DOWNLOAD PDF KCM 70Z7B WHEEL LOADER CUMMINS QSB6.7 ENGINE Shop Manual PN 93208-00870

70Z7B

93208-00870

SHOP MANUAL Disassembly & Reassembly Vol.2

Printed in Japan (K) （アメリカ用）

93208-00870

©2017 KCM Corporation. All rights reserved.

May 2017

Volume 2

SHOP MANUAL WHEEL LOADER

70Z7B Disassembly & Reassembly

Powered by CUMMINS QSB6.7 ENGINE Serial No. 70C6-5001 and up

93208-00870 Volume 2

SECTION AND GROUP SECTION 4 TRAVEL SYSTEM Group 1 Tire CONTENTS

WORKSHOP MANUAL

Group 2 Drive Unit Group 3 Axle Group 4 Propeller Shaft Group 5 Brake Valve Group 6 Steering Device Group 7 Secondary Steering Device

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.

(Blank)

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 Disassembly and Assembly of Drive Unit..............W4-2-2-1 Removal and Installation of Torque Converter ...W4-2-3-1 Disassembly and Assembly of Transmission ........W4-2-4-1 Disassembly and Assembly of Transmission Control Valve .............................................................W4-2-5-1 Removal and Installation of Parking Brake ..........W4-2-6-1

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 Assembly of Axle ......................................................... W4-3-3-17

Group 4 Propeller Shaft Removal and Installation of Propeller Shaft .........W4-4-1-1

Group 5 Brake Valve Removal and Installation of Brake Valve................W4-5-1-1 Disassembly of Brake Valve ........................................W4-5-2-1 Disassembly of Brake Valve ........................................W4-5-2-2 Assembly of Brake Valve ..............................................W4-5-2-3 Assembly of Brake Valve ..............................................W4-5-2-4

Group 6 Steering Device Removal and Installation of Steering Valve ..........W4-6-1-1 Disassembly of Steering Valve ..................................W4-6-2-1 Assembly of Steering Valve ........................................W4-6-2-4 Removal and Installation of Steering Cylinder ....W4-6-7-1 Disassembly of Steering Cylinder ............................W4-6-8-1 Assembly of Steering Cylinder ..................................W4-6-8-5

Group 7 Secondary Steering Device Removal and Installation of Secondary Steering Pump ...........................................................W4-7-1-1

70Z7B D&R

(Blank)

70Z7B D&R

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Front Tire

1

a

2

3 a-

Wheel Stopper

Removal Perform removal and installation dCAUTION: of the front tires in a group more than two personnel.

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

2. Remove the following parts. (Refer to W3-22-1.)  Front Fender (1)  Under guard (front) (2) (only for the machine with the under guard) 3. Place wheel stoppers (a) (2 used) to the left and right rear tires.

4. Loosen wheel bolts (3) (15 used) one turn. j : 36 mm

W4-1-1-1

WNEK50-04-01-001

SECTION 4 TRAVEL SYSTEM Group 1 Tire

a-

Stand

1, 2

3

a

4

WNEK50-04-01-005

d CAUTION: Machine weight: 14980 kg (33100 lb)

5. Raise the machine until tire (3) slightly gets away from the ground. Securely support the machine by using stand (a).

b

dCAUTION: Front tire (3) weight: 310 kg (685 lb)

2

6. Attach lifting tools (b) onto front tire (3). Hoist and hold front tire (3).

1

3

7. Remove wheel bolts (1) (15 used) and washers (2) (15 used). Remove front tires (3) from front axle (4). j : 36 mm

W4GB-03-01-003 b-

W4-1-1-2

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire

a-

Stand

1, 2

3

a

4

WNEK50-04-01-005

Installation

d

CAUTION: Front tire (3) weight: 310 kg (685 lb) IMPORTANT: Check the direction to install front tire (3). (Refer to Operator's Manual.)

1. Attach lifting tools (b) onto front tire (3). Hoist front tire (3).

b

2

2. Install front tire (3) to front axle (4) with washers (2) (15 used) and wheel bolts (1) (15 used).

1

3

j : 36 mm

d CAUTION: Machine weight: 14980 kg (33100 lb) 3. Remove stand (a) from the machine. Lower the machine and place tire (3) onto the ground.

W4GB-03-01-003 b-

W4-1-1-3

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire

1

a

2

3 a-

WNEK50-04-01-001

Wheel Stopper

4. Tighten wheel bolts (3) (15 used) according to the order as illustrated. j : 36 mm m : 890 N·m (660 lbf·ft) 5. Install the following parts. (Refer to W3-22-1.)  Front Fender (1)  Under Guard (front) (2) (only for the machine with under guard) IMPORTANT: Check air pressure of the tires. Check for any damage to the tires.

WNDB-04-01-001

fNOTE: Air Pressure of Tires: Standard Tire 20.5-25-12

Standard Air Pressure 375 kPa

6. Remove wheel stoppers (a) (2 used).

W4-1-1-4

SECTION 4 TRAVEL SYSTEM Group 1 Tire Applicable Tire Size

fNOTE: The machine may vibrate while driving

depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction.

Tire Size 20.5-25-12 20.5-25-12 20.5-25-12 23.5-25-16 20.5R25

Structure of Tire Bias Bias Radial Bias Radial

Standard Air Pressure 325 kPa 375 kPa 375 kPa 375 kPa 400 kPa

Tread Pattern L2 L3 L3 L3 L3

Adjust tire pressure in conformity with the work mode the machine is engaged in.  Driving on Public Roads ... Standard Pressure  Loading/excavation on normal ... Standard or ground surface slightly higher than standard pressure  Heavy-duty excavation ... Higher pressure in the standard pressure range  Operation on soft terrain or ... Bias Tires: sandy territory Slightly lower than standard pressure Radial Tires: Standard Pressure

W4-1-1-5

Air Pressure Adjustment Range 325 to 345 kPa 375 to 390 kPa 375 to 390 kPa 375 to 390 kPa 400 to 450 kPa

SECTION 4 TRAVEL SYSTEM Group 1 Tire (Blank)

W4-1-1-6

SECTION 4 TRAVEL SYSTEM Group 1 Tire Removal and Installation of Rear Tire 1

2

A

4

WNEK50-03-22-002

3

5

a

Detail A

Removal Perform removal and installation of dCAUTION: the rear tires in a group more than two personnel.

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

2. Remove the following parts. (Refer to W3-22-1.)  Rear Fender (Front) (1)  Rear Fender (rear) (2) (only for the machine with rear fender)  Under Guard (rear) (4) (only for the machine with under guard) 3. Insert wooden blocks (a) between both sides of rear frame (5) and rear axle (6) in order to prevent rear axle (6) from moving.

6 a-

4. Loosen wheel bolts (3) (15 used) one turn. j : 36 mm

W4-1-2-1

Wooden Block

W4FC-03-01-005

SECTION 4 TRAVEL SYSTEM Group 1 Tire

1

4, 5 a-

3

2

a

Stand

WNEK50-04-01-013

d CAUTION: Machine weight: 14980 kg (33100 lb)

b

5. Raise the machine until tire (3) slightly gets away from the ground. Securely support the machine by using stand (a). Lower the bucket onto the ground.

dCAUTION: Rear tire (3) weight: 310 kg (685 lb)

6. Attach lifting tools (b) onto rear tire (3). Hoist and hold rear tire (3).

3

5

4

7. Remove wheel bolts (4) (15 used) and washers (5) (15 used). Remove rear tires (3) from rear axle (2). j : 36 mm

W4GB-03-01-003 b-

W4-1-2-2

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire

4, 5 a-

3

2

a

Stand

WNEK50-04-01-013

Installation

dCAUTION: Rear tire (3) weight: 310 kg (685 lb)

b

IMPORTANT: Check the direction to install rear tire (3). (Refer to Operator's Manual.)

1. Attach lifting tools (b) onto rear tire (3). Hoist rear tire (3).

2. Install rear tire (3) to rear axle (2) with washes (5) (15 used) and wheel bolts (4) (15 used).

3

5

4

j : 36 mm

d CAUTION: Machine weight: 14980 kg (33100 lb) 3. Remove stand (a) from the machine. Lower the machine and place tire (3) onto the ground.

W4GB-03-01-003 b-

W4-1-2-3

Lifting Tool

SECTION 4 TRAVEL SYSTEM Group 1 Tire

1

2

A

4

WNEK50-03-22-002

3

a

5. Tighten wheel bolts (3) (15 used) according to the order as illustrated.

Detail A

j : 36 mm m : 890 N·m (660 lbf·ft) 6. Remove wooden blocks (a) (2 used).

7. Install the following parts. (Refer to W3-22-1.)  Rear Fender (Front) (1)  Rear Fender (rear) (2) (only for the machine with rear fender)  Under Guard (rear) (4) (only for the machine with under guard)

W4FC-03-01-005 a-

Wooden Block

IMPORTANT: Check air pressure of the tires. Check for any damage to the tires.

fNOTE: Air Pressure of Tires: Standard Tire 20.5-25-12

Standard Air Pressure 375 kPa

WNDB-04-01-001

W4-1-2-4

SECTION 4 TRAVEL SYSTEM Group 1 Tire Applicable Tire Size

fNOTE: The machine may vibrate while driving

depending on the tread pattern of tires. This is a sympathetic vibration due to tread pattern, not a malfunction.

Tire Size 20.5-25-12 20.5-25-12 20.5-25-12 23.5-25-16 20.5R25

Structure of Tire Bias Bias Radial Bias Radial

Standard Air Pressure 325 kPa 375 kPa 375 kPa 375 kPa 400 kPa

Tread Pattern L2 L3 L3 L3 L3

Adjust tire pressure in conformity with the work mode the machine is engaged in.  Driving on Public Roads ... Standard Pressure  Loading/excavation on normal ... Standard or ground surface slightly higher than standard pressure  Heavy-duty excavation ... Higher pressure in the standard pressure range  Operation on soft terrain or ... Bias Tires: sandy territory Slightly lower than standard pressure Radial Tires: Standard Pressure

W4-1-2-5

Air Pressure Adjustment Range 325 to 345 kPa 375 to 390 kPa 375 to 390 kPa 375 to 390 kPa 400 to 450 kPa

SECTION 4 TRAVEL SYSTEM Group 1 Tire (Blank)

W4-1-2-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Drive Unit 1

View A

14

3, 4, 5, 6

2

A

7

8, 9, 10

11 13 b

a a-

Stand

b-

WNEK50-04-02-001

Stand

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

2. Remove the engine (1) assembly from the machine body. (Refer to W3-4-1.)

3. Remove bolts, washers (6), clips (3), rubbers (4), and collars (5). j : 17 mm 4. Disconnect hoses (2, 14). j : 36 mm 5. Remove bolts, washers (13) (2 used). Remove the bracket (12) assembly. j : 19 mm 6. Remove bolts (8) (4 used), spring washers (9) (4 used), and washers (10) (4 used). Remove brackets (7, 11). j : 30 mm

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of bolt (8).

W4-2-1-1

12

WPD850-04-02-002

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

View A

2

2

A

1

2 2 2 2

2 3, 4

b

a a-

Stand

b-

WNEK50-04-02-001

Stand

7. Remove bolt, washer (3) and clip (4). j : 17 mm 8. Disconnect connectors (2) (8 used).

9. Remove pump device (1). (Refer to W3-8-1.)

W4-2-1-2

WNEK50-04-02-002

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

3 2 1

7 6 5

a

8 9 10 4 a-

Lifting Bracket

4 WNEK50-04-02-005

WNEK50-04-02-004

4

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

dCAUTION: Drive unit (4) weight: 500 kg (1110 lb)

10. Install the shackles (2 used) to lifting brackets (a) (2 places). Attach the nylon slings onto the shackles (2 used). Hoist and hold drive unit (4).

b

11. Remove socket bolts (10) (8 used) through the open part of cover (1). Remove diaphragm (9) from engine (7).

WNEK50-04-02-006

l : 8 mm

b-

f

NOTE: LOCTITE #263 or equivalent has been applied to the thread part of socket bolt (10).

fNOTE: Turn the vibration damper. Turn the diaphragm (9), Remove socket bolts (10) (8 used).

Place drive unit (4) onto stable stand dCAUTION: (b) in order not to fall down.

12. Remove bolts (5) (12 used) and spring washers (6) (12 used). Remove drive unit (4) from engine (7). j : 17 mm 13. Remove guide (8) from engine (7).

14. Remove the adapters from drive unit (4) if necessary.

W4-2-1-3

Stand

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

View A

7

7

6 5 a

8

8 c A

4 WNEK50-04-02-005

WNEK50-04-02-007 c-

Contact surface

4

Installation 1. Install all removed adapters to drive unit (4).

IMPORTANT: Check the direction to install guide (8).

2. Apply molybdenum grease onto the contact surface (c) of guide (8). Install guide (8) to engine (7).

dCAUTION: Drive unit (4) weight: 500 kg (1110 lb)

3. Install the shackles (2 used) to lifting brackets (a) (2 places). Attach the nylon slings onto the shackles (2 used). Hoist drive unit (4). b

Place a stable stand (b) under drive dCAUTION: unit (4) in order not to fall down the engine (7) assembly.

4. Install drive unit (4) to engine (7) with spring washers (6) (12 used) and bolts (5) (12 used) by fitting drive unit (4) to guide (8).

WNEK50-04-02-008 b-

j : 17 mm m : 36±3.6 N·m (26.5±2.7 lbf·ft)

W4-2-1-4

Stand

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

3 2 7

1

9 10

WNEK50-04-02-005

5. Apply LOCTITE #263 or equivalent onto the thread part of socket bolts (10) (8 used). Install diaphragm (9) to engine (7) through the open part of cover (1) with socket bolts (10) (8 used). l : 8 mm m : 53 N·m (39 lbf·ft)

fNOTE: Turn the vibration damper. Turn the diaphragm (9). Install socket bolts (10) (8 used).

6. Install cover (1) and bracket (2) with bolts, washers (3) (4 used). j : 17 mm m : 46 N·m (34 lbf·ft)

W4-2-1-5

WNEK50-04-02-004

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

View A

2

2

A

1

2 2 2 2

2 3, 4

5

a a-

Stand

b-

b

WNEK50-04-02-001

Stand

7. Install pump device (1). (Refer to W3-8-1-5.)

8. Connect connectors (2) (8 used).

9. Secure harness (5) with bolt, washer (3) and clip (4). j : 17 mm m : 50 N·m (37 lbf·ft)

W4-2-1-6

WNEK50-04-02-002

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

1

View A B

14

3, 4, 5, 6

2

A

7

8, 9, 10

11 13 b

a a-

Stand

b-

12

WNEK50-04-02-001

WPD850-04-02-002

Stand View B

2

10. Apply LOCTITE #263 or equivalent onto the thread part of bolts (8) (6 used). Install brackets (7, 11) with washers (10) (6 used), spring washers (9) (6 used), and bolts (8) (6 used). j : 30 mm m : 401 N·m (300 lbf·ft) 11. Install the bracket (12) assembly with bolts, washers (13) (2 used). c-

35°

c

j : 19 mm

WPD850-03-04-011

m : 90 N·m (66 lbf·ft) View C

IMPORTANT: Check the angle to install hoses (2).

12. Connect hoses (2, 14).

14 d

j : 36 mm m : 180 N·m (133 lbf·ft) 13. Secure hose (14) with bolts, washers (3) (2 used), clips (4) (4 used), rubbers (5) (2 used) and collars (6) (2 used). d-

j : 17 mm m : 50 N·m (37 lbf·ft)

15°

WNEK50-03-08-009

14. Install the engine (1) assembly to the body. (Refer to W3-4-1.)

W4-2-1-7

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit (Blank)

W4-2-1-8

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Drive Unit Drive Unit Assembly

1

2

4

3

5

WNDB-04-02-002

12-

Torque Converter Transmission

34-

Oil Filter Transmission Control Valve

5-

Parking Brake

W4-2-2-1

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Section A

Detail of Transmission Assembly (2) A

4

3

6 5

2 7 1 8

9

A WPD850-04-02-003

WPD850-04-02-004

Transmission Clutch Engagement as per Selected Speed Shift  Transmission Clutch Engagement Directional Control Clutch Selected Speed Low-Speed High-Speed Shift Forward Clutch Forward Clutch (KV) (6) (K4) (2) Forward Speed  1 (F1) Forward Speed  2 (F2)  Forward Speed 3 (F3) Forward Speed  4 (F4)  Forward Speed 5 (F5) Reverse Speed 1 (R1) Reverse Speed 2 (R2) Reverse Speed 3 (R3)

12-

First Speed Clutch (K1) Fast-Speed Forward Clutch (K4)

345-

Reverse Clutch (KR) Input Shaft (AN) Hydraulic Pump Drive

Reverse Clutch (KR) (3)

Speed Control Clutch First Speed Second Speed Clutch (K1) (1) Clutch (K2) (7)

Third Speed Clutch (K3) (8)

     











67-

Slow-Speed Forward Clutch (KV) Second Speed Clutch (K2)

W4-2-2-2

89-

Third Speed Clutch (K3) Output Shaft (AB)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit The drive unit is removed/installed and disassembled/ assembled every unit as below.  Oil Filter (3)  Refer to Removal and Installation of Oil Filter. (W4-22-4)  Torque Converter (1)  Refer to Removal and Installation of Torque Converter. (W4-2-3)  Transmission (2)  Refer to Removal and Installation of Hydraulic Pump Drive. (W4-2-4)  Refer to Removal and Installation of Clutch. (W4-2-4)  Refer to Disassembly and Assembly of Clutch. (W4-24)  Transmission Control Valve (4)  Refer to Removal and Installation of Transmission Control Valve. (W4-2-5)  Refer to Removal and Installation of Duct Plate. (W42-5)  Refer to Disassembly and Assembly of Transmission Control Valve. (W4-2-5)  Parking Brake (5)  Refer to Removal and Installation of Parking Brake (Replace the brake friction pad). (W4-2-6)  Refer to Removal and Installation of Flange at Output Shaft Side. (W4-2-6)

W4-2-2-3

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Oil Filter

WNEC-04-02-011

12-

O-Ring (2 Used) Filter Head

34-

Socket Bolt (2 Used) Oil Filter

5-

Duct Plate

W4-2-2-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal of Oil Filter 1. Remove oil filter (4) from filter head (2) by using a filter wrench.

2

2. Remove socket bolts (3) (2 used) by using a hexalobular internal wrench. Remove filter head (2) and O-rings (1) (2 used) from duct plate (5).

4 3

5

W4GB-03-02-008

1, 2

l : T40 (Hexalobular Internal Wrench)

W4GB-03-02-009

W4-2-2-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installation of Oil Filter 1. Apply oil onto O-rings (1) (2 used). Install O-rings (1) (2 used) to filter head (2). Install filter head (2) to duct plate (5) with socket bolts (3) (2 used) by using a hexalobular internal wrench. l : T40 (Hexalobular Internal Wrench)

5

1, 2

3

m : 34 N·m (25 lbf·ft)

W4GB-03-02-010

IMPORTANT: Take care not to tighten oil filter (4) too excessively in order not to deform.

2. Apply oil onto the seal surface of oil filter (4).

Tighten oil filter (4) to filter head (2) until it comes into contact with seal surface. Tighten oil filter (4) by 1/3 to 1/2 turn by using a filter wrench after it has come into contact with seal surface.

2

4

W4-2-2-6

W4GB-03-02-011

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Torque Converter

WNEC-04-02-001

1234-

Bolt (12 Used) Washer (12 Used) Diaphragm (2 Used) Washer (12 Used)

5678-

Bolt (4 Used) Spacer Ring Torque Converter Assembly Bolt (18 Used)

9- Torque Converter Housing 10- Oil Feeder Housing 11- O-Ring

W4-2-3-1

12- Torque Converter Input Speed Sensor

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal of Torque Converter IMPORTANT: When the torque converter side faces down with torque converter assembly (7) attached on the transmission, torque converter assembly (7) comes off.

1. Remove bolts (1) (12 used) and washers (2) (12 used). Remove diaphragms (3) (2 used) and washers (4) (12 used) from spacer ring (6). j : 17 mm 2. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the bolt holes in diagonal position, where the bolts have removed in step 1.

Torque converter assembly (7) weight: dCAUTION: 30 kg (66 lb) 3. Attach nylon slings onto the eyebolts. Hoist and remove torque converter assembly (7).

4. Remove bolts (5) (4 used). Remove spacer ring (6) from torque converter assembly (7). j : 19 mm 5. Remove bolts (8) (18 used). Remove torque converter housing (9) from oil feeder housing (10). j : 19 mm 6. Remove torque converter input speed sensor (12) from torque converter housing (9). Remove O-ring (11) from torque converter input speed sensor (12). j : 22 mm

W4-2-3-2

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installation of Torque Converter 1, 2

5

3

4

6

7

9

8

10

W4GB-03-02-001

1234-

Bolt (12 Used) Washer (12 Used) Diaphragm (2 Used) Washer (12 Used)

5678-

Bolt (4 Used) Spacer Ring Torque Converter Assembly Bolt (18 Used)

9- Torque Converter Housing 10- Oil Feeder Housing 11- *O-Ring

fNOTE: As for the item with mark *, refer to W4-2-3-1.

W4-2-3-3

12- *Torque Converter Input Speed Sensor

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installation of Torque Converter 1. Install torque converter housing (9) to oil feeder housing (10) with bolts (8) (18 used).

4. Attach nylon slings onto the eyebolts. Hoist and install torque converter assembly (7) to oil feeder housing (10).

j : 17 mm m : 68 N·m (50 lbf·ft) 2. Apply LOCTITE #262 onto bolts (5) (4 used). Install spacer ring (6) to torque converter assembly (7) with bolts (5) (4 used). j : 19 mm m : 115 N·m (85 lbf·ft) 3. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the diaphragm (3) mounting part of spacer ring (6) in diagonal position.

Torque converter assembly (7) weight: dCAUTION: 30 kg (66 lb) IMPORTANT: Check the spline joint meshed state of turbine shaft (b) and turbine (a) in torque converter assembly (7). Check the spline joint meshed state of drive tube (c) and the drive gear of hydraulic pump (d).

7 a

b

d

c WNEC-04-02-024

ab-

Turbine Turbine Shaft

cd-

Drive Tube Hydraulic Pump

W4-2-3-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Check that pickup disc (f) can be seen through the center of mounting hole (e) for torque converter input speed sensor (12) in torque converter housing (9).

IMPORTANT: Apply grease onto the lip part in order not to damage the oil seal of hydraulic pump (d) due to the spline joint of drive tube (c).

6. Install O-ring (11) to torque converter input speed sensor (12). Install torque converter input speed sensor (12) to torque converter housing (9).

9

f

e d

c WNEC-04-02-024

cd-

Drive Tube Hydraulic Pump

e-

f-

Mounting Hole for Torque Converter Input Speed Sensor (12) Pickup Disc

5. Remove the eyebolts (2 used). Install diaphragms (3) (2 used) and washers (4) (12 used) to spacer ring (6) with washers (2) (12 used) and bolts (1) (12 used). j : 19 mm m : 115 N·m (85 lbf·ft)

W4-2-3-5

j : 22 mm m : 30 N·m (22lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit (Blank)

W4-2-3-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Transmission Disassembly and Assembly of Hydraulic Pump Drive

a

WNEC-04-02-009

W4-2-4-1

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

Portion a

WNEC-04-02-010

1234567-

Socket Bolt (15 Used) Socket Bolt (21 Used) Socket Bolt (4 Used) Socket Bolt (2 Used) Plate Oil Feeder Housing Gasket

891011121314-

O-Ring Hydraulic Pump Socket Bolt (10 Used) O-Ring (10 Used) Stator Shaft Transmission Case Piston Ring

15161718192021-

Hydraulic Pump Drive Shaft Ball Bearing Transmission Case Cover Retaining Ring Pressure Plate Spring Piston

W4-2-4-2

22- Tab Washer

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal of Hydraulic Pump Drive 3. Remove socket bolts (3) (4 used) at bolt mounting position (c) by using a hexalobular wrench.

1. Remove socket bolts (2) (21 used) at bolt mounting position (a) by using a hexalobular wrench.

l : T40 (Hexalobular Wrench)

l : T40 (Hexalobular Wrench) a

c

a-

Bolt Mounting Position WNEC-04-02-012

c-

Bolt Mounting Position WNEC-04-02-012

2. Remove socket bolts (1) (15 used) at bolt mounting position (b) by using a hexalobular wrench.

4. Remove socket bolts (4) (2 used). Remove plate (5).

l : T40 (Hexalobular Wrench)

b

b

b-

Bolt Mounting Position WNEC-04-02-012

W4-2-4-3

l : 8 mm

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 5. Remove socket bolts (10) (10 used). Remove the oil feeder housing (6) assembly and gasket (7) from transmission case (13). Remove O-rings (11) (10 used) from socket bolts (10) (10 used).

8. Remove stator shaft (12) from transmission case (13).

l : 8 mm

13

IMPORTANT: Do not disassemble hydraulic pump (9).

6. Remove hydraulic pump (9) from oil feeder housing (6) by using a plastic hammer. Remove O-ring (8) from hydraulic pump (9).

6

12

8, 9 W4GB-03-02-044

W4GB-03-02-040

7. Push pressure plate (19) with the bolt (M6). Remove tab washer (22). Remove pressure plate (19), spring (20), and piston (21) from oil feeder housing (6).

22

21

6

19

20

W4GB-03-02-043

W4-2-4-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9. Remove retaining ring (18) from transmission case cover (17). Remove the hydraulic pump drive shaft (15) assembly from transmission case cover (17).

10. Remove ball bearing (16) from hydraulic pump drive shaft (15) by using a press.

16

15

W4GB-03-02-063

11. Remove piston ring (14) from hydraulic pump drive shaft (15).

15

W4GB-03-02-065

14

W4-2-4-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of Hydraulic Pump Drive 1. Install ball bearing (16) to hydraulic pump drive shaft (15) by using a press.

2. Install piston ring (14) to hydraulic pump drive shaft (15).

3. Apply grease onto piston ring (14). Install the hydraulic pump drive shaft (15) assembly to transmission case cover (17).

4. Install retaining ring (18) to transmission case cover (17).

W4-2-4-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 5. Install piston (21), spring (20), and pressure plate (19) to oil feeder housing (6).

7. Apply grease onto gasket (7). Install special tools (a) (ZF No.: 5870 204 011) (2 used) to transmission case (13). Fit gasket (7) to special tools (a) (ZF No.: 5870 204 011) (2 used). Install gasket (7) to transmission case (13). a

a

13 21 6

20

19 W4GB-03-02-045

7

6. Push pressure plate (19) with the bolt (M6). Secure pressure plate (19) with tab washer (22).

a-

Special Tool W4GB-03-02-047

8. Fit oil feeder housing (6) to special tools (a) (ZF No.: 5870 204 011) (2 used). Install oil feeder housing (6) to transmission case (13).

22

6

a

a

6

13

W4GB-03-02-046

a-

Special Tool W4GB-03-02-048

W4-2-4-7

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Do not tilt stator shaft (12) when installing.

9. Install special tools (b) (ZF No.: 5870 204 007) (2 used) to oil feeder housing (6). Fit stator shaft (12) to special tools (b) (ZF No.: 5870 204 007) (2 used).

Install stator shaft (12) to oil feeder housing (6).

IMPORTANT: Check that pump housing (c) and cam disc (d) of hydraulic pump (9) have been installed as illustrated. d

c

b b

cd-

12

Pump Housing Cam Disc W4GB-03-02-057

6

b-

Special Tool W4GB-03-02-049

IMPORTANT: Do not tilt hydraulic pump (9) when installing.

11. Fit hydraulic pump (9) to special tools (b) (ZF No.: 5870 204 007) (2 used). Install hydraulic pump (9) to oil feeder housing (6).

9 6

10. Install O-ring (8) to hydraulic pump (9). Apply oil onto O-ring (8).

9

8 W4GB-03-02-058 W4GB-03-02-057

12. Apply oil onto O-ring (11). Install O-ring (11) to socket bolts (10) (10 used).

11

10

W4GB-03-02-059

W4-2-4-8

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 13. Install socket bolts (10) (8 used) to oil feeder housing (6). Remove special tools (b) (ZF No.: 5870 204 007) (2 used). Install socket bolts (10) (2 used) to the positions for removed special tools (b) (ZF No.: 5870 204 007) (2 used).

15. Install socket bolts (1) (15 used) to bolt mounting position (f ) by using a hexalobular wrench. l : T40 (Hexalobular Wrench) m : 23 N·m (17 lbf·ft)

l : 8 mm m : 46 N·m (34 lbf·ft)

f

9

10 6

f

W4GB-03-02-060

f-

Bolt Mounting Position WNEC-04-02-012

14. Install socket bolts (2) (21 used) to bolt mounting position (e) by using a hexalobular wrench.

16. Install socket bolts (3) (4 used) to bolt mounting position (g) by using a hexalobular wrench.

l : T40 (Hexalobular Wrench)

l : T40 (Hexalobular Wrench)

m : 23 N·m (17 lbf·ft)

m : 23 N·m (17 lbf·ft) e

g

e-

Bolt Mounting Position WNEC-04-02-012

g-

W4-2-4-9

Bolt Mounting Position WNEC-04-02-012

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 17. Install plate (5) with socket bolts (4) (2 used). l : 8 mm m : 34 N·m (25 lbf·ft) 18. Remove special tools (a) (ZF No.: 5870 204 011) (2 used).

W4-2-4-10

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Clutch

3. Remove socket bolts (5) (4 used). Remove output shaft (6) and screen sheet (8) from transmission case (3).

Removal of Clutch, Input Shaft, and Output Shaft Transmission case cover (1) weight: 73 dCAUTION: kg (165 lb)

l : 6 mm

1. Install eyebolts (M20, Pitch 2.5 mm) (3 used) to transmission case cover (1) as illustrated. Attach nylon slings onto the eyebolts. Hoist and hold transmission case cover (1).

6 8

5 3

1

W4GB-03-02-075

4. Remove screen sheet (7) from transmission case (3).

W4GB-03-02-074

3

2. Remove socket bolts (2) (35 used), socket bolts (20) (6 used), and plate (4). Remove transmission case cover (1) from transmission case (3). l : 8 mm 7

1 W4GB-03-02-111

2

5. Remove taper roller bearings (9) (2 used) and screen sheet (8) at both ends of output shaft (6) by using a puller.

3 6 4

20

9

WNDB-04-02-003

WNEC-04-02-025

W4-2-4-11

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 5. Remove piston rings (10) (6 used) from the clutch shafts (6 used).

