Preview

PART NO.
WNEM50-EN-00
ZW250-6
WHEEL LOADER
Workshop Manual
WORKSHOP MANUAL
ZW250-6
Wheel Loader
URL:http://www.hitachi-c-m.com
WNEM50-EN-00
Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TONEM50-EN
Technical Manual (Troubleshooting) : Vol. No.TTNEM50-EN
PRINTED IN JAPAN (K) 2017, 05 Workshop Manual : Vol. No.WNEM50-EN
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling and
Assembling
Precautions for Disassembling and
Assembling..................................................................W1-1-1-1
Group 2 Tightening
Tightening Bolts and Nuts...........................................W1-2-1-1
Piping Joint.......................................................................W1-2-1-4
Group 3 Painting
Group 4 Bleeding Air
Bleed Air from the Hydraulic System.......................W1-4-1-1
Bleed Air from the Fuel System..................................W1-4-1-2
Bleeding Air from Brake (Axle)...................................W1-4-1-3
Group 5 Preparation
Preparations for Inspection and Maintenance.....W1-5-1-1
Releasing Pressure from Front Attachment
Hydraulic Circuit........................................................W1-5-1-6
Releasing Pressure from Ride Control
Accumulator................................................................W1-5-1-7
Releasing Pressure from Parking Brake
Accumulator................................................................W1-5-1-8
Releasing Pressure from Hydraulic Oil Tank..........W1-5-1-9
Releasing Pressure from Reserve Tank................. W1-5-1-10
NEM50W-1-1
(Blank)
NEM50W-1-2
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and  If a part or component cannot be removed after

Assembling removing its securing nuts and bolts, do not attempt
to remove it forcibly. Find the cause (s), and then
Precautions for Disassembling take the appropriate measures to remove it.
 Orderly arrange disassembled parts. Mark and tag
 Clean the Machine
them if necessary.
Thoroughly wash the machine before bringing it
 Store common parts, such as bolts and nuts with
into the shop. Bringing a dirty machine into the shop
reference to where they are to be used and in a
may cause machine components to be contaminated
manner that will prevent loss.
during disassembling / assembling, resulting in
 Inspect the contact or sliding surfaces of
damage to machine components as well as decreased
disassembled parts for abnormal wear, sticking, or
efficiency in service work.
other damage.
 Measure and record the degree of wear and
 Inspect the Machine
clearances.
Be sure to thoroughly understand all disassembling
/ assembling procedures beforehand to help avoid
 Precautions for Assembling
incorrect disassembling of components as well as
 Be sure to clean all parts and inspect them for any
personal injury.
damage. If any damage is found, repair or replace
Check and record the items listed below to prevent
part.
problems from occurring in the future.
 Dirt or debris on the contact or sliding surfaces may
 The machine model, machine serial number, and
shorten the service life of the machine. Take care not
hour meter reading.
to contaminate any contact or sliding surfaces.
 Reason for disassembly (symptoms, failed parts, and
 Apply appropriate lubricant oil to parts in order to
causes).
prevent them from seizing.
 Clogging of filters and oil, water, or air leaks, if any.
 Be sure to replace O-rings, backup rings, oil seals, and
Capacities and condition of lubricants.
floating seals with new ones once they have been
 Loose or damaged parts.
disassembled. Apply grease before installing.
 Be sure that liquid-gasket-applied surfaces are clean
 Prepare and Clean Tools and Disassembly Area
and dry.
Prepare the necessary tools to be used and the area for
 If an anti-corrosive agent has been used on a new
disassembling work.
part, be sure to thoroughly clean the part to remove
the agent.
Precautions for Disassembling and Assembling
 Fit the matching marks made when disassembling
 Precautions for Disassembling and assemble them.
 Cap the open ends in case the hoses and pipes have  Be sure to use the designated tools to assemble
been disconnected. In addition, attach identification bearings, bushings, and oil seals.
tags onto the connectors, hoses, and pipes for  Keep a record of the number of tools used for
assembling. disassembly / assembly. After assembling is
 Before disassembling, clean the exterior of the completed, count the number of tools so as to make
components and place on a workbench. sure that no forgotten tools remain in the assembled
 Drain hydraulic oil and gear oil from the hydraulic machine.
components and reduction gear.
 Be sure to provide appropriate containers for
draining fluids.
 Use matching marks for easier reassembling if
necessary.
 Be sure to use the specified special tools when
instructed.
W1-1-1-1
SECTION 1 GENERAL
Precautions for Using Floating Seal 1
1. In general, replace the floating seal with a new one

after disassembling.
If the floating seal is required to be reused, follow
these procedures:
 Keep seal rings together as a matched set with seal
ring (1) surfaces together. Apply oil to sliding surface
(e) of seal ring (1). W178-02-11-001
2
 Check sliding surface (e) of seal ring (1) for scuffing,
scoring, corrosion, deformation, or uneven wear.
Check the step part of seal ring (1).
 Check O-ring (2) for tears, breaks, deformation, or
hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following to prevent
trouble.
 Clean the floating seal and seal mounting bores with
cleaning solvent. a
Use a wire brush to remove mud, rust, or dirt from
seal mounting bores. After cleaning, thoroughly dry
parts with compressed air. c
 Clean seal ring (1) and O-ring (2) mounting bores. b
Check the bore surface for scuffing or scoring by
d
touching the surface with finger.
 After installing the floating seal, check that O-ring (2)
W178-02-11-002
is not twisted, and that it is installed correctly on seal
ring (1). a - Correct c - Twist of O-Ring
 After installing the floating seal, check that O-ring b - Incorrect d - Bend of O-Ring
(2) and seal ring sliding surface (e) is parallel with
seal mating surface (f ) by measuring the distances f
between (e) and (f ) at point (A) and (B), as illustrated.
If these distances differ, correct O-ring (2) seating. a A b A
B B
A=B A≠B
W178-02-11-003
a - Correct e - Sliding Surface

b - Incorrect f - Seal Mating Surface
W1-1-1-2
SECTION 1 GENERAL
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings a
safely.
 Attach protectors (soft material) on the corners of
the load so that the nylon sling does not directly
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
 Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If the temperature of the lifted
load is over 100 °C (212 °F), do not lift the load.
 Do not lift acid or alkali chemicals.
 Take care not to allow the sling to become wet. The W102-04-02-016
load may slip.
a - Correct Eyehole Lifting
 When required to use more than one sling, use slings
Method
with the same width and length to keep the lifted
load balanced. b
 When lifting a load using an eyehole, be sure to
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
 Avoid using twisted, bound, connected, or hitched
slings.
 Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
 When removing the slings from under the load, take
care not to damage the nylon slings. Avoid contact
with protrusions. W105-04-01-008
 Avoid dragging slings on the ground, throwing
slings, or pushing slings with a metal object. b - Incorrect Eyehole Lifting
Method
 When using with other types of slings (wire rope) or
accessories (shackle), protect the joint so that the
nylon sling is not damaged.
 Store the nylon slings indoors so that they won’t
deteriorate with heat, sun light, or chemicals.
c W162-01-01-009
c - Bent of Sling
W1-1-1-3
SECTION 1 GENERAL
dCAUTION: If a load is lifted with a damaged

nylon sling, serious personal injury may result.
Be sure to visually check the nylon sling for any
damage before using.
2. Before using a nylon sling, visually check the nylon

sling for any damage corresponding to following
examples. If any damage is found, cut and discard
the sling.
Even if no damage is found, do not use slings older
than 7 years.
Damaged Appearance a
a
W162-01-01-002 W162-01-01-006
e
a - Broken Sewing Thread a - Broken Sewing Thread e - Separation of Belt
b f
W162-01-01-003 W162-01-01-007
b
b - Scuffing b - Scuffing f - Scoring
c
c g
W162-01-01-004
W162-01-01-008
c - Fuzz d - Broken Sewing Thread
c - Fuzz g - Broken Warp
W162-01-01-005
a - Broken Sewing Thread
W1-1-1-4
SECTION 1 GENERAL
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies
adjusted to specification. Allowable errors will be
indicated if necessary.
“Allowable Limit”
1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is difficult after exceeding this
limit.
3. Repair or adjustment is impossible after exceeding
this limit.
Therefore, in consideration of operation efficiency
and maintenance expense, proper maintenance
shall be carried out before reaching the “Allowable
Limit”.
W1-1-1-5
SECTION 1 GENERAL
(Blank)
W1-1-1-6
SECTION 1 GENERAL
Group 2 Tightening
Tightening Bolts and Nuts
dCAUTION: Use tools appropriate for the work

to be done. Makeshift tools and procedures
can create safety hazards. For loosening and
tightening nuts and bolts, use correct size tools.
Otherwise, tightening tools may slip, potentially
causing personal injure.
fNOTE:
 Use penetrating oil to help loosen nut and bolts.

 Make sure bolt and nut threads are clean before

installing.
WDAA-01-02-001
Bolt Types
Tighten the nuts or bolts correctly to the torque
specifications.
As the different types and grades of bolt are used,
use and tighten the correct bolts correctly when
assembling the machine or components.
Specified Tightening Torque Chart

Tightening torque Wrench size
N·m (kgf·m) (lbf-ft) mm
Bolt Dia.
mm (in) Hexagon Flanged
Socket
Bolt Bolt
Bolt
(8~11T) (8T)
(11T) (8T) (4T)
6 (0.24) 3~4 (0.3~0.4) (2.2~3) 10 10 5
8 (0.31) 30 (3) (22) 20 (2) (14.8) 10 (1) (7.4) 13 12 6
10 (0.39) 65 (6.5) (48) 50 (5) (36.9) 20 (2) (14.8) 17 14 8
12 (0.47) 110 (11) (81) 90 (9) (66.4) 35 (3.5) (25.8) 19 17 10
14 (0.55) 180 (18) (133) 140 (14) (104) 55 (5.5) (40.6) 22 12
16 (0.63) 270 (27) (199) 210 (21) (155) 80 (8) (59) 24 22 14
18 (0.71) 400 (40) (295) 300 (30) (221) 120 (12) (88.5) 27 14
20 (0.79) 550 (55) (406) 400 (40) (295) 170 (17) (125) 30 27 17
22 (0.87) 750 (75) (553) 550 (55) (406) 220 (22) (162) 32
24 (0.94) 950 (95) (700) 700 (70) (516) 280 (28) (207) 36 32 19
27 (1.06) 1400 (140) (1033) 1050 (105) (774) 400 (40) (295) 41
30 (1.18) 1950 (195) (1438) 1450 (145) (1069) 550 (55) (406) 46
33 (1.30) 2600 (260) (1918) 1950 (195) (1438) 750 (75) (553) 50
36 (1.42) 3200 (320) (2360) 2450 (245) (1807) 950 (95) (700) 55
W1-2-1-1
SECTION 1 GENERAL
Group 2 Tightening
IMPORTANT: The following items are applied to both

fine and coarse pitch threads.
 Apply lubricant to the bolts and nuts in order
to reduce friction coefficient of them. (For
example, spindle oil with white zinc B dissolved
in it)
 Torque tolerance is ±10 %.
 Use the bolts of correct length. The bolts that
are too long cannot be tightened as the bolt tip
comes into contact with the bottom of bolt hole.
Also the bolts that are too short cannot develop
sufficient tightening force.
 The torque given in the chart on the previous
page are for general use only, however,
a different torque is given for a specific
application. Use the specified torque.
 Clean the nut and bolt threads and remove dirt
or corrosion before installing.
Tightening Order
When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
a b c
1 12 9 4 1 6 7 14
1, 4 6 3
4 5
2 13 8 5 2 3 10 11
2, 3
W105-01-01-003
a - Equally tighten upper and b - Tighten diagonally c - Tighten from center

lower alternately diagonally
W1-2-1-2
SECTION 1 GENERAL
Group 2 Tightening
Precautions for Spilt Flange

IMPORTANT:
Clean the sealing surfaces. Check if there are

any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
WDAA-01-02-005
O-ring.
Use only specified O-rings. Inspect O-rings for

any damage. Do not file the O-ring surfaces. Incorrect
When installing O-ring into a groove, use grease
in order to hold O-ring in place.
While tightening the bolt by hand, check that

flange is installed to the port correctly. Do not
pinch the O-ring.
Tighten the bolts up and down, right and left

alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
Do not use an impact wrench. It is difficult to

evenly tighten the bolts by using an impact
wrench. Using an impact wrench often causes
uneven tightening of bolts or damage to
O-rings.
Nut and Bolt Locking

W105-01-01-008
 Lock Plate
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice. Correct Incorrect
 Split Pin
IMPORTANT: Do not turn in the loosening direction
a b
in order to align the grooves and holes on the nut.
Always turn in the tightening direction. Do not
reuse the split pins. Correct Correct Incorrect
 Wire
IMPORTANT: Attach wires to bolts in the bolt-
tightening direction. Do not reuse the wires.
a
WDAA-01-02-007
a- Bend along edge sharply b- Do not bend it round
Correct Correct
Incorrect
Correct d Incorrect
c
WDAA-01-02-008
c- Tighten d- Loosen
W1-2-1-3
SECTION 1 GENERAL
Group 2 Tightening
Piping Joint
IMPORTANT:
 The torque given in table below are for general
use only, however, a different torque is given for
a specific application. Use the specified torque.
 Apply lubricant, such as the Grease Spray to
the bolts and nuts in order to reduce friction
coefficient of them.
 Torque tolerance is ±10 %.
 Slightly apply lubricant onto the threads first by
using the Grease Spray.
W1-2-1-4
SECTION 1 GENERAL
Group 2 Tightening
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1 4 3 5 2
 Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
and (5), possibly cracking the adapter. Tighten
union nut (3) to the specifications.
 Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint. Take
care not to damage them when connecting / a - Joint Body WDAA-01-02-009
a
disconnecting.
37 °
30 °
b c
b - Male Union Joint c - Female Union Joint

WDAA-01-02-010
Wrench Size Tightening Torque

Description (mm)
Union Nut N·m (kgf·m) (lbf·ft)
30° male 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (200)
55 380 (38) (280)
60 380 (38) (280)
37° female 17 25 (2.5) (18)
19 30 (3) (22)
22 40 (4) (30)
27 80 (8) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
fNOTE: Tightening torque of 37 ° male coupling without

union is similar to tightening torque of 37° female.
W1-2-1-5
SECTION 1 GENERAL
Group 2 Tightening
Pipe Joint
Pipe connection (metal joint)
(Union Nut Wrench Size: 17, 19, 22, 27)
Metal (3) of adapter (1) and pipe (2) seals pressure oil.
 Precautions for use

Do not damage sealing surfaces (4) and (5) when
disassembling and assembling. 1 4 5 3 2
Tightening Torque
Use the specified tightening torque in the table below.
Wrench Size 17 19 22 27
(mm)
N·m 25 30 40 80 M1M7-07-005
Tightening
(kgf·m) (2.5) (3) (4) (8)
Torque
(lbf·ft) (18) (22) (30) (59)
O-ring Seal Joint

