Valve (Multi-Function Joystick Type) Disassembly and Assembly...................................... W3-10-4-1 Removal and Installation.......................................... W3-10-3-1 Pilot Valve (Two Lever Type )............................................W2-1-2-1 Assembly......................................................................... W3-10-2-8 Disassembly................................................................... W3-10-2-1 Removal and Installation.......................................... W3-10-1-1 Pin, Standard..........................................................................W2-2-1-1 Pipe Joint.................................................................................W1-2-1-5 Piping Joint.............................................................................W1-2-1-4 Planetary Carrier Assembly...............................................W4-3-3-3 Disassembly......................................................................W4-3-3-9 Precautions for Disassembling and Assembling.......W1-1-1-1 Precautions for Split Flange..............................................W1-2-1-3 Precautions for Using Floating Seal...............................W1-1-1-2 Precautions for Using Nylon Sling..................................W1-1-1-3 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment)...................................................... W4-3-3-30 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, Disassembly and Assembly..................W3-8-4-5 Propeller Shaft.......................................................................W4-4-1-1 Removal and Installation.............................................W4-4-1-1 Pump Device, Disassembly and Assembly..................W3-8-2-1 Pump Device, Removal and Installation......................W3-8-1-1

Q Quick Coupling.....................................................................W1-2-1-6 R Radiator, Bleeding Air.........................................................W1-4-1-4 Radiator, Replacement.......................................................W3-5-1-1 Radiator Assembly...............................................................W3-5-1-1 Rear Axle Assembly.............................................................W4-3-3-1 Rear Axle, Removal and Installation..............................W4-3-2-1 Rear Tire, Removal and Installation................................W4-1-2-1 Regulator Disassembly and Assembly.........................................W3-8-4-1 Installation.........................................................................W3-8-2-3 Removal..............................................................................W3-8-2-2 Removal and Installation Accessory Pump..............................................................W3-8-5-1 Air Cleaner.........................................................................W3-4-3-1 Axle Oil Cooler (Option)............................................. W4-11-1-1 Battery Disconnect Switch (Option)...................... W3-15-1-1 Brake Valve........................................................................W4-5-1-1 Bucket.................................................................................W5-1-3-1 Bucket Cylinder................................................................W5-2-2-1 Cab.......................................................................................W3-1-1-1 Center Hinge (Pin)..........................................................W3-3-1-1 Charging Block.............................................................. W3-11-1-1 Control Valve, Multiple..................................................W3-9-1-1 Counterweight.................................................................W3-2-1-1 Covers.............................................................................. W3-4-2-10 Deck.................................................................................. W3-4-2-10 Drive Unit...........................................................................W4-2-1-1 Engine.................................................................................W3-4-1-1 Exterior Parts....................................................................W3-4-2-1 Fan Control Valve (Option)....................................... W3-12-5-1 Fan Motor....................................................................... W3-12-1-1 Fan Pump........................................................................ W3-12-3-1 Front Attachment...........................................................W5-1-1-1 Front Axle...........................................................................W4-3-1-1 Front Tire............................................................................W4-1-1-1 Fuel Tank............................................................................W3-7-1-1 Hydraulic Hoses of Front Chassis Side.....................W3-3-2-1 Hydraulic Oil Tank...........................................................W3-6-1-1 Lever (Bell Crank)............................................................W5-1-2-1 Lift Arm Cylinder.............................................................W5-2-1-1 Muffler............................................................................. W3-13-1-1 Pilot Valve (Multi-Function Joystick Type) .......... W3-10-3-1 Pilot Valve (Two Lever Type ) .................................. W3-10-1-1 Propeller Shaft.................................................................W4-4-1-1 Pump Device....................................................................W3-8-1-1 Rear Axle............................................................................W4-3-2-1 Rear Tire..............................................................................W4-1-2-1 Reversing Fan Motor (Option)................................. W3-12-6-1 Ride Control Accumulator (Option)...................... W3-14-1-1 Ride Control Valve (Option)...................................... W3-14-1-1 Secondary Steering Pump...........................................W4-9-1-1 Steering Accumulator...................................................W4-8-3-1 90Z6 D&R