The transmission case cover (1) dCAUTION: assembly weight: 240 kg (530 lb)

10 10

7. Hoist and hold the transmission case cover (1) assembly. Remove the transmission case cover (1) assembly from transmission case (3).

10

3 1

W4GB-03-02-077

3

6. Install transmission case cover (1) to transmission case (3). Check that the mating surfaces fit correctly.

Install special tool (a) (ZF No.: 5870 204 011) to all clutch shafts.

fNOTE: The flat washer and hexagon nut (M10) can be

used in place of special tool (a) (ZF No.: 5870 204 011) as illustrated.

W4GB-03-02-079

8. Remove socket bolts (21) (6 used). Remove oil pipes (11) (2 used) from transmission case (3). Remove O-rings (12) (2 used for each) from both sides of oil pipes (11) (2 used). l : 6 mm

1

12 a

3

12

11

11

12 21 12 a-

Special Tool

3

W4GB-03-02-078

21

WNDB-04-02-005

W4-2-4-12

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9. Install the transmission case cover (1) assembly to the maintenance stand.

1

11. The following figure shows the layout of clutches which are left in transmission case cover (1). The numbers at the clutch shaft end correspond to the types of clutches. Record the numbers in order to be clear about the mounting positions of clutches when assembling.

AN KR

KV

K4

K2

K1

K3

W4GB-03-02-080

10. Turn over the transmission case cover (1) assembly.

Remove all special tools (a) (ZF No.: 5870 260 010 W4GB-03-02-082

a-

Special Tool

a W4GB-03-02-081

W4-2-4-13

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 12. Remove piston rings (13) (6 used) from the clutch shafts (6 used).

14. Remove second speed clutch (K2) from transmission case cover (1).

K2

13 13 KR

KV

K4

1

K2

1 K3

K1

W4GB-03-02-084

W4GB-03-02-106

13

13. Raise fast-speed forward clutch (K4) a little from transmission case cover (1) and hold it. Remove first speed clutch (K1) from transmission case cover (1).

Return fast-speed forward clutch (K4).

15. Remove third speed clutch (K3) from transmission case cover (1).

1

K4

K3

K1

1

W4GB-03-02-083

W4-2-4-14

W4GB-03-02-085

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 16. Raise slow-speed forward clutch (KV) and reverse clutch (KR) a little from transmission case cover (1) and hold them. Remove fast-speed forward clutch (K4) from transmission case cover (1).

IMPORTANT: Do not change any combinations of the outer ring and inner ring of the taper roller bearing, which are used for each clutch and input shaft (14). Put the matching marks on the outer ring and inner ring.

18. Remove the outer rings (8 used) of the taper roller bearing from transmission case cover (1).

1

1 W4GB-03-02-086

K4

17. Raise slow-speed forward clutch (KV), reverse clutch (KR), and input shaft (14) (AN) at the same time and remove them from transmission case cover (1).

KR KV

14

1 W4GB-03-02-087

W4-2-4-15

W4GB-03-02-088

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 19. Remove piston rings (15) (2 used) from input shaft (14).

IMPORTANT: As the movement of turbine shaft (17) is secured in the shaft direction by snap ring (18), it can not be removed in the usual way. Do not remove turbine shaft (17) unless necessary.

IMPORTANT: Do not remove input gear (AN) unless necessary.

15 14

17, 18 AN

15

W4GB-03-02-089

20. Remove the inner ring of taper roller bearing (16) at both sides of input shaft (14) by using a puller.

W4GB-03-02-091

16 14

16

W4GB-03-02-089

W4-2-4-16

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installation of Clutch, Input Shaft, and Output Shaft

f

NOTE: Install input gear (AN) in the same way as step 1 to step 2 when it has been removed.

fNOTE: Install turbine shaft in the same way as step 3 to step 4 when it has been removed.

3. Install snap ring (18) to turbine shaft (17).

Put heat-resisting gloves when dCAUTION: installing input gear (AN).

18

1. Cool input shaft (14) to about -80 °C (-112 °F). Heat input gear (AN) to about +120 °C (248 °F). Install input gear (AN) to input shaft (14).

17 14

W4GB-03-02-095

4. Install turbine shaft (17) to input shaft (14).

AN W4GB-03-02-092

2. Install retaining ring (19) to input shaft (14).

17

14

19 W4GB-03-02-096

14 W4GB-03-02-093

W4-2-4-17

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (16).

5. Heat the inner ring of taper roller bearing (16) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (16) to both sides of input shaft (14) by using a press.

16 14

W4GB-03-02-097

6. Install piston rings (15) (2 used) to input shaft (14).

Apply oil onto piston rings (15) (2 used).

15

15

14

W4GB-03-02-098

W4-2-4-18

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Refer to the following figure for the mounting position. Do not change the combinations of the outer rings and the inner rings of bearings.

7. Install the outer ring corresponding to the taper roller bearing at each clutch shaft end to transmission case (3) and transmission case cover (1).

8. Install reverse clutch (KR), input shaft (14), and slow-speed forward clutch (KV) to transmission case cover (1) at the same time.

14

KR KV

3

AN KR

KV K2

1

K4

W4GB-03-02-101 K3

K1

9. Raise input shaft (14) a little and install fast-speed forward clutch (K4) to transmission case cover (1).

AB W4GB-03-02-099

AN KR

14

1 KV

K4

K2

K4

1

K1

AB

K3

W4GB-03-02-102

W4GB-03-02-100

W4-2-4-19

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 10. Install third speed clutch (K3) to transmission case cover (1).

12. Raise fast-speed forward clutch (K4) a little and install first speed clutch (K1) to transmission case cover (1).

K1

1

K3

1

W4GB-03-02-105

W4GB-03-02-103

11. Install second speed clutch (K2) to transmission case cover (1).

13. Check that each gear engages securely and that each clutch is installed in the correct position. Install piston rings (13) (6 used) to each clutch shaft. Apply grease onto piston rings (13) (6 used).

13 13

K2 KR

1

KV

K4 K2

1 K3

K1 W4GB-03-02-104

13

W4-2-4-20

W4GB-03-02-106

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 14. Install special tools (a) (ZF No.: 5870 260 010) to all clutch shafts.

18. Install transmission case cover (1) to transmission case (3).

19. Remove special tools (a) (ZF No.: 5870 260 010) from all clutches.

a

a-

a Special Tool W4GB-03-02-107 a-

The transmission case cover (1) dCAUTION: assembly weight: 240 kg (530 lb)

Special Tool W4GB-03-02-109

15. Turn over the transmission case cover (1) assembly.

Install eyebolts (M20, Pitch 1.75 mm) (3 used) to the transmission case cover (1) assembly.

16. Attach nylon slings onto the eyebolts. Hoist and hold the transmission case cover (1) assembly.

Remove the transmission case cover (1) assembly from the maintenance stand.

Transmission case (3) weight: 76 kg dCAUTION: (170 lb) 17. Attach nylon slings onto transmission case (3). Hoist and hold transmission case (3). Install transmission case (3) to the maintenance stand.

W4-2-4-21

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Transmission case cover (1) weight: 73 dCAUTION: kg (165 lb)

22. Install screen sheet (7) to transmission case (3).

3

20. Hoist and remove transmission case cover (1) from transmission case (3).

1 7

W4GB-03-02-111

3

W4GB-03-02-109

23. Install output shaft (6) to transmission case (3). Fit the mounting hole of screen sheet (8) to that of screen sheet (7). Install screen sheet (8) to screen sheet (7) with socket bolts (5) (4 used).

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (9).

21. Heat the inner ring of taper roller bearing (9) to about +120 °C (248 °F). Install screen sheet (8) through output shaft (6) and install the inner ring of taper roller bearing (9) by using a press. Install the inner ring of taper roller bearing (9) at the opposite side.

l : 6 mm m : 23 N·m (17 lbf·ft) 6

9 6 8 7, 8 3

W4GB-03-02-110

W4-2-4-22

5

W4GB-03-02-112

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 24. Install O-rings (12) (4 used) to both ends of oil pipes (11) (2 used).

12

11

27. Apply Form-In-Place Gasket (LOCTITE #574) onto the cover mating surface of transmission case (3).

12

W4GB-03-02-113

3

25. Install oil pipes (11) (2 used) to transmission case cover (3) .

W4GB-03-02-116

Transmission case cover (1) weight: 73 dCAUTION: kg (165 lb)

3

11

IMPORTANT: Check the mounting hole position for oil pipes (11) (2 used) on transmission case cover (1) and the position of oil pipes (11) (2 used) when installing.

11

28. Install transmission case cover (1) to transmission case (3).

W4GB-03-02-114

26. Install piston rings (10) (6 used) to all clutch shaft ends. Apply grease onto piston rings (10) (6 used).

1

10

3 W4GB-03-02-117

10

W4GB-03-02-115

W4-2-4-23

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 29. Install special tool (b) (ZF No.: 5870 280 007) to the shaft part of slow-speed forward clutch (KV) and check that it turns. Check it for all clutches. If any abnormality is found, disassemble it again, trace it, and correct the cause. b

b-

Special Tool W4GB-03-02-119

30. Install plate (4) and socket bolts (2) (35 used) to transmission case cover (1). l : 8 mm m : 46 N·m (34 lbf·ft)

4 2

1

W4GB-03-02-120

W4-2-4-24

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Clutch First Speed Clutch (K1)

WNDB-04-02-007

12345678-

Taper Roller Bearing Piston Ring Shaft Stud Piston Ring Disc Carrier Piston O-Ring

910111213141516-

O-Ring Washer Coil Spring Guide Ring Snap Ring Disc Inner Clutch Disc (9 Used) Outer Clutch Disc (8 Used)

1718192021222324-

Disc End Shim Snap Ring Running Disc Axial Needle Cage Axial Washer Needle Cage Idler

W4-2-4-25

2526272829-

Axial Washer Axial Needle Cage Running Disc Retaining Ring Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Second Speed Clutch (K2)

WNDB-04-02-008

12345678-

Taper Roller Bearing Piston Ring Shaft Stud Piston Ring Disc Carrier Piston O-Ring

910111213141516-

O-Ring Washer Coil Spring Guide Ring Snap Ring Disc Inner Clutch Disc (8 Used) Outer Clutch Disc (7 Used)

1718192021222324-

Disc End Shim Snap Ring Running Disc Axial Needle Cage Axial Washer Needle Cage (2 Used) Idler

W4-2-4-26

2526272829-

Axial Washer Axial Needle Cage Running Disc Retaining Ring Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Third Speed Clutch (K3)

WNDB-04-02-009

12345678-

Taper Roller Bearing Piston Ring Shaft Stud Piston Ring Disc Carrier Piston O-Ring

910111213141516-

O-Ring Washer Coil Spring Guide Ring Snap Ring Disc Inner Clutch Disc (8 Used) Outer Clutch Disc (7 Used)

1718192021222324-

Disc End Shim Snap Ring Running Disc Axial Needle Cage Axial Washer Needle Cage (2 Used) Idler

W4-2-4-27

25262729-

Axial Washer Axial Needle Cage Running Disc Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly of First Speed Clutch (K1), Second Speed Clutch (K2), and Third Speed Clutch (K3) 8. Compress coil spring (11) by using special tool (a) (ZF No.: 5870 345 088). Remove snap ring (13) from disc carrier (6). Release coil spring (11). Remove coil spring (11) from disc carrier (6).

1. Remove piston rings (2, 5) from shaft (3) of each clutch.

2. Remove stud (4) from shaft (3) of each clutch.

Remove taper roller bearings (1, 29) from shaft (3) by using the special tools (ZF No.: 5870 026 100, 5873 001 059, 5873 002 001, and 5873 002 038).

a

3. Remove retaining ring (28) (only K1 and K2), running disc (27), axial needle cage (26), and axial washer (25) from disc carrier (6).

4. Remove idler (24) from disc carrier (6).

5. Remove needle cage (23), axial washer (22), axial needle cage (21), and running disc (20) from idler (24).

6

6. Remove disc carrier (6) from shaft (6) by using a puller.

7. Remove snap ring (19) from disc carrier (6). Remove end shim (18), outer clutch discs (16) (8 used), inner clutch discs (15) (9 used), and disc (14) from disc carrier (6).

fNOTE: Number of inner clutch disc (15): 8 used (K2, K3)

a-

Special Tool W4GB-03-02-124

9. Supply low-pressure air through the oil hole of disc carrier (6) and remove piston (7) from disc carrier (6).

Number of outer clutch disc (16): 7 used (K2, K3)

W4GB-03-02-125

10. Remove O-rings (8, 9) from piston (7).

W4-2-4-28

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit First Speed Clutch (K1)

14

16

17

19

6

18 10

15

WPD850-04-02-007

12345678-

*Taper Roller Bearing *Piston Ring *Shaft *Stud *Piston Ring Disc Carrier Piston *O-Ring

910111213141516-

*O-Ring *Washer *Coil Spring *Guide Ring *Snap Ring Disc Inner Clutch Disc (9 Used) Outer Clutch Disc (8 Used)

1718192021222324-

Disc End Shim Snap Ring *Running Disc *Axial Needle Cage *Axial Washer *Needle Cage *Idler

fNOTE: As for the item with mark *, refer to W4-2-4-25.

W4-2-4-29

2526272829-

*Axial Washer *Axial Needle Cage *Running Disc *Retaining Ring *Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Second Speed Clutch) (K2) and Third Speed Clutch (K3)

14

16 19

6

18 7

15

WNEC-04-02-022

12345678-

*Taper Roller Bearing *Piston Ring *Shaft *Stud *Piston Ring Disc Carrier Piston *O-Ring

910111213141516-

*O-Ring *Washer *Coil Spring *Guide Ring *Snap Ring Disc Inner Clutch Disc (8 Used) Outer Clutch Disc (7 Used)

1718192021222324-

Disc End Shim Snap Ring *Running Disc *Axial Needle Cage *Axial Washer *Needle Cage (2 Used) *Idler

fNOTE: As for the item with mark *, refer to W4-2-4-26

for Second Speed Clutch (K2). As for the item with mark *, refer to W4-2-4-27 for Third Speed Clutch (K3).

W4-2-4-30

25262729-

*Axial Washer *Axial Needle Cage *Running Disc *Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of First Speed Clutch (K1), Second Speed Clutch (K2), and Third Speed Clutch (K3)

fNOTE: First speed clutch (K1), second speed clutch (K2),

3. Install washer (10), coil spring (11), and guide ring (12) to disc carrier (6).

and third speed clutch (K3) are similar. Therefore, third speed clutch (K3) is explained here.

12 11

IMPORTANT: Check that the ball part of valve (a) in piston (10) is not clogged.

1. Apply oil onto O-rings (8, 9). Install O-rings (8, 9) to piston (7).

10

10

6 9

a

W4GB-03-02-146

4. Compress coil spring (11) by using special tool (b) (ZF No.: 5870 345 088). Install snap ring (13) to disc carrier (6).

8 a-

Valve W4GB-03-02-126

b

2. Install piston (7) to disc carrier (6) by using special tool (b) (ZF No.: 5870 345 088). Check the direction of piston (7) in the figure.

10 11 6

6

b-

Special Tool W4GB-03-02-129

W4GB-03-02-127

W4-2-4-31

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Install disc (14) with the non-coating surface facing to the piston (7) side. Do not apply oil onto each disc in order to set the disc clearance correctly.

5. Install inner clutch discs (15) (7 used), outer clutch discs (16) (7 used), and disc (14) to disc carrier (6).

IMPORTANT: Select snap ring (19) so that the disc clearance is correct.

7. Set a dial gauge to end shim (18). Set the dial gauge to 0 (zero) when pressure of about 100 N (22.5 lbf ) is applied to end shim (18).

fNOTE: The both surfaces of outer clutch disc (16) are

coated. Refer to W4-2-4-27 for the order to install inner clutch disc (15) and outer clutch disc (16).

fNOTE: Number of inner clutch disc (15): 9 used (K1) Number of outer clutch disc (16): 8 used (K1)

17 16 15 14

W4GB-03-02-134

8. Record the value of the dial gauge when end shim (18) is raised by using screwdriver (d). If the disc clearance value is different from the specification, replace snap ring (19) with that of different thickness.

6

W4GB-03-02-132

fNOTE:

  Disc clearance specification (first speed clutch) (K1): 2.5 to 2.8 mm   Disc clearance specification (second speed clutch) (K2) and (third speed clutch) (K3): 2.0 to 2.3 mm

6. Install end shim (18) to disc carrier (6). Install snap ring (19) to disc carrier (6).

NOTE: Thickness of snap ring (19): 2.65 mm (0.1 in) (Standard)

f

fNOTE: Selected thickness of snap ring (18): 2.1 to 4.2 mm

18

d

6

W4GB-03-02-133

d-

Screwdriver WNEC-04-02-027

W4-2-4-32

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9. After adjustment of the disc clearance, remove all discs. Apply oil onto each disc. Install them again.

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (1).

IMPORTANT: Install running disc (20) with the chamfered surface facing to the idler (24) side.

13. Install running disc (20), axial needle cage (21), and axial washer (22) to shaft (3).

10. Heat the inner ring of taper roller bearing (1) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (1) to shaft (3).

22 21

11. Heat the center of disc carrier (6) to about +120 °C (248 °F).

20 3

W4GB-03-02-138

14. Install needle cages (23) (2 used) to shaft (3).

6

W4GB-03-02-136

fNOTE: Number of needle cage (23): 1 used (K1)

Put heat-resisting gloves when dCAUTION: installing disc carrier (6).

12. Install disc carrier (6) to shaft (3).

6

3

W4GB-03-02-137

W4-2-4-33

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 15. In order to engage the spline of idler (24) and the gear teeth of inner clutch disc (15) with shaft (3), install idler (24) to shaft (3) by turning it right and left.

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (29).

17. Heat the inner ring of taper roller bearing (29) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (29) to shaft (3).

29 24

3 3 W4GB-03-02-139

IMPORTANT: Install running disc (27) with the chamfered surface facing to the axial needle cage (26) side.

16. Install axial washer (25), axial needle cage (26), running disc (27), and retaining ring (28) (only K1 and K2) to idler (24).

27 26 25 24

W4GB-03-02-141

fNOTE: When the parts have been installed correctly in step 16, the level difference of upper surface of running disc (27) and shaft (3) are the same. If running disc (27) is higher, check the engagement of idler (24) and inner clutch disc (15).

W4-2-4-34

W4GB-03-02-142

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 18. Install stud (4) to shaft (3).

fNOTE: Install nuts (M10) (2 used) to the top of stud

(4) and secure it. Then, install stud (4) to shaft (3). After installing stud (4), remove nuts (M10) (2 used) from stud (4). m : 17 N·m (37 lbf·ft)

fNOTE: Supply low-pressure air and check the clutch

operation. When it has been assembled correctly, the clutch operation sound can be heard.

W4GB-03-02-143

19. Install piston rings (2, 5) to shaft (3).

W4-2-4-35

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Slow-Speed Forward Clutch (KV) and Reverse Clutch (KR)

WNDB-04-02-010 1234567-

Taper Roller Bearing Piston Ring Shaft Stud Piston Ring Needle Cage Idler

891011121314-

Ball Bearing Snap Ring Snap Ring Snap Ring End Shim Disc Outer Clutch Disc (9 Used)

15161718192021-

Inner Clutch Disc (10 Used) Disc Snap Ring Guide Ring Coil Spring Washer O-Ring

W4-2-4-36

22232425-

O-Ring Piston Disc Carrier Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly of Slow-Speed Forward Clutch (KV) and Reverse Clutch (KR) 1. Remove piston rings (2, 5) from shaft (3).

8. Compress coil spring (19) by using special tool (a) (ZF No.: 5870 345 088). Remove snap ring (17) from disc carrier (24). Release coil spring (19). Remove guide ring (18), coil spring (19), and washer (20) from disc carrier (23).

2. Remove stud (4) from shaft (3). Remove taper roller bearings (1, 25) from shaft (3) by using the special tools (ZF No.: 5870 026 100 and 5873 001 057).

3. Remove snap ring (10) from shaft (3). Remove disc carrier (24) from shaft (6) by using a puller.

4. Remove idler (7) from shaft (3) by using a press.

a

5. Remove needle cage (6) from shaft (3).

6. Remove snap ring (9) from idler (7). Remove ball bearing (8) from idler (7).

7. Remove snap ring (11) from disc carrier (24).

Remove end shim (12), outer clutch discs (14) (9 used), inner clutch discs (15) (10 used), and disc (16) from disc carrier (24).

24

a-

Special Tool

W4GB-03-02-124

9. Supply low-pressure air through the oil hole of disc carrier (24) and remove piston (23) from disc carrier (24).

W4GB-03-02-125

10. Remove O-rings (21, 22) from piston (23).

W4-2-4-37

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Slow-Speed Forward Clutch (KV) and Reverse Clutch (KR)

16

14

11 24

12 23

15

W4GB-03-02-147

1234567-

*Taper Roller Bearing *Piston Ring *Shaft *Stud *Piston Ring *Needle Cage *Idler

891011121314-

*Ball Bearing *Snap Ring Snap Ring Snap Ring End Shim Disc Outer Clutch Disc (9 Used)

15161718192021-

Inner Clutch Disc (10 Used) Disc *Snap Ring *Guide Ring *Coil Spring *Washer *O-Ring

fNOTE: As for the item with mark *, refer to W4-2-4-36.

W4-2-4-38

22232425-

*O-Ring Piston Disc Carrier *Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of Slow-Speed Forward Clutch (KV) and Reverse Clutch (KR) IMPORTANT: Check that the ball part of valve (a) in piston (23) is not clogged.

1. Apply oil onto O-rings (21, 22). Install O-rings (21, 22) to piston (23).

3. Install washer (20), coil spring (19), and guide ring (18) to disc carrier (24).

18 19

23

22

a

20

24

W4GB-03-02-146

21 a-

Valve W4GB-03-02-126

2. Install piston (23) to disc carrier (24) by using special tool (b) (ZF No.: 5870 345 088). Check the direction of piston (23) in the figure.

4. Compress coil spring (19) by using special tool (b) (ZF No.: 5870 345 088) and special tool (c) (ZF No.: 5870 345 124). Install snap ring (15) to disc carrier (23). b, c

23

15

24

23

W4GB-03-02-127

b, c- Special Tool W4GB-03-02-129

W4-2-4-39

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Install disc (16) with the non-coating surface facing to the piston (23) side. Do not apply oil onto each disc in order to set the disc clearance correctly.

5. Install inner clutch discs (15) (10 used), outer clutch discs (14) (9 used), and disc (16) to disc carrier (24).

IMPORTANT: Select snap ring (11) so that the disc clearance is correct.

7. Set a dial gauge to end shim (12). Set the dial gauge to 0 (zero) when pressure of about 100 N (22.5 lbf ) is applied to end shim (12).

fNOTE: The both surfaces of outer clutch disc (14) are

coated. Refer to W4-2-4-36 for the order to install inner clutch disc (15) and outer clutch disc (14).

13 15 14 16 W4GB-03-02-134

24

8. Record the value of the dial gauge when end shim (12) is raised by using screwdriver (d). If the disc clearance value is different from the specification, replace snap ring (11) with that of different thickness.

W4GB-03-02-132

6. Install end shim (12) and snap ring (11) to disc carrier (24).

fNOTE: Disc clearance specification: 2.45 to 2.75 mm fNOTE: Selected thickness of snap ring (10): 2.1 to 4.2

fNOTE: Thickness of snap ring (11): 2.65 mm (0.1 in) (Standard)

mm

11 d

24 dW4GB-03-02-133

W4-2-4-40

Screwdriver WNEC-04-02-027

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9. After adjustment of the disc clearance, remove all discs. Apply oil onto each disc. Install them again.

14. Install idler (7) to shaft (3) by using a press.

10. Engage idler (7) with inner discs (15) (10 used) and install it to disc carrier (24) by turning it right and left. This work is done in order to arrange inner disc (15) and outer disc (14). After this work, remove idler (7).

7

3

W4GB-03-02-152

7 24

15. Heat the center of disc carrier (24) to about +120 °C (248 °F).

W4GB-03-02-148

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (1).

11. Heat the inner ring of taper roller bearing (1) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (1) to shaft (3).

12. Install needle cage (6) to shaft (3).

13. Install ball bearing (8) to idler (7). Install snap ring (9) to idler (7).

9 8

7

W4GB-03-02-151

W4-2-4-41

W4GB-03-02-153

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Put heat-resisting gloves when dCAUTION: installing disc carrier (24).

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing

IMPORTANT: Engage the gear teeth of idler (7) and clutch disc (15) carefully when installing.

16. Install disc carrier (24) to shaft (3).

(25).

17. Heat the inner ring of taper roller bearing (25) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (25) to shaft (3).

18. Install stud (4) to shaft (3).

fNOTE: Install nuts (M10) (2 used) to the top of stud

(4) and secure it. Then, install stud (4) to shaft (3). After installing stud (4), remove nuts (M10) (2 used) from stud (4).

24

m : 17 N·m

7 3 W4GB-03-02-154

fNOTE: Supply low-pressure air and check the clutch

operation. When it has been assembled correctly, the clutch operation sound can be heard.

24

3 W4GB-03-02-155

W4GB-03-02-156

19. Install piston rings (2, 5) to shaft (3).

W4-2-4-42

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Fast-Speed Forward Clutch (K4)

WNDB-04-02-011

123456789-

Taper Roller Bearing Piston Ring Shaft Stud Piston Ring Gear Snap Ring Axial Washer Axial Needle Cage

101112131415161718-

Axial Washer Needle Cage (2 Used) Idler Axial Washer Axial Needle Cage Running Disc Snap Ring End Shim Disc

192021222324252627-

Inner Clutch Disc (5 Used) Outer Clutch Disc (4 Used) Disc Snap Ring Guide Ring Coil Spring Washer Piston O-Ring

W4-2-4-43

28293031-

O-Ring Disc Carrier Snap Ring Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly of Fast-Speed Forward Clutch (K4) IMPORTANT: Do not disassemble snap ring (7) and gear (6).

1. Remove piston rings (2, 5) from shaft (3).

9. Compress coil spring (24) by using special tool (a) (ZF No.: 5870 345 088). Remove snap ring (22) from disc carrier (29). Release coil spring (24). Remove coil spring (24) from disc carrier (29).

2. Remove stud (4) from shaft (3). Remove taper roller bearings (1, 31) from shaft (3) by using the special tools (ZF No.: 5870 026 100 and 5873 001 057).

a

3. Remove snap ring (30) from shaft (3). Remove disc carrier (29) from shaft (6) by using a puller.

4. Remove running disc (15), axial needle cage (14), and axial washer (13) from idler (12).

5. Remove idler (12) from shaft (3).

29

6. Remove needle cages (11) (2 used), axial washer (10), axial needle cage (9), and axial washer (8) from shaft (3).

7. Remove snap ring (7) from shaft (3). Remove gear (6) from shaft (3).

8. Remove snap ring (16) from disc carrier (29).

Remove end shim (17), outer clutch discs (20) (4 used), inner clutch discs (19) (5 used), and disc (20) from disc carrier (29).

a-

Special Tool

W4GB-03-02-124

10. Supply low-pressure air through the oil hole of disc carrier (29) and remove piston (26) from disc carrier (29).

W4GB-03-02-125

11. Remove O-rings (27, 28) from piston (24).

W4-2-4-44

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Fast-Speed Forward Clutch (K4)

21

20

18

29

16

17 26

19

WNEC-04-02-023

123456789-

*Taper Roller Bearing *Piston Ring *Shaft *Stud *Piston Ring *Gear *Snap Ring *Axial Washer *Axial Needle Cage

101112131415161718-

*Axial Washer *Needle Cage (2 Used) *Idler *Axial Washer *Axial Needle Cage *Running Disc Snap Ring End Shim Disc

192021222324252627-

Inner Clutch Disc (5 Used) Outer Clutch Disc (4 Used) Disc *Snap Ring *Guide Ring *Coil Spring *Washer Piston *O-Ring

fNOTE: As for the item with mark *, refer to W4-2-4-43.

W4-2-4-45

28293031-

*O-Ring Disc Carrier *Snap Ring *Taper Roller Bearing

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of Fast-Speed Forward Clutch (K4) 4. Compress coil spring (24) by using special tool (b) (ZF No.: 5870 345 088). Install snap ring (22) to disc carrier (29).

IMPORTANT: Check that the ball part of valve (a) in piston (26) is not clogged.

1. Apply oil onto O-rings (27, 28). Install O-rings (26, 27) to piston (26).

24

b

27

a

24 28 a-

29

Valve W4GB-03-02-126 b-

W4GB-03-02-129

2. Install piston (26) to disc carrier (29) by using special tool (a) (ZF No.: 5870 345 088). Check the direction of piston (26) in the figure.

26

29

Special Tool

IMPORTANT: Install disc (21) with the non-coating surface facing to the piston (26) side. Do not apply oil onto each disc in order to set the disc clearance correctly.

5. Install inner clutch discs (19) (5 used), outer clutch discs (20) (4 used), and disc (18) to disc carrier (29).

fNOTE: The both surfaces of outer clutch disc (20) are

coated. Refer to W4-2-4-43 for the order to install inner clutch disc (19) and outer clutch disc (20).

W4GB-03-02-127

18

3. Install washer (25), coil spring (24), and guide ring (23) to disc carrier (29).

23

19 20 21

24

29

25 W4GB-03-02-132

29

W4GB-03-02-146

W4-2-4-46

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 6. Install end shim (17) to disc carrier (29). Install snap ring (16) to disc carrier (29).

8. Record the value of the dial gauge when end shim (17) is raised by using screwdriver (d). If the disc clearance value is different from the specification, replace snap ring (16) with that of different thickness.

fNOTE: Thickness of snap ring (16): 2.65 mm (0.1 in) (Standard)

17

fNOTE: Disc clearance specification: 1.35 to 1.65 mm fNOTE: Selected thickness of snap ring (16): 2.1 to 4.2 mm

29 d

W4GB-03-02-133

IMPORTANT: Select snap ring (16) so that the disc clearance is correct.

7. Set a dial gauge to end shim (17). Set the dial gauge to 0 (zero) when pressure of about 100 N (10 kgf, 22.5 lbf ) is applied to end shim (17).

d-

Screwdriver WNEC-04-02-027

9. After adjustment of the disc clearance, remove all discs. Apply oil onto each disc. Install them again.

10. Engage idler (12) with inner discs (19) (6 used) and install it to disc carrier (29) by turning it right and left. This work is done in order to arrange inner disc (19) and outer disc (20). After this work, remove idler (12).