O-ring (6) is installed against the end surface of adapter
(7) and seals pressure oil.
7 6 9
IMPORTANT:
Replace O-ring (6) with a new one when

reinstalling.
Before tightening union nut (9), confirm that

O-ring (6) is seated correctly in O-ring groove
(8). Tightening union nut (9) with O-ring (6)
displaced will damage O-ring (6), resulting in oil
leakage. 8 10 a
WDAA-01-02-011
Do not damage O-ring groove (8) of adapter (7)
 a - Joint Body
or sealing surface (10) on the hose side. Damage
to O-ring (6) may cause oil leakage.
If union nut (9) is found to be loose, causing
 Wrench Size
Tightening Torque
oil leakage, do not tighten it to stop the leak. (mm)
Instead, replace O-ring (6) with a new one, then Union Nut N·m (kgf·m) (lbf·ft)
tighten union nut (9) after confirming that 19 30 (3) (22)
O-ring (6) is securely seated in O-ring groove (8). 22 70 (7) (52)
27 95 (9.5) (70)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 350 (35) (260)
W1-2-1-6
SECTION 1 GENERAL
Group 2 Tightening
Quick Coupling
3 1
1. Coupling procedure
 Push socket ring (1) into plug (3) by rotating it fully
counterclockwise and then pulling it toward you.
 Release socket ring (1). Check that socket ring (1)
is returned by the spring force and the coupling is
locked completely by ball (2). At this time, check if
socket ring (1) is returned to the original position (to
M1M7-07-006
the rightmost direction). 2
2. Separating procedure
 Remove the hose by rotating socket ring (1) fully
counterclockwise and then pulling it. Because no
check function is attached inside, be careful that oil
flows out.
 Cap the removed hoses using special plug.
d CAUTION:
 When disconnecting, do not damage joint
surface.
 When disconnecting, clean the joint part and
thoroughly wipe off the cleaning solution to
prevent any foreign material from entering.
 Complete the joint disconnecting / connecting
procedure. Check enough if oil leaks especially
after installation.
 After installation, check if socket ring (1)
is returned to the original position (to the
rightmost direction).
W1-2-1-7
SECTION 1 GENERAL
Group 2 Tightening
Screw-In Connection R G
30°
Depending on types of screw and sealing, different
types of screw-in connection are used.
IMPORTANT: Check that the thread pitch and thread

type (tapered or straight) are the correct type
before using any screw-in connection. (In general, a b
the screw-in connection of male tapered thread is a - Male Tapered Thread b - Male Straight Thread
used except for measurement purpose.) W105-01-01-018

(mm) N·m (kgf·m, lbf·ft)
Joint Body FC material SS material
19 15 (1.5, 11) 35 (3.5, 26)
22 30 (3, 22) 50 (5, 37)
27 50 (5, 37) 95 (9.5, 70)
Seal Tape Application 36 70 (7, 52) 160 (16, 118)
Seal tape is used in order to seal clearances between 41 110 (11, 81) 200 (20, 148)
male and female threads so that any leaks between 50 160 (16, 118) 330 (33, 245)
threads may be prevented. Therefore, apply just 60 200 (20, 148)
enough seal tape to fill up thread clearances. Avoid lap
winding.
c
 Application Procedure
Check that the thread surface is clean and, free of dirt
or damage. Apply the seal tape around threads in order
d e
to leave one to two pitch threads uncovered. Wrap the W105-01-01-019
seal tape in the same direction as the threads.
c - Internal Thread e - Clearance
d - External Thread
f
Low-Pressure-Hose Clamp Tightening
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
T-Bolt Type Band Clamp:

4.5 N·m (0.45 kgf·m, 3.3 lbf·ft)
Worm Gear Type Band Clamp:

6 to 7 N·m (0.6 to 0.7 kgf·m, 4.4 to 5.2 lbf·ft)
f - Leave one to two pitch
M114-07-041
threads uncovered
g h
WDAA-01-02-012 M114-07-043
g - T-Bolt Type Band Clamp h - Worm Gear Type Band Clamp
W1-2-1-8
SECTION 1 GENERAL
Group 2 Tightening
Connecting Hose
dCAUTION: When replacing the hoses, use only

genuine Hitachi service parts. Using hoses other
Incorrect Correct
than genuine Hitachi hoses may cause oil leaks,

hose rupture or separation of fitting, possibly
resulting in a fire on the machine. Do not install
kinked hoses. Application of high oil pressure,
vibration, or an impact to a kinked hose may
result in oil leaks, hose rupture or separation of
fitting. Utilize the print marks on hoses when W105-01-01-011
installing in order to prevent hose from being
kinked. Take necessary measures to protect hoses
from rubbing against each other. If the hoses rub Incorrect a Correct
against each other, wear to the hoses may result
and lead to hose rupture. Take care so that the
hoses do not come into contact with the moving
parts or sharp objects.
W105-01-01-012
a - Rubbing Against Each Other
Incorrect Correct
b b
W105-01-01-013
a - Rubbing Against Each Other b - Clamp
Incorrect Correct
a
b
W105-01-01-014
a - Rubbing Against Each Other b - Clamp
W1-2-1-9
SECTION 1 GENERAL
Group 2 Tightening
(Blank)
W1-2-1-10
SECTION 1 GENERAL
Group 3 Painting
7 8 9
6
10
5
11
4
3 12
2
13
1
14
15
16
17
18
19
WNEK50-01-03-001
Surfaces to Be Painted Painting Colour

1 Lift Arm TAXI Yellow
2 Bell Crank (Lever) TAXI Yellow
3 Pipe High Grade Black
4 Bracket (Control Valve) High Grade Black
5 Bracket (Bucket Auto-Leveler) TAXI Yellow
6 Bucket Cylinder TAXI Yellow
7 Lift Arm Auto Leveler TAXI Yellow
8 Bracket (Pipe) TAXI Yellow
10 Pin (Lift Arm) TAXI Yellow
11 Pipe (Lift Arm Cylinder) High Grade Black
12 Pin (Lift Arm Cylinder) TAXI Yellow
13 Lift Arm Cylinder TAXI Yellow
14 Pin (Bucket Cylinder) TAXI Yellow
15 Pin (Bell Crank (Lever)) TAXI Yellow
16 Pin (Bucket Link) TAXI Yellow
17 Bucket Link TAXI Yellow
18 Bucket TAXI Yellow
19 Teeth TAXI Yellow
W1-3-1-1
SECTION 1 GENERAL
Group 3 Painting
8
2
5 WNEK50-01-03-002

1 Cab (Outside) High Grade Black
2 Plate Shining Silver
3 Rear Console (Inner) High Grade Black
4 Seat Bracket High Grade Black
5 Cab Under Cover High Grade Black
6 Cockpit High Grade Black
7 Side Console (Inner) High Grade Black
8 Cab (Inside) High Grade Black
W1-3-1-2
SECTION 1 GENERAL
Group 3 Painting
1 2 3 4 5 6 7 8 9
12
10 11
23
22
21
20 13
17
19
16 WNEK50-01-03-004
18
15
14 24

1 Horn Bracket TAXI Yellow
2 Light Bracket High Grade Black
3 Articulation Lock Bar Scarlet Red
4 Hydraulic Oil Tank High Grade Black
5 Cap High Grade Black
6 Filter Cover High Grade Black
7 Engine cover Heat-Resistant Black
8 Cover Heat-Resistant Black
9 Pipe (Rain Cap) High Grade Black
10 Cover TAXI Yellow
11 Rear Cover TAXI Yellow
12 Cover TAXI Yellow
13 Rear Grill High Grade Black
14 Bracket (Combination Light) High Grade Black
15 Side Cover (Rear) High Grade Black
16 Plate High Grade Black
17 Handle High Grade Black
18 Side Cover (Front) TAXI Yellow
19 Lower Cover TAXI Yellow
21 Pipe Guard High Grade Black
22 Steering Cylinder TAXI Yellow
23 Pin (Steering Cylinder) TAXI Yellow
24 Corner Cover TAXI Yellow
W1-3-1-3
SECTION 1 GENERAL
Group 3 Painting
2 5
3 6 13
7
14
15
10 1
12 11
85Z7BW-01-03-01

1 Step High Grade Black
2 Battery Box TAXI Yellow
3 Rear Fender (Front) High Grade Black
4 Tool Box TAXI Yellow
5 Handrail High Grade Black
6 Rear Fender (Front) (Cover) Do not paint it.
7 DEF Tank Box TAXI Yellow
8 Step (Rear) High Grade Black
9 Deck High Grade Black
10 Step (Front) High Grade Black
11 Front Fender (Cover) Do not paint it.
12 Front Fender TAXI Yellow
13 Front Cover TAXI Yellow
14 Rear Fender (Rear) Do not paint it.
15 Bracket (Rear Fender (Rear)) High Grade Black
16 Bracket (Mud Guard) High Grade Black
W1-3-1-4
SECTION 1 GENERAL
Group 3 Painting
3 4
2
5
1
6
12
7
WNEK50-01-03-006
11 10

1 Front Frame TAXI Yellow
2 Plate High Grade Black
3 Support (Real Axle) High Grade Black
4 Pin High Grade Black
5 Counterweight TAXI Yellow
6 Fuel Tank TAXI Yellow
7 Rear Axle Refer to W1-3-1-8.
8 Inspection Cover TAXI Yellow
9 Rear Frame TAXI Yellow
10 Front Axle Refer to W1-3-1-9.
11 Guard High Grade Black
12 Under Guard High Grade Black
W1-3-1-5
SECTION 1 GENERAL
Group 3 Painting
WNEK50-01-03-003

1 Rim TAXI Yellow
W1-3-1-6
SECTION 1 GENERAL
Group 3 Painting
1 A 2 3 2
6 C 5 4 WNEC-01-03-007
View A 7 View C
WNEC-01-03-008
View B 8
WNEC-01-03-010
WNEC-01-03-009

1 Rear Axle High Grade Black
2 Rim (Wheel) Mounting Part (Shaded Area) Do not paint it.
3 Axle End and Rim (Wheel) TAXI Yellow
4 Boss Part (Shaded Area) Do not paint it.
5 Boss Part (Shaded Area) Do not paint it.
6 Flange Part (Shaded Area) Do not paint it.
7 Name Plate Do not paint it.
8 End of Boss Part (Shaded Area) Do not paint it.
W1-3-1-7
SECTION 1 GENERAL
Group 3 Painting
1 2 1 3 4
6 5 A WNEC-01-03-011
View A
7 8
WNEC-01-03-012

1 Rim (Wheel) Mounting Part (Shaded Area) Do not paint it.
2 Axle End and Rim (Wheel) TAXI Yellow
3 Front Axle High Grade Black
4 Axle Mounting Part (Shaded Area) Do not paint it.
5 Flange Part (Shaded Area) Do not paint it.
6 Name Plate Do not paint it.
7 Nut Surface (Shaded Area) Do not paint it.
8 Connector Do not paint it.
W1-3-1-8
SECTION 1 GENERAL
Bleed Air from the Hydraulic System.

Bleed air from the hydraulic system as follows when
hydraulic oil has been drawn, the suction filter and
suction pipe have been replaced, or the pump device and
cylinders have been removed/installed.
IMPORTANT: If air is accumulated inside of the pump IMPORTANT: If air is accumulated inside of the
and if the engine starts in lacking of hydraulic oil, cylinder and if the cylinder is operated suddenly
the pump may be damaged. in lacking of hydraulic oil, the seal may be
 Bleeding Air from Pump damaged or the cylinder may seize.
1. Remove reducer (1) with the bleeder valve on top of  Bleeding Air from Hydraulic Circuit
the pump. Add hydraulic oil to the pump. 1. After refilling hydraulic oil, start the engine. Operate
each cylinder several times evenly. Slowly start
j : 41 mm each operation. At this time, never fully stroke the
2. After filling hydraulic oil in the pump, install reducer cylinders during initial operation stage.
(1) with the bleeder valve. 2. As the pilot circuit has an air bleed device, air in the
j : 41 mm pilot circuit will be bled while performing the above
operation.
m : 80 N·m (59 lbf·ft) 3. Reset the front attachment in position for checking
hydraulic oil level.
4. Stop the engine. Check hydraulic oil level. Add
hydraulic oil if necessary.
1
WNEK50-03-08-014
W1-4-1-1
SECTION 1 GENERAL
Bleed Air from the Fuel System

IMPORTANT: Air in the fuel system may make the
engine hard to start or make it run irregularly. 1
After running the fuel tank dry, draining water
from fuel filter or fuel pre-filter (a) or replacing
the fuel filter, be sure to bleed the air from the fuel
system.
1. Loosen air bleed plug (1), operate feed pump (2)

until no air bubble is observed in the fuel from the
air bleed plug.
2. After no air bubble is spouted from air bleed plug
(1), tighten air bleed plug (1) and operate the feed
b
pump (2) until it becomes difficult to move.
3. Once the feed pump (2) becomes difficult to move, 2
push the disk part of feed pump (2) back to the a
original position.
4. Start the engine. Check the fuel system for fuel 85Z7BW-01-04-01
leaks.
a- Pre-Filter b- Main Filter
W1-4-1-2
SECTION 1 GENERAL
Bleeding Air from Brake (Axle)
dCAUTION: If air is mixed in the service brake

circuit, the brake function is reduced and serious
hazard may occur. Bleed air from the service brake
system after removing and installing the pipe 1, 2
lines and changing hydraulic oil. 1, 2
fNOTE: Perform this work on all wheels (4 places) by two

or more persons. Air bleeder (1) is located around the
center on the front and rear axles. T4GB-05-04-004
1. Set the parking brake switch of front console to the

ON position, start the engine, and increases service
brake oil pressure.
2. Remove cap (2) of air bleeder (1). Insert one side of 3
clear vinyl tube (3) into air bleeder (1) and insert the 1
other side into container (4) to prevent hydraulic oil
from scattering.
3. Depress brake pedal (5) several times. Loosen air
bleeder (1) for 1/2 to 1 turn to drain hydraulic oil oil
while depressing brake pedal (4). 4
j : 10 mm
4. After draining hydraulic oil, tighten air bleeder (1),
and then return brake pedal (5). T4GB-05-04-005
5. Repeat steps 3 to 4 until flesh hydraulic oil without

no air bobbles flows out in vinyl tube (3).
6. When no air bobbles are observed in vinyl tube (3),
tighten air bleeder (1) while depressing brake pedal
(5).
j : 10 mm
m : 10 N·m (7.4 lbf·ft)

7. Bleed air at other 2 places in the same way as step 3
to step 6.
dCAUTION: After completing above air bleeding

procedures at 4 places, repeat the same procedure 5
T4GB-05-04-006
at 4 places again to ensure that air is completely
bled.
W1-4-1-3
SECTION 1 GENERAL
(Blank)
W1-4-1-4
SECTION 1 GENERAL
Group 5 Preparation
Preparations for Inspection and Maintenance

1 2
dCAUTION: Components, hydraulic oil, lubricant,
and coolant just after operation are too hot. Wait
until they cool. Then, start the work.
dCAUTION: If ride control switch (2) is in the AUTO

position, the lift arm may unexpectedly rise. Set
ride control switch (2) to the OFF position. Caution
that accident may occur due to an unexpected lift
arm movement.
dCAUTION: If the machine is unexpectedly moved,

a serious accident may result. Be sure to apply the
parking brake when parking the machine.
Securing work place and work staffs MNEC-07-001
Before starting work, park the machine in a firm and large

space, keep bystanders clear of the machine. Slowly move
the front attachment. Secure work staffs for the work. 3 4 5 6
When using a signal person, coordinate hand signals
before starting.
Inspection and Maintenance Position

Unless otherwise specified, set machine for inspection
and maintenance position as described below before
starting work.
1. Park the machine on a level and solid surface.