INDEX Removal and Installation Steering Cylinder............................................................W4-8-1-1 Steering Pilot Valve.........................................................W4-6-1-1 Steering Valve...................................................................W4-7-1-1 Step................................................................................... W3-4-2-10 Stop Valve....................................................................... W4-10-1-1 Removal Axle Support (Rear Axle)..............................................W4-3-3-4 Bearing Cage Assembly............................................. W4-3-3-13 Bottom Covers (Option)...............................................W4-4-1-1 Brake................................................................................. W4-3-3-10 Differential Case Assembly....................................... W4-3-3-11 Engine Roof.......................................................................W3-4-2-6 Housings............................................................................W4-3-3-6 Pilot Pump.........................................................................W3-8-2-2 Regulator...........................................................................W3-8-2-2 Second Propeller Shaft.................................................W4-4-1-2 Side Cover..........................................................................W3-4-2-2 Third Propeller Shaft......................................................W4-4-1-5 Removing Charging Pump...............................................W4-2-3-1 Removing Control Valve, Transmission.........................W4-2-3-3 Removing Speed Sensor....................................................W4-2-3-4 Replacement Air Cooler...........................................................................W3-5-1-1 Oil Cooler...........................................................................W3-5-1-1 Radiator..............................................................................W3-5-1-1 Torque Converter Cooler..............................................W3-5-1-1 Reversing Fan Motor (Option) Removal and Installation.......................................... W3-12-6-1 Ride Control Accumulator (Option) Removal and Installation.......................................... W3-14-1-1 Ride Control Accumulator Pressure Release Procedure........................................W1-5-1-2 Ride Control Device.......................................................... W3-14-1-1 Ride Control Valve (Option) Assembly......................................................................... W3-14-2-4 Disassembly................................................................... W3-14-2-1 Removal and Installation.......................................... W3-14-1-1 Ring Gear Backlash, Adjustment.................................. W4-3-3-20 Ring Gear Teeth Engagement, Adjustment............. W4-3-3-20 S Screw-In Connection...........................................................W1-2-1-7 Seal Joint.................................................................................W1-2-1-5 Seal Tape Application..........................................................W1-2-1-7 Second Propeller Shaft, Installation..............................W4-4-1-7 Second Propeller Shaft, Removal...................................W4-4-1-2 Secondary Steering Device ..............................................W4-9-1-1 Secondary Steering Pump, Removal and Installation.........................................................................W4-9-1-1 Side Cover, Installation.......................................................W3-4-2-4 Side Cover, Removal............................................................W3-4-2-2 Specified Tightening Torque Chart................................W1-2-1-1 Speed Sensor, Installing.....................................................W4-2-3-8 Speed Sensor, Removing...................................................W4-2-3-4 Split Flange, Precautions...................................................W1-2-1-3

Standard Dimensions for Lift Arm and Bucket..........W2-2-2-1 Steering Accumulator, Removal and Installation.....W4-8-3-1 Steering Cylinder Assembly............................................................................W4-8-2-4 Disassembly......................................................................W4-8-2-1 Removal and Installation.............................................W4-8-1-1 Steering Pilot Valve Assembly............................................................................W4-6-2-4 Disassembly......................................................................W4-6-2-1 Removal and Installation.............................................W4-6-1-1 Steering Valve, Disassembly and Assembly................W4-7-2-1 Steering Valve, Removal and Installation....................W4-7-1-1 Step, Removal and Installation..................................... W3-4-2-10 Stop Valve Assembly......................................................................... W4-10-2-2 Disassembly................................................................... W4-10-2-1 Installation Position, Adjustment........................... W4-10-1-3 Removal and Installation.......................................... W4-10-1-1 Structure Axle Oil Cooler Assembly (Option)........................ W4-11-2-1 Axle Oil Cooler Pump Unit (Option)...................... W4-11-2-2 Brake Valve........................................................................W4-5-3-1 Check Valve Assembly (Option).............................. W4-11-2-4 Drive Unit...........................................................................W4-2-2-1 Fan Control Valve (Option)....................................... W3-12-5-3 Fan Motor....................................................................... W3-12-2-1 Fan Pump........................................................................ W3-12-4-7 T Third Propeller Shaft, Installation...................................W4-4-1-6 Third Propeller Shaft, Removal........................................W4-4-1-5 Tightening Bolts and Nuts................................................W1-2-1-1 Tightening Torque Chart...................................................W1-2-1-1 Tire.............................................................................................W4-1-1-1 Torque Chart..........................................................................W1-2-1-1 Torque Converter Assembly.............................................W4-2-1-1 Torque Converter Cooler, Replacement.......................W3-5-1-1 Torque Proportional Differential (TPD).... W4-3-4-1, W4-3-4-8 TPD....................................................................... W4-3-4-1, W4-3-4-8 Disassembly......................................................................W4-3-4-5 Transmission Assembly......................................................W4-2-1-1 Disassembly and Assembly.........................................W4-2-3-1 Removal and Installation.............................................W4-2-1-1 Structure............................................................................W4-2-2-1 U Union Joint.............................................................................W1-2-1-4

90Z6 D&R