W4GB-03-02-134

12 29

W4GB-03-02-148

W4-2-4-47

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (1).

14. Install axial washer (8), axial needle cage (9), and axial washer (10) to shaft (3).

11. Heat the inner ring of taper roller bearing (1) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (1) to shaft (3).

3

d

CAUTION: Put heat-resisting gloves when installing gear (6).

12. Cool shaft (3) to about -80 °C (-112 °F). Heat gear (6) to about +120 °C (248 °F). Install gear (6) to shaft (3).

10 9

fNOTE: Install gear (6) with the longer hub up.

8

W4GB-03-02-163

3

15. Install needle cages (11) (2 used) to shaft (3).

3

11

6 W4GB-03-02-160

13. Install snap ring (7) to shaft (3).

W4GB-03-02-164

3 7

W4GB-03-02-161

W4-2-4-48

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 16. Install idler (12) to shaft (3).

19. In order to engage the spline of idler (12) and the gear teeth of inner clutch disc (19) with shaft (3), install disc carrier (29) to shaft (3) by turning it right and left.

3

12

3

29

W4GB-03-02-165

W4GB-03-02-167

IMPORTANT: Install running disc (15) with the chamfered surface facing to the axial needle cage (14) side.

17. Install axial washer (13), axial needle cage (14), and running disc (15) to idler (12).

20. Install retaining ring (30) to shaft (3).

15

3

14 29 13

12 W4GB-03-02-168

W4GB-03-02-166

Put heat-resisting gloves when dCAUTION: installing disc carrier (29).

18. Heat the center of disc carrier (29) to about +120 °C (248 °F).

W4-2-4-49

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 22. Install stud (4) to shaft (3).

Put heat-resisting gloves when dCAUTION: installing the inner ring of taper roller bearing (31).

21. Heat the inner ring of taper roller bearing (31) to about +120 °C (248 °F). Install the inner ring of taper roller bearing (31) to shaft (3).

fNOTE: Install nuts (M10) (2 used) to the top of stud

(4) and secure it. Then, install stud (4) to shaft (3). After installing stud (4), remove nuts (M10) (2 used) from stud (4). m : 17 N·m

23. Install piston rings (2, 5) to shaft (3).

31

W4GB-03-02-170

fNOTE: Supply low-pressure air and check the clutch

operation. When it has been assembled correctly, the clutch operation sound can be heard.

W4GB-03-02-169

W4-2-4-50

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Transmission Control Valve Removal and Installation of Transmission Control Valve

WNEC-04-02-014

1-

Duct Plate

2-

Plate

3-

Control Valve

W4-2-5-1

4-

Socket Bolt (23 Used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal of Transmission Control Valve 1. Remove socket bolts (4) (23 used) by using a hexalobular internal wrench. Remove control valve (3) and plate (2) from duct plate (1). l : T27 (Hexalobular Internal Wrench)

W4-2-5-2

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Installation of Transmission Control Valve 1. Install plate (2) and control valve (3) to duct plate (1) with socket bolts (4) (23 used) by using a hexalobular internal wrench. l : T27 (Hexalobular Internal Wrench) m : 9.5 N·m (7 lbf·ft)

W4-2-5-3

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Duct Plate 1

2

3

9

8

123-

Nut (14 Used) Duct Plate Socket Bolt (36 Used)

456-

Switch O-Ring Piston

1

789-

Spring Gasket Safety Valve

fNOTE: As for the item with mark *, refer to W4-2-4-1.

W4-2-5-4

7

6

4, 5

W4GB-03-02-012

10- *Transmission Case Cover

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal of Duct Plate 1. Remove switch (4), piston (6), and spring (7) from duct plate (2). Remove O-ring (5) from switch (4). j : 22 mm 2. Remove nuts (1) (14 used). j : 13 mm 3. Remove socket bolts (3) (37 used) by using a hexalobular internal wrench. Remove duct plate (2) and gasket (8) from transmission case cover (10) . l : T27 (Hexalobular Internal Wrench) 4. Remove safety valve (9) from transmission case cover (10).

W4-2-5-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of Duct Plate

3. Apply LOCTITE #243 onto socket bolts (3) (37 used). Install duct plate (2) to transmission case cover (10) with socket bolts (3) (37 used) by using a hexalobular internal wrench.

1. Install safety valve (9) to transmission case cover (10).

l : T27 (Hexalobular Internal Wrench) 10

m : 23 N·m (17 lbf·ft)

9

10

W4GB-03-02-014

2 W4GB-03-02-016

2. Apply grease onto gasket (8). Install gasket (8) to transmission case cover (10).

4. Install nuts (1) (14 used) to transmission case cover (10) .

10

j : 13 mm m : 23 N·m (17 lbf·ft) 5. Apply grease onto O-ring (5). Install O-ring (5) to switch (4). Install spring (7), piston (6), and switch (4) to duct plate (2). j : 22 mm m : 30 N·m (22.1 lbf·ft) 8 W4GB-03-02-015

2 7 6 4, 5

W4-2-5-6

W4GB-03-02-013

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Disassembly and Assembly of Transmission Control Valve 1 37

36

2 3 4

38

35 5 6

34

7 39

31 33

8

30

9 10

32

41 40

11 29

12

28 13 14 15

27 25 26

WNEC-04-02-013

16

24

17 18 23 19

20 21 22 W4GB-03-02-017 123456789101112-

Cover Gasket Pressure Regulator (3 Used) Socket Bolt (18 Used) Housing Cover Piston (3 Used) Spring (3 Used) Gasket Valve Block Assembly Orifice (6 Used) Spring (3 Used) Piston (3 Used)

131415161718192021222324-

Gasket Housing Cover Socket Bolt (18 Used) Fixing Plate (3 Used) Pressure Regulator (3 Used) Gasket Wire Harness Cover Socket Bolt (14 Used) Retaining Clamp Socket Bolt (3 Used) Piston (3 Used)

252627282930313233343536-

Spring (3 Used) Spring Piston O-Ring Plug Spring (3 Used) Piston (3 Used) Spring Control Piston Socket Bolt (3 Used) Fixing Plate (3 Used) Socket Bolt (14 Used)

W4-2-5-7

3738394041-

Socket Bolt (18 Used) Duct Plate Middle Sheet Housing Screen (6 Used)

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 9. Remove socket bolts (34) (3 used) by using a hexalobular internal wrench. Remove fixing plates (35) (3 used) and pressure regulators (3) (3 used) from housing cover (5).

Disassembly of Transmission Control Valve 1. Put the matching marks on the wire harness (19) mounting part of valve block assembly (9).

2. Remove retaining clamp (22) from cover (20).

3. Remove socket bolts (21) (14 used) by using a hexalobular internal wrench. Remove cover (20) and gasket (18) from housing cover (14). l : T27 (Hexalobular Internal Wrench) 4. Remove socket bolts (36) (14 used) by using a hexalobular internal wrench. Remove cover (1) and gasket (2) from housing cover (5). l : T27 (Hexalobular Internal Wrench) 5. Remove wire harness (19) from housing covers (5, 14).

6. Remove socket bolts (23) (3 used) by using a hexalobular internal wrench. Remove fixing plates (16) (3 used) and pressure regulators (17) (3 used) from housing cover (14). l : T27 (Hexalobular Internal Wrench) 7. Remove socket bolts (15) (2 used) in diagonal position by using a hexalobular internal wrench.

Install the special tools (ZF No.: 5870 204 036) (2 used) to the positions for removed socket bolts (15) (2 used). Evenly loosen socket bolts (15) (16 used) by using a hexalobular internal wrench. Remove housing cover (14) and gasket (13) from housing (40) without tilting housing cover (14). Remove the special tools (ZF No.: 5870 204 036) (2 used).

l : T27 (Hexalobular Internal Wrench) 10. Remove socket bolts (4) (2 used) in diagonal position by using a hexalobular internal wrench.

Install the special tools (ZF No.: 5870 204 036) (2 used) to the positions for removed socket bolts (4) (2 used). Evenly loosen socket bolts (4) (16 used) by using a hexalobular internal wrench. Remove housing cover (5) and gasket (8) from housing (40) without tilting housing cover (5). Remove the special tools (ZF No.: 5870 204 036) (2 used). l : T27 (Hexalobular Internal Wrench) 11. Remove pistons (6, 31) (3 used for each), springs (7, 30) (3 used for each), control piston (33), and spring (32) from housing (40).

12. Remove socket bolts (37) (18 used) by using a hexalobular internal wrench. Remove duct plate (38) and middle sheet (39) from housing (40). l : T27 (Hexalobular Internal Wrench) 13. Remove screens (41) (6 used) from middle sheet (39).

14. Remove plug (29) from housing (40). Remove O-ring (28) from plug (29). l : 5 mm 15. Remove orifices (10) (6 used) from housing (40).

l : T27 (Hexalobular Internal Wrench) 8. Remove pistons (12, 24) (3 used for each), springs (11, 25) (3 used for each), spring (26), and piston (27) from housing (40).

W4-2-5-8

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Assembly of Transmission Control Valve

3. Push pistons (12) (3 used). Install pins (dia. 5 mm) (3 used) to position (b) in housing (40). Secure pistons (12) (3 used) to housing (40).

IMPORTANT: Check all disassembled parts and replace any defective parts if necessary. Check that each piston moves smoothly after it has been installed in housing (40). Replace defective pistons.

12

1. Install orifices (10) (6 used) to position (a) in housing (40) with the hollow up.

40

a

40 W4GB-03-02-021

b b-

4. Install special tools (c) (ZF No.: 5870 204 036) (2 used) to housing (40). Fit gasket (13) and housing cover (14) to special tools (c) (ZF No.: 5870 204 036) (2 used). Install gasket (13) and housing cover (14) to housing (40).

W4GB-03-02-019

a a-

Pin Mounting Position

Mounting Position of Orifice (10)

2. Apply oil onto pistons (12, 24) (3 used for each) and piston (27). Place housing (40) in the direction as illustrated. Install pistons (12, 24) (3 used for each) and piston (27) to housing (40) with springs (25, 11) (3 used for each) and spring (26).

14

c

40

c

40 11

WNEC-04-02-015

25

c-

27 24

24 26

12

12 W4GB-03-02-020

W4-2-5-9

Special Tool

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 5. Install socket bolts (15) (16 used) to housing cover (14) by using a hexalobular internal wrench.

Remove special tools (c) (ZF No.: 5870 204 036) (2 used). Install socket bolts (15) (2 used) to the positions for removed special tools (c) (ZF No.: 5870 204 036) (2 used) by using a hexalobular internal wrench.

7. Install pressure regulators (17) (3 used) to housing cover (14) in the direction as illustrated. Turn the claws of fixing plates (16) (3 used) down. Install fixing plates (16) (3 used) with socket bolts (23) (3 used) by using a hexalobular internal wrench. l : T27 (Hexalobular Internal Wrench) m : 5.5 N·m (4.1 lbf·ft)

l : T27 (Hexalobular Internal Wrench) m : 5.5 N·m (4.1 lbf·ft)

17

14

16

14

W4GB-03-02-025

6. Push pistons (12) (3 used). Remove pins (dia. 5 mm) (3 used) from housing (40).

W4-2-5-10

W4GB-03-02-026

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 8. Apply oil onto pistons (6, 31) (3 used for each) and piston (33). Install pistons (6, 31) (3 used for each) and piston (33) to housing (40) with springs (7, 30) (3 used for each) and spring (32).

10. Install special tools (e) (ZF No.: 5870 204 036) (2 used) to housing (40). Fit gasket (8) and housing cover (5) to special tools (e) (ZF No.: 5870 204 036) (2 used). Install gasket (8) and housing cover (5) to housing (40).

40 5 7

32 e

e

30

40 31

33

31 6

6

W4GB-03-02-027

9. Push pistons (6) (3 used). Install pins (dia. 5 mm) (3 used) to position (d) in housing (40). Secure pistons (6) (3 used) to housing (40).

W4GB-03-02-028 e-

Special Tool

11. Install socket bolts (4) (16 used) to housing cover (5) by using a hexalobular internal wrench. Remove special tools (e) (ZF No.: 5870 204 036) (2 used).

Install socket bolts (4) (2 used) to the positions for removed special tools (e) (ZF No.: 5870 204 036) (2 used) by using a hexalobular internal wrench.

6

l : T27 (Hexalobular Internal Wrench)

40

m : 5.5 N·m (4.1 lbf·ft) 12. Push pistons (6) (3 used). Remove pins (dia. 5 mm) (3 used) from housing (40). d d-

WNEC-04-02-016

Pin Mounting Position

W4-2-5-11

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit 13. Install pressure regulators (3) (3 used) to housing cover (5) in the direction as illustrated. Turn the claws of fixing plates (35) (3 used) down. Install fixing plates (35) (3 used) with socket bolts (34) (3 used) by using a hexalobular internal wrench.

15. Install gasket (18) to housing cover (14). Fit the pin of the wire harness (19) socket to the groove on cover (20). Install cover (20) to housing cover (14) with socket bolts (21) (14 used) by using a hexalobular internal wrench.

l : T27 (Hexalobular Internal Wrench)

l : T27 (Hexalobular Internal Wrench)

m : 5.5 N·m (4.1 lbf·ft)

m : 5.5 N·m (4.1 lbf·ft) 20

14

3 5

W4GB-03-02-029 W4GB-03-02-031

14. Fit the matching marks made when disassembling and connect wire harness (19) to pressure regulators (3, 17) (3 used for each).

16. Secure the wire harness (19) socket to cover (20) with retaining clamp (22).

19 17

20

19

22

W4GB-03-02-030

W4GB-03-02-032

17. Install gasket (2) to housing cover (5). Install cover (1) to housing cover (5) with socket bolts (36) (14 used) by using a hexalobular internal wrench. l : T27 (Hexalobular Internal Wrench) m : 5.5 N·m (4.1 lbf·ft)

W4-2-5-12

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit IMPORTANT: Install screens (41) (6 used) with them facing to the duct plate (38) side.

18. Install screens (41) (6 used) to middle sheet (39).

e

20. Fit duct plate (38) to special tools (f ) (ZF No.: 5870 204 063) (2 used). Install duct plate (38) to housing (40). Install socket bolts (37) (16 used) to duct plate (38) by using a hexalobular internal wrench.

Remove special tools (f ) (ZF No.: 5870 204 063) (2 used). Install socket bolts (37) (2 used) to the positions for removed special tools (f ) (ZF No.: 5870 204 063) (2 used) by using a hexalobular internal wrench.

e

l : T27 (Hexalobular Internal Wrench) m : 11 N·m (8.1 lbf·ft)

f W4GB-03-02-034 e-

38

40

Mounting Position of Screen (41)

19. Install special tools (f ) (ZF No.: 5870 204 063) (2 used) to housing (40). Fit middle sheet (39) to special tools (f ) (ZF No.: 5870 204 063) (2 used).

Install middle sheet (39) to housing (40). f

39 40

W4GB-03-02-037 f-

Special Tool

21. Install O-ring (28) to plug (29). Install plug (29) to housing (40). l : 5 mm m : 6 N·m (4.4 lbf·ft) W4GB-03-02-035 f-

Special Tool

29 40

W4GB-03-02-038

W4-2-5-13

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit (Blank)

W4-2-5-14

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Parking Brake a

1

Section A-A

2

A

1

3

a

A

4 WPD850-04-02-005

5

6, 7 a-

Transmission WNEC-04-02-046

Removal 1. Release parking brake (1) manually. (Refer to W4-26-6.)

4. Remove bolts (6) (6 used) and washers (7) (6 used).

Remove brake disc (4) from flange (5).

2. Loosen bolts (2) (2 used) and nuts (3) (2 used).

j : 17 mm

j : 24 mm 3. Remove bolts (2) (2 used). Remove the parking brake (1) assembly from transmission (a). j : 24 mm

W4-2-6-1

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

1

2

3

4

a

5 a-

5

WPD850-04-02-006

Brake Disc

Spring force of lining spring (3) is dCAUTION: applied to adjusting screw (2).

7. Remove brake pads (5) (2 used) from the parking brake (1) assembly.

5. Push and hold upper side of lining spring (3) by using a plate.

6. Remove adjusting screw (2) and nut (4). Remove lining spring (3) from the parking brake (1) assembly. l : 6 mm j : 13 mm

W4-2-6-2

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

1

3

2

5 a-

Brake Disc

Installation 1. Install brake pads (5) (2 used) to the parking brake (1) assembly.

2. Install lining spring (3) to the parking brake (1) assembly.

Spring force of lining spring (3) is dCAUTION: applied to adjusting screw (2).

3. Push and hold upper side of lining spring (3) by using a plate.

4. Install lining spring (3) with adjusting screw (2) and nut (4). l : 6 mm j : 13 mm m : 3.3 to 4.2 N·m (2.2 to 3.0 lbf·ft)

W4-2-6-3

4

a

5

WPD850-04-02-006

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit

a

1

Section A-A

2

A

1

3

a

A

4 WPD850-04-02-005

5

6, 7 a-

Transmission WNEC-04-02-046

5. Install brake disc (4) to flange (5) with bolts (6) (6 used) and washers (7) (6 used).

8. Adjust the parking brake (1). (Refer to W4-2-6-5.)

j : 17 mm m : 68 N·m (50 lbf·ft) 6. Install the parking brake (1) assembly to transmission (a) with bolts (2) (2 used). j : 24 mm m : 46 N·m (34 lbf·ft) 7. Tighten nuts (3) (2 used). j : 24 mm m : 230 N·m (170 lbf·ft)

W4-2-6-4

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Adjustment of parking brake

dCAUTION:

1

2

3

 Once the parking brake is released, the machine can not stop by brake. Before releasing the parking brake or doing connecting work, secure the tire by wheel stopper.

fNOTE: Even if the parking brake is released, the service brake can be operated.

IMPORTANT: Confirm that the parking brake is operated normally before adjusting the parking brake.

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

2. Remove cap (4) from the parking brake (2) assembly.

a

WNEC-04-02-049

4

3. Remove lock nut (6). j : 24 mm 4. Release parking brake (2).

5

6

fNOTE: Release parking brake (2) only while pushing

switch (a) of parking brake solenoid valve (3).

5. Turn set bolt (5) clockwise and contact with brake pad (7) to brake disc (1). l : 8 mm 6. Turn set bolt (5) in one to three forth counterclockwise in order to adjust the clearances (b) (2 places) between brake disk (1) and brake pads (7) (2 used): collectlly.

MNEC-06-004

fNOTE: The clearances (b) (2 places) between the brake disc (1) and brake pads (7) (2 used): 0.25 to 0.75 mm 7. Install lock nut (6).

7

1

7

j : 24 mm m : 80 N·m (59 lbf·ft) 8. Install cap (4).

b

b WNEC-04-02-047

W4-2-6-5

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit The manual release of the parking brake

dCAUTION:  The machine is no brake function after releasing the parking brake manually.  Set the wheel stopper in order not to move the machine.  Adjust the parking brake before reusing the machine.

1

fNOTE: Even if the parking brake is released, the service brake can be operated.

7

MNEC-06-003

1. Remove cap (1).

2. Remove lock nut (2) by using a tool (3).

4

2

j : 24 mm 3. Turn set bolt (4) counterclockwise by using a hexagonal wrench (5). Push brake disc (7) until the brake disc (7) is completely released. At this time, the torque is 70 N·m (7 kgf·m, 52 lbf·ft) or more which make hexagonal wrench (5) rotate. l : 8 mm 4. Install and lightly tighten lock nut (2) until it comes in contact with piston (6).

MNEC-06-004

5. Install cap (1) in order to protect from dust.

2

6

3

4

5 MNEC-06-005

W4-2-6-6

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit Removal and Installation of Flange at Output Shaft Side

View A

1

2

3

4

6

13 WNDB-04-02-012

B

A

15

View B

7 4

14

9

10 11

12

WNEC-04-02-052

Removal 1. Remove bolts (1) (2 used), washer (2), and O-ring (3). j : 13 mm 2. Remove flange (4).

3. Remove shaft seal (6) from transmission case (14).

4. Remove the parking brake assembly and brake disc (13). (Refer to W4-2-6-1.)

5. Remove bolts (12) (2 used), washer (11), and O-ring (10). j : 13 mm 6. Remove flange (9).

7. Remove shaft seal (7) from transmission case cover (15).

W4-2-6-7

WNDB-04-02-013

13

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit ViewA

1

2

3

4

6

WNDB-04-02-012

A

4

14

a

WNEC-04-02-052

Installation 14

1. Apply grease onto shaft seal (6). Install shaft seal (6) to transmission case (14) by using special tool (a) (ZF NO.:5870-048-057).

2. Install flange (4) to the output shaft.

3. Install O-ring (3) and washer (2) to flange (4) with bolts (1) (2 used). j : 13 mm

WNEC-04-02-054

m : 34 N·m (25 lbf·ft)

a-

W4-2-6-8

Special Tool

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit ViewB

7

10 11

9

12

13 WNDB-04-02-013

13

B

15 a

WNEC-04-02-052

15

4. Apply grease onto shaft seal (7). Install shaft seal (7) to transmission case cover (15) by using special tool (a) (ZF No. : 5870-048-057).

5. Install flange (9) to the output shaft.

6. Install O-ring (10) and washer (11) to flange (9) with bolts (12) (2 used). j : 13 mm

WNEC-04-02-053 a-

m : 34 N·m (25 lbf·ft) 7. Install brake disc (13) and the parking brake assembly. (Refer to W4-2-6-3.)

W4-2-6-9

Special Tool

SECTION 4 TRAVEL SYSTEM Group 2 Drive Unit (Blank)

W4-2-6-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal and Installation of Front Axle 1

4

5

3 2

WNEK50-03-13-001

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

WNEK50-04-03-001

2. Remove front cover (1). (Refer to W3-22-1.)

3. Loosen clamp (4). Disconnect hose (5). j : 7 mm 4. Lower the lift arm. Set the machine position for inspection and maintenance. (Refer to W1-5-1.)

5. Remove front tires (2) (2 used) from front axle (3).

(Refer to W4-1-1.)

Removal 1. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.)

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

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

W4-3-1-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle

6, 7 5

1

a

4 a-

3

2

WNEK50-04-03-002

Vehicle Front Side

6. Remove propeller shaft (1) from front axle (4). (Refer to W4-4-1.)

7. Remove bolts, washers (3) (3 used). Remove guard (2). j : 17 mm 8. Remove bolt, washer (6) and clip (7). j : 17 mm 9. Disconnect connectors (5) (2 used).

W4-3-1-2

5

WNEK50-04-03-003

SECTION 4 TRAVEL SYSTEM Group 3 Axle

Detail A

A

1

WNEK50-04-03-004

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

W4-3-1-3

WNEK50-04-03-005

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

2

3 5 W4GB-03-03-104

2 5

4

5

WNEK50-04-03-006

a

dCAUTION: Front axle (5) weight: 780 kg (1720 lb) 11. Attach nylon slings onto front axle (5). Hoist and hold front axle (5).

W4GB-03-03-106 a-

12. Place stand (a) under front axle (5).

IMPORTANT: Take care not to damage the sensor at the bottom of front axle (5).

13. Remove bolts (1) (8 used), washers (2) (16 used), and nuts (4) (8 used). Remove front axle (5) from front frame (3). Place it on stand (a). j : 36 mm

W4-3-1-4

Stand

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

2

3

4

14. Disconnect the both ends of pipes (4) (2 used). j : 22 mm 15. Remove bolt, washer (2). Remove block (3) from front axle (1). j : 17 mm 16. Remove the adapters from front axle (1) if necessary.

W4-3-1-5

WNEK50-04-03-007

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

2

3

4

Installation 1. Install all removed adapters to front axle (1).

2. Install block (3) to front axle (1) with bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft) 3. Connect the both ends of pipes (4) (2 used). j : 22 mm m : 40 N·m (29.5 lbf·ft)

W4-3-1-6

WNEK50-04-03-007

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

2

3

5 2 5

4 WNEK50-04-03-006

4. Set the front axle (5) assembly under the mounting position of front axle (5).

dCAUTION: Front axle (5) weight: 780 kg (1720 lb) 5. Attach nylon slings onto front axle (5). Hoist front axle (5).

6. Install front axle (5) to front frame (3) with nuts (4) (8 used), washers (2) (16 used), and bolts (1) (8 used). j : 36 mm m : 785±150 N·m (580 lbf·ft)

W4-3-1-7

W4GB-03-03-104

SECTION 4 TRAVEL SYSTEM Group 3 Axle

Detail A

A

1

a

WNEK50-04-03-004 a-

Vehicle Front Side

7. Connect hose (1). j : 22 mm m : 40 N·m (29.5 lbf·ft)

W4-3-1-8

WNEK50-04-03-005

SECTION 4 TRAVEL SYSTEM Group 3 Axle

6, 7 5

1

8

5

WNEK50-04-03-003

8. Connect connectors (5) (2 used).

9. Secure harness (8) with clip (7) and bolt, washer (6).

4

3

2

WNEK50-04-03-002

11. Install propeller shaft (1) to front axle (4). (Refer to W4-4-1.)

j : 17 mm m : 50 N·m (37 lbf·ft) 10. Install guard (2) with bolts, washers (3) (3 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W4-3-1-9

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

4

5

3

WNEK50-04-03-001

2

WNEK50-03-13-001

12. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.)

17. Set the machine position (lift arm raise) for inspection and maintenance. (Refer to W1-5-1.)

13. Connect hose (5) with clamp (4).

18. Install front cover (1). (Refer to W3-22-1.)

j : 7 mm m : 3 N·m (2.2 lbf·ft) 14. Bleed air from the brake (axle). (Refer to W1-4-1.)

15. Set the machine position (lift arm lower) for inspection and maintenance. (Refer to W1-5-1.)

16. Install front tires (2) (2 used) to front axle (3). (Refer to W4-1-1.)

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

W4-3-1-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal and Installation of Rear Axle

2

A

3

1

WNEK50-03-22-008

WNEK50-04-03-008

Detail A

a

IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

4, 5

Removal a-

WNEK50-04-03-009

Air Breather

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

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

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

2. Remove rear tires (1) (2 used) from rear axle (3).

(Refer to W4-1-2.)

3. Open side cover (front) (2).

4. Loosen clamp (4). Disconnect hose (5). j : 7 mm

W4-3-2-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle A

Detail A

3

2

a

1

WNEK50-04-03-011 a-

Vehicle Front Side

WNEK50-04-03-010

5. Remove propeller shaft (1). (Refer to W4-4-1.)

6. Disconnect pipe (3). j : 17 mm 7. Disconnect hose (2). j : 22 mm

W4-3-2-2

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

a

a-

Vehicle Front Side

WNEK50-04-03-012

8. Disconnect pipe (1). j : 17 mm

W4-3-2-3

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1 2 3

5 W4GB-03-03-111

5

7, 8

a

6

5 a-

Stand

W4GB-03-03-113

2 4 9 WNEK50-04-03-013

The rear axle (5) assembly weight: 750 dCAUTION: kg (1660 lb) 9. Secure support (6, 9) to rear axle (5) by using wires.

Attach nylon slings onto the rear axle (5) assembly.

Hoist and hold the rear axle (5) assembly.

10. Place stand (a) under rear axle (5).

11. Remove nuts (4) (8 used) and washers (2) (8 used).

Remove the rear axle (5) assembly from rear frame (3). Place it onto stand (a).

12. Remove the stand (a) under the vehicle.

fNOTE: Disassemble the rear axle (5) on the stand (a).

13. Loosen clamp (7). Disconnect hose (8). j : 7 mm

W4-3-2-4

SECTION 4 TRAVEL SYSTEM Group 3 Axle 3

1

2 1

5 7 6 5

4 WNEK50-04-03-014

17. Remove support (6) from rear axle (4).

14. Disconnect the both ends of pipes (1) (2 used). j : 22 mm 15. Remove bolt, washer (2). Remove block (3) from rear axle (4).

18. Remove dust seals (5) (2 used) and bushing (7) from support (6).

j : 17 mm

dCAUTION: Support (6) weight: 65 kg (145 lb)

16. Attach nylon slings onto support (6). Hoist and hold support (6). Remove the wires for fasting support (6) that have been installed in step 9.

W4-3-2-5

SECTION 4 TRAVEL SYSTEM Group 3 Axle

13

11 12

4

8 11 10

9

8

WNEK50-04-03-015

22. Remove bolts (8) (8 used). Remove thrust plate (12) from rear axle (4).

dCAUTION: Support (13) weight: 79 kg (175 lb) 19. Attach nylon slings onto support (13). Hoist and hold support (13). Remove the wires for fasting support (13) that have been installed in step 9.

j : 24 mm

20. Remove bolts (8) (8 used) and washers (9) (8 used).

Remove cover (10) from support (13).

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of bolt (8).

23. Remove thrust washer (11) from support (13).

j : 24 mm

fNOTE: LOCTITE #263 or equivalent has been applied to the thread part of bolt (8).

21. Remove thrust washer (11) from thrust plate (12).

W4-3-2-6

SECTION 4 TRAVEL SYSTEM Group 3 Axle

15 13

4

14 WNEK50-04-03-016

24. Remove support (13) from rear axle (4).

25. Remove dust seal (15) and bushing (14) from support (13).

26. Remove the adapters from rear axle (4) if necessary.

W4-3-2-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle

15 13

4

14 WNEK50-04-03-016

Installation a

1. Install all removed adapters to rear axle (4).

IMPORTANT: Check the direction to install dust seal (15).

2. Install bushing (14) and dust seal (15) to support (13).

dCAUTION: Support (13) weight: 79 kg (175 lb)

3. Apply grease onto the inner circumference of bushing (14). Attach nylon slings onto support (13).

Hoist support (13). Install support (13) to rear axle (4).

15 4 a-

4. Secure support (13) to rear axle (4) by using wires.

W4-3-2-8

Direction to Install

13

14 WNEK50-04-03-017

SECTION 4 TRAVEL SYSTEM Group 3 Axle

13

11 12

4

8 11 10

9

WNEK50-04-03-015

8

b

a

a

IMPORTANT: Check the direction to install thrust washer (11).

5. Install thrust washer (11) to support (13).

6. Apply LOCTITE #263 or equivalent onto bolts (8) (8 used). Install thrust plate (12) to rear axle (4) with bolts (8) (8 used).