2. Lower the working device such as bucket to the
ground. MNEC-01-036
3. Set the control lever lock switch to the lock position.

4. Turn ride control switch (2) OFF.
4
5. Set forward/reverse lever (3) to the neutral N
position. Set neutral lever lock (5) to the LOCK
position.
6. Apply the parking brake. (Turn parking brake (4)
ON.)
7. Secure the tires.
MNEC-01-058
8. Run the engine at slow idle speed without load for
five minutes.
W1-5-1-1
SECTION 1 GENERAL
Group 5 Preparation
9. Turn key switch (6) to the OFF position. Stop the

engine. Remove the key. 6
10. Before performing any work on the machine, attach
tag (Inspection and Maintenance) on the door or
front attachment control lever.
MNEC-01-036
W1-5-1-2
SECTION 1 GENERAL
Group 5 Preparation
Lock Frames
dCAUTION: Before beginning to work near the

frame center hinge (4), install articulation lock
5
bar (2) to securely lock and prohibit movement
between the front and rear frames. Avoid
accidents due to unexpected movement of the
machine.
1. Align the front and rear frame centers with each 1

other.
2. Remove β-form pin (4) and remove set pin (5) from
the rear frame hole. 4 3
2
3. Rotate articulation lock bar (3) to align it with the
front frame hole (1). 85Z7BW-01-05-01
4. Install set pin (5) into the front frame hole (1) and
the articulation lock bar (3) tip end hole. Install
β-form pin (4). Secure articulation lock bar (3) in the
specified position.
4
3
85Z7BW-01-05-02
W1-5-1-3
SECTION 1 GENERAL
Group 5 Preparation
dCAUTION: Never attempt to maintain the

machine when the engine is running in order to
prevent the accident. If maintenance work while
engine running is unavoidable, strictly comply
with the following items.
 One person should take the operator's seat
to be ready to stop the engine any time while
communicating with other workers.
 When working around moving parts is
unavoidable, pay special attention to ensure
that hands, feet, and clothing do not become SA-2294
entangled.
 If parts or tools are dropped or inserted into
the fan or the belt, they may fly off or be cut off.
Do not drop or insert parts and tools into the
moving parts.
 Set pilot control shut-off lever (1) to the LOCK
position so that the front attachment will not
move.
 Never touch the control levers and pedals.
If operating the control levers or pedals is
unavoidable, signal co-workers to evacuate to
safer place.
SA-026
MNEC-07-001
W1-5-1-4
SECTION 1 GENERAL
Group 5 Preparation
Inspection and Maintenance Position (Lift Arm

Raise)
2
d CAUTION: Support the lift arm by using a solid
support for inspection and maintenance with the
3
lift arm raised. Take care that due to lowering the

lift arm may result in the accidents.
Set the machine position for inspection and maintenance 1

in the same way as the previous procedures other than
following procedures. (Refer to W1-5-1-1.)
1. Raise lift arm (3) and dump bucket (2).

WNEC-01-06-001
2. Support lift arms (3) (both sides) certainly by using
solid support (1).
3. Set control lever lock switch (4) to the lock position. 4
4. Turn the key switch OFF to stop the engine. Remove
the key.
MNEC-07-001
W1-5-1-5
SECTION 1 GENERAL
Group 5 Preparation
Releasing Pressure from Front Attachment

Hydraulic Circuit
Release any remaining pressure by following the 1
procedures below when removing and installing the front
attachment.

five minutes.
2. Turn the key switch OFF to stop the engine.
3. Turn the key switch to the ON position again. Set
control lever lock switch (1) to the UNLOCK (b)
position.
4. With the key switch in the ON position, operate the
control lever 4 to 5 times in order to release any
pressure from the hydraulic circuit.
5. Return control lever lock switch (1) to the LOCK (a) MNEC-07-001
position.
6. Turn the key switch OFF.
MNEC-01-015
a- LOCK position b- UNLOCK position
W1-5-1-6
SECTION 1 GENERAL
Group 5 Preparation
Releasing Pressure from Ride Control

Accumulator
1
Release any remaining pressure as follows before
removing and installing the ride control accumulator.
1. Set the machine position (lift arm raise) for

inspection and maintenance. (Refer to W1-5-1-5.)
2. Release any pressure in the front attachment
hydraulic circuit. (Refer to W1-5-1-6.)
3. Release any pressure from the hydraulic oil tank.
(Refer to W1-5-1-9.)
4. Remove front cover (1). (Refer to W3-22-1.)
WNEC-04-08-003
5. Loosen lock nut (6) of control valve (2).
j : 13 mm 2
6. Loosen plug (3) by one turn and release any
remaining pressure. Tighten plug (3).
l : 4 mm
m : 7 N·m (5.2 lbf·ft) a
7. Tighten lock nut (4). A A
j : 13 mm
m : 10 N·m (7.4 lbf·ft)
a- Vehicle Front Side

TNED-03-02-003
Section A-A
4
3
TNED-03-02-007
W1-5-1-7
SECTION 1 GENERAL
Group 5 Preparation
Releasing Pressure from Parking Brake

Accumulator
Release any remaining pressure as follows before 1 4 2
removing/installing the parking brake accumulator.
1. Park the machine on a level and solid surface.

2. Lower the working device such as bucket to the
ground.
five minutes.
4. Turn key switch (2) to the OFF position. Stop the
engine.
5. Depress brake pedal (3) at least 50 times to release
pressure from the service brake circuit. 3 MNEC-01-036
6. Turn key switch (2) to the ON position again. Turn

parking brake switch (1) ON and OFF at least 50
times to release pressure from the parking brake 1
circuit.
7. Turn parking brake switch (1) to ON position (b).
Turn the key switch OFF.
fNOTE: The service brake primary pressure and parking

brake pressure can be monitored by using the service
menu of monitor (4). (Refer to T5-2 in the separated
volume, Technical Manual.)
a b MNEC-01-058
a- OFF Position b- ON Position
W1-5-1-8
SECTION 1 GENERAL
Group 5 Preparation
Releasing Pressure from Hydraulic Oil Tank
dCAUTION: Escaping fluid under pressure may

penetrate the skin and eyes, and cause serious
injury. Release pressure before disconnecting the
hydraulic piping or removing other equipment.
Hot hydraulic oil just after operation may spout
out and cause severe burns. Allow oil to cool
before starting any work.
Preparation
1. Park the machine on a solid and level surface.
Set the machine position for inspection and
maintenance. (Refer to W1-5-1-1.)
1 2 3
2. Stop the engine. Push air bleed button (1) of
hydraulic oil tank (3) and bleed air from hydraulic oil
tank (3).
fNOTE: When installing and operating vacuum pump

(a) to the position where cap (2) has been removed, W1R7-01-04-001
hydraulic oil tank becomes negative. This prevents
hydraulic oil from flowing out when disconnecting
hoses. Operate vacuum pump (a) continuously while
working. a
W1R7-01-04-002
a- Vacuum Pump
b- Hose
c- Adapter
W1-5-1-9
SECTION 1 GENERAL
Group 5 Preparation
Releasing Pressure from Reserve Tank
dCAUTION: Do not loosen the radiator cap until

the system has cooled. Hot steam may spout out,
possibly causing severe burns. Wait until coolant
cools and loosen the cap slowly. Release all
pressure and remove the cap.
Preparation
1. Park the machine on a solid and level surface. 1
Set the machine position for inspection and
maintenance. (Refer to W1-5-1-1.)
2. Remove cap (1).
3. Stop the engine. Remove cap (2) from reserve tank
(3).
85Z7BW-01-05-03
2
85Z7BW-01-05-04
W1-5-1-10
MEMO
MEMO
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Group 1 Body
Center Hinge....................................................................W2-1-1-1
Pilot Valve (Two Lever Type ).......................................W2-1-2-1
Group 2 Front Attachment
Pin and Bushing...............................................................W2-2-1-1
Standard Dimensions for Lift Arm and Bucket.....W2-2-2-1
Cylinder..............................................................................W2-2-3-1
NEM50W-2-1
(Blank)
NEM50W-2-2
SECTION 2 MAINTENANCE STANDARD
Group 1 Body
Center Hinge
 Upper Hinge Part (A)  Lower Hinge Part (B)
4 5
4 5
6
a 6
a
85Z7BW-02-01-01 85Z7BW-02-01-02
Unit: mm (in)
Part Name Standard (a) Allowable Limit (a) Remedy
A Pin (1) 85 (3.35) 84.0 (3.30) Replace
Bushings (2), (3) 85 (3.35) 86.5 (3.40)
B Pin (4) 85 (3.35) 84.0 (3.30)
Bushings (5), (6) 85 (3.35) 86.5 (3.40)
W2-1-1-1
Group 1 Body
(Blank)
W2-1-1-2
Group 1 Body
Pilot Valve (Two Lever Type )
1 2
5
9
WNEC-02-01-003
1- Cam Shaft (2 Used) 4- Screw (4 Used) 7- Push Rod (4 Used)

2- Bushing (4 Used) 5- Bushing (4 Used) 8- Spool (4 Used)
3- Lever (2 Used) 6- Push Rod (3 Used) 9- Push Rod
W2-1-2-1
Group 1 Body
1. Spool (8) diameter

Difference between diameter of non-sliding part (a)
and sliding part (b) 8
a-b Unit: mm (in)
Allowable Limit
0.01 (0.0004)
fNOTE: In case the value is beyond the allowable limit,

replace the pilot valve assembly.
W4GB-02-06-016
2. Push Rods (6, 9, and 7) length 6, 9
Unit: mm (in)
Standard Allowable Limit c
c 87.7 (3.45) 86.7 (3.41)
d 36 (1.42) 36 (1.42) 7
d W4GB-02-06-017
3. Bushing (5) inner diameter

5
Unit: mm (in)
Standard Allowable Limit
8 (0.32) 8.5 (0.34) e
fNOTE: When the bushing in the sub assembly of W4GD-02-08-001

solenoid is worn away, replace the solenoid valve
assembly.
4. Looseness in the control part

When looseness on the upper end of lever (3) is 2
mm (0.08 in) or more due to the wear of screw (4),
cam shaft (1) or busing (2), replace the solenoid
valve assembly.
W2-1-2-2
Pin and Bushing

1
E F
D
a
C
G
H
1- Pin WNEC-02-03-001
B I
2
A W4GB-04-01-008
2- Bushing WNEC-02-03-002
Unit: mm (in)
Part Name Standard (a) Allowable Limit (a) Remedy
A Pin 85 (3.35) 84.0 (3.31) Replace
Bushing (Lift Arm) 85 (3.35) 86.5 (3.41)
B Pin 85 (3.35) 84.0 (3.31)
Bushing (Bucket Link) 85 (3.35) 86.5 (3.41)
C Pin 115 (4.53) 114.0 (4.49)
Bushing (Bell Crank) 115 (4.53) 116.5 (4.59)
D Pin 100 (3.94) 99.0 (3.90)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00)
E Pin 100 (3.94) 99.0 (3.90)
Bushing (Bucket Cylinder) 100 (3.94) 101.5 (4.00)
F Pin 100 (3.94) 99.0 (3.90)
Bushing (Lift Arm) 100 (3.94) 101.5 (4.00)
G Pin 100 (3.94) 99.0 (3.90)
Bushing (Lift Arm Cylinder) 100 (3.94) 101.5 (4.00)
H Pin 100 (3.94) 99.0 (3.90)
Bushing (Lift Arm Cylinder) 100 (3.94) 101.5 (4.00)
I Pin 85 (3.35) 84.0 (3.31)
Bushing (Bucket Link) 85 (3.35) 86.5 (3.41)
W2-2-1-1
(Blank)
W2-2-1-2
Standard Dimensions for Lift Arm and Bucket

1 2
i d
b
a
e
f c
WNEC-02-03-003
1- Bucket 2- Lift Arm
Unit: mm (in)
Dimensions
a 100 (3.94)
b 100 (3.94)
c 972 (38.3)
d 124 (4.88)
e 128 (5.04)
f 128 (5.04)
g 290 (11.4)
h 403 (15.9)
i 30 (1.18)
W2-2-2-1
(Blank)
W2-2-2-2
Cylinder
Rod Rod Bend and Run Out
b
a
A
W166-04-02-022
c d
W105-04-02-094 a- Cylinder Rod c- V Block
b- Dial Gauge d- 1 m (39.4 in)
Unit: mm (in)
Cylinder Name Recommended Size After Re- Bend Run Out Remedy
manufacturing (A) 0.5 mm/1 m 1.0 mm/1 m Replace
Lift Arm 85-0.012-0.027 (3.35-0.0005-0.0010) (0.020 in/39.4 in) (0.039 in/39.4 in)
Bucket 100-0.012-0.027 (3.94-0.0005-0.0010)
Steering 45-0.009-0.020 (1.78-0.0004-0.0008) IMPORTANT: When measuring the items, bend and
run out of the cylinder rod, the distance (d) may
not be able to keep 1 m (39.4 in). In this case, the
distance (d) of measurement is the full length of
the rod.
W2-2-3-1
(Blank)
W2-2-3-2
MEMO
MEMO
SECTION 3
BODY
CONTENTS
Group 1 Cab Assembly of Pilot Valve (Two Lever Type)........... W3-10-4-7
Removal and Installation of Cab...............................W3-1-1-1
Group 11 Brake Charge Valve
Group 2 Counterweight Removal and Installation of Brake Charge
Removal and Installation of Counterweight.........W3-2-1-1 Valve ........................................................................... W3-11-1-1
Structure of Brake Charge Valve ............................ W3-11-2-1
Group 3 Center Hinge Removal and Installation of Brake
Removal and Installation of Center Hinge.............W3-3-1-1 Accumulator............................................................. W3-11-3-1
Group 4 Engine Group 12 Manifold Valve
Removal and Installation of Engine.........................W3-4-1-1 Removal and Installation of Manifold Valve....... W3-12-1-1
Group 5 Radiator Assembly Disassembly of Manifold Valve............................... W3-12-2-1
Removal and Installation of Radiator Assembly of Manifold Valve..................................... W3-12-2-4
Assembly......................................................................W3-5-1-1 Group 13 Solenoid Valve
Group 6 Hydraulic Oil Tank Removal and Installation of 2-Spool Solenoid
Removal and Installation of Hydraulic Oil Valve Unit.................................................................. W3-13-1-1
Tank................................................................................W3-6-1-1 Structure of 2-Spool Solenoid Valve Unit............ W3-13-2-1
Removal and Installation of Parking Brake
Group 7 Fuel Tank Solenoid Valve Unit................................................ W3-13-3-1
Removal and Installation of Fuel Tank.....................W3-7-1-1 Structure of Parking Brake Solenoid Valve
Unit.............................................................................. W3-13-4-1
Group 8 Pump Device Structure of Parking Brake Solenoid Valve......... W3-13-5-1
Removal and Installation of Pump Device.............W3-8-1-1
Disassembly of Pump Device.....................................W3-8-2-1 Group 14 Flow Regulator Valve
Assembly of Pump Device...........................................W3-8-2-3 Removal and Installation of Flow Regulator
Disassembly of Main Pump.........................................W3-8-3-1 Valve............................................................................ W3-14-1-1
Assembly of Main Pump...............................................W3-8-3-5 Structure of Flow Regulator Valve......................... W3-14-2-1
Disassembly of Regulator............................................W3-8-4-1
Assembly of Regulator..................................................W3-8-4-3 Group 15 Cooling Fan System
Disassembly of Priority Valve......................................W3-8-5-1 Removal and Installation of Fan Valve.................. W3-15-1-1
Assembly of Priority Valve...........................................W3-8-5-3 Structure of Fan Valve................................................. W3-15-2-1
Structure of Pilot Pump................................................W3-8-6-1 Removal and Installation of Fan Motor................ W3-15-3-1
Structure of Fan Motor............................................... W3-15-4-1
Group 9 Control Valve Removal and Installation of Pilot Pump.............. W3-15-5-1
Removal and Installation of Control Valve.............W3-9-1-1 Disassembly of Pilot Pump....................................... W3-15-6-1
Disassembly of Control Valve.....................................W3-9-2-1 Assembly of Pilot Pump............................................. W3-15-6-3
Assembly of Control Valve...........................................W3-9-2-8
Group 16 Ride Control Accumulator
Group 10 Pilot Valve Removal and Installation of Ride Control
Removal and Installation of Pilot Valve Accumulator............................................................. W3-16-1-1
(Single Lever Type)................................................. W3-10-1-1
Removal and Installation of Pilot Valve Group 17 Battery Disconnect Switch
(Two Lever Type)..................................................... W3-10-2-1 Removal and Installation of Battery
Disassembly of Pilot Valve Disconnect Switch................................................. W3-17-1-1
(Single Lever Type)................................................. W3-10-3-1 Group 18 Aftertreatment Device
Assembly of Pilot Valve (Single Lever Type)....... W3-10-3-4 Removal and Installation of Aftertreatment
Disassembly of Pilot Valve (Two Lever Type)...... W3-10-4-1 Device......................................................................... W3-18-1-1
NEM50W-3-1
Group 19 DEF Tank
Removal and Installation of DEF Tank.................. W3-19-1-1
Group 20 Coolant Control Valve
Removal and Installation of Coolant Control
Valve............................................................................ W3-20-1-1
Group 21 DEF Supply Module
Removal and Installation of DEF Supply
Module....................................................................... W3-21-1-1
Group 22 Exterior Components
Removal and Installation of Exterior
Components............................................................ W3-22-1-1
NEM50W-3-2
SECTION 3 BODY
Group 1 Cab
Removal and Installation of Cab
2, 3
1
WNEK50-03-06-001

dCAUTION: Operate the steering wheel to the
right and left several times, and release any
injury. Release the pressure before disconnecting pressure in the circuit.
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation dCAUTION: Operate the brake pedal more than 50
times and release any pressure in the circuit.
may spout out and cause severe burns. Allow oil to
cool before starting any work. dCAUTION: Release any pressure from hydraulic
oil tank (1). (Refer to W1-5-1.)
IMPORTANT: The hoses and pipes contain hydraulic
oil. When removing the hoses and pipes, receive 2. Remove bolts, washers (4) (6 used). Remove the
oil with a container in order to avoid spilling oil. cover (2) assembly and O-ring (3).
IMPORTANT: Cap the open ends in case the hoses
j : 17 mm
and pipes have been disconnected. In addition,
attach identification tags onto the connectors,
hoses, and pipes for assembling. If the clips which 3. Place a container. Drain off hydraulic oil by using an
secure the hoses have been removed, install the oil feed pump.
clips after connecting the hoses.
fNOTE: Total oil amount of hydraulic oil tank (1): 174 L
(46 US gal)
Removal
1. Set the machine position for inspection and
maintenance. (Refer to W1-5-1.)
W3-1-1-1
SECTION 3 BODY
Group 1 Cab
2
1
OFF
ON
a
85Z7BW-03-01-01
a- Battery Box
4. 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 (b).
5. Set battery disconnect switch (2) to OFF position.
W3-1-1-2
SECTION 3 BODY
Group 1 Cab
1
3
85Z7BW-03-01-02 85Z7BW-03-01-03
6. Release any pressure in the the reserve tank. (Refer

to W1-5-1.)
7. Open side covers (front) (1) at left and right sides.
8. Place a container under hose (2). Loosen cock (3).

Drain off coolant. Close cock (3).
fNOTE: Amount of coolant: 33 L (3.7 US gal)
9. Release refrigerant of the air conditioner. (Refer to

T5-7 in the separated volume, Technical Manual.)
W3-1-1-3
SECTION 3 BODY
Group 1 Cab
10
11, 13
8, 9 11, 12
1 2 3 4 5 6
85Z7BW-03-01-04
6 7 3 85Z7BW-03-01-05
10. Remove the following parts at the right and left 12. Disconnect connectors (8, 9) and window washer
sides. (Refer to W3-22-1.) fluid tube (10). Remove bolts with washers (11) (2
used) and clips (12, 13) and remove deck (2).
 Step (3)
 Rear Fender (Front) (5) j : 17 mm
 Lower Cover (6)

11. Remove the following parts. (Refer to W3-22-1.)
 Cab Under Cover (1) (including the floorboard)
 Inspection Cover (4, 7)
W3-1-1-4
SECTION 3 BODY
Group 1 Cab
2, 3 85Z7BW-03-01-06
13. Remove bolts, washers (1) (4 used). Remove rubber

plate (2) and bracket (3).
j : 17 mm
W3-1-1-5
SECTION 3 BODY
Group 1 Cab
Detail A
7 5 8
2
3
a 4
A 6 1
85Z7BW-03-01-07 85Z7BW-03-01-08
a- Flow Regulator Valve
14. Disconnect hoses (1, 2, 3, 4). 16. Disconnect hose (8).

j : 19 mm j : 22 mm
15. Disconnect connectors (5, 6, 7).
W3-1-1-6
SECTION 3 BODY
Group 1 Cab
Detail A
A 85Z7BW-03-01-09 85Z7BW-03-01-10
a- Suction Pipe b- Flow Regulator Valve
17. Disconnect hose (1).
j : 27 mm
W3-1-1-7
SECTION 3 BODY
Group 1 Cab
Detail A 1
2
b
3
4, 5
a
1 2
6 7
85Z7BW-03-01-12
Detail B
9
8
A B 8
85Z7BW-03-01-11
a- Machine Front Side b- Cab
18. Remove bolt, washer (4) and clip (5).

85Z7BW-03-01-13
j : 17 mm
19. Disconnect connectors (1, 2) and connectors (3) (2

used).
20. Remove bolt, washer (6). Remove bracket (7).
j : 17 mm
21. Disconnect connectors (8) (2 used). Remove bolts,

washers (9) (2 used),and remove connectors (8) (2
used).
W3-1-1-8
SECTION 3 BODY
Group 1 Cab
85Z7BW-03-01-14
a- Machine Front Side
j : 27 mm
W3-1-1-9
SECTION 3 BODY
Group 1 Cab
3
4
2
5
6 4
3
1 3
85Z7BW-03-01-16 85Z7BW-03-01-17
23. Disconnect hose (1). 25. Loosen clamps (2) (2 used). Disconnect hoses (3) (2
used).
j : 22 mm
j : 8 mm
24. Remove bolt, washer (4), and clip (5).
j : 17 mm
j : 19 mm
W3-1-1-10
SECTION 3 BODY
Group 1 Cab
7, 8
9, 10
85Z7BW-03-01-15
27. Disconnect hose (7). Remove O-ring (8) from hose

(7).
j : 27 mm
28. Disconnect hose (9). Remove O-ring (10) from hose

(9).
j : 19 mm
W3-1-1-11
SECTION 3 BODY
Group 1 Cab
1, 2
a
85Z7BW-03-01-21 3 85Z7BW-03-01-20
a- Transmission Oil Filler Port
29. Remove bolts, washers (2) (2 used), and clips (1) (2 30. Disconnect hoses (3) (2 used).
used).
j : 22 mm
j : 17 mm
W3-1-1-12
SECTION 3 BODY
Group 1 Cab
View A
2
a
A
1
85Z7BW-03-01-19
1 85Z7BW-03-01-18

4, 5
j : 27 mm
85Z7BW-03-01-22
32. Disconnect hoses (2, 3).
j : 19 mm
fNOTE: Access the hoses from the maintenance hole

inside the cab (a).
33. Remove bolts, washers (4) (2 ued) and clips (5) (2

used).
j : 17 mm
34. Disconnect connector (6).
W3-1-1-13
SECTION 3 BODY
Group 1 Cab
1 2 c 3
b
a
a- Stop Valve (RH) c- Steering Pilot Valve 85Z7BW-03-01-23

b- Stop Valve (LH)
View A
j : 19 mm
j : 19 mm
j : 19 mm 5
85Z7BW-03-01-24
38. Remove bolt, washer (4) and cable (5).
j : 17 mm
W3-1-1-14
SECTION 3 BODY
Group 1 Cab
a
1
2
3 a
85Z7BW-03-01-25
a- Eyebolt Mounting Hole
39. Remove bolts (1) (4 used), washers (2) (4 used), and

plates (3) (4 used). dCAUTION:
(2540 lb)
The cab (4) assembly weight: 1150 kg
j : 24 mm 40. Install eyebolts (M16, Pitch 2 mm) (4 used) to

eyebolt mounting holes (a) (4 places) of the cab (4)
assembly. Attach nylon slings onto the eyebolts (4
used). Hoist and hold the cab (4) assembly.
W3-1-1-15
SECTION 3 BODY
Group 1 Cab
1 Detail A Detail B
a
B 9
1
1
A 3
a 4 2 a
6
2 5
7
8 13
WNEK50-03-01-030
10
11
14
12 15
85Z7BW-03-01-26 WNEK50-03-01-031
a- Rubber Cushion
41. Remove bolts (8) (2 used), plates (7) (2 used), and IMPORTANT: Do not allow the cab (1) assembly to
spacers (6) (2 used). come in contact with the front frame and hydraulic
oil tank when removing/installing the cab (1)
j : 46 mm assembly.
44. Remove the cab (1) assembly and washers (3, 13) (2
42. Remove bolts (9) (2 used), nuts (12) (2 used), plates used for each) from rear frame (2). Place the cab (1)
(11) (2 used), and spacers (10) (2 used). assembly on wooden blocks.
j : 46 mm
43. Remove nuts (5, 15) (2 used for each) and washers
(4, 14) (2 used for each).
j : 24 mm
W3-1-1-16
SECTION 3 BODY
Group 1 Cab
85Z7BW-03-01-25
a- Eyebolt Mounting Hole
Installation
dCAUTION:
(2540 lb)
The cab (1) assembly weight: 1150 kg
1. Install eyebolts (M16, Pitch 2 mm) (4 used) to

eyebolt mounting holes (a) (4 places) of the cab (1)
assembly. Attach nylon slings onto the eyebolts (4
used). Hoist the cab (1) assembly.
W3-1-1-17
SECTION 3 BODY
Group 1 Cab
1 Detail A Detail B
a
9
B 1
1
3
A
4 6 2 a
a
5
2 7
8 13
WNEK50-03-01-030
10
11
14
12 15
WNEK50-03-01-031
85Z7BW-03-01-26
a- Rubber Cushion
IMPORTANT: Do not allow the cab (1) assembly to 4. Install bolts (9) (2 used), spacers (10) (2 used), plates
come in contact with the front frame and hydraulic (11) (2 used), and nuts (12) (2 used).
oil tank when removing/installing the cab (1)
assembly. j : 46 mm
2. Install washers (3, 13) (2 used for each) and the cab m : 417 N·m (307 lbf·ft)
(1) assembly to rear frame (2).
5. Install spacers (6) (2 used), plates (7) (2 used), and
3. Install washers (4, 14) (2 used for each) and nuts (5, bolts (8) (2 used).
15) (2 used for each).
j : 46 mm
j : 24 mm
m : 417 N·m (307 lbf·ft)
m : 210 N·m (155 lbf·ft)
W3-1-1-18
SECTION 3 BODY
Group 1 Cab
1
2
3
85Z7BW-03-01-25
6. Install plates (3) (4 used), washers (2) (4 used), and

bolts (1) (4 used).
j : 24 mm
m : 80 N·m (59 lbf·ft)
W3-1-1-19
SECTION 3 BODY
Group 1 Cab
1 2 c 3
b
a
a- Stop Valve (RH) c- Steering Pilot Valve 85Z7BW-03-01-23

b- Stop Valve (LH)
View A
4
7. Connect hose (2).
j : 19 mm
m : 30 N·m (22 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)
5
85Z7BW-03-01-24
j : 19 mm
m : 30 N·m (22 lbf·ft)
10. Install cable (5) with bolts, washer (4).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-1-1-20
SECTION 3 BODY
Group 1 Cab
View A
2
a
A
3
C
1
85Z7BW-03-01-19
1 85Z7BW-03-01-18
7
IMPORTANT: Check the angle to install hose (1).
4, 5
j : 27 mm
m : 80 N·m (59 lbf·ft) 85Z7BW-03-01-22