13

ab-

j : 24 mm

11

4

12

8

11

WNEK50-04-03-018

Direction to Install Groove

m : 223 N·m (164 lbf·ft) IMPORTANT: Check the direction to install thrust washer (11).

7. Apply grease onto the mounting surface of thrust washer (11) for glue. Install thrust washer (11) to thrust plate (12).

IMPORTANT: When installing cover (10), do not drop thrust washer (11).

8. Apply LOCTITE #263 or equivalent onto bolts (8) (8 used). Install cover (10) to support (13) with washers (9) (8 used) and bolts (8) (8 used). j : 24 mm m : 223 N·m (164 lbf·ft)

W4-3-2-9

SECTION 4 TRAVEL SYSTEM Group 3 Axle 3

1

2 1

5 7 6 5

4 WNEK50-04-03-014

b

IMPORTANT: Check the direction to install dust seal (5) and bushing (7).

IMPORTANT: Install bushing (7) with slit (b) up.

9. Install bushing (7) and dust seals (5) (2 used) to support (6).

a

a

a

dCAUTION: Support (6) weight: 65 kg (145 lb)

10. Apply grease onto the inner circumference of bushing (7). Attach nylon slings onto support (6).

Hoist steering support (6). Install support (6) to rear axle (4).

5

11. Secure support (6) to rear axle (4) by using wires.

12. Install block (3) to rear axle (4) with bolt, washer (2).

ab-

7

6

Direction to Install Slit

5

4 WNEK50-04-03-019

j : 17 mm m : 50 N·m (37 lbf·ft)

13. Connect the both ends of pipes (1) (2 used). j : 22 mm m : 39 N·m (29 lbf·ft)

W4-3-2-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle 5

a

a-

Stand

W4GB-03-03-113

7, 8

5

WNEK50-04-03-013

14. Place the rear axle (5) assembly on stand (a).

15. Connect hose (8) with clamp (7).

16. Set the rear axle (5) assembly under the mounting position of rear axle (5).

j : 7 mm m : 3 N·m (2.2 lbf·ft)

W4-3-2-11

SECTION 4 TRAVEL SYSTEM Group 3 Axle

9 1 2 3

5 W4GB-03-03-111

6

5

2 4 10 WNEK50-04-03-013

The rear axle (5) assembly weight: 750 dCAUTION: kg (1660 lb) 17. Attach nylon slings onto the rear axle (5) assembly.

Hoist the rear axle (5) assembly.

18. Install the rear axle (5) assembly to rear frame (3) with washers (2) (8 used) and nuts (3) (8 used). At this time, lock bolt (1) by engaging hexagonal head of bolt (1) and square hole of lock plate (9). Remove the wires for fasting support (6, 10) that have been installed in step 4 and step 11.

BOLT j : 36 mm m : 950 N·m (700 lbf·ft) NUT j : 36 mm m : 890±170 N·m (660±125 lbf·ft)

W4-3-2-12

SECTION 4 TRAVEL SYSTEM Group 3 Axle

1

a

a-

Vehicle Front Side

WNEK50-04-03-012

19. Connect pipe (1). j : 17 mm m : 25 N·m (18.5 lbf·ft)

W4-3-2-13

SECTION 4 TRAVEL SYSTEM Group 3 Axle A

Detail A

3

2

a

1

WNEK50-04-03-011 a-

Vehicle Front Side

WNEK50-04-03-010

20. Connect hose (2). j : 22 mm m : 40 N·m (29.5 lbf·ft) 21. Connect pipe (3). Apply grease onto grease fittings (4) (2 used). j : 17 mm m : 25 N·m (18.5 lbf·ft) 22. Install propeller shaft (1). (Refer to W4-4-1.)

4

W4-3-2-14

WNEK50-04-03-020

SECTION 4 TRAVEL SYSTEM Group 3 Axle Detail A

a

A

3 4, 5 a-

WNEK50-04-03-009

Air Breather

WNEK50-04-03-008

2

23. Connect hose (5) with clamp (4). j : 7 mm m : 3 N·m (2.2 lbf·ft) 24. Install rear tires (1) (2 used) to rear axle (3). (Refer to W4-1-2.)

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

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

1

26. Close side cover (front) (2).

WNEK50-03-22-008

W4-3-2-15

SECTION 4 TRAVEL SYSTEM Group 3 Axle (Blank)

W4-3-2-16

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Axle

WNDB-04-03-002

W4-3-3-1

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Axle Equipped with TPD

WNDB-04-03-003

W4-3-3-2

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Axle Equipped with LSD

WNDB-04-03-004

W4-3-3-3

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Planetary Carrier Assembly (70)

WNDB-04-03-005

W4-3-3-4

SECTION 4 TRAVEL SYSTEM Group 3 Axle 123456789101112131516171819202122232425-

Level Gauge Housing Pin (8 Used) Plug (4 Used) Case Bleeder Valve (2 Used) Housing Bolt (18 Used) Washer (18 Used) Drain Plug Bolt (32 Used) Washer (32 Used) Plug (2 Used) Plug Cover Bolt (24 Used) Washer (24 Used) Shim Bearing (2 Used) Brake Disc (4 Used) Brake Ring (2 Used) Ring Gear (2 Used) Brake Ring (4 Used) End Plate (2 Used)

262728293031323334353637383940414245464748495051-

Pin (4 Used) D-Ring (2 Used) Brake Piston (2 Used) D-Ring (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case A Ring Gear Bolt (12 Used) Washer (12 Used) Differential Case B Thrust Washer (2 Used) Side Gear (2 Used) Spring (16 Used) Adapter (16 Used) Button Head Bolt (16 Used) Shaft (2 Used) Bearing Retainer (2 Used) Bolt (20 Used) Washer (20 Used) Dowel Pin (4 Used) Spider Bearing Spacer

5253545556575960616263646566676869707172737475-

Spacer Bearing Dust Cover (Only Front Axle) Oil Seal O-Ring Pinion Bolt Washer Yoke Bearing Cage O-Ring Shim Pinion (4 Used) Thrust Washer (4 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) Oil Seal (2 Used)

fNOTE: The quantity of parts is the quantity per one axle.

W4-3-3-5

7677787980818283848586878889909293959697-

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) Planetary Carrier (2 Used) Retaining Ring (6 Used) Retainer Plate (2 Used) Steel Ball (6 Used) Thrust Washer (12 Used) Bearing (12 Used) Planetary Gear (6 Used) Collar (6 Used) Planetary Shaft (6 Used) Plug (4 Used) Thermometer Sensor (Front Axle) 98- Packing (Front Axle)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Axle The axle assembly weight: Front/rear: dCAUTION: 780 kg/750 kg (1720 lb/1660 lb)

4. Remove housing (2) from case (5) by using a plastic hammer.

5. Remove the shaft (42) assembly from side gear (38).

Removal of Housings (2, 7) 1. Place a container under case (5). Remove drain plug (10) from case (5). Drain gear oil from case (5). l : 12.7 mm

fNOTE: Gear oil amount: 34 L (7.5 US gal) The housing (2) assembly weight: dCAUTION: Front/rear: 260 kg/240 kg (574 lb/529 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.

42 W4GB-03-03-005

7

6. Remove housing (7) and the shaft (42) assembly at the opposite side in the same way.

2

W4GB-03-03-004

3. Remove bolts (11) (16 used) and washers (12) (16 used) from housing (2). j : 16 mm

fNOTE: LOCTITE #263 or equivalent has been applied to thread part of bolt (11).

W4-3-3-6

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Housings (2, 7)

Housing (2) weight: Front/rear: 125 dCAUTION: kg/105 kg (276 lb/232 lb)

The housing (2) assembly weight: dCAUTION: Front/rear: 260 kg/240 kg (574 lb/529 lb) 7. Place the housing (2) assembly with the differential gear mounting side up. Secure axle shaft (73) with the plate and bolt.

9. Remove axle shaft (73) from housing (2) by using a press.

a

2

b

73 ab-

73

WNEC-04-03-014

Bolt Plate

WNEC-04-03-015

10. Remove the inner race of bearing (72) from housing (2).

Planetary carrier assembly (70) dCAUTION: weight: 38 kg (84 lb) 8. Attach the nylon slings onto planetary carrier assembly (70). Remove bolt (71). Hoist and remove planetary carrier assembly (70) from axle shaft (73) by using a pry bar. Remove shim (19) if it has been installed. j : 36 mm

fNOTE: LOCTITE #263 or equivalent has been applied to thread part of bolt (71).

W4-3-3-7

SECTION 4 TRAVEL SYSTEM Group 3 Axle 11. Remove the inner race of bearing (74) from axle shaft (73) by using a bearing separator. Remove oil seal (75).

14. Disassemble housing (7) in the same way.

73 74

75 W4GB-03-03-010

12. Remove the outer race of bearings (72, 74) at the differential gear side and wheel side from housing (2). Remove the outer race of bearing by tapping the outer surface evenly.

13. 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).

23

W4GB-03-03-011

W4-3-3-8

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Planetary Carrier Assembly (70) 18. Remove bearings (90) (2 used) and collar (93) from planetary gear (92).

15. Remove retaining ring (86) from planetary carrier (85).

86

90

91

85

92

W4GB-03-03-012 W4GB-03-03-014

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.

20. Remove retainer plate (87) from planetary carrier (85).

85 87 92

W4GB-03-03-013

17. Remove the planetary gear (92) assembly, spacers (94) (2 used), and thrust washers (89) (2 used).

fNOTE: If spacer (94) and bearing (90) is reused, mark them for assembling.

W4-3-3-9

W4GB-03-03-015

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Brake 21. Remove end plate (25), brake ring (24), brake disc (21), brake ring (22), brake disc (21), and brake ring (24) from case (5) in sequence. Remove pins (67) (8 used) from case (5).

25. Remove D-rings (27, 29) from brake piston (28).

26. Remove the brake at the opposite side in the same way.

22. Remove button head bolts (41) (8 used), adapters (40) (8 used), and springs (39) (8 used) from brake piston (28). l : 6 mm

fNOTE: LOCTITE #263 or equivalent has been applied to thread part of button head bolt (41).

40

39

41

W4GB-03-03-016

23. Install the special tool (ST 7789) with bolts (M16) (2 used) by using the housing (2) mounting surface of case (5).

24. Supply compressed air through the hydraulic pressure port slowly and remove brake piston (28) from case (5).

ST 7789

W4GB-03-03-017

W4-3-3-10

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Bearing Cage (62) Assembly 27. Remove bolts (17) (24 used) and washers (18) (24 used). Remove cover (16) from case (5). j : 17 mm 28. Record gear teeth contact state and backlash of ring gear (33) at this time.

The bearing cage (62) assembly dCAUTION: weight: Front/rear: 42 kg/48 kg (93 lb/106 lb) 29. Attach nylon slings onto the bearing cage (62) assembly. Hoist and hold the bearing cage (62) assembly.

30. Remove bolts (8) (18 used) and washers (9) (18 used) from bearing cage (62). j : 24 mm 31. Install bolts (8) (2 used) which have been removed at step 30 to thread part (C) for pullers of bearing cage (62) in case of the front axle. Tighten bolts (8) (2 used) evenly. Remove bearing cage (62), pinion gear (57), and shim (64).

C

C

62

8, 9 W4GB-03-03-018

C-

Thread Part for Pullers

j : 24 mm

W4-3-3-11

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Bearing Cage (62) Assembly 32. Place bearing cage (62) onto a stand with the yoke (61) side up. Remove bolt (59) and washer (60) from flange (61). j : 24 mm

fNOTE: LOCTITE #263 or equivalent has been applied to thread part of bolt (59).

33. Remove O-ring (56).

38. Remove oil seal (55) from bearing cage (62).

39. Remove the inner race of bearing (53) from bearing cage (62).

40. Remove the outer races of bearings (50, 53) from bearing cage (62) by tapping each outer surface evenly.

41. Remove O-ring (63) from bearing cage (62).

34. Remove yoke (61) from pinion (57). Remove dust cover (54) (only front axle) from yoke (61).

35. Remove pinion (57) from bearing cage (62) by using a press.

57 62

W4GB-03-03-019

36. Remove spacers (51, 52) from pinion (57).

37. Remove the inner race of bearing (50) from pinion (57) by using a separator.

50 57

W4GB-03-03-020

W4-3-3-12

SECTION 4 TRAVEL SYSTEM Group 3 Axle Removal of Differential Case Assembly The differential case assembly weight: dCAUTION: TPD/LSD: 71 kg/80 kg (157 lb/177 lb)

45. Remove adjusting nut (69) from bearing retainer (45) by using the special tool (ST 7791). Remove the outer race of bearing (20) at the opposite side.

46. Remove bearing retainer (45) at the opposite side in the same way.

42. Attach the nylon slings onto the differential case assembly. Hoist and hold the differential case assembly.

43. Remove bolts (46) (10 used), washers (47) (10 used), and lock plate (68) from bearing retainer (45). j : 17 mm 44. Install bolts (46) (2 used) which have been removed at step 43 to the screw hole for pullers of bearing retainer (45). Tighten them evenly. Remove bearing retainer (45).

The differential case assembly weight: dCAUTION: TPD/LSD: 71 kg/80 kg (157 lb/177 lb) IMPORTANT: When removing and installing the differential case assembly, take care not to contact the inner race of bearing (20) with case (5).

47. Remove the differential case assembly from case (5).

j : 17 mm

5

45

W4GB-03-03-023 W4GB-03-03-022

W4-3-3-13

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Case (only Axle equipped with TPD)

dCAUTION: Ring gear (33) weight: 24 kg (53 lb) dCAUTION: Do not drop ring gear (33).

48. Remove bolts (30) (16 used) and washers (31) (16 used) from differential case A (32). Remove ring gear (33) from differential case A (32).

51. 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).

36

65

38

j : 24 mm

30, 31 33

32 32

49 W4GB-03-03-026

W4GB-03-03-024

52. Remove the inner races of bearings (20) (2 used) from differential case B (36) and differential case A (32) by using a bearing puller.

49. Put the matching marks at the jointed part between differential case B (36) and differential case A (32).

Remove bolts (34) (12 used) and washers (35) (12 used) from differential case B (36). j : 17 mm 20 36 34, 35

36 W4GB-03-03-027

32

W4GB-03-03-025

Differential case A (32) weight: 26 kg dCAUTION: (58 lb) 50. Tap the center of spider (49) and remove differential case A (32) from differential case B (36).

W4-3-3-14

SECTION 4 TRAVEL SYSTEM Group 3 Axle Disassembly of Differential Case (only Axle equipped with LSD)

dCAUTION: Ring gear (33) weight: 24 kg (53 lb) dCAUTION: Do not drop ring gear (33).

55. Remove plate (82), plates (80) (2 used), discs (81) (2 used), pressure ring (78), and side gear (79) from differential case B (77).

53. Remove bolts (30) (16 used) and washers (31) (16 used) from differential case A (76). Remove ring gear (33) from differential case A (76).

78

j : 24 mm 77

33 30, 31 76

W4GB-03-03-030

77

W4GB-03-03-028

56. Remove spider (83) and pinions (84) (4 used) from differential case B (77). Remove other side gear (79), pressure ring (78), discs (81) (2 used), plates (80) (2 used), and plate (82).

54. Install the bolts (M12, Pitch 1.25 mm) (2 used) to pulling-out bolt holes (E) (2 places) of differential case A (76). Tighten them evenly. Remove differential case A (76) from differential case B (77).

Remove the bolts (M12, Pitch 1.25 mm) (2 used).

84 83

77 76

E

E

W4GB-03-03-031

77

W4GB-03-03-029 E-

Pulling-Out Bolt Hole

W4-3-3-15

SECTION 4 TRAVEL SYSTEM Group 3 Axle 57. Remove the inner race of bearing (20) from differential case B (77) by using a bearing puller.

20

77

W4GB-03-03-032

58. Remove the inner race of bearing (20) from differential case A (76) by using a bearing puller.

76

20 W4GB-03-03-040

W4-3-3-16

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Axle 1

4

5

96

97, 98

A

6

7

2

11, 12

10

8, 9

20

39

WNDB-04-03-007

View A

13 15 16

17, 18

WNDB-04-03-008

 Axle equipped with TPD

24

22

26 67 28

30, 31 34, 35 27 29 32 33 36 48

40

25 41 46, 47

21

68 69

19

42 38 45 37 75 74 73 71 72 70

23

50

3 65 66

49

64 63

57

62

52 53

54

61

W4-3-3-17

56

59

60

55

51

WNDB-04-03-009

SECTION 4 TRAVEL SYSTEM Group 3 Axle  Axle equipped with LSD

24

22

26 67 28

30, 31 27 29 76 77 33 78 81 80 82

39

40 41 20

25

21

46, 47

19

68 69

42 45 79 75 74 73 71 72 70

23

50

84

64 63

51

83

62

57

53

52

3

54

55 61 59 60

56

92

93

WNDB-04-03-010

 Planetary Carrier Assembly (70) 88

89

90

95 85

87

86

WNDB-04-03-011

W4-3-3-18

SECTION 4 TRAVEL SYSTEM Group 3 Axle 123456789101112131516171819202122232425-

Level Gauge Housing Pin (8 Used) Plug (4 Used) Case Bleeder Valve (2 Used) Housing Bolt (18 Used) Washer (18 Used) Drain Plug Bolt (32 Used) Washer (32 Used) Plug (2 Used) Plug Cover Bolt (24 Used) Washer (24 Used) Shim Bearing (2 Used) Brake Disc (4 Used) Brake Ring (2 Used) Ring Gear (2 Used) Brake Ring (4 Used) End Plate (2 Used)

262728293031323334353637383940414245464748495051-

Pin (4 Used) D-Ring (2 Used) Brake Piston (2 Used) D-Ring (2 Used) Bolt (16 Used) Washer (16 Used) Differential Case A Ring Gear Bolt (12 Used) Washer (12 Used) Differential Case B Thrust Washer (2 Used) Side Gear (2 Used) Spring (16 Used) Adapter (16 Used) Button Head Bolt (16 Used) Shaft (2 Used) Bearing Retainer (2 Used) Bolt (20 Used) Washer (20 Used) Dowel Pin (4 Used) Spider Bearing Spacer

5253545556575960616263646566676869707172737475-

Spacer Bearing Dust Cover (Only Front Axle) Oil Seal O-Ring Pinion Bolt Washer Yoke Bearing Cage O-Ring Shim Pinion (4 Used) Thrust Washer (4 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) Oil Seal (2 Used)

fNOTE: The quantity of parts is the quantity per one axle.

W4-3-3-19

7677787980818283848586878889909293959697-

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) Planetary Carrier (2 Used) Retaining Ring (6 Used) Retainer Plate (2 Used) Steel Ball (6 Used) Thrust Washer (12 Used) Bearing (12 Used) Planetary Gear (6 Used) Collar (6 Used) Planetary Shaft (6 Used) Plug (4 Used) Thermometer Sensor (Front Axle) 98- Packing (Front Axle)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Axle IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

Assembly of Differential Case (only Axle equipped with TPD)

4. Install the inner race of bearing (20) to differential case B (36) by using a press or a plastic hammer.

Differential case A (32) weight: 26 kg dCAUTION: (58 lb)

5. 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).

1. Install the inner race of bearing (20) to differential case A (32) by using a press or a plastic hammer.

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).

6. Fit side gear (38) to pinion (65) of differential case A (32). Fit the matching marks made when 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.

37

20

32

32

W4GB-03-03-033

36

3. Install side gear (38) to differential case A (32).

Engage side gear (38) with spider (49) with pinions (65) (4 used) and thrust washers (66) (4 used) attached.

fNOTE: Install spider (49) to the mounting hole of differential case A (32) by using a plastic hammer.

W4GB-03-03-035

7. Apply LOCTITE #263 or equivalent to the thread part of bolts (34) (12 used). Install differential case B (36) to differential case A (32) in diagonal order with bolts (34) (12 used) and washers (35) (12 used). j : 17 mm m : 98 N·m (72 lbf·ft)

65

66

49

32

W4GB-03-03-034

W4-3-3-20

SECTION 4 TRAVEL SYSTEM Group 3 Axle 8. Install ring gear (33) to differential case A (32) with the gear surface up. Contact 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).

16

1 3

14

5

12

7

j : 24 mm 10

9

11

8 13

6 33

4

2

15

WNDB-04-03-012

W4GB-03-03-036

9. Turn over the differential case A (32) assembly.

Remove bolts (30) (2 used) and washers (31) (2 used) which have been tighten temporarily in step 8. Apply LOCTITE #263 or equivalent to the thread part of bolts (30) (16 used). Install bolts (30) (16 used) and washers (31) (16 used).

fNOTE: Refer to the illustration for the order to tighten bolts (30).

j : 24 mm m : 225 N·m (166 lbf·ft)

32 30, 31 33

W4GB-03-03-037

W4-3-3-21

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Differential Case (only Axle equipped with LSD) 10. Install the inner races of bearings (20) (2 used) to differential case A (76) and differential case B (77) by using a press or a plastic hammer.

11. Install plate (82), plate (80), disc (81), plate (80), disc (81), and pressure ring (78) to differential case B (77) in sequence. Install side gear (79) to disc (81) by fitting the spline part.

14. Install pressure ring (78) to differential case B (77).

Install disc (81), plate (80), disc (81), and plate (80) in sequence. At this time, fit disc (81) to the spline of side gear (79), and install disc (81) to differential case B (77).

fNOTE: Fit the convex part of plate (82) to the concave

78

groove (4 places) of differential case B (77). Install it. In addition, install the groove surface of plate (82) to the side gear (79) side.

12. Install pinions (84) (4 used) to spider (83). Engage the spider (83) assembly with side gear (79) and install it to differential case B (77). At this time, fit spider (83) to the V-groove of pressure ring (78).

77

84

W4GB-03-03-030

83

15. Install discs (81) (2 used) and plates (80) (2 used) to differential case B (77).

77

W4GB-03-03-031

13. Engage side gear (79) with pinion (84). Install it.

W4-3-3-22

SECTION 4 TRAVEL SYSTEM Group 3 Axle 16. Apply grease onto plate (82). Install plate (82) to differential case A (76).

fNOTE: Fit the convex part of plate (82) to the concave groove (4 places) of differential case B (77). Install it. In addition, install the groove surface of plate (82) to the side gear (79) side.

18. Turn over differential case B (77) which has been temporarily installed. Install ring gear (33) to differential case B (77) with the gear surface up.

Contact 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.

77

76

82

30, 31 30, 31

33

W4GB-03-03-039

17. Turn over differential case A (76). Temporarily install differential case A (76) with bolts (F) (M12, Pitch 1.25 mm) (2 used).

F

76

F

W4GB-03-03-040 F-

Bolt for Temporary Installation

W4-3-3-23

W4GB-03-03-041

SECTION 4 TRAVEL SYSTEM Group 3 Axle 19. Turn over the differential case assembly. Remove bolts (F) (M12, Pitch 1.25 mm) (2 used) which have been temporarily installed in step 17.

20. Apply LOCTITE #263 or equivalent to the thread part of bolts (30) (16 used). Install ring gear (33) with bolts (30) (16 used) and washers (31) (16 used).

16

1 3

14

5

12

7

fNOTE: Refer to the illustration for the order to tighten bolts (30).

10

9

j : 24 mm m : 225 N·m (166 lbf·ft)

11

8 13

6 4

33 30, 31

2

15

WNDB-04-03-012

77

W4GB-03-03-042

W4-3-3-24

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Bearing Cage 21. Install the outer races of bearings (50, 53) to bearing cage (62) by using a press.

22. Apply grease onto O-ring (63). Install O-ring (63) to bearing cage (62).

26. 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 : 17 mm

23. Install the inner race of bearing (50) to pinion (57).

fNOTE: Use a press which can provide at approx. 93 kN

24. Install spacers (51, 52) to pinion (57).

(21000 lbf).

52 51

a

57

W4GB-03-03-043 W4GB-03-03-045

25. Install bearing cage (62) to pinion (57). Install the inner race of bearing (53) to pinion (57).

a-

Thread Part (C)

fNOTE: Instead of loading by using a press, rotation

resistance can be also measured by temporary installing yoke (61) and washer (60) with bolt (59).

53

j : 24 mm m : 225 N·m (166 lbf·ft) 27. If rotation resistance is lower than the standard value, remove pinion (57) and grind spacer (52) for adjustment.

62

fNOTE: Rotational resistance standard value: 14.7 to

57

24.5 N (11 lbf to 18.1 lbf)

W4GB-03-03-044

W4-3-3-25

SECTION 4 TRAVEL SYSTEM Group 3 Axle 28. Apply LOCTITE #263 or equivalent to the outer surface of oil seal (55). Install oil seal (55) to bearing cage (62).

29. Apply grease onto the lip part of oil seal (55).

30. Apply LOCTITE #263 or equivalent to the inner surface of dust cover (54) (only front axle). Install dust cover (54) (only front axle) to yoke (61). Fit yoke (61) to the spline of pinion (57). Install it. Up and down yoke (61) and fix any deformations on the seal-lip part of oil seal (55).

31. Insert O-ring (56) to the groove between yoke (61) and pinion (57). Install washer (60) to yoke (61).

32. Apply LOCTITE #263 or equivalent to the thread part of bolt (59). Install yoke (61) to pinion (57) with bolt (59) and washer (60). Check that pinion (57) rotates smoothly.

61 54

62

W4GB-03-03-046

W4-3-3-26

j : 24 mm m : 225 N·m (166 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Differential Case 33. Install the outer races (2 used) of bearing (20) to bearing retainers (45) (2 used).

36. Apply LOCTITE #263 or equivalent to bolts (46) (10 used).Support the differential case assembly and install bearing retainers (45) (2 used) to case (5) with bolts (46) (10 used) and washers (47) (10 used).

34. Turn adjusting nut (69) until it touches the outer race of bearing (20).

j : 17 mm m : 98 N·m (72 lbf·ft)

69

47

45

W4GB-03-03-047

The differential case assembly weight: dCAUTION: TPD/LSD: 61 kg/65 kg (135 lb/144 lb) IMPORTANT: When removing and installing the differential case assembly, take care not to touch the inner race of bearing (20) with case (5).

35. Attach nylon slings onto the differential case assembly. Hoist and hold the differential case assembly. Fit the differential case assembly to the notch of ring gear (33). Install it to case (5).

33 5

W4GB-03-03-048

W4-3-3-27

46 45 W4GB-03-03-049

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Bearing Cage (62) Assembly 37. Install shim (64) between case (5) and bearing cage (62).

40. Tighten adjusting nuts (69) on both sides by using the special tool (ST 7791).

The bearing cage (62) assembly dCAUTION: weight: Front/rear: 42 kg/48 kg (93 lb/106 lb)

m : 120 N·m (89 lbf·ft)

38. Attach nylon slings onto the bearing cage (62) assembly. Hoist and hold the bearing cage (62) assembly.

ST 7791

39. Apply LOCTITE #263 or equivalent to bolts (8) (18 used). Install the bearing cage (62) assembly to case (5) with bolts (8) (18 used) and washers (9) (18 used). j : 17 mm m : 98 N·m (72 lbf·ft) 5

69 9 8

W4GB-03-03-051

62

W4GB-03-03-050

W4-3-3-28

SECTION 4 TRAVEL SYSTEM Group 3 Axle Adjustment of Ring Gear Backlash and Adjustment of Ring Gear Teeth Engagement 41. Secure adjusting nut (69) with lock plate (68), bolt (46), and washer (47).

69

45. 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.

68

W4GB-03-03-052 W4GB-03-03-054

42. Install a dial gauge to the tooth outer end of ring gear (33).

43. Secure pinion (57), turn ring gear (33) forward and backward, and measure backlash.

46. For adjustment of engagement of teeth, refer to (A) to (E) in the following. After adjusting engagement of teeth, check backlash again. a d

b c

W4GB-03-03-055

W4GB-03-03-053

ab-

44. 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 (57). If backlash is small, adjust it in the contrary way.

fNOTE: Ring gear (33) backlash: 0.25 to 0.36 mm (0.010 to 0.014 in)

W4-3-3-29

Tow Part (Small End) Face

cd-

Flank Heel Part (Big End)

SECTION 4 TRAVEL SYSTEM Group 3 Axle A. Normal Engagement

C. Contact of Heel Part

Normal engagement of the tooth surface is 40 % or more around the center of the tooth. The adjustments of (B) to (E) are the checking method for the convexity of the teeth. Be careful as the engagement is reverse for the concave side.

For 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 (57). Next, increase the thickness of shim (64) of bearing cage (62) and move pinion (57) away from ring gear (33).

NOTE: Shim (64) thickness: 0.1 mm (0.004 in), 0.2 mm (0.008 in), 0.25 mm (0.01 in)

f

33 W4GB-03-03-056

57

33

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 (57). Next, reduce the thickness of shim (64) of bearing cage (62) and move pinion (57) close to ring gear (33).

NOTE: Shim (64) thickness: 0.1 mm (0.004 in), 0.2 mm (0.008 in), 0.25 mm (0.01 in)

f

57

33

W4GB-03-03-057

W4-3-3-30

W4GB-03-03-058

SECTION 4 TRAVEL SYSTEM Group 3 Axle D. Contact of Face Part For adjustment, reduce the thickness of shim (64) of bearing cage (62) and move pinion (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 (57).

NOTE: Shim (64) thickness: 0.1 mm (0.004 in), 0.2 mm (0.008 in), 0.25 mm (0.01 in)

f

57

33

W4GB-03-03-059

E. Contact of Flank Part For adjustment, increase the thickness of shim (64) of bearing cage (62) and move pinion (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 (57).

NOTE: Shim (64) thickness: 0.1 mm (0.004 in), 0.2 mm (0.008 in), 0.25 mm (0.01 in)

f

57

33

W4GB-03-03-060

W4-3-3-31

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 response of service brake becomes slow.

47. Measure dimension (b) (1 place) between the brake piston (28) mounting part and the housing (2) end surface of case (5). Record it.

5

 Small clearance: The early wear and seizure of brake disc may occur.

For adjustment of clearance (x) of the brake disc, measure dimensions (a, b, c) inside the axle and select end plate (25) that has different thickness.

A

WNDB-04-03-015

b

48. Measure dimension (a) (4 places 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.

WNDB-04-03-013

fNOTE: Refer to W4-3-3-36 for installation of ring gear (23).