View C 1
12. Connect hoses (2, 3).
j : 19 mm a
m : 30 N·m (22 lbf·ft)
13. Connect connector (6).
WNEK50-03-01-032
14. Secure connector (6) and harness (7) with clips (5) (2 a- 45°
used) and bolts, washers (4) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-1-1-21
SECTION 3 BODY
Group 1 Cab
1, 2
a
85Z7BW-03-01-21 3 85Z7BW-03-01-20
a- Transmission Oil Filler Port
15. Connect hoses (3) (2 used).
j : 22 mm
m : 40 N·m (29.5 lbf·ft)
16. Secure hoses (3) (2 used) with clips (1) (2 used), and
bolts, washers (2) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-1-1-22
SECTION 3 BODY
Group 1 Cab
7, 8
9, 10
85Z7BW-03-01-15
17. Apply ND-OIL8 to O-ring (10). Install O-ring (10) to 18. Apply ND-OIL8 to O-ring (8). Install O-ring (8) to
hose (9). Connect hose (9). hose (7). Connect hose (7).
j : 19 mm j : 27 mm
m : 11.8 to 14.7 N·m (8.7 to 10.8 lbf·ft) m : 29.4 to 34.3 N·m (21.7 to 25.3 lbf·ft)
19. Add compressor oil. (Refer to T5-7 in the separated

volume, Technical Manual.)
W3-1-1-23
SECTION 3 BODY
Group 1 Cab
3
4
2
5
6 4
3
1 3
85Z7BW-03-01-16 85Z7BW-03-01-17
20. Connect hose (1). 22. Secure hoses (3) (2 used) with clip (5), and bolt,
washer (4).
j : 19 mm
j : 17 mm
m : 30 N·m (22 lbf·ft)
m : 50 N·m (37 lbf·ft)
21. Connect hoses (3) (2 used) with clamps (2) (2 used).
j : 8 mm
j : 22 mm
m : 4.5 N·m (3.3 lbf·ft)
m : 40 N·m (29.5 lbf·ft)
W3-1-1-24
SECTION 3 BODY
Group 1 Cab
85Z7BW-03-01-14
j : 27 mm
m : 80 N·m (59 lbf·ft)
W3-1-1-25
SECTION 3 BODY
Group 1 Cab
Detail A 1
2
b
3
4, 5
a
1 2
6 7
85Z7BW-03-01-12
Detail B
9
8
A B 8
85Z7BW-03-01-11
a- Machine Front Side b- Cab
25. Install connectors (8) (2 used) with bolts, washers (9) 85Z7BW-03-01-13
(2 used). Connect connectors (8) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
26. Secure harness (10) with bracket (7) and bolt, 28. Secure harness (11) with clip (5) and bolt, washer
washer (6). (4).
j : 17 mm j : 17 mm
m : 50 N·m (37 lbf·ft) m : 50 N·m (37 lbf·ft)
27. Connect connectors (1, 2) and connectors (3) (2

used).
W3-1-1-26
SECTION 3 BODY
Group 1 Cab
Detail A
A 85Z7BW-03-01-09 85Z7BW-03-01-10
a- Suction Pipe b- Flow Regulator Valve
j : 27 mm
m : 80 N·m (59 lbf·ft)
W3-1-1-27
SECTION 3 BODY
Group 1 Cab
Detail A
7 5 8
2
3
a 4
A 6 1
85Z7BW-03-01-07 85Z7BW-03-01-08
a- Flow Regulator Valve
30. Connect hose (8). 31. Connect connectors (5, 6, 7).
j : 22 mm
32. Connect hoses (1, 2, 3, 4).
m : 40 N·m (29.5 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-1-1-28
SECTION 3 BODY
Group 1 Cab
2, 3
1
WNEK50-03-06-001
33. Add coolant to the radiator. 35. Install O-ring (3).

36. Install the cover (2) assembly with bolts, washers (4)
(6 used).
34. Fill hydraulic oil tank (1) with hydraulic oil.
j : 17 mm
(46 gal) m : 50 N·m (37 lbf·ft)
W3-1-1-29
SECTION 3 BODY
Group 1 Cab
2
1
OFF
ON
a
85Z7BW-03-01-01
a- Battery Box
37. Set battery disconnect switch (2) to the ON position.
38. Close cover (1).
W3-1-1-30
SECTION 3 BODY
Group 1 Cab
2, 3 85Z7BW-03-01-06
39. Bleed air from the hydraulic system. (Refer to W1-4- 43. Install bracket (3) and rubber plate (2) with bolts,
1.) washers (1) (4 used).
IMPORTANT: Check the hydraulic oil level and the j : 17 mm
coolant level. Start the engine and check for any
oil and coolant leaks. m : 50 N·m (37 lbf·ft)
40. Operate the steering wheel to the stroke end

several times and bleed air from the circuit.
41. Bleed air from the brake (axle). (Refer to W1-4-1.)
42. Fill refrigerant in the air conditioner. (Refer to T5-7 in

the separated volume, Technical Manual.)
W3-1-1-31
SECTION 3 BODY
Group 1 Cab
10
11, 13
8, 9 11, 12
1 2 3 4 5 6
85Z7BW-03-01-04
6 7 3 85Z7BW-03-01-05
44. Install the following parts. (Refer to W3-22-1.) 46. Install the following parts at the right and left sides.
(Refer to W3-22-1.)
 Cab Under Cover (1)
 Lower Cover (6)
 Rear Fender (Front) (5)
45. Connect connectors (8, 9) and window washer  Step (3)
liquid tube (10) and fix with clips (12, 13) and bolts,
washers (11) (2 used). Install deck (2).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-1-1-32
SECTION 3 BODY
Group 2 Counterweight
Removal and Installation of Counterweight
2 85Z7BW-03-02-01
Removal IMPORTANT: If rear grill (1) is kept closed and

counterweight (2) is removed, rear grill (1) may be
damaged.
2. Open rear grill (1).
W3-2-1-1
SECTION 3 BODY
2
1
a- Hoisting Position 85Z7BW-03-02-02
4. Remove bolts (3) (6 used) and washers (4) (6 used).

dCAUTION:
(4696 lb)
Counterweight (1) weight: 2130 kg Remove counterweight (1) from rear frame (2).
3. Attach the nylon slings onto hoisting positions j : 36 mm

(a) (2 places) of counterweight (1). Hoist and hold
counterweight (1).
W3-2-1-2
SECTION 3 BODY
2
1
a- Hoisting Position
85Z7BW-03-02-02
A View A 2
Installation
IMPORTANT: Keep the rear grill open when
installing.
dCAUTION:
(4696 lb)
Counterweight (1) weight: 2130 kg
1. Attach nylon slings onto hoisting positions (a) b b

(2 places) of counterweight (1). Hoist and fit
counterweight (1) to the mounting holes on rear
frame (2). 1
IMPORTANT: When installing counterweight (1), 85Z7BW-03-02-03
install counterweight (1) while positions (b) (2
places) of counterweight (1) with rear frame (2).
2. Install counterweight (1) to rear frame (2) with bolts
(3) (6 used) and washers (4) (6 used).
j : 36 mm
m : 700 N·m (516 lbf·ft)
W3-2-1-3
SECTION 3 BODY
85Z7BW-03-02-01
3. Close rear grill (1).
W3-2-1-4
SECTION 3 BODY
Group 3 Center Hinge
Removal and Installation of Center Hinge
b 3
a WNEK50-03-03-021
a- Stand 85Z7BW-03-03-24
b- Wire Rope
Removal
IMPORTANT: The hose and pipe contain hydraulic oil.
dCAUTION: Machine weight: 18040 kg (39800 lb)
4. Support front frame (1) and rear frame (2) by using
When removing the hose and pipe, receive oil with
stable stands (a).
a container in order to avoid spilling oil.
and pipes have been disconnected. In addition, 5. Apply rope (b) to the towing pin and sling rear
attach identification tags onto the connectors, frame (2) using a crane so that the rear frame (2) will
hoses, and pipes for assembling. If the clips which not fall backward.
secure the hoses have been removed, install the
clips after connecting the hoses. dCAUTION: When using a crane, insufficient
signal and sling could cause an accident resulting
in injury or death. To prevent such an accident,
1. Set the machine position for inspection and observe the following items:
 Check the sling before using it and do not use
improper sling.
2. Remove the following parts.
 Use the signals as agreed upon before starting
 Front Attachment (Refer to W5-1-1.) work.
 Cab Assembly (Refer to W3-1-1.)
 Propeller Shaft (Refer to W4-4-1.)  Stay out of the working area while using a crane.
 Steering Cylinder (Refer to W4-6-7.)
W3-3-1-1
SECTION 3 BODY
A Detail A
1
WNEK50-04-06-005 3 85Z7BW-03-03-01
a- Multiple Control Valve
j : 17 mm View B
4, 5
6. Disconnect hoses (3) (3 used).
j : 19 mm
j : 41 mm
j : 22 mm
85Z7BW-03-03-02
W3-3-1-2
SECTION 3 BODY
Detail A
7
a
85Z7BW-03-03-03 85Z7BW-03-03-04
a- Multiple Control Valve b- 2-Spool Solenoid Valve Unit
9. Disconnect hose (6). 10. Disconnect hose (7).
j : 41 mm j : 17 mm
W3-3-1-3
SECTION 3 BODY
A Detail A Without Emergency Steering
a 1
WNEK50-04-06-012
a- Steering Valve
WNEK50-04-06-005
Detail A With Emergency Steering
b 1
j : 19 mm
12. Disconnect hose (2) (for the machine without
emergency steering).
Disconnect hose (3) (for the machine with
emergency steering). 3
j : 36 mm
j : 17 mm
WNEK50-04-06-006
b- Steering Valve (With
Emergency Steering Check
Block)
W3-3-1-4
SECTION 3 BODY
Detail A Without Emergency Steering

A
a
85Z7BW-03-03-05
a- Steering Valve
85Z7BW-03-03-07
b 5
j : 19 mm
14. Disconnect hose (6). (Only the machine with the
emergency steering) 6
j : 36 mm
15. Disconnect hose (5). (Only the machine with the 4
emergency steering)
j : 22 mm
85Z7BW-03-03-06
b- Steering Valve (With
Block)
W3-3-1-5
SECTION 3 BODY
Detail A
2
1
3
85Z7BW-03-03-09
A 85Z7BW-03-03-08
16. Remove bolt, washer (3) (4 used) and plates (1, 2).
(Only the machine with the emergency steering)
j : 17 mm
W3-3-1-6
SECTION 3 BODY
Detail A
a
A 2, 4 5, 6
2, 3
5, 6 85Z7BW-03-03-11
85Z7BW-03-03-10
17. Remove bolts, washers (2) (3 used), clips (3) (2 used),

and clip (4).
j : 17 mm
18. Remove bolt, washer (5) (2 used) and clip (6) (2
used).
j : 17 mm
j : 19 mm
W3-3-1-7
SECTION 3 BODY
Detail A
10, 11
8, 9
8, 9
6, 7
2, 5
2, 3, 4, 5
85Z7BW-03-03-13
85Z7BW-03-03-10
IMPORTANT: Put matching marks on the hose for IMPORTANT: Put matching marks on the hose for
installing clips (5). installing clips (7, 9, 11).
20. Remove bolt, washer (2) (4 used), nut (3), washer (4), 22. Remove bolts, washers (6) (2 used) and clips (7) (2
and clips (5) (4 used). used).
j : 17 mm j : 17 mm
21. Remove hose (1). 23. Remove bolts, washers (8) (2 used), and clips (9) (2
used).
j : 22 mm
j : 17 mm
j : 17 mm
W3-3-1-8
SECTION 3 BODY
Detail A 1, 2 11
14
12
10 8, 9
85Z7BW-03-03-15
85Z7BW-03-03-14
Detail B b
5
4 6
3 7
b- Front Frame WNEK50-03-03-011
25. Remove bolt, washer (8) and clip (9). 29. Remove bolt, washer (1) and bracket (2).
j : 17 mm j : 19 mm
26. Disconnect the connectors (10) (2 used). 30. Bind and place the disconnected hoses and wire
27. Put matching marks on clamp (5), each hose and harnesses outside of the work area.
harnesses in order to be clear about the position for
securing the hoses when installing (part B).
28. Remove bolts, washers (3) (2 used), washers (6) (2
used), and nuts (7) (2 used). Remove plate (4) and
clamp (5).
j : 19 mm
W3-3-1-9
SECTION 3 BODY
Detail A
2
A
85Z7BW-03-03-12 85Z7BW-03-03-17
31. Remove bolts, washers (2) (2 used) and bracket (1).
j : 19 mm
W3-3-1-10
SECTION 3 BODY
5
a
6
8
7
3
9
b
1 2 85Z7BW-03-03-18
85Z7BW-03-03-19
a- Upper Hinge b- Lower Hinge
32. Remove bolts (1) (5 used) and washers (2) (5 used) 34. Remove bolt (6), washer, spring (7), and washer (8).
from bush (4).
j : 26 mm
j : 24 mm
35. Push out upper center hinge pin (5) and lower
33. Insert M12 x 1.75 x 90 mm bolt (3) into the bottom center hinge pin (9) respectively using a jack or
center of bush (4). Tighten the bolt (3) to remove “Porto-power”.
bush (4).
j : 17 mm
W3-3-1-11
SECTION 3 BODY
1
2
5
3
4
5 8
90W14014 9
a 10
8
9
b 85Z7BW-03-03-20
a- Bar b- Front Frame
36. Slowly turn the rear tires both the right and the left 37. Remove sleeve (1), bolts (2) (8 used), spring washers
sides using a bar to separate the rear frame. (3) (8 used), cover (4), dust seals (5) (2 used), bearing
(6), and shim (7) in front frame (b) upper center
fNOTE: While turning the rear tires, check that the hinge in order.
garage jack under the tank shifts back together with the
rear frame. In addition, adjust the height using the rear j : 21 mm
crane whenever the height adjustment is necessary.
38. Remove bearing retainers (8) (2 used), dust seals (9)
d CAUTION: Frame separation is dangerous work.
To ensure your safety, be careful in doing this
(2 used), and bearing (10) in front frame (b) lower
center hinge.
work.
W3-3-1-12
SECTION 3 BODY
a- Rear Frame
85Z7BW-03-03-21
IMPORTANT: Once bushing (1) has been removed,

replace it with the new one.
39. Remove rear frame upper center hinge pin bush (1)
and rear frame lower center hinge pin bush (2) (2
used).
W3-3-1-13
SECTION 3 BODY
1 12 [Upper Hinge Section]

8
a
7
Front a a
11
9
7
a
10 Grease nipple
installation direction
6
22.5
[Lower Hinge Section]
b Front
2
a
Split of outer
bearing
Grease nipple
installation direction 20
5
85Z7BW-03-03-23
3
Top side Bottom side
Dust seal installation direction

2 85Z7BW-03-03-22
90WNEC-03-03-06
a- Front Frame b- Rear Frame
Assembly 4. Temporarily install bearing (6) and cover (7) in the

front frame upper center hinge with bolt (8) (8 used)
1. Install rear frame upper center hinge pin bush (1)
and spring washers (9) (8 used).
and rear frame lower center hinge pin bush (2) (2
used). fNOTE: When replacing bearing (6) with a new one,
2. Install spherical bearing (3) onto the front frame adjust the clearance between the front frame upper
lower center hinge. Install the bearing outer ring so center pin and cover (7) to 0.1 ± 0.05 mm (0.0039 ±
that the split is perpendicular to the front – rear line 0.0020 in) using shim (10).
of the machine. Thickness of available shim: 0.1, 0.2, 0.3, 0.5, 1.0 mm
(0.004, 0.008, 0.012, 0.020, 0.040 in)
3. Install bearing retainers (4) (2 used), dust seals (5) (2
used) in the front frame lower center hinge. fNOTE: Install cover (7) so that the grease nipple
mounting hole is positioned at the specified angle.
fNOTE: Take care of the correct direction of dust seals (5)
j : 22 mm
as shown.
m : 210 N·m (155 lbf·ft)
5. Install dust seals (11) (2 used) in the front frame

upper center hinge. Install sleeve (12).
fNOTE: After installing dust seal (11) to the upper hinge,

caulk four points (a).
W3-3-1-14
SECTION 3 BODY
5
a
6
8
90W14014
85Z7BW-03-03-19
a- Bar b- Upper Hinge c- Lower Hinge
6. Be sure to support the front chassis using a stand, 8. Install upper center hinge pin (5) and lower center
jack, blocks, etc. and sling the rear chassis using a hinge pin (9) into the rear chassis.
crane so that the front and rear chassis do not fall
9. Install washer (8), washer, spring (7), and bolt (6).
down.
7. While supporting the bottom of the tank using a fNOTE: Take care of the grease nipple installation angle.
garage jack, slowly turn the rear tires both the right j : 26 mm
and the left sides using a bar to align the holes of
the front and rear chassis upper center pins. m : 441 N·m (325 lbf·ft)
fNOTE: When moving the rear chassis, move the

supporting stand together.
dWARNING: Moving the separated chassis is

dangerous work. To ensure your safety, be careful
in doing this work.
W3-3-1-15
SECTION 3 BODY
1 2 85Z7BW-03-03-18
10. Install bush (4) in the upper center pin.