Detail A

a

2

5 b

22

24 25

a

28 x

c

2

23 WNDB-04-03-016

WNDB-04-03-014

21

W4-3-3-32

SECTION 4 TRAVEL SYSTEM Group 3 Axle Special tool (ST 7880) weight: 20 kg dCAUTION: (45 lb)

fNOTE: In order to identify the thickness of end plate

(25), check the quantity of identification marks which have been put at positions (d, e) as illustrated. The thickness of end plate (25) is 21.7 mm (0.85 in) in the figure below.

49. Set end plate (25), brake rings (24) (2 used), 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.

d

25

e ST 7880 c

WNDB-04-03-021

WNEC-04-03-020

50. Calculate clearance (x) of the brake disc in the following formula.

Clearance (x) (calculated value) of brake disc = a + b–c (unit: mm, in) 51. If clearance (x) (calculated value) of the brake disc is not within the standard, change end plate (25).

(1) If clearance (x) (calculated value) of the brake disc is 1.3 (0.051 in) to 2.1 mm (0.083 in), do not need to change end plate (25).

(2) If clearance (x) (calculated value) of the brake disc is less than 1.3 mm (0.051 in), change end plate (25) to thinner end plate (25).

Identification Mark on End Plate (25) Quantity at Quantity at Position (d) Position (e) 3 3 2 2 3 0 1 1 2 0 1 0

Thickness mm in 21.7 22.1 22.3 22.5 22.7 23.1

0.85 0.87 0.88 0.89 0.90 0.91

52. Record clearance (x) (calculated value) of the brake disc and end plate (25) which has been selected.

53. Adjust the clearances (4 places) of all brake discs for front and rear axles.

(3) If clearance (x) (calculated value) of the brake disc is over 2.1 mm (0.083 in), change end plate (25) to thicker end plate (25).

fNOTE: Clearance (x) (standard) of brake disc: 1.3 mm (0.051 in) (lower limit), 2.1 mm (0.083 in) (upper limit)

W4-3-3-33

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Brake Use the parts which are used dCAUTION: for adjustment of brake disc clearance when

57. Install shaft (42) to the spline of side gear (38) (in case of axle equipped with LSD: (79)) in case (5).

installing the brake.

54. Install D-rings (27, 29) to the groove of the outer surface of brake piston (28). Apply grease onto D-rings (27, 29).

58. Install two pieces of pins (67) (8 used) to the bottom of case (5). Then, install brake ring (24).

Select the thickness of brake ring (24) dCAUTION: which has been selected for adjustment of brake

55. Install brake piston (28) to case (5) by using the special tool (ST 7789).

disc clearance.

59. Install two pieces of pins (67) (8 used) to the bottom of case (5). Then, install brake ring (24).

a ST 7789

5

28 a-

67

W4GB-03-03-061

Thrust Bolt (M16, Pitch 2.0 mm, Thread part length: 50 mm or more)

56. Apply LOCTITE #263 or equivalent to button head bolt (41). Install springs (39) (8 used), adapters (40) (8 used), and button head bolts (41) (8 used) to case (5) through the piston hole of brake piston (28).

24 W4GB-03-03-062

60. Install brake disc (21) to the spline of shaft (42).

Install brake ring (22).

61. Install second brake disc (21) so that the open hole fits to that of first brake disc (21).

l : 6 mm m : 49 N·m (36 lbf·ft) m : 41 N·m (30 lbf·ft) (a)

a

41

40

39

W4GB-03-03-016

W4-3-3-34

SECTION 4 TRAVEL SYSTEM Group 3 Axle Select the thickness of end plate (25) dCAUTION: which has been selected for adjustment of brake disc clearance.

62. Install brake ring (24) and end plate (25) to case (5).

63. Install other pins (67) (6 used) by using a plastic hammer.

67

W4GB-03-03-063

64. Install the brake at opposite side in the same way.

W4-3-3-35

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly of Housings (2, 7) 65. 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).

68. Turn over housing (2). Hoist housing (2) with the differential gear side up. Install housing (2) to axle shaft (73) by using a press.

Housing (2) weight: Front/rear: 125 dCAUTION: kg/105 kg (276 lb/232 lb) 66. Attach nylon slings onto housing (2). Hoist and hold housing (2) with the wheel side up. Install the outer race and inner race of bearing (74) to housing (2).

2

IMPORTANT: Oil seal (75) is a separate-type parts. Install oil seal (75) to housing (2) without disassembling.

67. Apply grease onto the inside of housing (2).

Install oil seal (75) to housing (2) by using a plastic hammer.

73 WNEC-04-03-022

69. Install the outer race of bearing (72) to housing (2).

75

70. Install the inner race of bearing (72) to axle shaft (73).

2

71. Assemble housing (7) at the opposite side in the same way.

W4GB-03-03-064

W4-3-3-36

SECTION 4 TRAVEL SYSTEM Group 3 Axle Preload Adjustment of Axle Shaft Bearing (Shim Adjustment) Planetary carrier (70) weight: 38 kg dCAUTION: (84 lb) 72. Attach nylon slings onto planetary carrier (70).

Hoist and hold planetary carrier (70). In order to adjust preload, install planetary carrier (70) without installing the gear to axle shaft (73).

73. Install retainer plate (87) to planetary carrier (70).

Tighten bolt (71). Push the inner race of bearing (72) in axle shaft (73). At this time, turn housing (2). j : 36 mm m : 49 N·m (36 lbf·ft) 74. Loosen bolt (71). Remove retainer plate (87).

Measure level difference (Y) between the axle shaft (73) end surface and planetary carrier (70). Select shim (19) that is 0.03 to 0.10 mm (0.001 to 0.004 in) thicker than level difference (Y).

75. Install selected shim (19) and retainer plate (87) to the end of axle shaft (73) with bolt (71). j : 36 mm m : 49 N·m (36 lbf·ft) 76. Remove bolt (71). j : 36 mm 77. Attach a 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 values are out of 40 to 90 N (9.0 to 20.2 lbf ), adjust the shim again. If the value is small, reduce the thickness of shim (19). If the value is big, increase the thickness of shim (19).

26

j : 36 mm

fNOTE: Shim (19) thickness: 0.1 mm (0.004 in), 0.2 mm (0.008 in), 0.25 mm (0.01 in), 0.5 mm (0.02 in)

2

Y W4GB-03-03-068

73

Planetary carrier (70) weight: 38 kg dCAUTION: (84 lb)

70

W4GB-03-03-067 Y-

78. Attach nylon slings onto planetary carrier (70). Hoist and hold planetary carrier (70). Remove bolt (71).

Remove retainer plate (87), shim (19), and planetary carrier (70). j : 36 mm

Level Difference

W4-3-3-37

SECTION 4 TRAVEL SYSTEM Group 3 Axle Assembly and Installation of Planetary Carrier Assembly (70) 79. Install bearings (90) (2 used) and collar (93) to planetary gear (92).

90

81. Install steel ball (88) to planetary shaft (95). Install planetary shaft (95) to planetary carrier (85).

92

85 95 93

90

WNDB-04-03-018

80. 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). Install planetary gear (92) between thrust washers (89) (2 used).

W4GB-03-03-072

85 89

92

89 WNDB-04-03-019

W4-3-3-38

SECTION 4 TRAVEL SYSTEM Group 3 Axle IMPORTANT: Fit the notch of retaining ring (86) to the mounting groove for steel ball (88).

View S

86

Planetary carrier assembly (70) dCAUTION: weight: 38 kg (84 lb) 84. Attach nylon slings onto planetary carrier assembly (70). Hoist and hold planetary carrier assembly (70).

Install shim (19) which has been selected in step 64 to axle shaft (73). Install planetary carrier assembly (70) to housing (2).

a

85. Apply LOCTITE #263 or equivalent to 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 : 36 mm W4GB-03-03-074 a-

m : 1090 N·m (800 lbf·ft)

Steel Ball Mounting Groove

IMPORTANT: Do not hit the retaining ring by using a sharp tool.

IMPORTANT: When the retaining ring is damaged, replace it with the new one.

82. Install retaining ring (86) to planetary carrier (85).

83. Install retainer plate (87) to planetary carrier (85).

Install other planetary gears (92) (2 used) to planetary carrier (85) in the same way.

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.

W4-3-3-39

W4GB-03-03-075

SECTION 4 TRAVEL SYSTEM Group 3 Axle Installation of Housings (2, 7) 86. Apply LOCTITE #5127 to 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

88. Install drain plug (10) to case (5). Add oil to case (5).

fNOTE: Bead width: 2 to 3 mm (0.079 to 0.12 in)

fNOTE: Gear oil amount: 34 L (7.5 US gal)

l : 0.5 in

W4GB-03-03-076 W4GB-03-03-079

Housing (2) weight: Front/rear: 260 dCAUTION: kg/240 kg (574 lb/529 lb) 87. Apply LOCTITE #263 or equivalent to bolts (11) (16 used). Attach nylon slings onto housing (2). Hoist and hold housing (2). Fit housing (2) to the bolt hole of shaft (42). Install housing (2) to case (5) with bolts (11) (16 used) and washers (12) (16 used). Install housing (7) at the opposite side in the same way. j : 24 mm m : 225 N·m (166 lbf·ft)

11, 12

W4GB-03-03-077

W4-3-3-40

SECTION 4 TRAVEL SYSTEM Group 3 Axle 89. Apply LOCTITE #5127 to the cover (16) mounting surface of case (5). Apply LOCTITE so that there is no bead missed on the inside of bolt-hole lines

5

W4GB-03-03-078

90. Install cover (16) to case (5) with bolts (17) (24 used) and washers (18) (24 used). j : 17 mm m : 98 N·m (72 lbf·ft) 16

17,18

W4GB-03-03-080

W4-3-3-41

SECTION 4 TRAVEL SYSTEM Group 3 Axle (Blank)

W4-3-3-42

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft Removal and Installation of Propeller Shaft

1

2

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

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

2. Remove under guard (front) (1) and under guard (rear) (2). (Refer to W3-22-1.)

fNOTE: Only for the machine with under guard

W4-4-1-1

WNEK50-03-22-002

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1

A

a a-

WNEK50-04-04-001

Vehicle Front Side

3. Disconnect the both ends of pipe (1).

Detail A

j : 17 mm 1

WNEK50-04-04-004

W4-4-1-2

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

A

a-

WNEC-04-04-001

Vehicle Front Side

4. Remove grease fitting (1).

Detail A

1

j : 7 mm

fNOTE: Remove grease fitting (1) in order to drain grease.

WNEK50-04-04-002

W4-4-1-3

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

1 A

2 5

4 3

a-

WNEC-04-04-001

Vehicle Front Side

Detail A

Remove propeller shaft (4) while dCAUTION: holding it. Do not drop propeller shaft (4).

5

IMPORTANT: Propeller shaft (4) consists of two parts. If propeller shafts (4a, 4b) are removed individually, spline seal (6) may be damaged.

Propeller shaft (4) should be removed as an assembly.

4a

6

4b

WNEK50-04-04-002

The propeller shaft (4) assembly dCAUTION: weight: 29 kg (64 lb) 5. Set a stand and a jack under propeller shaft (4). Hold propeller shaft (4).

6. Put the matching marks at the mating part between propeller shaft (4) and propeller shaft (5).

7. Remove bolts (2) (4 used). Disconnect propeller shaft (4) from drive unit (3).

8. Remove bolts (1) (4 used). Remove propeller shaft (4) from propeller shaft (5). j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to

j : 3/4 in.

fNOTE: LOCTITE #263 or equivalent has been applied to bolt (2).

W4-4-1-4

bolt (1).

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1

a

A

7

6 5 4 3

a-

2

WNEK50-04-04-005

Vehicle Front Side

Detail A

Remove propeller shaft (1) while dCAUTION: holding it. Do not drop propeller shaft (1).

The propeller shaft (1) assembly dCAUTION: weight: 21 kg (47 lb)

1

9. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1).

8

10. Remove bolts (6) (4 used). Disconnect propeller shaft (1) from front axle (7). j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to

bolt (6).

11. Remove bolts (5) (2 used), nuts (3) (2 used), washers (4) (4 used), and spring washers (2) (2 used). Remove propeller shaft (1) from support (8). j : 30 mm

W4-4-1-5

WNEK50-04-04-002

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

A

5 4 3 2 a-

Vehicle Front Side

1

WNEK50-04-04-006

Detail A

12. Remove grease fitting (6).

4b

7

6

4a

j : 7 mm

fNOTE: Remove grease fitting (6) in order to drain grease.

Remove propeller shaft (4) while dCAUTION: holding it. Do not drop propeller shaft (4).

IMPORTANT: Propeller shaft (4) consists of two parts. If propeller shafts (4a, 4b) are removed individually, spline seal (7) may be damaged.

Propeller shaft (4) should be removed as an assembly.

13. Remove bolts (3) (4 used). Disconnect propeller shaft (4) from drive unit (5).

WNEK50-04-04-003

j : 19 mm

fNOTE: LOCTITE #263 or equivalent has been applied to bolt (3).

14. Remove bolts (2) (4 used). Remove propeller shaft (4) from rear axle (1). j : 3/4 in.

fNOTE: LOCTITE #263 or equivalent has been applied to bolt (2).

W4-4-1-6

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

A

5 4 3 2 a-

Vehicle Front Side

1

WNEK50-04-04-006

Detail A

Installation

4b

7

IMPORTANT: Install propeller shaft (4) with the propeller shaft (4b) side facing to the drive unit (5) side.

IMPORTANT: Propeller shaft (4) consists of two parts. If propeller shafts (4a, 4b) are installed individually, spline seal (7) may be damaged.

Propeller shaft (4) should be installed as an assembly.

1. Apply LOCTITE #263 or equivalent to bolts (3) (4 used). Install propeller shaft (4) to drive unit (5) with bolts (3) (4 used).

6

4a

WNEK50-04-04-003

j : 3/4 in. m : 145 N·m (107 lbf·ft) 2. Apply LOCTITE #263 or equivalent to bolts (2) (4 used). Install propeller shaft (4) to rear axle (1) with bolts (2) (4 used).

3. Install grease fitting (6). Apply grease.

j : 19 mm

j : 7 mm

m : 145 N·m (107 lbf·ft)

m : 4 N·m (3 lbf·ft)

W4-4-1-7

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1

a

A

7

6 5 4 3

a-

2

WNEK50-04-04-005

Vehicle Front Side

Detail A

The propeller shaft (1) assembly dCAUTION: weight: 21 kg (47 lb)

1

4. Set a stand and a jack under propeller shaft (1). Hold propeller shaft (1).

5. Install propeller shaft (1) to support (8) with bolts (5) (2 used), washers (4) (4 used), spring washers (2) (2 used) and nuts (3) (2 used).

8

j : 30 mm m : 206±10 N·m (152±7.4 lbf·ft) 6. Apply LOCTITE #263 or equivalent to bolts (6) (4 used). Install propeller shaft (1) to front axle (7) with bolts (6) (4 used). j : 19 mm m : 145 N·m (107 lbf·ft)

W4-4-1-8

WNEK50-04-04-002

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

1 A

2 5

4 3

a-

WNEC-04-04-001

Vehicle Front Side

Detail A

The propeller shaft (4) assembly dCAUTION: weight: 29 kg (64 lbf·ft)

5

4a

6

4b

7. Set a stand and a jack under propeller shaft (4). Hold propeller shaft (4).

fNOTE: When installing propeller shaft (4), its grease

fitting shall be in the same direction with propeller shaft (7). At this time, raise the machine off the ground in order to rotate tires.

IMPORTANT: Install propeller shaft (4) with the propeller shaft (4a) side facing to the propeller shaft (5) side.

IMPORTANT: Propeller shaft (4) consists of two parts. If propeller shafts (4a, 4b) are installed individually, spline seal (6) may be damaged.

Propeller shaft (4) should be installed as an assembly.

WNEK50-04-04-002

8. Apply LOCTITE #263 or equivalent to bolts (1) (4 used). Fit the matching marks made when removing and install propeller shaft (4) to propeller shaft (5) with bolts (1) (4 used). j : 19 mm m : 145 N·m (107 lbf·ft) 9. Apply LOCTITE #263 or equivalent to bolts (2) (4 used). Install propeller shaft (4) to drive unit (3) with bolts (2) (4 used). j : 3/4 in. m : 145 N·m (107 lbf·ft)

W4-4-1-9

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

a

A

a-

WNEC-04-04-001

Vehicle Front Side

10. Install grease fitting (1). Apply grease.

Detail A

1

j : 7 mm m : 4 N·m (3 lbf·ft)

WNEK50-04-04-002

W4-4-1-10

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1

A

a a-

WNEK50-04-04-001

Vehicle Front Side

11. Connect the both ends of pipe (1).

Detail A

j : 17 mm m : 25 N·m (18.5 lbf·ft) 1

12. Apply grease.

WNEK50-04-04-004

W4-4-1-11

SECTION 4 TRAVEL SYSTEM Group 4 Propeller Shaft

1

2

13. Install under guard (front) (1) and under guard (rear) (2). (Refer to W3-22-1.)

fNOTE: Only for the machine with under guard

W4-4-1-12

WNEK50-03-22-002

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Removal and Installation of Brake Valve

WNEK50-03-22-002

1

IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

Removal

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

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

2. Remove cab under cover (1). (Refer to W3-22-1.)

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

W4-5-1-1

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

View A

1

2

3 4

WNEK50-04-05-001 WNEK50-04-06-003 A

3. Disconnect hose (1) (2 used) and hoses (3, 4). j : 22 mm 4. Disconnect hose (2). j : 27 mm

W4-5-1-2

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

Detail A

1

2

9

WNEK50-04-06-003 A

8

3 7

5. Secure the hexagonal part of ball joint (5) by using a wrench. Remove nut (7) and washer (6). Remove ball joint (5) from bell crank (8).

Hexagonal Part of Ball Joint (5) j : 14 mm Nut (7) j : 17 mm 6. Secure the across flat of ball joint (5) by using a wrench. Loosen nut (4). Remove ball joint (5) and nut (4) from brake valve (3). j : 17 mm 7. Remove bolts (1) (4 used) and washers (2) (4 used).

Remove brake valve (3) from floor (9). j : 12 mm 8. Remove the adapters from brake valve (3) if necessary.

W4-5-1-3

6

5

4 WNEK50-04-05-003

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

Detail A

1

2

9

WNEK50-04-06-003 A

8

3 B

7

6

5

4

Installation WNEK50-04-05-003

1. Install all removed adapters to brake valve (3).

2. Install brake valve (3) to floor (9) with washers (2) (4 used) and bolts (1) (4 used).

View B

9

j : 12 mm m : 20 N·m (15 lbf·ft) 3. Install nut (4) and ball joint (5) to brake valve (3).

8

j : 17 mm

5 4

IMPORTANT: Check dimension (a) to install ball joint (5) and nut (4).

4. Secure the across flat of ball joint (5) by using a wrench. Secure ball joint (5) with nut (4). j : 17 mm

a-

a

113 mm (4.4 in)

3 WNEC-04-05-011

5. Secure the hexagonal part of ball joint (5) by using a wrench. Install ball joint (5) to bell crank (8) with washer (6) and nut (7).

m : 20 N·m (15 lbf·ft)

Hexagonal Part of Ball Joint (5) j : 14 mm Nut (7) j : 17 mm m : 50 N·m (37 lbf·ft)

W4-5-1-4

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

View A

1

2

3 4 B

WNEK50-04-05-001 WNEK50-04-06-003 A View B

6. Connect hose (2).

3

j : 27 mm

4

a

m : 80 N·m (59 lbf·ft)

b

IMPORTANT: Check the angle to install hoses (3, 4).

7. Connect hoses (3, 4) and hoses (1) (2 used). j : 22 mm m : 40 N·m (29.5 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine and check for any oil leaks.

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

WNEC-04-05-013 a-

W4-5-1-5

35°

b-

35°

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve

WNEK50-03-22-002

1

9. Install cab under cover (1). (Refer to W3-22-1.)

W4-5-1-6

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Disassembly of Brake Valve

WNEC-04-05-004

1234567-

Flange Cylinder Cylinder Spool (2 Used) Plug Stopper Spring

891011121314-

O-Ring O-Ring O-Ring (2 Used) Holder Rod Retainer Piston

15161718202122-

Boot Spring Spring Spring Packing Scraper Socket Bolt (2 Used)

W4-5-2-1

23242627283132-

Spring Retaining Ring Plug (2 Used) O-Ring (2 Used) Push Rod Plug O-Ring

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Disassembly of Brake Valve IMPORTANT: Put the matching marks on flange (1), cylinder (2), and cylinder (3) before disassembling.

1. Remove push rod (28) and boot (15) from flange (1).

IMPORTANT: Strong force deforms flange (1). Handle it with care.

2. Secure the flange (1) part in a vise with the cylinder (3) side up.

IMPORTANT: Keep the disassembled parts together by each cylinder in order not to confuse.

3. Remove plugs (26) (2 used) and O-rings (27) (2 used) from cylinders (2, 3).

IMPORTANT: The reaction force of spring (16) is applied to socket bolt (22). Slowly remove socket bolt (22) while holding cylinders (2, 3).

6. Remove socket bolts (22) (2 used) from cylinder (3). l : 6 mm 7. Remove cylinder (3) and O-ring (10) from the cylinder (2) assembly.

8. Remove spring (23), spool (4), and O-ring (9) from cylinder (2).

9. Remove cylinder (2) and O-ring (10) from flange (1).

10. Remove spring (16), holder (11), rod (12), springs (17, 18), and retainer (13) from flange (1).

11. Remove retaining ring (24) from flange (1).

j : 19 mm 4. Remove plug (31) and O-ring (32) from cylinder (2).

12. Remove piston (14), packing (20), and scraper (21) from flange (1).

j : 22 mm 5. Remove plug (5), O-ring (8), stopper (6), spring (7), and spool (4) from cylinder (3). j : 32 mm

W4-5-2-2

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Assembly of Brake Valve

A

24

15

16

17 18

B

a

22

b

23

28

5 6 8

1 14

21 20

13

11 12

10

2

32 4

31

10 9

3

A

C

4

7 22

B

WNEC-04-05-001

Section A-A

Section B-B d

27

e

26

27

26

WNEC-04-05-002 1234567-

Flange Cylinder Cylinder Spool (2 Used) Plug Stopper Spring

891011121314-

O-Ring O-Ring O-Ring (2 Used) Holder Rod Retainer Piston

abc-

Port PA Port PB Port T

de-

Port A Port B

WNEC-04-05-003 15161718202122-

Boot Spring Spring Spring Packing Scraper Socket Bolt (2 Used)

W4-5-2-3

23242627283132-

Spring Retaining Ring Plug (2 Used) O-Ring (2 Used) Push Rod Plug O-Ring

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve Assembly of Brake Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The brake valve is the susceptible hydraulic component to contamination. Keep the parts clean when assembling.

IMPORTANT: Check the direction to install packing (20) and scraper (21).

1. Apply hydraulic oil onto packing (20), scraper (21), and piston (14). Install packing (20), scraper (21), and piston (14) to flange (1).

1

IMPORTANT: Strong force deforms flange (1). Handle it with care.

3. Secure flange (1) in a vise with the piston (14) side down.

4. Apply grease onto O-ring (10). Install O-ring (10) to flange (1).

IMPORTANT: Install tip (a) of rod (12) to hole (b) of retainer (13) in order not to drop retainer (13) from rod (12).

5. Install springs (16, 17, 18), holder (11), and rod (12) to retainer (13). Install tip (a) of rod (12) to hole (b) of retainer (13).

a

20

21

13

WNEC-04-05-005 A b

IMPORTANT: Replace retaining ring (24) with the new one.

2. Install retaining ring (24) to piston (14).

View A WNEC-04-05-007 ab-

W4-5-2-4

Tip of Rod (12) Hole

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve 6. Install the retainer (13) assembly to flange (1).

7. Fit the matching marks and install cylinder (2) to the flange (1) assembly.

13. Install the cylinder (2) assembly and the cylinder (3) assembly to the flange (1) assembly with socket bolts (22) (2 used). l : 6 mm

8. Apply hydraulic oil onto O-rings (9, 10) and spool (4). Install O-rings (9, 10), spool (4), and spring (23) to cylinder (2).

9. Fit the matching marks and install cylinder (3) to cylinder (2).

m : 30+4.3-5.5 N·m (22+3.2-4.1 lbf·ft) 14. Tighten plug (5) to the specified torque. j : 32 mm

10. Apply grease onto O-ring (8).

11. Install O-ring (8) to plug (5).

12. Install spool (4), spring (7), and stopper (6) to cylinder (3). Temporarily tighten plug (5).

m : 68+10.4-9.2 N·m (50+7.7-6.8 lbf·ft) 15. Install O-rings (27) (2 used) to plugs (26) (2 used).

Install plugs (26) (2 used) to cylinders (2, 3). j : 19 mm

j : 32 mm

m : 22+2.5-2.4 N·m (16+1.8-1.8 lbf·ft) 16. Install O-ring (32) to plug (31). Install plug (31) to cylinder (2). j : 22 mm m : 39+8.1-7.6 N·m (29+6-5.6 lbf·ft)

W4-5-2-5

SECTION 4 TRAVEL SYSTEM Group 5 Brake Valve 17. Install boot (15) to the flange (1) assembly with hole (a) facing to the (b) side of port PA.

b

a

15

1 WNEC-04-05-006

ab-

Hole Port PA

18. Install push rod (28) to the flange (1) assembly.

W4-5-2-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Removal and Installation of Steering Valve

WNEK50-03-22-002

1

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

Removal

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

2. Remove cab under cover (1). (Refer to W3-22-1.)

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

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

W4-6-1-1

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

View A

6, 7

4

3

2

B

1

5 WPD850-04-06-007

A

WPD850-04-06-006

View B

C

3. Disconnect hoses (1) (2 used). j : 22 mm 4. Disconnect hose (2). j : 19 mm 5. Disconnect the pipe mount (8) side of hose (3).

8

j : 27 mm

WPD850-04-06-008

6. Remove bolt, washer (6) and clip (7).

Detail C

j : 17 mm 3

8

WNDB-04-06-020

W4-6-1-2

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

1

7

4

2

5

A

1

3

6

WNEK50-04-06-016

View A

WNEK50-04-06-017

9

8

7. Remove floor mat (3).

8. Remove screws (1) (6 used). Remove cover (2).

Remove steering valve (6) while dCAUTION: holding it. Do not drop steering valve (6).

9. Remove bolts, washers (4) (4 used) and spacers (5) (4 used). Remove steering valve (6) from steering column (7). j : 17 mm 10. Disconnect hoses (8, 9) from steering valve (6).

WPD850-04-06-007

j : 27 mm 11. Remove the adapters from steering valve (6) if necessary.

W4-6-1-3

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

1

7

4 2

5

A

6

3

1

WNEK50-04-06-017

View A

9

WNEK50-04-06-016

8

Installation 1. Install all removed adapters to steering valve (6).

2. Connect the steering valve (6) side of hose (8) to steering valve (6). j : 27 mm m : 95 N·m (70 lbf·ft) 3. Connect hose (9) to steering valve (6). j : 27 mm WPD850-04-06-007

m : 80 N·m (59 lbf·ft) 4. Install steering valve (6) to steering column (7) with bolts, washers (4) (4 used) and spacers (5) (4 used). j : 17 mm m : 39 N·m (29 lbf·ft) 5. Install cover (2) with screws (1) (6 used).

6. Install floor mat (3).

W4-6-1-4

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

View A

6, 7

4

3

2

B

1

5 WPD850-04-06-007

A

WPD850-04-06-006

View B

C

7. Install bolt, washer (6) and clip (7). j : 17 mm m : 50 N·m (37 lbf·ft) 8. Connect the pipe mount side of hose (3). j : 27 mm

8

m : 95 N·m (70 lbf·ft) 9. Connect hose (2).

WPD850-04-06-008

Detail C

j : 19 mm 3

m : 30 N·m (22 lbf·ft) 10. Connect hoses (1) (2 used). j : 27 mm m : 95 N·m (70 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering wheel to the steering end several times and check for any oil leaks.

8

WNDB-04-06-020

W4-6-1-5

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

WNEK50-03-22-002

1

11. Install cab under cover (1). (Refer to W3-22-1.)

W4-6-1-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Disassembly of Steering Valve

WNDB-04-06-006

1234567-

Screw (7 Used) Cap O-Ring (3 Used) Rotor Star Drive Plate

891011121314-

Spool Sleeve Pin Centering Spring Bearing Race (2 used) Retaining Ring Thrust Needle

15161718192021-

O-Ring Oil Seal Dust Seal Housing Spring Pin Ball Spring Pin (2 Used)

fNOTE: As for the item with mark *, refer to W4-6-2-5.

W4-6-2-1

22- Ball (2 Used) 23*- Overload Relief Valve (2 Used) 24*- Insert (2 used) 25*- Check Valve

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 4. Remove O-ring (3) from plate (7).

Disassembly of Steering Valve

5. Remove plate (7) from housing (18).

IMPORTANT: As the setting changes, do not disassemble overload relief valves (23) (2 used).

IMPORTANT: Do not disassemble inserts (24) (2 used) and check valve (25).

IMPORTANT: Strong force deforms housing (18).

Handle it with care.

1. Secure housing (8) in a vise (a) with the cap (21) side up.

6. Install the special tool (ST 7862) to the spline part of spool (8).

7. Install the cloth onto the teeth of star (5) which has been removed at step 4. Install star (5) to the gear part of drive (6).

2 a

8

c

5

6 ST 7862 WNDB-04-06-009 ca-

Vise

W202-02-14-002

2. Remove screws (1) (7 used) from cap (2). Remove cap (2) from housing (18). Remove O-ring (3) from cap (2). j : 13 mm IMPORTANT: When removing rotor (4), do not drop star (5).

3. Remove rotor (4) and star (5) from housing (18).

W4-6-2-2

Up

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device IMPORTANT: Do not disassemble sleeve assembly (a). a

9

11

12 13

6

10 WNDB-04-06-008 a-

Sleeve Assembly

8. Secure star (5) by one hand. Twist the special tool (ST 7862) at the right or left side by other hand.

Compress centering spring (11). Push and remove sleeve assembly (a) from the cap (2) side of housing (18) while compressing centering spring (11).

IMPORTANT: Take care not to drop and lose ball (20), balls (22) (2 used), spring pin (19), spring pins (21) (2 used), thrust needle (14), and bearing race (12) at the column side.

IMPORTANT: Record the hole positions where balls (20, 22) and spring pins (19, 21) have been installed.

11. Remove housing (18) from vise (a). Turn over housing (2). Remove ball (20), balls (22) (2 used), spring pin (19), spring pins (21) (2 used), thrust needle (14), and bearing race (12) at the column side. Place housing (8) on a clean cloth in order not to damage the finished side.

12. Remove O-ring (15) and oil seal (16) from housing (18) by using a screwdriver.

13. Remove dust seal (17) from housing (18) by using a screwdriver.

18 11 8

5

a ST 7862

WNDB-04-06-009

9. Remove star (5) from drive (6).

10. Remove special tool (ST 7862) from spool (8).

W4-6-2-3

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Assembly of Steering Valve C

A

A D

D C

B

B E

E WNDB-04-06-010

Section A-A

14

12

8

9

18

6

3

7

3

4

3

2

12

15

5

16

17

1

13

WNDB-04-06-011

11

10

W4-6-2-4

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

Section B-B

Section C-C 20

19

24

23

WNDB-04-06-013

Section E-E

22

WNDB-04-06-012

21 Section D-D

25

1234567-

Screw (7 Used) Cap O-Ring (3 Used) Rotor Star Drive Plate

WNDB-04-06-014

891011121314-

Spool Sleeve Pin Centering Spring Bearing Race (2 used) Retaining Ring Thrust Needle

WNDB-04-06-015

15161718192021-

O-Ring Oil Seal Dust Seal Housing Spring Pin Ball Spring Pin (2 Used)

W4-6-2-5

22232425-

Ball (2 Used) Overload Relief Valve (2 Used) Insert (2 used) Check Valve

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 5. Place housing (18) with the port surface up.

Assembly of Steering Valve IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

1. Install dust seal (17) to housing (18).

6. Install the special tool (ST 7862) to the spline part of spool (8) through housing (18).

18

IMPORTANT: Check the direction to install oil seal (16).

2. Remove oil seal (16) and O-ring (15) to housing (18).

18

5

8

16

15 6 ST 7862 WNDB-04-06-009 WNDB-04-06-016

3. Install thrust needle (14) and bearing race (12) at the column side to sleeve assembly (a). a

9

11

12 13

IMPORTANT: Install pin (10) in an almost horizontal position when installing sleeve assembly (a).

7. Secure star (5) by one hand. Twist the special tool (ST 7862) at the right or left side by other hand.

Compress centering spring (11). Push and install sleeve assembly (a) to the column side of housing (18) while compressing centering spring (11).

6 18 11

10 WNDB-04-06-008 a-

5

Sleeve Assembly

4. Install the cloth onto the teeth of star (5). Install star (5) to the gear part of drive (6).

a

10

ST 7862

WNDB-04-06-009

W4-6-2-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device IMPORTANT: If sleeve assembly (a) is installed correctly, the ends of sleeve assembly (a) and housing (18) will be flat.

8. Check that sleeve assembly (a) is installed to the end of housing (18).

14. Fit the screw (1) holes of housing (18). Install plate (7) to housing (18).

15. Install O-ring (3) to plate (7).

9. Remove star (5) from drive (6).

10. Remove special tool (ST 7862) from spool (8).

IMPORTANT: Strong force deforms housing (18).

Handle it with care.

11. Secure housing (8) in a vise.

21 a

a-

Vise

W202-02-14-002

12. Install O-ring (3) to housing (18).

13. Install ball (20), balls (22) (2 used), spring pin (19), and spring pins (21) (2 used) to housing (18). At this time, install them to the original holes recorded before disassembling.

W4-6-2-7

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 16. Turn the sleeve (9) assembly and set pin (10) and port side (d) of housing (18) 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 (6). Install drive (6). Assemble yoke part (c) of drive (6) and pin (10).

Set line (a) of the spline side edge of drive (6) and port side (d) of housing (18) in parallel position.

18. Face the O-ring (3) side of rotor (4) to the plate (7) side. Install star (5) while aligning the splines of star (5) and drive (6) so that line (j) connecting concave parts (i) of star (19) is parallel to line (a) on the spline side end of drive (6). Check that line (j) connecting concave parts (i) of star (5), line (a) on the spline side end, line (b) on yoke part (c) of drive (6) and line (g) connecting the centers of port L and port T, are parallel. Fit the bolt holes (k) on rotor (4) to holes on plate (15) while mating drive (6) and star (5).

a b

4 6

j

i

5 c

a W487-03-08-006

k

d

e

b

6

g

f

6 7

g

10 c abcd-

Line at the Spline Side End Line on the York Yoke Part Port Side

18

b W487-03-08-007

efg-

Port L Port T Line Connecting the Centers of Port L and Port T

10

d W202-02-14-031

17. Install O-ring (3) to rotor (4).

ij-

W4-6-2-8

Concave Part Line Connecting the Concave Parts

k-

Bolt Holes

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 19. Check that spring pins (21) (2 used) and balls (22) (2 used) have been installed to the end of screw (1) mounting holes (a) (2 places) in housing (18). Check that spring pin (19) and ball (20) have been installed to the end of screw (1) mounting hole (b) in housing (18). a

a

18

b

WNDB-04-06-018

20. Temporarily install cap (2) to housing (18) with screws (1) (7 used). j : 13 mm m : 17 N∙m (13 lbf·ft) 21. Tighten screws (1) (7 used) in the order as illustrated. j : 13 mm m : 28 to 34 N∙m (20.5 to 25 lbf·ft) 6

4

2

1

3

7

5

WNDB-04-06-018

W4-6-2-9

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device (Blank)

W4-6-2-10

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Removal and Installation of Steering Cylinder

WNEK50-03-22-002

1

IMPORTANT: The hose and pipe contain hydraulic oil.

When removing the hose and pipe, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

2. Remove under guard (front) (1) (only for the machine with under guard). (Refer to W3-22-1.)

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

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

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

W4-6-7-1

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a

1

3, 4 a-

2

WPD850-04-06-001

Vehicle Front Side

Removal of Steering Cylinder (Left) 3. Remove bolt, washer (3) and clip (4). j : 17 mm 4. Disconnect the both ends of pipe (2). j : 17 mm 5. Remove elbow (1). j : 14 mm

W4-6-7-2

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 1

3

2

WPD850-04-06-002

6. Disconnect hose (2). j : 19 mm 7. Disconnect hose (3). j : 27 mm 8. Disconnect hose (1). j : 27 mm

W4-6-7-3

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a

a-

Vehicle Front Side

1

9. Remove grease fitting (1). j : 10 mm

W4-6-7-4

WNEK50-04-06-020

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device A

Detail A

1

3

4 5

1

2

6

WNEK50-04-06-022

2

WNEK50-04-06-021

Steering cylinder (2) weight: 24 kg (53 dCAUTION: lb)

13. Disconnect steering cylinder (2) from rear frame (1).

10. Attach nylon slings onto steering cylinder (2). Hoist and hold steering cylinder (2).

15. In order not to extend the rod, pass the wires through the rod hole of steering cylinder (2) and secure the rod to the cylinder tube.

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

14. Retract steering cylinder (2).

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

11. Remove bolt, washer (4) and washer (5). Remove pin (3) by using a round bar and a hammer. j : 19 mm

12. Remove shims (6).

W4-6-7-5

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device A

Detail A

3

4

5

2 1

2 1

6

WNEK50-04-06-024

WNEK50-04-06-023

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

16. Remove bolt, washer (4) and washer (5). Remove pin (3) by using a round bar and a hammer. j : 19 mm 17. Remove shims (6).

18. Remove steering cylinder (1) from front frame (2).

19. Remove the adapters from steering cylinder (1) if necessary.

W4-6-7-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a

4

3 a-

Vehicle Front Side

1, 2 WPD850-04-06-003

Removal of Steering Cylinder (Right) 20. Remove bolt, washer (1) and clip (2). j : 17 mm 21. Disconnect the both ends of pipe (3). j : 17 mm 22. Remove elbow (4). j : 14 mm

W4-6-7-7

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 2

1

4

3

5

WPD850-04-06-004

23. Disconnect hose (1, 2, 3, 4). j : 27 mm 24. Disconnect hose (5). j : 19 mm

W4-6-7-8

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a

a-

Vehicle Front Side

WNEK50-04-06-027

1

25. Remove grease fitting (1). j : 10 mm

W4-6-7-9

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 1

Detail A

4

5

1

3

A

6

2 WNEK50-04-06-029

2 WNEK50-04-06-028

Steering cylinder (2) weight: 24 kg (53 dCAUTION: lb)

29. Disconnect steering cylinder (2) from rear frame (1).

26. Attach nylon slings onto steering cylinder (2). Hoist and hold steering cylinder (2).

31. In order not to extend the rod, pass the wires through the rod hole of steering cylinder (2) and secure the rod to the cylinder tube.

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

30. Retract steering cylinder (2).

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

27. Remove bolt, washer (4) and washer (3). Remove pin (5) by using a round bar and a hammer. j : 19 mm

28. Remove shims (6).

W4-6-7-10

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Detail A

3

4

5

2 1 A

6

2

WNEK50-04-06-031

1 WNEK50-04-06-030

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

32. Remove bolt, washer (4) and washer (5). Remove pin (3) by using a round bar and a hammer. j : 19 mm 33. Remove shim (6).

34. Remove steering cylinder (1) from front frame (2).

35. Remove the adapters from steering cylinder (1) if necessary.

W4-6-7-11

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Detail A

3

4

5

2 1 A

6 a

2

a-

WNEK50-04-06-031

1

Vehicle Front Side

WNEK50-04-06-030

Installation

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

Installation of Steering Cylinder (Right) 1. Install all removed adapters to steering cylinder (1).

Steering cylinder (1) weight: 24 kg (53 dCAUTION: lb) 2. Attach nylon slings onto steering cylinder (1). Hoist steering cylinder (1). Fit the hole at cylinder bottom side to the cylinder mounting hole of front frame (2).

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

4. Install pin (5) by using a hammer.

5. Install washer (4) and bolt, washer (3).

IMPORTANT: Use one or more shims (6) respectively at the top and bottom sides.

3. Fit shims (6) to the top and bottom sides of the cylinder bottom hole. Adjust the total clearance at the top and bottom sides of steering cylinder (1) and front frame (2) within 1 mm (0.039 in.).

fNOTE: Shim (6) thickness:

0.5 mm (0.02 in.), 1 mm (0.039 in.)

W4-6-7-12

j : 19 mm m : 90 N·m (66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 1

Detail A

4

5

1

3

A

6 a

2 WNEK50-04-06-029

2 a-

Vehicle Front Side WNEK50-04-06-028

6. Remove the wires from the rod holes of steering cylinder (2). Extend steering cylinder (2) and fit the cylinder rod hole to the mounting hole of rear frame (1).

IMPORTANT: Use one or more shims (6) respectively at the top and bottom sides.

7. Fit shims (6) to the top and bottom sides of the cylinder rod hole. Adjust the total clearance at the top and bottom sides of steering cylinder (2) and rear frame (1) within 1 mm (0.039 in.).

fNOTE: Shim (6) thickness:

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

8. Install pin (5) by using a hammer.

9. Install washer (3) and bolt, washer (4).

0.5 mm (0.02 in.), 1 mm (0.039 in.)

W4-6-7-13

j : 19 mm m : 90 N·m (66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

View A a

1

a-

WNEK50-04-06-027

1 A

IMPORTANT: Check the angle to install grease fitting (1).

10. Install grease fitting (1). Apply grease onto grease fitting (1). j : 10 mm

W4-6-7-14

60 °

WNEK50-04-06-032

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 2

4

3

Detail A

a

a

1

aA

5 a-

Vehicle Front Side

WPD850-04-06-004

IMPORTANT: Check the angle to install tee.

IMPORTANT: Check the angle to install hose (3).

11. Connect hoses (1, 2, 3, 4). j : 27 mm m : 120 N·m (89 lbf·ft) 12. Connect hose (5). j : 19 mm m : 30 N·m (22 lbf·ft)

W4-6-7-15

30°

3

WPD850-04-06-005

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a

4

a

5

a-

3 a-

1, 2

Vehicle Front Side

WPD850-04-06-003

13. Install elbow (4). j : 14 mm 14. Connect the both ends of pipe (3). j : 17 mm m : 25 N·m (18.5 lbf·ft) 15. Secure pipe (3) with clip (2) and bolt, washer (1).

Apply grease onto grease fitting (5). j : 17 mm m : 50 N·m (37 lbf·ft)

W4-6-7-16

Vehicle Front Side

WNEK50-04-06-034

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device A

Detail A

a

3

4

5

2 1

2 1

6

WNEK50-04-06-024

a-

Vehicle Front Side

WNEK50-04-06-023

Installation of Steering Cylinder (Left) 1. Install all removed adapters to steering cylinder (1).

Steering cylinder (1) weight: 24 kg (53 dCAUTION: lb) 2. Attach nylon slings onto steering cylinder (1). Hoist steering cylinder (1). Fit the hole at cylinder bottom side to the cylinder mounting hole of front frame (2).

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

4. Install pin (3) by using a hammer.

5. Install washer (5) and bolt, washer (4).

IMPORTANT: Use one or more shims (6) respectively at the top and bottom sides.

3. Fit shims (6) to the top and bottom sides of the cylinder bottom hole. Adjust the total clearance at the top and bottom sides of steering cylinder (1) and front frame (2) within 1 mm (0.039 in.).

fNOTE: Shim (6) thickness:

0.5 mm (0.02 in.), 1 mm (0.039 in.)

W4-6-7-17

j : 19 mm m : 90 N·m (66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device A

Detail A

1

3

4 5

1

2

6 a

WNEK50-04-06-022

2 a-

WNEK50-04-06-021

Vehicle Front Side

6. Remove the wires from the rod holes of the steering cylinder (2). Extend steering cylinder (2) and fit the cylinder rod hole to the mounting hole of rear frame (1).

IMPORTANT: Use one or more shims (6) respectively at the top and bottom sides.

7. Fit shims (6) to the top and bottom sides of the cylinder rod hole. Adjust the total clearance at the top and bottom sides of steering cylinder (2) and rear frame (1) within 1 mm (0.039 in.).

fNOTE: Shim (6) thickness:

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

8. Install pin (3) by using a hammer.

9. Install washer (5) and bolt, washer (4).

0.5 mm (0.02 in.), 1 mm (0.039 in.)

W4-6-7-18

j : 19 mm m : 90 N·m (66 lbf·ft)

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

View A a

1

a-

A

1 WNEK50-04-06-020

IMPORTANT: Check the angle to install grease fitting (1).

10. Install grease fitting (1). Apply grease onto grease fitting (1). j : 10 mm

W4-6-7-19

60 °

WNEK50-04-06-035

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 1

3

2

11. Connect hose (1). j : 27 mm m : 95 N·m (70 lbf·ft) 12. Connect hose (3). j : 27 mm m : 95 N·m (70 lbf·ft) 13. Connect hose (2). j : 19 mm m : 30 N·m (22 lbf·ft)

W4-6-7-20

WPD850-04-06-002

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

a a

1

3, 4 a-

2

WPD850-04-06-001

5

Vehicle Front Side a-

14. Install elbow (1). j : 14 mm 15. Connect the both ends of pipe (2). j : 17 mm m : 25 N·m (18.5 lbf·ft) 16. Secure pipe (2) with clip (4) and bolt, washer (3).

Apply grease onto grease fitting (5). j : 17 mm m : 50 N·m (37 lbf·ft)

W4-6-7-21

Vehicle Front Side

WNEK50-04-06-034

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device

1

IMPORTANT: Check the hydraulic oil level. Start the engine. Operate the steering cylinder to the stroke end several times and check for any oil leaks.

17. Install under guard (front) (1) (only for the machine with under guard). (Refer to W3-22-1.)

W4-6-7-22

WNEK50-03-22-002

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Disassembly of Steering Cylinder

20

18 17 16 15 14 12 13 12 19

11 10 8 6

9

7

5 4 3 2 1

WNDB-04-06-001

12345-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head

678910-

Washer O-Ring O-Ring Backup Ring Bushing

1112131415-

Retaining Ring Backup Ring (2 Used) O-Ring Dust Seal Seal Ring

W4-6-8-1

1617181920-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Disassembly of Steering Cylinder

4. Loosen cylinder head (5) by using hook wrench (b).

dCAUTION: Steering cylinder weight: 24 kg (53 lb)

Diameter of cylinder head (5): 84 mm

1. Hoist the cylinder. Secure the cylinder on a workbench horizontally. Drain off hydraulic oil from the cylinder.

b

20

W102-04-02-027

1

2. Install a protective cover to cylinder rod (1).

b-

5

W506-04-02-004

Hook Wrench

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

IMPORTANT: Do not damage the sliding surface of cylinder rod (1).

3. Extend the stopper (a) part of washer (6) by using a chisel and a hammer. Make it flat.

1

5

6

5. Remove the cylinder rod (1) assembly from cylinder tube (20). Secure it on the special tool (ST 5908) for cylinder.

20 Special Tool for Cylinder: ST 5908 W158-04-02-022

6. Cut away the crimped part by using a hand drill.

Remove set screw (19). l : 4 mm a a-

Stopper

WNDB-04-06-002

fNOTE: Set screw (19) has been crimped by using a punch (2 places) after installing.

fNOTE: LOCTITE #243 or equivalent has been applied on set screw (19).

W4-6-8-2

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 7. Remove nut (18) by using the special tool (ST 5908) for cylinder and the special tool for nut.

Special Tool for Nut:

9. Remove cylinder head (5) from cylinder rod (1) by using a plastic hammer.

10. Remove wear ring (17) and dust seal (14) from piston (16).

ST 3357: 58 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.

Special Tool for Cylinder: ST 5908 W158-04-02-022

IMPORTANT: Do not damage the seal groove.

11. Remove backup rings (15a) (2 used) from piston (16). Cut seal ring (15b) and ring (15c) by using a screwdriver and a hammer. Remove seal ring (15b) and ring (15c) from piston (16).

8. Remove piston (16) by using the special tool (ST 5908) for cylinder and the special tool for piston.

16

a

b

a

15

Special Tool for Piston: ST 3395: 52 mm c

WDBE-05-02-006 ab-

Special Tool for Cylinder: ST 5908 W158-04-02-022

W4-6-8-3

Backup Ring Seal Ring

c-

Ring

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 12. Remove backup rings (12) (2 used) and O-ring (13) from piston (16) by using a spatula.

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

13. Remove backup ring (9) and O-rings (7, 8) from cylinder head (5) by using a spatula.

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

14. Remove U-ring (3), backup ring (4a), and buffer ring (4b) from cylinder head (5) by using an awl.

3

5

IMPORTANT: Do not damage cylinder head (5).

15. Secure cylinder head (5) in a vise. Remove dust seal (2) from cylinder head (5) by using a screwdriver and a hammer.

IMPORTANT: Bushing (10) cannot be reused. If bushing (10) has been removed, replace it with the new one when assembling.

16. Remove retaining ring (11) and bushing (10).

fNOTE: Bushing (10) cannot be tapped and removed 4

WNDB-04-06-005

A

Detail A a

b

4

WDBE-05-02-008 a-

Backup Ring

b-

Buffer Ring

W4-6-8-4

from cylinder head (5). Cut off bushing (10) by using a lathe. Insert a screwdriver strongly and remove busing (10).

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Assembly of Steering Cylinder

2

6

7 3 4 10, 11 8, 9

5

1

20

16

14 15 17 12, 13, 12 18

19

WNEC-04-08-001

12345-

Cylinder Rod Dust Seal U-Ring Buffer Ring Cylinder Head

678910-

Washer O-Ring O-Ring Backup Ring Bushing

1112131415-

Retaining Ring Backup Ring (2 Used) O-Ring Dust Seal Seal Ring

W4-6-8-5

1617181920-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device Assembly of Steering Cylinder IMPORTANT: Before assembling, apply hydraulic oil onto parts in order to prevent them from seizing.

IMPORTANT: The seals which have been removed cannot be reused.

1. Install bushing (10) to cylinder head (5) by using the special tool for bushing.

IMPORTANT: Check the direction to install backup ring (4a).

4. Install U-ring (3), buffer ring (4b), and backup ring (4a) to cylinder head (5).

3

5

Special Tool for Bushing (Rod Outer Diameter): ST 3398: 45 mm 2. Install retaining ring (11) to cylinder head (5).

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.

3. Install dust seal (2) to cylinder head (5) by using the special tool for dust seal.

4

WNDB-04-06-005

A

Detail A

Special Tool for Dust Seal (Rod Outer Diameter): ST 3399: 45 mm

a

b

4

WDBE-05-02-008 a-

Backup Ring

b-

Buffer Ring

5. Install O-rings (7, 8) and backup ring (9) to cylinder head (5).

W4-6-8-6

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device 8. Hoist and secure cylinder rod (1) on the special tool (ST 5908) for cylinder.

Put heat-resisting gloves when dCAUTION: installing seal ring (15b).

IMPORTANT: Check the direction to install backup ring (15a).

6. Install ring (15c) to piston (16) by using a screwdriver which has made the angle round. Dip seal ring (15b) for approximately five minutes in hydraulic oil which is heated at 150 to 180 °C (302 to 356 °F) by using the electric heater in order to make seal ring (15b) soft. Install seal ring (15b) to piston (16) by using the special tool for seal ring.

After installing seal ring (15b), adjust it by using the special tool for seal ring. Install backup rings (15a) (2 used) to piston (16).

Special Tool for Cylinder: ST 5908 W158-04-02-022

9. Install the cylinder head (5) assembly to cylinder rod (1) by using the special tool for cylinder head.

Special Tool for Seal Ring (Tube Inner Diameter):

Special Tool for Cylinder Head (Rod Outer Diameter):

ST 3396: 70 mm

ST 3400: 45 mm

Special Tool for Seal Ring (Tube Inner Diameter):

10. Install the piston (16) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

ST 3397: 70 mm

Special Tool for Piston: 16

a

b

a

15

ST 3395: 52 mm m : 491±49 N·m (360±36 lbf·ft)

c

WDBE-05-02-006 ab-

Backup Ring Seal Ring

c-

Ring

Special Tool for Cylinder: ST 5908 W158-04-02-022

7. Install O-ring (13) and backup rings (12) (2 used) to piston (16).

W4-6-8-7

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device IMPORTANT: Fit the cylinder rod (1) assembly to the center of cylinder tube (20) and install it straight in order not to damage the rings.

11. Install nut (18) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut.

Special Tool for Nut:

14. Secure cylinder tube (20) on a workbench horizontally. Install washer (6) and the cylinder rod (1) assembly to cylinder tube (20). At this time, fit the bent part of washer (6) to notch (a) of cylinder tube (20) and install washer (6).

ST 3357: 58 mm m : 491±49 N·m (360±36 lbf·ft)

fNOTE: New washer (6) is not bent. The position adjustment of washer (6) is not necessary.

Special Tool for Cylinder: ST 5908

1

5

6

20

W158-04-02-022

12. Apply LOCTITE #243 or equivalent to set screw (19).

Install set screw (19) to nut (18). Crimp set screw (19) by using a punch (2 places). l : 4mm m : 15 N·m (11 lbf·ft) a

13. Install wear ring (17) and dust seal (14) to piston (16).

WNDB-04-06-003 a-

W4-6-8-8

Notch

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device IMPORTANT: Do not damage the sliding surface of cylinder rod (1).

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. Bend washer (6) by using a chisel and a hammer in order not to loosen cylinder head (5). At this time, bend one of three notches (c) for the hook wrench of cylinder head (5) in order not to loosen. (In case of new washer (6), bend notch (b) of cylinder tube (20) in order not to loosen.)

15. Tighten cylinder head (5) to cylinder tube (20) by using hook wrench (a).

Diameter of cylinder head (5): 84 mm m : 491±49 N·m (360±36 lbf·ft)

a

1

5

6

20

20

b

1 a-

5

W506-04-02-004

Hook Wrench c b-

W4-6-8-9

Notch

WNDB-04-06-004 c-

Notch

SECTION 4 TRAVEL SYSTEM Group 6 Steering Device (Blank)

W4-6-8-10

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device Removal and Installation of Secondary Steering Pump

1

2

Detail A

5, 6

A

3 b

8

4

a

7

ab-

Battery Box Vehicle Front Side

WNEK50-03-01-002

WNEK50-03-01-001

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

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

 Without battery disconnect switch 2. Open covers (2, 3).

3. Remove bolt, washer (1). Remove rubber plate (4). j : 17 mm 4. Remove bolt, washer (5) and clip (6). j : 17 mm IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then disconnect ground (7).

5. Loosen bolt (8). Disconnect ground (7). j : 17 mm

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

W4-7-1-1

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device

Detail A

2

1 A

a

a-

Battery Box

b

WNEK50-03-17-001 c bc-

 With battery disconnect switch 6. Open cover (1).

IMPORTANT: Turn the key switch to the OFF position, wait 5 minutes or longer, and then turn battery disconnect switch (2) to the OFF position.

7. Set battery disconnect switch (2) to OFF position (b).

W4-7-1-2

OFF Position ON Position

WNEK50-03-22-043

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 1

3

8. Open side covers (front) (1) at left and right sides.

9. Remove the following parts. (Refer to W3-22-1.)  Lower Cover (2)  Rear Fender (Front) (3)

W4-7-1-3

2

WPD850-03-01-003

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 2

a

a

1 a-

WPD850-04-07-001

Vehicle Front Side

1 a-

10. Remove bolts, washers (1) (4 used). Place rubber plate (2) outside of the work area. j : 17 mm 11. Remove bolt, washer (3). Remove bracket (4). j : 17 mm

W4-7-1-4

Vehicle Front Side

4

3

WPD850-04-07-002

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 2

View A

1

2

7 A

10 a

9

3

3

WPD850-04-07-003

12. Remove nut (6). Disconnect terminal (5). j : 12 mm 13. Disconnect connector (4).

14. Disconnect hose (2). j : 22 mm 15. Disconnect hose (3). j : 27 mm 16. Remove bolts, washers (7) (4 used). Remove secondary steering pump (1) and ground (9) from bracket (10). j : 17 mm 17. Remove the adapters from secondary steering pump (1) if necessary.

W4-7-1-5

5, 6

4

WPD850-04-07-004

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 2

View A

1

2

7 A

10 a

9

3

3

WPD850-04-07-003

Installation 1. Install all removed adapters to secondary steering pump (1).

2. Install secondary steering pump (1) and ground (9) to bracket (10) with bolts, washers (7) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft) 3. Connect hose (3). j : 27 mm m : 80 N·m (59 lbf·ft) 4. Connect hose (2). j : 22 mm m : 40 N·m (29.5 lbf·ft) 5. Connect connector (4).

6. Connect terminal (5) with nut (6). j : 12 mm m : 8.2 to 9.8 N·m (6 to 7.2 lbf·ft)

W4-7-1-6

5, 6

4

WPD850-04-07-004

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device

1

2 Detail A

A

3 5, 6

8

4

a

a-

Battery Box

WNEK50-03-01-001

 Without battery disconnect switch 7. Connect ground (7). Tighten bolt (8). j : 17 mm m : 50 N·m (37 lbf·ft) 8. Secure ground (7) with clip (6) and bolt, washer (5). j : 17 mm m : 50 N·m (37 lbf·ft) 9. Install rubber plate (4) with bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft) 10. Close covers (2, 3).

W4-7-1-7

7

WNEK50-03-01-002

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device

Detail A

2

1 A

a

a-

Battery Box

WNEK50-03-17-001

b c bc-

 With battery disconnect switch 11. Set battery disconnect switch (2) to ON position (c).

12. Close cover (1).

W4-7-1-8

OFF Position ON Position

WNEK50-03-22-043

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 2

a

a

1 a-

4

3

WPD850-04-07-002

Vehicle Front Side

1 a-

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

13. Install bracket (4) with bolt, washer (3). j : 17 mm m : 50 N·m (37 lbf·ft) 14. Install rubber plate (2) with bolts, washers (1) (4 used). j : 17 mm m : 50 N·m (37 lbf·ft)

W4-7-1-9

Vehicle Front Side

WPD850-04-07-001

SECTION 4 TRAVEL SYSTEM Group 7 Secondary Steering Device 1

3

15. Install the following parts. (Refer to W3-22-1.)  Lower Cover (2)  Rear Fender (Front) (3) 16. Close left and right side covers (front) (1).

W4-7-1-10

2

WPD850-03-01-003

SECTION 5

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment Removal and Installation of Front Attachment...W5-1-1-1 Removal and Installation of Bell Crank ..................W5-1-2-1 Removal and Installation of Bucket.........................W5-1-3-1 Removal and Installation of Bushing ......................W5-1-4-1

Group 2 Cylinder Removal and Installation of Lift Arm Cylinder.....W5-2-1-1 Removal and Installation of Bucket Cylinder .......W5-2-2-1 Disassembly of Lift Arm Cylinder and Bucket Cylinder ........................................................................W5-2-3-1 Assembly of Lift Arm Cylinder and Bucket Cylinder ........................................................................W5-2-3-5

70Z7B D&R

(Blank)

70Z7B D&R

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Front Attachment 1

2

3

4

a-

Stand

WNEK50-05-02-001

a

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

2. Start the engine. Raise lift arm (1). Set lift arm cylinder (2) in the horizontal position. Operate bucket cylinder (3). Dump and place bucket (4) on stand (a). Stop the engine.

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

W5-1-1-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

View A

5 1

6 2,3 WNEK50-05-01-022 A

4

WNEK50-05-01-021

3. Disconnect connector (5).

6. Remove another headlight (1) assembly in the same way as step 3 to step 5.

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

5. Remove bolts (2) (4 used) and washers (3) (4 used).

Remove the headlight (1) assembly and rubber cushions (4) (4 used). j : 19 mm

W5-1-1-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

1, 2

5

A

WPD850-05-01-001

7 View A

3 4 a-

a

WNEK50-05-01-023

Vehicle Front Side

6

9

7. Disconnect connector (4).

8. Remove bolt, washer (1) and washer (2). j : 17 mm 9. Remove bolts, washers (5) (3 used). Remove the angle sensor (3) assembly.

a-

Vehicle Front Side

WPD850-05-01-002

j : 17 mm 10. Disconnect terminals (7) (2 used).

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

Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

11. Remove bolts, washers (9) (2 used). Remove the horn (6) assembly. j : 17 mm 12. Remove another horn (6) assembly in the same way as step 10 to step 11.

IMPORTANT: After removing bucket cylinder (8), do not operate the bucket.