11. Install washers (2) (5 used) and bolts (1) (5 used).
Apply lubrication oil to the bolt (1) thread.
j : 24 mm
m : 422 N·m (311 lbf·ft)
W3-3-1-16
SECTION 3 BODY
Detail A
2
A
85Z7BW-03-03-12 85Z7BW-03-03-17
12. Install bracket (1) with bolts, washers (2) (2 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-3-1-17
SECTION 3 BODY
Detail A
1, 2 11
14
12
A
10 8, 9
85Z7BW-03-03-15
Detail B b
5
4 6
85Z7BW-03-03-14
3 7
b- Front Frame WNEK50-03-03-011
13. Secure hoses (14) (12 used) with bracket (2) and 16. Secure harness (13) with clip (9) and bolt, washer
bolts, washer (1). (8).
j : 19 mm j : 17 mm

14. Connect connectors (10) (2 used).
15. Secure hoses (11, 12) (2 each used) and harness (13)
with clamp (5), plate (4), bolts, washers (3) (2 used),
washers (6) (2 used) and nuts (7) (2 used) by fitting
the matching marks.
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-3-1-18
SECTION 3 BODY
Detail A 14
10, 11
15 8, 9
8, 9
6, 7
13 1
A 2, 5
12 16 2, 3, 4, 5
a 85Z7BW-03-03-13
15
10, 11
85Z7BW-03-03-10
85Z7BW-03-03-25
a- 15°
17. Secure hose (15) with clip (11) and bolt, washer (10). 20. Connect hose (1).
j : 22 mm
j : 17 mm
m : 40 N·m (29.5 lbf·ft)
m : 50 N·m (37 lbf·ft)
21. Secure hose (12) with clips (5) (3 used), and bolts,
18. Secure hoses (14) (5 used) with clips (9) (2 used) and washers (2) (3 used) by fitting the matching marks.
j : 17 mm
j : 17 mm
m : 50 N·m (37 lbf·ft)
m : 50 N·m (37 lbf·ft)
22. Secure hose (12) and harness (16) with collar (13),
19. Secure hoses (13) (4 used) with clips (7) (2 used), clip (5), nut (3), washer (4), and bolt, washer (2).
and bolts, washers (6) (2 used) by fitting the
matching marks. j : 17 mm
j : 17 mm m : 50 N·m (37 lbf·ft)
m : 50 N·m (37 lbf·ft)
W3-3-1-19
SECTION 3 BODY
Detail A
a
2, 4 5, 6
8 2, 3
5, 6 85Z7BW-03-03-11
5, 6
A
2, 3
85Z7BW-03-03-10 b
b 85Z7BW-03-03-26
a- Multiple Control Valve b- 30 °
23. Connect hoses (1) (3 used). 25. Secure hose (7) with clips (3) (2 used) and bolts,
washers (2) (2 used).
j : 19 mm
j : 17 mm
m : 30 N·m (22 lbf·ft)
m : 50 N·m (37 lbf·ft)
24. Secure hose (8) with clips (6) (2 used) and bolts,
washers (5) (2 used). 26. Secure hose (1) with clip (4) and bolt, washer (2).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-3-1-20
SECTION 3 BODY
Detail A
2
1
3
85Z7BW-03-03-08 85Z7BW-03-03-09
A
27. Secure plates (1, 2) with bolts, washers (3) (4 used).

j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-3-1-21
SECTION 3 BODY
85Z7BW-03-03-05
a- Steering Valve

85Z7BW-03-03-07 5
b
28. Connect hose (5). (Only the machine with the 4

emergency steering)
j : 22 mm
85Z7BW-03-03-06
m : 40 N·m (29.5 lbf·ft) b- Steering Valve (With
29. Connect hose (6). (Only the machine with the Block)
emergency steering)
j : 36 mm
m : 180 N·m (133 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-3-1-22
SECTION 3 BODY
A
a 1
WNEK50-04-06-012
a- Steering Valve
WNEK50-04-06-005 Detail A With Emergency Steering
b 1
31. Connect hose (2). (for the machine without

emergency steering)
3
Connect hose (3). (for the machine with emergency
steering)
j (2) : 36 mm
m : 180 N·m (133 lbf·ft)
j (3) : 17 mm
m : 25 N·m (18.5 lbf·ft) WNEK50-04-06-006

32. Connect hoses (1) (2 used). b- Steering Valve (With
j : 19 mm Block)
m : 30 N·m (22 lbf·ft)
W3-3-1-23
SECTION 3 BODY
Detail A
A
85Z7BW-03-03-03
6
c
85Z7BW-03-03-04

b- 2-Spool Solenoid Valve Unit
a c- 15 °
85Z7BW-03-03-27
IMPORTANT: Check the angle to install hose (6). 34. Connect hose (7).
j : 17 mm
j : 41 mm
m : 15 N·m (11 lbf·ft)
m : 210 N·m (155 lbf·ft)
W3-3-1-24
SECTION 3 BODY
2 View A
4, 5
a 3
3 85Z7BW-03-03-01
2
b
85Z7BW-03-03-02

b- 5°
85Z7BW-03-03-28
35. Connect hose (1). 38. Secure hoses (3) (3 used) with clip (4) and bolt,
washer (5).
j : 22 mm
j : 17 mm
m : 40 N·m (29.5 lbf·ft)
m : 50 N·m (37 lbf·ft)
j : 41 mm
m : 210 N·m (155 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-3-1-25
SECTION 3 BODY
3
1
a
85Z7BW-03-03-24
a- Stand WNEK50-03-03-021
b- Wire Rope
42. Install front cover (3). (Refer to W3-22.)

dCAUTION: Machine weight: 18040 kg (39800 lb)
39. Remove stands (a) from front frame (1) and rear dCAUTION:
frame (2). Secure tires (4 used) by using wheel  After reinstallation, apply grease the center
stoppers. hinge pins, and operate them. During operation,
40. Remove rope (b) from rear frame (2). check the pions for abnormal noise and
looseness.
41. Install the following parts.
 Insufficient air bleeding in brake oil line could
 Front Attachment (Refer to W5-1-1.) cause an accident resulting in injury or death. Be
 Cab Assembly (Refer to W3-1-1.) sure to completely bleed the brake of air. For air
 Propeller Shaft (Refer to W4-4-1.) bleeding procedure, refer to W1-4-1.
 Steering Cylinder (Refer to W4-6-7.)
W3-3-1-26
SECTION 3 BODY
Group 4 Engine
Removal and Installation of Engine
2, 3
1
WNEK50-03-06-001
dCAUTION: Escaping fluid under pressure may dCAUTION: Operate the steering wheel to the
penetrate the skin and eyes, and cause serious right and left several times, and release any
injury. Release the pressure before disconnecting pressure in the circuit.
the hydraulic pipings or removing other
equipment. Hot hydraulic oil just after operation dCAUTION: Operate the brake pedal more than 50
may spout out and cause severe burns. Allow oil to times and release any pressure in the circuit.
cool before starting any work.
IMPORTANT: The hose and pipe contain hydraulic oil. dCAUTION: Release any pressure from hydraulic
When removing the hose and pipe, receive oil with oil tank (1). (Refer to W1-5-1.)
a container in order to avoid spilling oil. 2. Remove bolts, washers (4) (6 used). Remove the
IMPORTANT: Cap the open ends in case the hoses cover (2) assembly and O-ring (3).
attach identification tags onto the connectors, j : 17 mm
hoses, and pipes for assembling. If the clips which 3. Place a container. Drain off hydraulic oil by using an
secure the hoses have been removed, install the oil feed pump.
Removal (46 gal)

IMPORTANT: After stopping the engine, the DEF
pump continues to be operated for a specified
time in order to return DEF from the hose to the
DEF tank. When 5 minutes pass after the engine
has been stopped, start the work.
W3-4-1-1
SECTION 3 BODY
Group 4 Engine
1 11
7 6 5 4 3 2
85Z7BW-03-04-01
2 6
7
3 9 10 8 85Z7BW-03-01-05
4. Remove the following parts at the right and left 5. Remove the following parts. (Refer to W3-22-1.)
sides. (Refer to W3-22-1.)
 Step (5)  Deck (6)
 Rear Fender (Front) (3)  Inspection Cover (4, 9, 10)
 Lower Cover (2)  Engine Cover (1)
 Under Guard Rear (8) (Only for the machine with
under guard)
 Rear Cover (11)
W3-4-1-2
SECTION 3 BODY
Group 4 Engine
1
85Z7BW-03-01-03
6. Release any pressure in the reserve tank. (Refer to

W1-5-1.)
W3-4-1-3
SECTION 3 BODY
Group 4 Engine
4 9
3
5
1
2 8
a
b 7
85Z7BW-03-04-02 85Z7BW-03-04-03
a- Machine Front Side b- Fuel Tank
8. Place a container under drain plug (3). Loosen drain 11. Loosen clamps (6) (2 used). Disconnect the both
plug (3). Drain off engine oil. Tighten drain plug (3). ends of hose (7).
j : 24 mm j : 8 mm
m : 93 N∙m (69 lbf·ft) 12. Remove propeller shafts (5, 9) from drive unit (8).
(Refer to W4-4-1.)
fNOTE: Amount of engine oil: 25 L (6.6 US gal) 13. Release refrigerant of the air conditioner. (Refer to
T5-7 in the separated volume, Technical Manual.)
9. Loosen clamp (1). Disconnect hose (2). 14. Remove the cab assembly. (Refer to W3-1-1.)
j : 8 mm
IMPORTANT: Do not apply liquid packing onto drain

plug (4).
10. Place a container under drain plug (4). Remove
drain plug (4). Drain off transmission oil. Install drain
plug (4).
j : 22 mm
m : 80 N·m (59 lbf·ft)
fNOTE: Amount of transmission oil: 40 L (10.6 gal)
W3-4-1-4
SECTION 3 BODY
Group 4 Engine
a 4 2 3
85Z7BW-03-04-04
15. Disconnect hose (1) and hoses (2) (3 used).
j : 17 mm
j : 22 mm
j : 19 mm
W3-4-1-5
SECTION 3 BODY
Group 4 Engine
3
1
a
2

85Z7BW-03-04-05
j : 36 mm j : 27 mm
j : 41 mm j : 36 mm
W3-4-1-6
SECTION 3 BODY
Group 4 Engine
1
3
1, 9
11
8
a
1, 10 5

2 4 6, 7
85Z7BW-03-04-06
22. Remove bolts, washers (1) (3 used) and clips (3, 9, 24. Place a container under the disconnecting part
10). of suction pipe (6). Loosen clamps (2) (2 used).
Disconnect the both ends of the suction pipe (8)
j : 17 mm assembly.
fNOTE: Clip (9) is equipped for the machine with j : 11 mm