13. Remove bucket cylinder (8). (Refer to W5-2-2.)

W5-1-1-3

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Section A 1 1

2

8, 9 4

A

5 6

7

3

3 WNEK50-05-01-025

WNEK50-05-02-003

19. Remove another lift arm cylinder (1) from lift arm (3) in the same way as step 14 to step 18.

Lift arm cylinder (1) weight: 130 kg dCAUTION: (290 lb) 14. Attach nylon slings onto lift arm cylinder (1). Hoist and hold lift arm cylinder (1).

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

20. Start the engine. Retract lift arm cylinders (2).

21. Stop the engine. In order not to extend the rod, pass the wires through the rod hole of lift arm cylinders (1) (2 used) and secure the rod to the cylinder tube.

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

15. Remove bolt (5) and washers (4, 6). Remove pin (7) by using a round bar and a hammer. j : 24 mm 16. Remove spacers (8) and shims (9).

17. Remove lift arm cylinder (1) from lift arm (3).

18. Set wooden blocks in between lift arm cylinder (1) and front frame (2). Support lift arm cylinder (1).

W5-1-1-4

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

1

Section A

5, 6

3 7

2

8

4

9

3

10 4

WNEK50-05-01-027

WNEK50-05-01-026

27. Remove other pin (7) in the same way as step 23 to step 26.

The front attachment assembly dCAUTION: weight: 2620 kg (5780 lb) 22. Attach nylon slings onto lift arm (4). Hoist and hold the front attachment assembly.

23. Disconnect the both ends of pipe (2). j : 17 mm 24. Remove elbow (1).

IMPORTANT: Slowly move the machine in reverse direction while taking care not to contact the lift arm (4) mounting part of front frame (3) and lift arm (4).

28. Start the engine. Move the vehicle in reverse direction and remove the front attachment assembly from front frame (3). Stop the engine.

29. Remove the front attachment assembly from front frame (3). Place it onto wooden blocks.

j : 14 mm Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury.

25. Remove bolt (9) and washers (8, 10). Remove pin (7) by using a round bar and a hammer. j : 19 mm 26. Remove spacer (5) and shim (6).

W5-1-1-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

Section A

3

4 3

4

WNEK50-05-01-026

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing the front attachment. Replace them if any defect is observed. (Refer to W2-2-1.)

IMPORTANT: Check the pins and bushings. Replace if necessary. (Refer to W5-1-4.)

IMPORTANT: Apply grease onto the inner circumference of bushings and dust seals when installing the pin. In addition, apply anti-rust oil onto the inner circumference of the boss.

The front attachment assembly dCAUTION: weight: 2620 kg (5780 lb) 1. Attach nylon slings onto lift arm (4). Hoist the front attachment assembly.

2. Start the engine. Move the machine forward. Fit the lift arm (4) mounting hole to the front frame (3) mounting hole. Stop the engine.

W5-1-1-6

WNEK50-05-01-027

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

1

Section A

5, 6

3 2

7

11

4

8 9

3

10 4

WNEK50-05-01-027

WNEK50-05-01-026

IMPORTANT: Use one or more spacer (5) or shim (6) respectively at the right and left sides.

3. Install spacers (5) or shims (6) to the left and right side of the lift arm (4) mounting hole. Adjust total clearance of right and left between lift arm (4) and front frame (3) within 1.5 mm (0.059 in.).

5. Install washers (8, 10) and bolt (9). j : 24 mm m : 210 N·m (155 lbf·ft) 6. Install elbow (1). j : 14 mm

fNOTE: Spacer (5) thickness: 2.3 mm (0.091 in.), Shim (6) thickness: 1.6 mm (0.063 in.)

d

m : 13 to 18 N·m (9.6 to 13.5 lbf·ft)

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

4. Install pin (7) by using a hammer.

7. Connect the both ends of pipe (2). Apply grease onto grease fitting (11). j : 17 mm m : 25 N·m (18.5 lbf·ft) 8. Install another pin (7) in the same way as step 3 to step 7.

W5-1-1-7

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Section A 1 1

8, 9

2

4 A

5 6 10

7

3

3 WNEK50-05-01-025

9. Remove the wires from the rod holes of lift arm cylinder (1). Start the engine. Extend lift arm cylinder (1) and fit the cylinder rod side hole to the lift arm (3) mounting hole. Stop the engine.

10. Remove wooden blocks set in step 18.

IMPORTANT: Use one or more spacer (8) or shim (9) respectively at the right and left sides.

11. Install spacers (8) or shims (9) at the left and right side of the cylinder bottom side hole. Adjust total clearance of right and left between lift arm cylinder (1) and lift arm (3) within 1.5 mm (0.059 in.).

fNOTE: Spacer (8) thickness: 2.3 mm (0.091 in.), Shim (9) thickness: 1.6 mm (0.063 in.)

WNEK50-05-02-003

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

12. Install pin (7) by using a hammer.

13. Install washers (4, 6) and bolt (5). j : 24 mm m : 210 N·m (155 lbf·ft) 14. Apply grease to grease fitting (10).

15. Install another lift arm cylinder (1) in the same way as step 9 to step 14.

W5-1-1-8

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

a

6

9

1, 2

5

A

a-

Vehicle Front Side

WPD850-05-01-002

View A

3 4 a-

Vehicle Front Side WNEK50-05-01-023

20. Install the angle sensor (3) assembly with bolts, washers (5) (3 used). j : 17 mm m : 50 N·m (37 lbf·ft) 7

WPD850-05-01-001

21. Install washer (2) and bolt, washer (1). j : 17 mm m : 50 N·m (37 lbf·ft)

16. Install bucket cylinder (8). (Refer to W5-2-2.)

22. Connect connector (4).

17. Install the horn (6) assembly with bolts, washers (9) (2 used). j : 17 mm m : 50 N·m (37 lbf·ft) 18. Connect terminals (7) (2 used).

19. Install another horn (6) assembly in the same way as step 17 to step 18.

W5-1-1-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment

View A

5 1

6 2,3 WNEK50-05-01-022 A

4

WNEK50-05-01-021

23. Install the headlight (1) assembly and rubber cushions (4) (4 used) with washers (3) (4 used) and bolts (2) (4 used). j : 19 mm

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

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

m : 50 N·m (37 lbf·ft) 24. Install connector (5) to bracket (6).

25. Connect connector (5).

26. Install another headlight (1) assembly in the same way as step 23 to step 25.

W5-1-1-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bell Crank Section A 1 2 3

1

A

4 5

6 2 WNEK50-05-01-015

7 WNEK50-05-01-014

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

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

dCAUTION: Bucket link (2) weight: 47 kg (105 lb) 2. Attach nylon slings onto bucket link (2). Hoist and hold bucket link (2).

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

3. Remove bolt (4) and washers (3, 5). Remove pin (6) by using a round bar and a hammer. j : 19 mm 4. Remove spacers (7).

W5-1-2-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

Section A

3, 4 5

A

1 6 7

2 2

8

WNEK50-05-02-013

WNEK50-05-02-012

7. Remove spacers (3) and shims (4).

Bucket cylinder (1) weight: 113 kg dCAUTION: (250 lb)

8. Remove bucket cylinder (1) from bell crank (2).

5. Attach nylon slings onto bucket cylinder (1). Hoist and hold bucket cylinder (1).

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

6. Remove bolt (7) and washers (6, 8). Remove pin (5) by using a round bar and a hammer.

9. Start the engine. Retract bucket cylinder (1).

10. Stop the engine. In order not to extend the rod, pass wires through the rod hole of bucket cylinder (1) and secure the rod to the cylinder tube. Place wooden blocks. Place bucket cylinder (1) onto the wooden blocks.

j : 24 mm

W5-1-2-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

2

Section A

1 3

4 5

6

WNEK50-05-01-017

1

WPD850-05-01-003

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

11. Install pin (3) to bell crank (1) by using a hammer.

Install washers (4, 6) and bolt (5). j : 24 mm m : 210 N·m (155 lbf·ft)

fNOTE: Use pin (3), washers (4, 6) and bolt (5) which are used for the bucket cylinder (2) rod mounting parts.

W5-1-2-3

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

3

Section A 1 4 5 2 6

7

8, 9 1

2

WNEK50-05-01-019

WPD850-05-01-003

dCAUTION: Bell crank (1) weight: 260 kg (575 lb) 12. Attach nylon slings onto pin (3) which has been installed in step 11. Hoist and hold bell crank (1).

14. Remove spacers (8) and shims (9).

15. Remove bell crank (1) from lift arm (2). Place it onto wooden blocks.

dCAUTION: Pin (7) weight: 31 kg (69 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury.

13. Remove bolt (5) and washers (4, 6). Remove pin (7) by using a round bar and a hammer. j : 24 mm

W5-1-2-4

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

A

Section A

1 2

3 4

WNEK50-05-01-020

5

WNEK50-05-01-017

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

16. Remove bolt (4) and washers (3, 5). Remove pin (2) from bell crank (1) by using a round bar and a hammer. j : 24 mm

W5-1-2-5

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

A

Section A

1 2

3 4

WNEK50-05-01-020

5

WNEK50-05-01-017

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing bell crank (1). (Refer to W2-2-1.)

IMPORTANT: Check pins and bushings. If any damage is observed, replace it. (Refer to W5-1-4.)

IMPORTANT: Apply grease onto the inner circumference of bushings and dust seals when installing the pin. In addition, apply anti-rust oil to the inner circumference of the boss.

1. Install pin (2) to bell crank (1) by using a hammer.

Install washers (3, 5) and bolt (4). j : 24 mm m : 210 N·m (155 lbf·ft)

fNOTE: Use pin (2), washers (3, 5) and bolt (4) which are

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

W5-1-2-6

used for the bucket cylinder rod mounting parts.

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

3

Section A 1 4 5 2 6

10 7

8, 9 1

2

WNEK50-05-01-019

WPD850-05-01-003

dCAUTION: Bell crank (1) weight: 260 kg (575 lb) 2. Attach nylon slings onto pin (3) which has been installed in step 1. Hoist bell crank (1). Fit the mounting hole of bell crank (1) to the mounting hole of lift arm (2).

IMPORTANT: Use one or more spacer (8) or shim (9) respectively at the right and left sides.

3. Fit spacers (8) or shims (9) to both sides of the bell crank (1) mounting hole. Adjust the total clearance at the left and right sides of bell crank (1) and lift arm (2) within 1.5 mm (0.059 in.).

fNOTE: Spacer (8) thickness: 2.3 mm (0.091 in.), Shim (9)

dCAUTION: Pin (7) weight: 31 kg (69 lb) Metal fragments may fly off when dCAUTION: a hammer is used. Wear necessary protection, such as goggles, hard hat, etc. in order to prevent personal injury.

4. Install pin (7) by using a hammer.

5. Install washers (4, 6) and bolt (5). j : 24 mm m : 210 N·m (155 lbf·ft) 6. Apply grease to the grease fitting (10).

thickness: 1.6 mm (0.063 in.)

W5-1-2-7

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment A

Section A

1 2

3 4

5

WNEK50-05-01-017

1

WPD850-05-01-003

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

7. Remove bolt (4) and washers (3, 5). Remove pin (2) from bell crank (1) by using a round bar and a hammer. j : 24 mm

W5-1-2-8

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

Section A

3, 4 5

A

9 1 6 7

2 2

8

WNEK50-05-02-013

WNEK50-05-02-012

8. Remove the wires from the rod holes of bucket cylinder (1). Start the engine. Extend bucket cylinder (1) and fit the cylinder rod hole to the mounting hole of bell crank (2). Stop the engine.

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

IMPORTANT: Use one or more spacer (3) or shim (4) respectively at the right and left sides.

9. Fit spacers (3) or shims (4) to the left and right sides of the cylinder bottom hole. Adjust the total clearance at the left and right sides of bucket cylinder (1) and bell crank (2) within 1.5 mm (0.059 in.).

f

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

10. Install pin (5) by using a hammer.

11. Install washers (6, 8) and bolt (7). j : 24 mm m : 210 N·m (155 lbf·ft) 12. Apply grease to the grease fitting (9).

NOTE: Spacer (3) thickness: 2.3 mm (0.091 in.), Shim (4) thickness: 1.6 mm (0.063 in.)

W5-1-2-9

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Section A

8

9

2 1

3

1

4 5

A

6

WNEK50-05-01-015

2 7

WNEK50-05-01-014

dCAUTION: Bucket link (2) weight: 47 kg (105 lb)

13. Attach nylon slings onto bucket link (2). Hoist bucket link (2). Fit the mounting hole of bucket link (2) to the mounting hole of bell crank (1).

IMPORTANT: Use one or more spacers (7) respectively at the right and left sides.

14. Fit spacers (7) to both sides of the bell crank (1) mounting hole. Adjust the total clearance at the left and right sides of bell crank (1) and bucket link (3) within 1.5 mm.

f

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

15. Install pin (6) by using a hammer.

16. Install bolt (4) and washers (3, 5). j : 19 mm m : 90 N·m (66 lbf·ft) 17. Apply grease to the grease fitting (9).

NOTE: Spacer (7) thickness: 1.6 mm (0.063 in.), 2.3 mm (0.091 in.)

W5-1-2-10

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bucket 1

Section A

4

1

3

A

9

3

2 WNEK50-05-01-010

8

7

6

5

4 WNEK50-05-01-011

Removal

5. Remove spacers (9).

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

6. Remove bucket link (3) from bucket (1).

7. Remove O-rings (4) (2 used).

2. Start the engine. Operate lift arm (2). Set bucket (1) horizontally and place it on wooden blocks. Stop the engine.

dCAUTION: Bucket link (3) weight: 47 kg (105 lb) 3. Attach nylon slings onto bucket link (3). Hoist and hold bucket link (3).

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

4. Remove bolt (7) and washers (6, 8). Remove pin (5) by using a round bar and a hammer. j : 19 mm

W5-1-3-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

Section A

3

A

2

8

3

7

6

5

4

1

WNEK50-05-01-013

2 WNEK50-05-01-012

dCAUTION: Bucket (1) weight: 1350 kg (2980 lb)

10. Remove spacers (8).

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

12. Remove bucket (1) and O-rings (3) (4 used) from lift arm (2).

8. Attach nylon slings onto bucket (1). Hoist and hold bucket (1).

11. Remove other pin (4) in the same way as step 9 to step 10.

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

9. Remove bolt (6) and washers (5, 7). Remove pin (4) by using a round bar and a hammer. j : 19 mm

W5-1-3-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

a

Section A

3

A

2

8

3 7 a-

2

6

5

9

Boss Part

4

1

a

WNEK50-05-01-013

WNEK50-05-01-012

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing the bucket. (Refer to W2-2-1.)

IMPORTANT: Check pins and bushings. If any damage is observed, replace it. (Refer to W5-1-4.)

IMPORTANT: Apply grease onto the inner surface of bushings and dust seals when installing the pin. In addition, apply anti-rust oil onto the inner surface of the boss.

1. Install O-rings (3) (4 used) to the boss part (a) (4 places) of bucket (1).

dCAUTION: Bucket (1) weight: 1350 kg (2980 lb)

2. Attach nylon slings onto bucket (1). Hoist bucket (1).

Fit the mounting hole of bucket (1) to the mounting hole of lift arm (1).

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

4. Install pin (4) by using a hammer.

5. Install washers (5, 7) and bolt (6). j : 19 mm m : 90 N·m (155 lbf·ft) 6. Apply grease to the grease fitting (9).

7. Install other pin (4) in the same way as step 3 to step 6.

8. Move O-rings (3) (4 used) which are installed in step 1 to the connecting part of bucket (1) and lift arm (2).

IMPORTANT: Use one or more spacers (8) respectively at the right and left sides.

3. Fit spacers (8) to both sides of the bucket (1) mounting hole. Adjust the total clearance at the left and right sides of bucket (1) and lift arm (2) within 1.5 mm (0.059 in.).

fNOTE: Spacer (8) thickness: 1.6 mm (0.063 in.), 2.3 mm (0.091 in.)

W5-1-3-3

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment 1

a

Section A

4

1

10

3

A

9

11

3 WNEK50-05-01-010

8 a-

9. Install O-rings (4) (4 used) to the boss part (a) (2 places) of bucket (1).

dCAUTION: Bucket link (3) weight: 47 kg (105 lb) 10. Attach nylon slings onto bucket link (3). Hoist bucket link (3).

7

6

a

5

Boss Part

4

WNEK50-05-01-011

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

13. Install pin (5) by using a hammer.

11. Start the engine. Fit the mounting hole of bucket link (3) to the mounting hole of bucket (1) by operating bucket cylinder (10).

14. Install washers (6, 8) and bolt (7).

IMPORTANT: Use one or more spacers (9) respectively at the right and left sides.

12. Fit spacers (9) to both sides of the bucket (1) mounting hole. Adjust the total clearance at the left and right sides of bucket (1) and bucket link (3) within 1.5 mm (0.059 in.).

m : 90 N·m (155 lbf·ft)

j : 19 mm

15. Apply grease to the grease fitting (11).

16. Move O-rings (4) (2 used) which are installed in step 9 to the connecting part of bucket (1) and bucket link (3).

fNOTE: Spacer (9) thickness: 1.6 mm (0.063 in.), 2.3 mm (0.091 in.)

W5-1-3-4

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Removal and Installation of Bushing H

E

G

F I A

D B

C

Part

A Bucket Link

Part Number of Pieces Dust Seal Bushing (1) (2) 2 2

Bushing (3) -

WNEK50-05-01-001

Bushings (2, 3) Cross section mounting tool ST 7692 a: 74 mm (2.9 in)

1

a

2

WNEK50-05-01-002

B Bucket Link

2

2

-

ST 7692 b: 74 mm (2.9 in)

1

b

2

WNEK50-05-01-003

C Lift Arm

4

2

2

ST 7692 c: 74 mm (2.9 in)

inside

1

c

outside

D Lift Arm

4

4

-

ST 7693 d: 99 mm (3.9 in)

1

2

WNEK50-05-01-004

3 d

2

WNEK50-05-01-005

E Lift Arm

4

4

-

ST 7722 e: 99 mm (3.9 in)

1

e

2

WNEK50-05-01-006

W5-1-4-1

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment H

E

G

F I A

D B

C

Part

Part Number of Pieces Dust Seal Bushing (1) (2) F Bell Crank 2 2

Bushing (3) -

WNEK50-05-01-001

Bushings (2, 3) Cross section mounting tool ST 7720 f: 113 mm (4.4 in)

1

f

2

WNEK50-05-01-007

G Bucket Cylinder

2

2

-

ST 7722 g: 99 mm (3.9 in)

1

g

2

WNEK50-05-01-008

H Bucket Cylinder

2

2

-

ST 7722 h: 99 mm (3.9 in)

1

h

2

WNEK50-05-01-009

I

Lift Arm Cylinder

4

4

-

ST 7722 i: 99 mm (3.9 in)

1

i

2

WNEK50-05-01-009

W5-1-4-2

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment Bushings (2, 3) mounting direction

Removal 1. Remove dust seal (1) and bushings (2, 3).

a

fNOTE: If bushings (2, 3) can not be removed, burn out them.

Installation IMPORTANT: For handling HN bushing for the front attachment, check the followings. b

Precautions when installing the bushing If a hammer is used to install the bushing, the bushing may be damaged. Use a press when installing the bushing.

WNEC-05-01-028 a-

Precautions when reinforcing the 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.

2.5 mm (0.098 in)

b-

15 °

Bushing (2) mounting direction at lift arm part (c)

IMPORTANT: Check the direction to install bushings (2, 3).

1. Install bushings (2, 3) by using a press and the special tool.

c

2

c

2. Install dust seal (1).

WNEC-05-01-025 c-

W5-1-4-3

Groove

SECTION 5 FRONT ATTACHMENT Group 1 Front Attachment (Blank)

W5-1-4-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Lift Arm Cylinder 1

2

3

4 5

a-

Stand

WNEK50-05-02-001

a

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

2. Start the engine. Raise lift arm (1). Set lift arm cylinder (2) in the horizontal position. Dump bucket (5) and place it on stand (a) by operating the bucket cylinder. Stop the engine.

3. Remove front fender (4). (Refer to W3-22-1.)

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

W5-2-1-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Section A 1 1

8, 9 4

2 A

5 6

7

3

3 WNEK50-05-02-002

WNEK50-05-02-003

9. Disconnect another lift arm cylinder (1) from lift arm (3) in the same way as step 4 to step 8.

Lift arm cylinder (1) weight: 130 kg dCAUTION: (290 lb) 4. Attach nylon slings onto lift arm cylinder (1). Hoist and hold lift arm cylinder (1).

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

5. Remove bolt (5) and washers (4, 6). Remove pin (7) by using a round bar and a hammer.

10. Start the engine. Retract lift arm cylinders (1) (2 used).

11. Stop the engine. In order not to extend the rod, pass the wires through the rod hole of lift arm cylinders (1) (2 used) and secure the rod to the cylinder tube.

j : 24 mm 6. Remove spacers (8) and shims (9).

7. Disconnect lift arm cylinder (1) from lift arm (3).

8. Set wooden blocks between lift arm cylinder (1) and front frame (2). Support lift arm cylinder (1).

W5-2-1-2

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

2, 3, 4

1

WNEK50-05-02-004

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

Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

12. Remove socket bolts (2) (8 used) and flanges (3) (4 used). Disconnect hoses (1) (2 used). Remove O-rings (4) (2 used). l : 8 mm 13. Disconnect other hoses (1) (2 used) in the same way as step 12.

W5-2-1-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Section A

1

1

9

2 2

8 7

A

6 5 WNEK50-05-02-006

3, 4

WNEK50-05-02-005

16. Remove spacers (3) and shims (4).

14. Remove grease fitting (6).

17. Remove lift arm cylinder (1) from front frame (2).

j : 10 mm

18. Remove another lift arm cylinder (1) in the same way as step 14 to step 17.

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

15. Remove bolt (8) and washers (7, 9). Remove pin (5) by using a round bar and a hammer. j : 24 mm

W5-2-1-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Section A

1

1

9

2 2

8 7

A

6 5 WNEK50-05-02-006

3, 4

WNEK50-05-02-005

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing lift arm cylinder (1). (Refer to W2-2-1.)

IMPORTANT: Apply grease onto the inner circumference of bushings and dust seals when installing the pin. In addition, apply anti-rust oil to the inner circumference of the boss.

IMPORTANT: Check pins and bushings. If any damage is observed, replace it. (Refer to W5-1-4.)

Lift arm cylinder (1) weight: 130 kg dCAUTION: (290 lb)

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

3. Install pin (5) by using a hammer.

4. Install washers (7, 9) and bolt (8). j : 24 mm m : 210 N·m (155 lbf·ft) 5. Install grease fitting (6). Apply grease to the grease fitting (6).

1. Attach nylon slings onto lift arm cylinder (1). Hoist lift arm cylinder (1). Fit the hole at cylinder bottom side to the cylinder mounting hole of front frame (2).

IMPORTANT: Use one or more spacer (3) or shim (4) respectively at the right and left sides.

2. Fit spacers (3) or shims (4) to the left and right sides of the cylinder bottom hole. Adjust the total clearance at the left and right sides of lift arm cylinder (1) and front frame (2) within 1.5 mm (0.059 in.).

j : 10 mm m : 4 N·m (3 lbf·ft) 6. Set wooden blocks between lift arm cylinder (1) and front frame (2). Support lift arm cylinder (1).

7. Install another lift arm cylinder (1) in the same way as step 1 to step 6.

fNOTE: Spacer (3) thickness: 2.3 mm (0.091 in.), Shim (4) thickness: 1.6 mm (0.063 in.)

W5-2-1-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

2, 3, 4

1

WNEK50-05-02-004

8. Install O-rings (4) (2 used). Connect hoses (1) (2 used) with flanges (3) (4 used) and socket bolts (2) (8 used). l : 8 mm m : 50 N·m (37 lbf·ft) 9. Connect other hoses (1) (2 used) in the same way as step 8.

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

W5-2-1-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Section A 1 1

8, 9 4 A

5 6 10

7

3

3 WNEK50-05-02-002

10. Remove the wires from the rod holes of the lift arm cylinder (1). Start the engine. Extend lift arm cylinder (1) and fit the cylinder rod hole to the mounting hole of lift arm cylinder (3). Stop the engine.

WNEK50-05-02-003

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

13. Install pin (7) by using a hammer.

11. Remove wooden blocks installed in step 6.

IMPORTANT: Use one or more spacer (8) or shim (9) respectively at the right and left sides.

12. Fit spacers (8) or shims (9) to the left and right sides of the cylinder bottom hole. Adjust the total clearance at the left and right sides of lift arm cylinder (1) and lift arm (3) within 1.5 mm (0.059 in.).

14. Install washers (4, 6) and bolt (5). j : 24 mm m : 210 N·m (155 lbf·ft) 15. Apply grease to the grease fitting (10).

fNOTE: Spacer (8) thickness: 2.3 mm (0.091 in.), Thickness of shim (9): 1.6 mm (0.063 in.)

W5-2-1-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 2

4

a-

Stand

WNEK50-05-02-001

a

16. Install front fender (4). (Refer to W3-22-1.)

17. Install another lift arm cylinder (2) in the same way as step 10 to step 16.

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

W5-2-1-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Removal and Installation of Bucket Cylinder A

Detail A

1

2

3

4

WNEK50-05-02-008

WNEK50-05-02-007

IMPORTANT: The hoses and pipes contain hydraulic oil. When removing the hoses and pipes, receive oil with a container in order to avoid spilling oil.

IMPORTANT: Cap the open ends in case the hoses and pipes have been disconnected. In addition, attach identification tags onto the connectors, hoses, and pipes for assembling. If the clips which secure the hoses have been removed, install the clips after connecting the hoses.

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

2. Remove bolts, washers (1) (4 used). Remove guard (3) and shim (2) from bucket cylinder (4). j : 19 mm

W5-2-2-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder View A 1

B

A

4

3

2 WNEK50-05-02-010

WNEK50-05-02-009

View B

5

14

3. Remove bolts, washers (3) (2 used) and nuts (4) (2 used). Remove bracket (2) from bucket cylinder (1).

6, 7 13

j : 17 mm 4. Remove bolt, washer (10), nut (11), and clip (12). j : 17 mm 5. Disconnect connector (14).

10, 11, 12

6. Remove nuts (6) (4 used), washers (7) (4 used), bracket (13), connector (14) assembly and U-bolts (9) (2 used). Remove bracket (8) and the proximity switch (5) assembly. j : 17 mm

W5-2-2-2

9

8 WNEK50-05-02-011

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

Section A

3, 4 5

A

1 6 7

2 2

8

WNEK50-05-02-013

WNEK50-05-02-012

9. Remove spacers (3) and shims (4).

Bucket cylinder (1) weight: 113 kg dCAUTION: (250 lb)

10. Remove bucket cylinder (1) from bell crank (2).

7. Attach nylon slings onto bucket cylinder (1). Hoist and hold bucket cylinder (1).

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

11. Start the engine. Retract bucket cylinder (1).

12. Stop the engine. In order not to extend the rod, pass wires through the rod hole of bucket cylinder (1) and secure the rod to the cylinder tube.

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

8. Remove bolt (7) and washers (6, 8). Remove pin (5) by using a round bar and a hammer. j : 24 mm

W5-2-2-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

3, 4, 5

WNEK50-05-02-014

2

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

Release any pressure in the front dCAUTION: attachment hydraulic circuit. (Refer to W1-5-1.)

13. Remove socket bolts (3) (4 used) and flanges (4) (2 used). Disconnect hose (2). Remove O-ring (5). l : 8 mm 14. Disconnect hose (1) in the same way as step 12.

W5-2-2-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

2, 3

4

WNEK50-05-02-015

15. Remove bolt, washer (2) and clip (3). j : 17 mm 16. Disconnect the both ends of pipe (4). j : 17 mm 17. Remove elbow (1). j : 14 mm

W5-2-2-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

A

2

Section A

3, 4

1

2

5

6

7 8 WNEK50-05-02-017

WNEK50-05-02-016

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

18. Remove bolt (7) and washers (6, 8). Remove pin (5) by using a round bar and a hammer. j : 24 mm 19. Remove spacers (3) and shims (4).

20. Remove bucket cylinder (1) from front frame (2).

W5-2-2-6

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

A

2

Section A

3, 4

1

2

5

6

7 8 WNEK50-05-02-017

WNEK50-05-02-016

Installation IMPORTANT: Check outer diameter, inner diameter, wear, and damage of all pins and bushings before installing bucket cylinder (1). (Refer to W2-2-1.)

IMPORTANT: Check pins and bushings. If any damage is observed, replace it. (Refer to W5-1-4.)

IMPORTANT: Apply grease onto the inner circumference of bushings and dust seals when installing the pin. In addition, apply anti-rust oil to the inner circumference of the boss.

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

3. Install pin (5) by using a hammer.

4. Install washers (6, 8) and bolt (7).

Bucket cylinder (1) weight: 113 kg dCAUTION: (250 lb) 1. Attach nylon slings onto bucket cylinder (1). Hoist bucket cylinder (1). Fit the hole at cylinder bottom side to the cylinder mounting hole of front frame (2).

IMPORTANT: Use one or more spacer (3) or shim (4) respectively at the right and left sides.

2. Fit spacers (3) or shims (4) to the left and right sides of the cylinder bottom hole. Adjust the total clearance at the left and right sides of bucket cylinder (1) and front frame (2) within 1.5 mm (0.059 in.).

fNOTE: Spacer (3) thickness: 2.3 mm (0.091 in.), Shim (4) thickness: 1.6 mm (0.063 in.)

W5-2-2-7

j : 24 mm m : 210 N·m (155 lbf·ft)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

2, 3

4

WNEK50-05-02-015

5

5. Install elbow (1).

9. Apply grease to the grease fitting (5).

j : 14 mm m : 13 to 18 N·m (9.6 to 13.5 lbf·ft) 6. Temporarily install both ends of pipe (4), clip (3), and bolt, washer (2).

7. Tighten both ends of pipe (4). j : 17 mm m : 25 N·m (18.5 lbf·ft) 8. Tighten bolt, washer (2). j : 17 mm m : 50 N·m (37 lbf·ft)

W5-2-2-8

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder B

1

View A

2

a a-

WNEK50-05-02-018

10 °

View B

1

3, 4, 5

b

2 A WNEK50-05-02-014

IMPORTANT: Check the angle to install hose (2).

10. Install O-ring (5). Connect hose (2) with flanges (4) (2 used) and socket bolts (3) (4 used). l : 8 mm m : 50 N·m (37 lbf·ft) IMPORTANT: Check the angle to install hose (1).