emergency steering device. 25. Remove socket bolts (5) (4 used). Disconnect
suction pipe (6). Remove O-ring (7).
l : 10 mm
j : 36 mm
26. Remove hydraulic oil tank (11). (Refer to W3-6-1.)
W3-4-1-7
SECTION 3 BODY
Group 4 Engine
3 4
10
11 5, 6
5, 6 2
1
7, 8
12
2
View A
85Z7BW-03-04-44
A
27. Disconnect hose (12). 30. Remove bolt, washer (5), and clip (6).
j : 19 mm j : 17 mm
28. Loosen clamp (4). Disconnect hose (3). 31. Loosen clamp (1). Disconnect hose (2).
j : 8 mm j : 8 mm
29. Remove bolts, washers (7) (2 used), clips (8,9), and
clamp (10). Disconnect hose (11).
j : 17 mm
j : 8 mm
W3-4-1-8
SECTION 3 BODY
Group 4 Engine
6 A 9
4
8
2, 3
2, 3 85Z7BW-03-04-09
9
8
7 7
85Z7BW-03-04-08
Detail A 85Z7BW-03-04-10
32. Remove the aftertreatment device (1) assembly. 34. Loosen clamp (4) and remove hose (5).
(Refer to W3-18-1.)
j : 8 mm
33. Remove the bolts, washers (2) (2 used) and clips (3)
(2 used). 35. Disconnect connectors (6) (2 used).
36. Loosen clamps (7) (2 used) and remove hoses (8, 9).
j : 17 mm
j : 8 mm
W3-4-1-9
SECTION 3 BODY
Group 4 Engine
Detail A
4 3 2 85Z7BW-03-04-12
B Detail B 6
5 9 7
A 85Z7BW-03-04-11
8 85Z7BW-03-04-13
37. Loosen clamp (1) and disconnect hose (2). 39. Loosen clamps (5, 6). Disconnect the both ends of
hose (7).
j : 8 mm
j : 8 mm
38. Loosen clamp (3) and disconnect hose (4).
j : 8 mm
j : 11 mm
W3-4-1-10
SECTION 3 BODY
Group 4 Engine
5 6
1
7, 8
10 9
2, 3 85Z7BW-03-04-14 85Z7BW-03-04-15
41. Disconnect connectors (1) (2 used). 44. Remove nuts (7) (4 used), washers (8) (4 used), and
plates (9) (2 used).
42. Remove bolt (2), washer (3) and clips (4) (2 used).
j : 17 mm
j : 17 mm
45. Remove rubber sheet (10).
W3-4-1-11
SECTION 3 BODY
Group 4 Engine
3 1
4
2
9, 10
8
5
4
11 85Z7BW-03-04-17
a- Fuel Tank
4 6 85Z7BW-03-04-16
46. Loosen clamps (1, 2). Disconnect the both ends of 49. Remove bolt, washer (9) and clip (10). Disconnect
hose (3). hose (11).
j : 11 mm j : 17 mm
47. Loosen clamps (4) (4 used) and disconnect the both
ends of hoses (5, 6).
j : 8 mm
48. Loosen clamp (7). Disconnect hose (8).
W3-4-1-12
SECTION 3 BODY
Group 4 Engine
B 7
5, 6
10
a
8
3 4
9
A 11
85Z7BW-03-04-19
Detail A 2 1 View B
85Z7BW-03-04-18
14 12, 13 85Z7BW-03-04-20
50. Loosen clamp (2). Disconnect hose (1). 53. Remove bolts, washers (8) (2 used) and remove fuel
filter (9).
51. Remove bolt (4) and disconnect connector (3).
j : 17 mm
j : 13 mm
54. Remove bolts, washers (10) (2 used). Remove cover
(11).
Remove fuel pump (7).
j : 17 mm
j : 10 mm
55. Remove bolt (12), washer (13), and clip (14).
j : 17 mm
W3-4-1-13
SECTION 3 BODY
Group 4 Engine
Detail B
14,15,16,17 18,19,20,21 11,12,13 85Z7BW-03-04-23
A Detail C
C
85Z7BW-03-04-21
a
22
View A 1 10 9
b 23
a
2, 3
85Z7BW-03-04-24
24 25
a- Machine Front Side c- Alternator

b- Starter
8 7
4 5, 6, 26 85Z7BW-03-04-22
56. Remove nut (2) and washer (3), and disconnect 60. Remove covers (14, 18), nuts (15, 19) and washers
ground (1). (16, 20). Disconnect terminals (17, 21).
j : 19 mm j : 8 mm
57. Remove cover (26), nut (5) and washer (6), and j : 13 mm
disconnect terminal (4).
j : 19 mm Loosen clamp (24) and disconnect hose (25).
58. Disconnect connector (7). Remove bolts, washers (9) j : 8 mm
(2 used), and remove bracket (10).
j : 19 mm
59. Remove bolt (11) and washer (12), and disconnect
ground (13).
j : 13 mm
W3-4-1-14
SECTION 3 BODY
Group 4 Engine
17,18,19
16
15
3 1 2
14
4
17,18,19
20
a 5, 9
8 6, 7
10, 11
A
a
10, 13
10, 12
85Z7BW-03-04-25 Detail A
a- Machine Front Side 6
8 85Z7BW-03-04-26
9
62. Loosen nut (4) of tension pulley (3). 68. Remove bolts (17) (4 used) and washers (18) (4
used). Remove compressor (20) assembly and
j : 14 mm collars (19) (4 used). Place the compressor (20)
63. Loosen adjusting bolt (2) and loosen belt (1). assembly outside of the work area.
Remove belt (1).
j : 12 mm
j : 14 mm
64. Remove bolt, washer (5), nut (6), washer (7), and
clips (8, 9).
j : 17 mm
65. Remove bolts, washers (10) (3 used), and clips (11,
12, 13).
j : 17 mm
66. Remove screw (14) and cable (5).
W3-4-1-15
SECTION 3 BODY
Group 4 Engine
1
View A
2, 3, 4
85Z7BW-03-04-27
dCAUTION: Support assembly (1) weight: 200 kg

(441 lb)
69. Attach nylon sling to support assembly (1) and
temporarily lift and hold.
70. Remove 8 each of bolts (2), washers (3) and sleeves
(4) indicated by bold arrows. Remove support
assembly (1).
j : 30 mm
W3-4-1-16
SECTION 3 BODY
Group 4 Engine
11, 12, 13
2, 3
9
8
16
14
5
A
10 7 15 85Z7BW-03-04-29
Detail A
6 17
1
a
4
85Z7BW-03-04-28

18 19
85Z7BW-03-04-32
71. Remove bolt, washer (4) and bolts, washers (2) (3 73. Remove socket bolts (7) (2 used) and clip (8).
used), and sleeves (3) (3 used). Remove bracket (1)
assembly. l : 4 mm
74. Disconnect connectors (9, 10).
j : 17 mm
75. Remove nut (11) and washer (12). Disconnect
72. Loosen clamps (6) (2 used). Disconnect the both
ground (13).
ends of hose (5).
j : 10 mm
j : 11 mm
j : 27 mm
j : 41 mm
78. Loosen clamps (17) (2 used). Disconnect hoses (18,
19).
j : 8 mm
W3-4-1-17
SECTION 3 BODY
Group 4 Engine
View A
B 3
1, 2
A
View B
C 5
View C
a 85Z7BW-03-04-30
85Z7BW-03-04-31
79. Remove bolt, washer (1), and clip (2). Disconnect
cable (3).
j : 17 mm
80. Remove bolts, washers (4) (2 used). Remove bracket
assembly (5).
j : 19 mm
81. Place a container under the connecting part of
hoses (6, 7), then disconnect hoses (6, 7).
j : 41 mm
W3-4-1-18
SECTION 3 BODY
Group 4 Engine
3 1
b
Detail A Detail B
10 11
a 12 12
b
7
c 9
c
7
A 2 6
5 8
5
B
4 4
85Z7BW-03-04-33
85Z7BW-03-04-34
a- Lifting Bracket (Engine) c- Mount Bracket of Rear Frame
b- Lifting Bracket (Drive Unit) (2)
84. Remove the engine (2) assembly from rear frame (1).
dCAUTION: The engine (2) assembly weight: 1260 Remove bolts (10, 11) (2 each) and washers (12) (4
kg (2778 lb) used) from the engine (2) assembly.
82. Install shackles (4 used) to lifting brackets (a, b) (2
85. Remove rubbers (7, 9) (2 each) from mount brackets
places for each) of engine (2) and drive unit (3).
(c) (4 places) of rear frame (1).
Attach nylon slings onto the shackles (4 used). Hoist
and hold the engine (2) assembly.
83. Remove nuts (4) (4 used), washers (5) (4 used),
plates (6, 8) (2 each), and rubbers (7) (2 used).
j : 30 mm
W3-4-1-19
SECTION 3 BODY
Group 4 Engine
4
1
a b
85Z7BW-03-04-35
a- Stand b- Stand
dCAUTION: Place the engine (3) assembly onto

stable stands (a, b) in order not to fall down.
fNOTE: Secure the engine (3) side on stand (b) by using

engine mount brackets (rear side) (4) (2 used).
86. Remove pump device (1) from drive unit (2). (Refer
to W3-8-1.)
87. Remove drive unit (2) from engine (3). (Refer to W4-
2-1.)
88. Remove the adapters from engine (3) if necessary.
W3-4-1-20
SECTION 3 BODY
Group 4 Engine
4
1
a b
85Z7BW-03-04-35
a- Stand b- Stand
Installation
1. Install all removed adapters to engine (3).
2. Install drive unit (2) to engine (3). (Refer to W4-2-1.)
3. Install pump device (1) to drive unit (2). (Refer to
W3-8-1.)
W3-4-1-21
SECTION 3 BODY
Group 4 Engine
3 1
b Detail A Detail B
10 11
a 12 12
b
7
c 9
c
7
A 2 6
5 8
5
B 4 4
85Z7BW-03-04-33
85Z7BW-03-04-34
a- Lifting Bracket (Engine) c- Mount Bracket of Rear Frame

b- Lifting Bracket (Drive Unit) (2)
6. Install the engine (2) assembly to mount brackets

dCAUTION: The engine (2) assembly weight: 1260 (c) (4 places) of rear frame (1). Install washers (12) (4
kg (2778 lb) used) and bolts (10, 11) (2 each). Install rubbers (7)
4. Install shackles (4 used) to lifting brackets (a, b) (2 (2 used), plates (6, 8) (2 each), washers (5) (4 used),
places for each) of engine (2) and drive unit (3). and nuts (4) (4 used) onto the rear of mount bracket
Attach nylon slings onto the shackles (4 used). Hoist (c).
the engine (2) assembly.
j : 30 mm
5. Install rubbers (7, 9) (2 each) to mount brackets (c)
(4 places) of rear frame (1). m : 400 N·m (300 lbf·ft)
W3-4-1-22
SECTION 3 BODY
Group 4 Engine
View A
1, 2
View B
C
4
5
a 85Z7BW-03-04-30
View C
6
b 6
b
7
7 85Z7BW-03-04-36 85Z7BW-03-04-31
a- Machine Front Side b- 30˚
IMPORTANT: Check the angle to install hoses (6, 7). 9. Install cable (3) with bolt, washer (1) and clip (2).
j : 17 mm
j : 41 mm
m : 50 N·m (37 lbf·ft)
m : 210 N·m (155 lbf·ft)
8. Install bracket assembly (5) and fix with bolts,
washers (4) (2 used)
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-4-1-23
SECTION 3 BODY
Group 4 Engine
2, 3
11, 12, 13
9
5 8
16
A
14
1 6
a 10 7 20 15 85Z7BW-03-04-29
4
85Z7BW-03-04-28
Detail A b
16
17 15
B
c 14
16
18 19 85Z7BW-03-04-37
a- Machine Front Side b- 20°
85Z7BW-03-04-32 c- 30°
10. Connect hoses (18, 19) and fix with clamps (17) (2 15. Secure harness (20) with clip (8) and socket bolts (7)
used). (2 used).
j : 8 mm j : 4 mm
m : 4 N·m (3 lbf·ft) m : 9±1 N·m (6.6±0.7 lbf·ft)

11. Connect hose (16). 16. Connect the both ends of hose (5) with clamps (6) (2
used).
j : 41 mm
j : 11 mm
m : 210 N·m (155 lbf·ft)
m : 12 N·m (8.9 lbf·ft)
j : 27 mm fNOTE: Insert hose (5) by 63.5 mm (2.5 in) at engine side,

by 50 mm (2 in) at cooler side.
m : 95 N·m (70 lbf·ft)
13. Connect ground (13) with washer (12) and nut (11). 17. Install the bracket (1) assembly with bolt, washer (4),
bolts, washers (2) (3 used), and sleeves 3) (3 used).
j : 10 mm
j : 17 mm
m : 3 to 4 N·m (2.2 to 3 lbf·ft)
14. Connect connectors (9, 10). m : 50 N·m (37 lbf·ft)
W3-4-1-24
SECTION 3 BODY
Group 4 Engine
1
View A
2, 3, 4
85Z7BW-03-04-27
dCAUTION: Support assembly (1) weight: 200 kg

(441 lb)
18. Attach nylon sling to support assembly (1). Hoist
and move it onto the rear frame.
19. Install 8 each of bolts (2), washers (3) and sleeves (4)
indicated by bold arrows.
j : 30 mm
m : 400 N·m (295 lbf·ft)
W3-4-1-25
SECTION 3 BODY
Group 4 Engine
17,18,19
16
15
14
17,18,19
20 View B View C
5, 9 21 5
8 6, 7 9
b
10, 11 21
A
23 a
8
10, 13 c d
10, 11
B 10, 12
Detail A 85Z7BW-03-04-38
6
5 C
a- Machine Front Side c- 60°
b- 30° d- 45°
8
9
85Z7BW-03-04-26
20. Install collars (19) (4 used) and compressor (20) 23. Secure cables (22, 23) and hose (21) with clips (11, 12,
assembly with washers (18) (4 used) and bolts (17) (4 13), and bolts, washers (10) (3 used).
used).
j : 17 mm
j : 12 mm
m : 50 N·m (37 lbf·ft)
m : 24.5 to 29.4 N·m (18 to 22 lbf·ft)
24. Secure cable (23) with clips (8, 9), washer (7), nut (6)
21. Connect connector (16). and bolt, washer (5).
22. Install cable (15) with screw (14). j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-4-1-26
SECTION 3 BODY
Group 4 Engine
3 1 2
4 d 1
b
a
a
c
85Z7BW-03-04-25 WNEK50-03-04-042
a- Machine Front Side b- 412±49 N (93±11 lbf ) d- Fan Pulley

c- Compressor Pulley
25. Install belt (1). Adjust the belt (1) tension correctly 26. Tighten nut (4) of tension pulley (3).
by moving tension pulley (3) by using adjusting bolt
(2). j : 14 mm
j : 14 mm m : 32 to 46 N·m (23.5 to 34 lbf·ft)
IMPORTANT: Check and adjust the belt tension so

that the belt tension at the point (b) is 412±49 N
(93±11 lbf) by using tension gauge.
IMPORTANT: The belt does not fit when replacing
with a new one. Therefore, adjust the belt tension
again after running the engine at slow idle for 3 to
5 minutes.
fNOTE: The belt tension should be 588±98 N (132±22 lbf)

when the belt is replaced with new one.
W3-4-1-27
SECTION 3 BODY
Group 4 Engine
Detail B
14,15,16,17 18,19,20,21 11,12,13 85Z7BW-03-04-23
Detail C
A
C
85Z7BW-03-04-21
a 22
View A 1 10 9 23
b
a
2, 3
85Z7BW-03-04-24
24 25
a- Machine Front Side c- Alternator

b- Starter
8 7
4 5, 6, 26
85Z7BW-03-04-22
27. Connect hoses (25, 23) and fix with clamps (24, 22). 29. Connect ground (13) with washer (12) and bolt (11).
j : 8 mm j : 13 mm
m (24): 4 N·m (3 lbf·ft) m : 10 N·m (7.4 lbf·ft)
m (22): 20 N·m (15 lbf·ft) 30. Install bracket (10) with bolts (9) (2 used). Connect
connector (7).
fNOTE: Insert hose (23) by 37 mm (1.5 in). j : 19 mm
28. Install terminals (17, 21) with nuts (15, 19) and m : 90 N·m (66 lbf·ft)
washers (16, 20). Install covers (14, 18). 31. Connect terminal (4) with washer (6) and nut (5).
Install cover (26).
j (15) : 8 mm
j : 19 mm
m : 2.5 N·m (1.85 lbf·ft)
m : 35 N·m (26 lbf·ft)
j (19): 13 mm
32. Install ground (1) with nut (2) and washer (3).
m : 10 N·m (7.4 lbf·ft)
j : 19 mm
m : 35 N·m (26 lbf·ft)
W3-4-1-28
SECTION 3 BODY
Group 4 Engine
B 7
5, 6
10
8
3 4 A
9
11
Detail A 2 1 1
85Z7BW-03-04-19
View B
b
b
2
15 85Z7BW-03-04-39
b- 5 mm (0.2 in)
14 12, 13 85Z7BW-03-04-20
33. Fix hydraulic oil cooler hose (15) with clip (14), 36. Install fuel pump (7) with bolts (5) (2 used) and
washer (13), and bolt (12). washers (6) (2 used).
j : 17 mm j : 13 mm
m : 50 N·m (37 lbf·ft) m : 10 N·m (3.7 lbf·ft)