11. Connect hose (1) in the same way as step 10.

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

W5-2-2-9

b-

10 °

WNEK50-05-02-019

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 1

Section A

3, 4 5

A

9 1 6 7

2 2

8

WNEK50-05-02-013

WNEK50-05-02-012

12. Remove the wires from the rod holes of bucket cylinder (1). Start the engine. Extend bucket cylinder (1) and fit the cylinder rod hole to the mounting hole of bell crank (2). Stop the engine.

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

IMPORTANT: Use one or more spacer (3) or shim (4) respectively at the right and left sides.

13. Fit spacers (3) or shims (4) to the left and right sides of the cylinder bottom hole. Adjust the total clearance at the left and right sides of bucket cylinder (1) and bell crank (2) within 1.5 mm (0.059 in.).

f

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

14. Install pin (5) by using a hammer.

15. Install washers (6, 8) and bolt (7). j : 24 mm m : 210 N·m (155 lbf·ft) 16. Apply grease to the grease fitting (9).

NOTE: Spacer (3) thickness: 2.3 mm (0.091 in.), Shim (4) thickness: 1.6 mm (0.063 in.)

W5-2-2-10

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder View A 1

B

A

4

3

2 WNEK50-05-02-010

WNEK50-05-02-009

View B

5

14 15

17. Temporary install the proximity switch (5) assembly, connector (14) assembly and bracket (13) with U-bolts (9) (2 used), washers (7) (4 used), and nuts (6) (4 used).

6, 7

13

18. Connect connector (14).

19. Secure harness (15) with clip (12), bolt, washer (10), and nut (11).

10, 11, 12

9

8

j : 17 mm

WNEK50-05-02-011

m : 50 N·m (37 lbf·ft) 20. Install bracket (2) to bucket cylinder (1) with nuts (4) (2 used) and bolts, washers (3) (2 used).

5

j : 17 mm 5

m : 50 N·m (37 lbf·ft) 21. Adjust the mounting position of the proximity switch (5) assembly. (Refer to Operator's Manual.)

After adjustment, tighten nuts (6) (4 used). j : 17 mm

a

b

2 a-

m : 20 N·m (15 lbf·ft)

W5-2-2-11

5 to 10 mm (0.2 to 0.4 in.)

2

WNDB-05-02-003 b-

100 mm (3.9 in.) (When the bucket is horizontal on the ground) (Reference)

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder A

Detail A

1

2

3

5 6 7

4

WNEK50-05-02-008

WNEK50-05-02-007

22. Install shim (2) and guard (3) to bucket cylinder (4) with bolts, washers (1) (4 used). j : 19 mm

26. Adjust the number of shims (2) and washers (5) to be installed according to the clearance between bucket cylinder (4) and rubber cushion (6).

fNOTE: Shim (2) thickness: 0.5 mm (0.02 in.), Washer (5)

m : 90 N·m (66 lbf·ft) 23. Ensure that the clearance between bucket cylinder (4) and cushion rubber (6) is 5 to 10 mm (0.2 to 0.4 in.). If clearance is not 5 to 10 mm (0.2 to 0.4 in.), adjust the clearance by following steps 24 to 28.

24. Remove bolts, washers (1) (4 used). Remove guard (3) and shim (2) from bucket cylinder (4).

thickness: 2.3 mm (0.091 in.)

27. Install washer (5) and rubber cushion (6) to guard (3) with screw (7).

fNOTE: There are two screw (7) mounting holes. Front

side is used for this machine.

28. Install shim (2) and guard (3) to bucket cylinder (4) with bolts, washers (1) (4 used).

j : 19 mm

j : 19 mm

25. Remove screw (7). Remove rubber cushion (6) and washer (5) from guard (3).

m : 90 N·m (66 lbf·ft) 29. Bleed air from the hydraulic system. (Refer to W1-41.)

W5-2-2-12

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Lift Arm Cylinder and Bucket Cylinder

Lift Arm Cylinder 21

19 18 17 16 15 13

14

13

20

12

11 10 9 8 7 6 4

5

3 2 1 WNEC-05-02-025

W5-2-3-1

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Bucket Cylinder

21

19 15 18 17 16 15 13

14

13 20

11 10 9 8 7 6 4 3

5 12

2

1

123456-

Cylinder Rod Dust Seal U-Ring Buffer Seal Cylinder Head O-Ring

WNEC-05-02-026

7891011-

O-Ring Backup Ring Bushing Retaining Ring Socket Bolt (14 Used) (Lift Arm Cylinder: 12 Used)

12131415-

Set Screw Backup Ring (2 Used) O-Ring Piston Ring (2 Used) (Lift Arm Cylinder: 1 Used) 16- Seal Ring

W5-2-3-2

1718192021-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Disassembly of Lift Arm Cylinder and Bucket Cylinder  The procedure starts on the premise that the pipes and the bands securing the pipes have been removed.

NOTE: The bucket cylinder is explained here.

f

CAUTION: Lift arm cylinder weight: 130 kg (290 dlb)

4. Secure cylinder rod (1) on the special tool (ST 5908) for cylinder. Put the matching marks on the ends of cylinder rod (1), piston (17), and nut (19).

Bucket cylinder weight: 113 kg (250 lb) 1. Hoist the cylinder. Secure the cylinder on a workbench horizontally. Drain hydraulic oil from the cylinder.

Special Tool for Cylinder: ST 5908 W158-04-02-022

W102-04-02-027

2. Fully extend and support cylinder rod (1). Remove socket bolts (11) (14 used) (lift arm cylinder: 12 used) from cylinder head (5).

(Lift arm cylinder) l : 12 mm (Bucket cylinder) l : 14 mm IMPORTANT: Pull out cylinder rod (1) straightly in order not to damage the sliding surface.

3. Tap and remove cylinder head (5) with cylinder rod (1) together from cylinder tube (21) by using a plastic hammer.

W5-2-3-3

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 5. Cut away the crimped part by using a hand drill.

Remove set screw (20).

7. Remove the piston (17) assembly from cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

fNOTE: Set screws (20) (2 used) have been crimped by

Special Tool for Piston:

using a punch at two places after installing them.

ST 3402: 96 mm (Lift arm cylinder)

l : 4 mm 6. Remove nut (19) from cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut.

Special Tool for Nut:

ST 3401: 120 mm (Bucket cylinder) 8. Remove piston rings (15) (2 used) (lift arm cylinder: 1 used), wear ring (18), seal ring (16), backup rings (13) (2 used), and O-ring (14) from piston (17).

9. Remove the cylinder head (5) assembly from cylinder rod (1).

ST 3404: 87 mm (Lift arm cylinder) ST 3403: 97 mm (Bucket cylinder)

IMPORTANT: Do not remove bushing (9) unless necessary.

10. Remove dust seal (2), U-ring (3), buffer seal (4), retaining ring (10), bushing (9), O-ring (7), backup ring (8), and O-ring (6) from cylinder head (5).

Special Tool for cylinder: ST 5908 W158-04-02-022

W5-2-3-4

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Lift Arm Cylinder and Bucket Cylinder

Lift Arm Cylinder 11 12

5

21

1

A B

2

3

4

6 7, 8

Detail A

15 9

10

16

18

13, 14, 13 19, 20

17

Detail B W4GD-04-02-004

W5-2-3-5

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder

Bucket Cylinder 1

21

5

D E C

11

2

3

4

6

7, 8

13, 14, 13 9

15 19

15 16 18

10

20

12 17

Detail D

Detail E

View C WNEC-05-02-035

123456-

Cylinder Rod Dust Seal U-Ring Buffer Seal Cylinder Head O-Ring

7891011-

O-Ring Backup Ring Bushing Retaining Ring Socket Bolt (14 Used) (Lift Arm Cylinder: 12 Used)

12131415-

Set Screw Backup Ring (2 Used) O-Ring Piston Ring (2 Used) (Lift Arm Cylinder: 1 Used) 16- Seal Ring

W5-2-3-6

1718192021-

Piston Wear Ring Nut Set Screw Cylinder Tube

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder Assembly of Lift Arm Cylinder and Bucket Cylinder

fNOTE: The bucket cylinder is explained here.

5. Install seal ring (16) to piston (17) by using the special tool A.

1. Install bushing (9) to cylinder head (5).

After installing seal ring (16), adjust seal ring (16) by using the special tool B.

Special Tool for Bushing (Rod Outer Diameter): ST 7647: 75 mm (Lift arm cylinder)

Special Tool A (Tube Inner Diameter):

ST 7639: 85 mm (Bucket cylinder)

ST 7649: 125 mm (Lift arm cylinder)

IMPORTANT: Check the direction to install.

2. Install U-ring (3) and buffer seal (4) to cylinder head (5).

ST 7648: 150 mm (Bucket cylinder) Special Tool B (Tube Inner Diameter): ST 7685: 125 mm (Lift arm cylinder)

3. Install dust seal (2) to cylinder head (5) by using the special tool and a plastic hammer.

Special Tool for Dust Seal (Rod Outer Diameter):

ST 7684: 150 mm (Bucket cylinder) 6. Install wear ring (18), piston rings (15) (2 used) (lift arm cylinder: 1 used), O-ring (14), and backup rings (13) (2 used) to piston (17).

ST 7638: 75 mm (Lift arm cylinder) ST 7637: 85 mm (Bucket cylinder) 4. Install O-rings (6, 7), backup ring (8), and retaining ring (10) to cylinder head (5).

7. Install the cylinder head (5) assembly to cylinder rod (1).

Special Tool for Cylinder Head (Rod Outer Diameter): ST 7776: 75 mm (Lift arm cylinder) ST 7635: 85 mm (Bucket cylinder)

W5-2-3-7

SECTION 5 FRONT ATTACHMENT Group 2 Cylinder 8. Fit the matching marks before disassembling and install the piston (17) assembly to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for piston.

10. Apply LOCTITE #243 or equivalent to set screw (20).

Install set screw (20) to nut (19). Crimp set screw (20) by using a punch (2 places). l : 4 mm

Special Tool for Piston:

m : 15±1.5 N·m (11±1.1 lbf·ft)

ST 3402: 96 mm (Lift arm cylinder)

CAUTION: Fit the cylinder rod (1) assembly to the dcenter of cylinder tube (24) and install it in order

ST 3401: 120 mm (Bucket cylinder) m : 980±98 N·m (720±72 lbf·ft)

not to damage the rings.

11. Secure cylinder tube (21) on a workbench horizontally. Install the cylinder rod (1) assembly into cylinder tube (21).

9. Fit the matching marks before disassembling and install nut (19) to cylinder rod (1) by using the special tool (ST 5908) for cylinder and the special tool for nut:

12. Apply LOCTITE #243 or equivalent to socket bolts (11) (14 used) (lift arm cylinder: 12 used). Install cylinder head (5) to cylinder tube (21) with socket bolts (11) (14 used) (lift arm cylinder: 12 used).

Special Tool for Nut: ST 3404: 87 mm (Lift arm cylinder) ST 3403: 97 mm (Bucket cylinder)

(Lift arm cylinder)

m : 1860±186 N·m (1380±138 lbf·ft)

l : 12 mm m : 226 to 235 N·m (167 to 175 lbf·ft) (Bucket cylinder) l : 14 mm m : 344 to 363 N·m (254 to 268 lbf·ft)

Special Tool for Cylinder: ST 5908 W158-04-02-022

W5-2-3-8

INDEX A Adjustment of Brake Disc Clearance ......................... W4-3-3-32 Adjustment of Parking Brake ..........................................W4-2-6-5 Adjustment of Ring Gear Backlash............................. W4-3-3-29 Adjustment of Ring Gear Teeth Engagement ........ W4-3-3-29 Aftertreatment Device, Removal and Installation..................................................................... W3-18-1-1 Applicable Tire Size ........................................ W4-1-1-5, W4-1-2-5 Assembly of Axle .............................................................. W4-3-3-17 Assembly of Brake Valve ...................................................W4-5-2-3 Assembly of Bucket Cylinder...........................................W5-2-3-5 Assembly of Control Valve................................................W3-9-2-5 Assembly of Fan Pump ................................................... W3-15-6-3 Assembly of Lift Arm Cylinder ........................................W5-2-3-5 Assembly of Main Pump ...................................................W3-8-3-5 Assembly of Manifold Valve.......................................... W3-12-2-4 Assembly of Pilot Valve................................................... W3-10-3-4 Assembly of Pilot Valve (Two Lever Type) ................ W3-10-4-7 Assembly of Pump Device ...............................................W3-8-2-3 Assembly of Regulator ......................................................W3-8-4-3 Assembly of Ride Control Valve................................... W3-16-2-4 Assembly of Steering Cylinder .......................................W4-6-8-5 Assembly of Steering Valve..............................................W4-6-2-4 Axle, Assembly .................................................................. W4-3-3-17 Axle, Disassembly ................................................................W4-3-3-1 Axle Shaft Bearing, Preload Adjustment .................. W4-3-3-37 B Battery Box, Removal and Installation ....................W3-22-1-60 Battery Disconnect Switch, Removal and Installation..................................................................... W3-17-1-1 Bell Crank, Removal and Installation ............................W5-1-2-1 Bleed Air from the Fuel System ......................................W1-4-1-2 Bleed Air from the Hydraulic System. ..........................W1-4-1-1 Bleeding Air from Brake (Axle) ........................................W1-4-1-3 Bolts, Tightening ..................................................................W1-2-1-1 Brake (Axle), Bleed Air ........................................................W1-4-1-3 Brake Accumulator, Removal and Installation ....... W3-11-3-1 Brake Charge Valve, Removal and Installation ....... W3-11-1-1 Brake Charge Valve, Structure...................................... W3-11-2-1 Brake Disc Clearance, Adjustment ............................. W4-3-3-32 Brake Valve, Assembly .......................................................W4-5-2-3 Brake Valve, Disassembly ..................................................W4-5-2-1 Brake Valve, Removal and Installation .........................W4-5-1-1 Bucket, Removal and Installation ..................................W5-1-3-1 Bucket, Standard Dimensions .........................................W2-2-2-1 Bucket Cylinder, Assembly ...............................................W5-2-3-5 Bucket Cylinder, Disassembly .........................................W5-2-3-1 Bucket Cylinder, Removal and Installation .................W5-2-2-1 Bucket Dump Stopper .......................................................W2-2-2-2 Bucket Roll Back Stopper ..................................................W2-2-2-2 Bushing ...................................................................................W2-2-1-1 Bushing, Removal and Installation................................W5-1-4-1

C Cab, Removal and Installation ........................................W3-1-1-1 Cab Under Cover, Removal and Installation .........W3-22-1-25 Center Hinge .........................................................................W2-1-1-1 Center Hinge, Removal and Installation .....................W3-3-1-1 Clutch, Removal and Installation ................................ W4-2-4-11 Connecting Hose .................................................................W1-2-1-9 Control Valve, Assembly....................................................W3-9-2-5 Control Valve, Disassembly ..............................................W3-9-2-1 Control Valve, Removal and Installation .....................W3-9-1-1 Coolant Control Valve, Removal and Installation.. W3-20-1-1 Cooling Fan System ......................................................... W3-15-1-1 Counterweight, Removal and Installation .................W3-2-1-1 Cylinder ...................................................................................W2-2-3-1 D Deck, Removal and Installation ................................... W3-22-1-5 DEF Supply Module, Removal and Installation ..... W3-21-1-1 DEF Tank Box, Removal and Installation ................W3-22-1-28 DEF Tank, Removal and Installation........................... W3-19-1-1 Disassembly and Assembly of Drive Unit ...................W4-2-2-1 Disassembly and Assembly of Transmission .............W4-2-4-1 Disassembly and Assembly of Transmission Control Valve....................................................................W4-2-5-1 Disassembly of Axle............................................................W4-3-3-1 Disassembly of Brake Valve..............................................W4-5-2-1 Disassembly of Bucket Cylinder .....................................W5-2-3-1 Disassembly of Control Valve ..........................................W3-9-2-1 Disassembly of Fan Pump ............................................. W3-15-6-1 Disassembly of Lift Arm Cylinder...................................W5-2-3-1 Disassembly of Main Pump .............................................W3-8-3-1 Disassembly of Manifold Valve .................................... W3-12-2-1 Disassembly of Pilot Valve ............................................. W3-10-3-1 Disassembly of Pilot Valve (Two Lever Type) .......... W3-10-4-1 Disassembly of Pump Device ..........................................W3-8-2-1 Disassembly of Regulator .................................................W3-8-4-1 Disassembly of Ride Control Valve ............................. W3-16-2-1 Disassembly of Steering Cylinder ..................................W4-6-8-1 Disassembly of Steering Valve ........................................W4-6-2-1 Disassembly of Steering Valve, Disassembly .............W4-6-2-1 Drive Unit, Disassembly and Assembly .......................W4-2-2-1 Drive Unit, Removal and Installation ............................W4-2-1-1 Duct Plate, Removal and Installation ...........................W4-2-5-4 E Engine, Removal and Installation ..................................W3-4-1-1 Engine Cover, Removal and Installation................... W3-22-1-9 Expansion Tank, Releasing Pressure .......................... W1-5-1-10 Exterior Components, Removal and Installation .. W3-22-1-1 F Fan Motor, Removal and Installation......................... W3-15-3-1 Fan Motor, Structure........................................................ W3-15-4-1 Fan Pump, Assembly ....................................................... W3-15-6-3 70Z7B D&R

INDEX Fan Pump, Disassembly.................................................. W3-15-6-1 Fan Pump, Removal and Installation ......................... W3-15-5-1 Fan Valve, Removal and Installation .......................... W3-15-1-1 Fan Valve, Structure ......................................................... W3-15-2-1 Flange at Output Shaft Side, Removal and Installation........................................................................W4-2-6-7 Floating Seal, Precautions ................................................W1-1-1-2 Flow Regulator Valve, Removal and Installation ... W3-14-1-1 Flow Regulator Valve, Structure .................................. W3-14-2-1 Front Attachment ................................................................W2-2-1-1 Front Attachment, Removal and Installation ............W5-1-1-1 Front Axle, Removal and Installation............................W4-3-1-1 Front Cover, Removal and Installation ...................... W3-22-1-3 Front Fender, Removal and Installation ................... W3-22-1-4 Front Tire, Removal and Installation .............................W4-1-1-1 Fuel System, Bleed Air........................................................W1-4-1-2 Fuel Tank, Removal and Installation .............................W3-7-1-1 H Hose, Connecting ................................................................W1-2-1-9 Hydraulic Circuit, Releasing Pressure ...........................W1-5-1-6 Hydraulic Oil Tank, Releasing Pressure ........................W1-5-1-9 Hydraulic Oil Tank, Removal and Installation ............W3-6-1-1 Hydraulic Pump Drive, Disassembly and Assembly ...........................................................................W4-2-4-1 Hydraulic System, Bleed Air .............................................W1-4-1-1 I Inspection Cover, Removal and Installation .........W3-22-1-28 Inspection and Maintenance Position (Lift Arm Raise) ................................................................W1-5-1-5 L Left Side Cover (Rear), Removal and Installation .........................................................................................W3-22-1-51 Lever, Removal and Installation .....................................W5-1-2-1 Lift Arm Cylinder, Assembly.............................................W5-2-3-5 Lift Arm Cylinder, Disassembly .......................................W5-2-3-1 Lift Arm Cylinder, Removal and Installation ..............W5-2-1-1 Lift Arm, Standard Dimensions ......................................W2-2-2-1 Lock Frames ...........................................................................W1-5-1-3 Lower Cover, Removal and Installation ..................W3-22-1-31

N Nuts, Tightening ..................................................................W1-2-1-1 Nylon Sling, Precautions ...................................................W1-1-1-3 O Oil Filter, Removal and Installation ...............................W4-2-2-4 P Painting ...................................................................................W1-3-1-1 Parking Brake, Adjustment ..............................................W4-2-6-5 Parking Brake, Manual Release .......................................W4-2-6-6 Parking Brake, Removal and Installation.....................W4-2-6-1 Parking Brake Accumulator, Releasing Pressure ......W1-5-1-8 Parking Brake Solenoid Valve, Structure .................. W3-13-5-1 Parking Brake Solenoid Valve Unit, Removal and Installation..................................................................... W3-13-3-1 Parking Brake Solenoid Valve Unit, Structure ........ W3-13-4-1 Pilot Pump, Structure .........................................................W3-8-6-1 Pilot Valve (Single Lever Type), Assembly ................ W3-10-3-4 Pilot Valve (Single Lever Type), Disassembly .......... W3-10-3-1 Pilot Valve (Single Lever Type), Removal and Installation..................................................................... W3-10-1-1 Pilot Valve (Two Lever Type), Assembly .................... W3-10-4-7 Pilot Valve (Two Lever Type), Disassembly .............. W3-10-4-1 Pilot Valve (Two Lever Type), Removal and Installation..................................................................... W3-10-2-1 Pin .............................................................................................W2-2-1-1 Piping Joint ............................................................................W1-2-1-4 Precautions for Disassembling and Assembling......W1-1-1-1 Precautions for Spilt 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) .................................................................. W4-3-3-37 Preparations for Inspection and Maintenance .........W1-5-1-1 Priority Valve, Removal and Installation ......................W3-8-7-1 Priority Valve, Structure .....................................................W3-8-5-1 Propeller Shaft, Removal and Installation ..................W4-4-1-1 Pump Device, Assembly....................................................W3-8-2-3 Pump Device, Disassembly ..............................................W3-8-2-1 Pump Device, Removal and Installation .....................W3-8-1-1 Q Quick Coupling ....................................................................W1-2-1-7

M Main Pump, Assembly ..................................................W3-8-3-5 Main Pump, Disassembly ............................................W3-8-3-1 Manifold Valve, Assembly ........................................ W3-12-2-4 Manifold Valve, Disassembly................................... W3-12-2-1 Manifold Valve, Removal and Installation .......... W3-12-1-1 Manual Release of Parking Brake .............................W4-2-6-6 Mud Cover, Removal and Installation ................W3-22-1-26

R Radiator Assembly, Removal and Installation ...........W3-5-1-1 Rear Axle, Removal and Installation .............................W4-3-2-1 Rear Cover, Removal and Installation......................W3-22-1-21 Rear Fender (Front), Removal and Installation ...... W3-22-1-5 Rear Fender (Rear), Removal and Installation ........ W3-22-1-7 Rear Grill, Removal and Installation .........................W3-22-1-44 Rear Tire, Removal and Installation ...............................W4-1-2-1

70Z7B D&R

INDEX Regulator, Assembly ...........................................................W3-8-4-3 Regulator, Disassembly .....................................................W3-8-4-1 Releasing Pressure from Expansion Tank................. W1-5-1-10 Releasing Pressure from Hydraulic Circuit .................W1-5-1-6 Releasing Pressure from Hydraulic Oil Tank...............W1-5-1-9 Releasing Pressure from Parking Brake Accumulator ....................................................................W1-5-1-8 Releasing Pressure from Ride Control Accumulator ....................................................................W1-5-1-7 Removal and Installation of Aftertreatment Device ............................................................................. W3-18-1-1 Removal and Installation of Battery Box ................W3-22-1-60 Removal and Installation of Battery Disconnect Switch.............................................................................. W3-17-1-1 Removal and Installation of Bell Crank ........................W5-1-2-1 Removal and Installation of Brake Accumulator ... W3-11-3-1 Removal and Installation of Brake Charge Valve... W3-11-1-1 Removal and Installation of Brake Valve .....................W4-5-1-1 Removal and Installation of Bucket ..............................W5-1-3-1 Removal and Installation of Bucket Cylinder ............W5-2-2-1 Removal and Installation of Bushing ...........................W5-1-4-1 Removal and Installation of Cab ....................................W3-1-1-1 Removal and Installation of Cab Under Cover .....W3-22-1-25 Removal and Installation of Center Hinge .................W3-3-1-1 Removal and Installation of Clutch ............................ W4-2-4-11 Removal and Installation of Control Valve .................W3-9-1-1 Removal and Installation of Coolant Control Valve ................................................................................ W3-20-1-1 Removal and Installation of Counterweight .............W3-2-1-1 Removal and Installation of DEF Supply Module............................................................................ W3-21-1-1 Removal and Installation of DEF Tank....................... W3-19-1-1 Removal and Installation of DEF Tank Box ............W3-22-1-28 Removal and Installation of Deck ............................... W3-22-1-5 Removal and Installation of Drive Unit........................W4-2-1-1 Removal and Installation of Duct Plate .......................W4-2-5-4 Removal and Installation of Engine ..............................W3-4-1-1 Removal and Installation of Engine Cover .............. W3-22-1-9 Removal and Installation of Exterior Components ................................................................. W3-22-1-1 Removal and Installation of Fan Motor .................... W3-15-3-1 Removal and Installation of Fan Pump ..................... W3-15-5-1 Removal and Installation of Fan Valve ...................... W3-15-1-1 Removal and Installation of Flange at Output Shaft Side ..........................................................................W4-2-6-7 Removal and Installation of Flow Regulator Valve ................................................................................ W3-14-1-1 Removal and Installation of Front Attachment ........W5-1-1-1 Removal and Installation of Front Axle .......................W4-3-1-1 Removal and Installation of Front Cover ................. W3-22-1-3 Removal and Installation of Front Fender ............... W3-22-1-4 Removal and Installation of Front Tire .........................W4-1-1-1 Removal and Installation of Fuel Tank .........................W3-7-1-1 Removal and Installation of Hydraulic Oil Tank ........W3-6-1-1 Removal and Installation of Inspection Cover .....W3-22-1-28

Removal and Installation of Left Side Cover (Rear) .............................................................................W3-22-1-51 Removal and Installation of Lever .................................W5-1-2-1 Removal and Installation of Lift Arm Cylinder ..........W5-2-1-1 Removal and Installation of Lower Cover ..............W3-22-1-31 Removal and Installation of Manifold Valve ........... W3-12-1-1 Removal and Installation of Mud Cover .................W3-22-1-26 Removal and Installation of Oil Filter ...........................W4-2-2-4 Removal and Installation of Parking Brake ................W4-2-6-1 Removal and Installation of Parking Brake Solenoid Valve Unit .................................................... W3-13-3-1 Removal and Installation of Pilot Valve (Single Lever Type) ..................................................... W3-10-1-1 Removal and Installation of Pilot Valve (Two Lever Type) ......................................................... W3-10-2-1 Removal and Installation of Priority Valve ..................W3-8-7-1 Removal and Installation of Propeller Shaft ..............W4-4-1-1 Removal and Installation of Pump Device .................W3-8-1-1 Removal and Installation of Radiator Assembly ......W3-5-1-1 Removal and Installation of Rear Axle .........................W4-3-2-1 Removal and Installation of Rear Cover .................W3-22-1-21 Removal and Installation of Rear Fender (Front) .. W3-22-1-5 Removal and Installation of Rear Fender (Rear) .... W3-22-1-7 Removal and Installation of Rear Grill .....................W3-22-1-44 Removal and Installation of Rear Tire...........................W4-1-2-1 Removal and Installation of Ride Control Accumulator ................................................................. W3-16-3-1 Removal and Installation of Ride Control Valve .... W3-16-1-1 Removal and Installation of Right Side Cover (Rear) .............................................................................W3-22-1-55 Removal and Installation of Secondary Steering Pump ..................................................................................W4-7-1-1 Removal and Installation of Side Cover (Front).................................................. W3-22-1-32, W3-22-1-38 Removal and Installation of Steering Cylinder .........W4-6-7-1 Removal and Installation of Steering Valve ...............W4-6-1-1 Removal and Installation of Step (Front) ................. W3-22-1-5 Removal and Installation of Step (Rear) .................W3-22-1-28 Removal and Installation of Tool Box ......................W3-22-1-28 Removal and Installation of Torque Converter .........W4-2-3-1 Removal and Installation of Under Guard (Front)............................................................................W3-22-1-70 Removal and Installation of Under Guard (Rear) .............................................................................W3-22-1-59 Ride Control Accumulator, Releasing Pressure .........W1-5-1-7 Ride Control Accumulator, Removal and Installation..................................................................... W3-16-3-1 Ride Control Valve, Assembly ....................................... W3-16-2-4 Ride Control Valve, Disassembly ................................. W3-16-2-1 Ride Control Valve, Removal and Installation ........ W3-16-1-1 Right Side Cover (Rear), Removal and Installation...................................................................W3-22-1-55 Ring Gear Backlash, Adjustment................................. W4-3-3-29 Ring Gear Teeth Engagement, Adjustment ............ W4-3-3-29

70Z7B D&R

INDEX S Secondary Steering Pump, Removal and Installation........................................................................W4-7-1-1 Side Cover (Front), Removal and Installation......................................... W3-22-1-32, W3-22-1-38 Specified Tightening Torque Chart ...............................W1-2-1-1 Spilt Flange, Precautions ..................................................W1-2-1-3 Standard Dimensions for Lift Arm and Bucket .........W2-2-2-1 Steering Cylinder, Assembly ............................................W4-6-8-5 Steering Cylinder, Disassembly ......................................W4-6-8-1 Steering Cylinder, Removal and Installation..............W4-6-7-1 Steering Valve, Assembly ..................................................W4-6-2-4 Steering Valve, Removal and Installation....................W4-6-1-1 Step (Front), Removal and Installation ..................... W3-22-1-5 Step (Rear), Removal and Installation .....................W3-22-1-28 Structure of Brake Charge Valve.................................. W3-11-2-1 Structure of Fan Motor ................................................... W3-15-4-1 Structure of Fan Valve ..................................................... W3-15-2-1 Structure of Flow Regulator Valve .............................. W3-14-2-1 Structure of Parking Brake Solenoid Valve .............. W3-13-5-1 Structure of Parking Brake Solenoid Valve Unit .... W3-13-4-1 Structure of Pilot Pump .....................................................W3-8-6-1 Structure of Priority Valve .................................................W3-8-5-1 T Tightening Bolts and Nuts ...............................................W1-2-1-1 Tightening Torque Chart...................................................W1-2-1-1 Tire Size .............................................................. W4-1-1-5, W4-1-2-5 Tool Box, Removal and Installation ..........................W3-22-1-28 Torque Converter, Removal and Installation .............W4-2-3-1 Transmission, Disassembly and Assembly .................W4-2-4-1 Transmission Clutch Engagement ................................W4-2-2-2 Transmission Control Valve, Disassembly and Assembly ...........................................................................W4-2-5-1 U Under Guard (Front), Removal and Installation...W3-22-1-70 Under Guard (Rear), Removal and Installation ....W3-22-1-59

70Z7B D&R