34. Install cover (11) with bolts, washers (10) (2 used). 37. Install connector (3) and fix with bolt (4).
j : 17 mm j : 13 mm

35. Install fuel filter (9) with bolts, washers (8) (2 used). IMPORTANT: Take care of installation direction and
insertion amount of hose (1).
j : 17 mm
38. Connect hose (1) and fix with clamp (2).
m : 50 N·m (37 lbf·ft)
j : 8 mm
m : 4 N·m (3 lbf·ft)
W3-4-1-29
SECTION 3 BODY
Group 4 Engine
9, 10
Detail A Detail B 5 Detail C
6
b
b
b
b
11 a
85Z7BW-03-04-17 4
4
a- Fuel Tank 1 5 4
3 6
85Z7BW-03-04-40
4 Detail D Detail E
2 2 3 1
8
5
4
b c
3
7 85Z7BW-03-04-41
b- 50 mm (1.97 in) c- 60 mm (2.36 in)
4 6 85Z7BW-03-04-16
39. Fix hose (11) with clip (10) and bolt, washer (9). IMPORTANT: Take care of installation direction and
insertion amount of hoses (3).
j : 17 mm
42. Connect the both ends of hose (3) and fix with
m : 50 N·m (37 lbf·ft) clamps (1, 2).
40. Connect hose (8) and fix with clamp (7). j : 11 mm
m : 12 N·m (8.9 lbf·ft)

IMPORTANT: Take care of installation direction and
insertion amount of hoses (5, 6).
41. Connect the both ends of hoses (5, 6) and fix with
clamps (4) (2 each used).
j : 8 mm
m : 20 N·m (15 lbf·ft)
W3-4-1-30
SECTION 3 BODY
Group 4 Engine
5 6
1
7, 8
10 9
85Z7BW-03-04-15 2, 3 85Z7BW-03-04-14
43. Install rubber sheet (10) with plates (9) (2 used), 44. Connect hoses (5, 6).
washers (8) (4 used), and nuts (7) (4 used).
45. Fix clips (4) (2 used) with bolt (2) and washer (3).
j : 17 mm
j : 17 mm
m : 50 N·m (37 lbf·ft)
m : 50 N·m (37 lbf·ft)
W3-4-1-31
SECTION 3 BODY
Group 4 Engine
Detail B 6
5 9 7
8 85Z7BW-03-04-13
B
Detail C Detail D Detail E Detail F
9 5 6
a
b
A 85Z7BW-03-04-11
Detail A
c 7 d
8
Detail G
1
4 3
e 85Z7BW-03-04-42
85Z7BW-03-04-12
4 3 2 a- 33.5 mm (1.32 in) d- 41 mm (1.61 in)
b- 50 mm (1.97 in) e- 3 mm (0.12 in)
c- 29 mm (1.14 in)
IMPORTANT: Check the direction to install hose (9). 49. Connect hose (4) with clamp (3).
47. Connect hose (9) with clamps (8) (2 used).
j : 8 mm
j : 11 mm
m : 12 N·m (8.9 lbf·ft)
m : 12 N·m (9 lbf·ft) 50. Connect hose (2) with clamp (1).
IMPORTANT: Check the direction to install hose (7).
j : 8 mm
48. Connect the both ends of hose (7) with clamps (5,
6). m : 4 N·m (3 lbf·ft)
j : 8 mm
m : 20 N·m (15 lbf·ft)
W3-4-1-32
SECTION 3 BODY
Group 4 Engine
6 A 9
4
8
2, 3
2, 3 85Z7BW-03-04-09
Detail A 9
8
7 7
85Z7BW-03-04-08
85Z7BW-03-04-10
7
51. Connect hoses (8, 9) with clamps (7) (2 used).
j : 8 mm
m : 1.6 N·m (1.2 lbf·ft)

53. Connect hose (5) with clamp (4). 30 mm (1.2 in)
85Z7BW-03-04-43
j : 8 mm 8, 9
54. Install hose (5) with clips (3) (2 used), and bolts,
j : 17 mm
m : 50 N·m (37 lbf·ft)

55. Install aftertreatment device (1). (Refer to W3-18.)
W3-4-1-33
SECTION 3 BODY
Group 4 Engine
3 4
10 45°
11
5, 6
5, 6 2
1
7, 8
12
2
View A
85Z7BW-03-04-44
A
56. Connect hose (2) with clamp (1). 59. Connect hose (3) with clamp (4).
j : 8 mm j : 8 mm

57. Connect hose (2) with clip (6) and bolt, washer (5). 60. Connect hose (12).
j : 17 mm j : 19 mm

58. Secure hose (11) with clamp (10), clips (8, 9), and
j : 8 mm
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-4-1-34
SECTION 3 BODY
Group 4 Engine
2
B
1 3
1, 9
11 12
8
A
a
1, 10 5
C
2 4 6, 7 85Z7BW-03-04-06
Detail A
Detail B Detail C
c c c d
e e e f
1, 10
12
2 2 85Z7BW-03-04-46
85Z7BW-03-04-45
b- 35°
c- 34 mm (1.34 in) e- 3 mm (0.12 in)
d- 49 mm (1.93 in) f- 10 mm (0.39 in)
61. Install hydraulic oil tank (11). (Refer to W3-6-1.) 64. Connect hose (4).
62. Install O-ring (7). Install suction pipe (6) with socket j : 36 mm
bolts (5) (4 used).
m : 180 N·m (133 lbf·ft)
l : 10 mm
65. Secure hose (4) and cable (11) with bolts, washers
m : 90 N·m (66 lbf·ft) (1) (3 used) and clips (3, 9, 10).
63. Connect the both ends of the suction pipe (8) j : 17 mm
assembly with clamps (2) (2 used).
m : 50 N·m (37 lbf·ft)
j : 11 mm
m : 10 N·m (7.4 lbf·ft)
W3-4-1-35
SECTION 3 BODY
Group 4 Engine
A
4
B Detail A Detail B
1
3
3
1
a 2 5° 30°
85Z7BW-03-04-05 85Z7BW-03-04-47
j : 41 mm
j : 36 mm
m : 210 N·m (155 lbf·ft)
m : 180 N·m (133 lbf·ft) 69. Connect hose (4).
j : 36 mm
m : 180 N·m (133 lbf·ft)
j : 27 mm
m : 95 N·m (70 lbf·ft)
W3-4-1-36
SECTION 3 BODY
Group 4 Engine
a 4 2 3 85Z7BW-03-04-04
j : 19 mm
m : 30 N·m (22 lbf·ft)

j : 22 mm
m : 40 N·m (34 lbf·ft)

1
IMPORTANT: Check the angle to install hose (1). 30°
85Z7BW-03-04-48
72. Connect hose (1) and hoses (2) (3 used).
j : 17 mm
m : 25 N·m (18.5 lbf·ft)
W3-4-1-37
SECTION 3 BODY
Group 4 Engine
4 9
3
1
2
5
a
8
6
b 85Z7BW-03-04-02
a- Machine Front Side b- Fuel Tank

a
7
85Z7BW-03-04-03
11
73. Install the cab assembly. (Refer to W3-1-1.)

74. Install propeller shafts (5, 9) to drive unit (8). (Refer
to W4-4-1.)
75. Connect the both ends of hose (7) with clamps (6) (2
used).
j : 8 mm
85Z7BW-03-01-26
76. Connect hose (2) with clamp (1).
j : 8 mm
79. Open cap (11).
80. Add transmission oil to drive unit (8).
77. Add engine oil to the engine.
fNOTE: Amount of transmission oil: 40 L (10.6 US gal)
fNOTE: Amount of engine oil: 25 L (6.6 US gal)
78. Add coolant to the radiator.
W3-4-1-38
SECTION 3 BODY
Group 4 Engine
3 4, 5 1
85Z7BW-01-05-03
81. Install engine cover (1). (Refer to W3-22-1.) IMPORTANT: Check the hydraulic oil level,
transmission oil level, coolant level, and engine oil
level. Start the engine and check for any oil and
coolant leaks.
IMPORTANT: Warm up the engine. Operate the
(46 gal)
machine for 15 minutes or longer until SCR
83. Install O-ring (4). exhaust temperature becomes 190°C (374°F) or
84. Install the cover (3) assembly with bolts, washers (5) higher. Check the DEF hose for DEF leaks.
(6 used). 88. Operate the steering wheel to the stroke end
several times and bleed air from the circuit.
j : 17 mm
m : 50 N·m (37 lbf·ft)
85. Fill refrigerant in the air conditioner. (Refer to T5-7 in
the separated volume, Troubleshooting.)
86. Bleed air from the fuel system. (Refer to W1-4-1.)
87. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
W3-4-1-39
SECTION 3 BODY
Group 4 Engine
1 11
7 6 5 4 3 2
85Z7BW-03-04-01
2 6
7
3 9 10 8 85Z7BW-03-01-05
90. Install the following parts. (Refer to W3-22-1.) 91. Install the following parts at the right and left sides.
(Refer to W3-22-1.)
under guard)  Lower Cover (2)
 Inspection Cover (4, 9, 10)  Rear Fender (Front) (3)
 Deck (6)  Step (5)
 Rear Cover (11)
 Engine Cover (1)
W3-4-1-40
SECTION 3 BODY
Group 5 Radiator Assembly
Removal and Installation of Radiator

Assembly
2, 3 4
85Z7BW-01-05-03

dCAUTION: Release any pressure from hydraulic
injury. Release the pressure before disconnecting 2. Remove bolts, washers (4) (6 used). Remove the
the hydraulic pipings or removing other cover (2) assembly and O-ring (3).
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Allow oil to j : 17 mm
3. Place a container. Remove hydraulic oil using an oil
IMPORTANT: The hose and pipe contain hydraulic oil. supply pump.
a container in order to avoid spilling oil. fNOTE: Total amount of hydraulic oil tank (1): 180 L
IMPORTANT: Cap the open ends in case the hoses (47.6 gal)
hoses, and pipes for assembling. If the clips which
fNOTE: When disassembling or assembling the radiator
assembly, disassemble or assemble the radiator,
intercooler, and torque converter oil cooler respectively.
Removal
W3-5-1-1
SECTION 3 BODY
1
4
5
3
85Z7BW-01-05-03 85Z7BW-03-01-03
4. Release any pressure in reserve tank (a). (Refer to 6. Place a container under hose (3). Loosen cock (2).
W1-5-1.) Drain off coolant. Close cock (2).
5. Open left and right side covers (1). fNOTE: Amount of coolant: 39 L (10.3 gal)
7. Remove cover (4) and left and right covers (5) and
grill assembly (6). (Refer to W3-22-1.)
W3-5-1-2
SECTION 3 BODY
3, 4
5 6
16, 17
7
2
10
9 18
8
11, 12
1
13
15
14
85Z7BW-03-05-02
85Z7BW-03-05-01
8. Loosen clamps (2) (2 used). Disconnect the both 13. Disconnect connector (13).
ends of hose (1).
9. Loosen bolt, washer (3) and clip (4). Disconnect
hose (5). j : 8 mm
15. Remove 4 each of bolts, washers (16) and sleeves
j : 17 mm
(17) indicated by bold arrows. Remove reserve tank
10. Loosen clamp (6). Disconnect hose (7). (18) assembly.
11. Loosen clamps (8) (2 used). Disconnect hoses (9, 10). j : 19 mm
j : 8 mm
j : 17 mm
W3-5-1-3
SECTION 3 BODY
5 9 3
14
10, 11, 8
12, 13
6, 7 85Z7BW-03-05-03
16. Loosen clamps (2, 3). Disconnect the both ends of 20. Remove 4 each of bolts, washers (10), washers
hose (1). (11), rubber sheet (12), tubes (13). Remove torque
converter cooler (14).
j : 11 mm
j : 17 mm
j : 8 mm
j : 17 mm
j : 36 mm
W3-5-1-4
SECTION 3 BODY
2, 3, 4 13
7
1
2, 3, 4, 5 14, 15
6
9, 10, 11 17
12 16
85Z7BW-03-05-05
85Z7BW-03-05-04
21. Remove 4 each of nuts (2), washers (3), and clips (4, 25. Disconnect connector (13).
5) indicated by bold arrows.
26. Remove bolt, washer (14) and clip (15). Disconnect
j : 17 mm hoses (16, 17).
22. Remove nut (2), washer (3) and clip (4). j : 17 mm
j : 17 mm j : 41 mm
IMPORTANT: When disassembling or assembling the
condenser (1) assembly, be sure not to damage
the core and hoses.
bushing (11) (4 used). Remove the condenser (1)
assembly from frame (12) and place it outside of the
working area.
j : 13 mm
W3-5-1-5
SECTION 3 BODY
1
7
6
5
4
2 1
85Z7BW-03-05-06
85Z7BW-03-05-07
29. Remove 6 each of bolts, washers (4), washers (5),

d CAUTION: Hydraulic oil cooler assembly (1)
weight: 50 kg (110 lb)
tubes (6), and bushing (7). Remove hydraulic oil
cooler (8).
27. Attach nylon sling to hydraulic oil cooler assembly
(1). Hoist and temporarily hold the assembly. j : 17 mm
28. Remove bolts, washers (2) (4 used). Remove

hydraulic oil cooler assembly (1) and plates (3) (2
used).
j : 19 mm
W3-5-1-6
SECTION 3 BODY
8
b
3, 4
2
5
7 9, 10
1
85Z7BW-03-05-08
a- Radiator 85Z7BW-03-05-09
b- Air Cooler
30. Loosen clamp (2). Disconnect radiator (a) side of 33. Disconnect connector (7).
pipe (1) assembly.
34. Remove fan motor assembly (8). (Refer to W3-xx-xx).
j : 8 mm 35. Loosen clamp (9). Disconnect hose (10).
32. Loosen clamp (6). Disconnect air cooler (b) side of
pipe (5) assembly.
j : 11 mm
W3-5-1-7
SECTION 3 BODY
14
7
13
3 11, 12
2
11, 12
9
1 10
8
6
5 4
85Z7BW-03-05-10 85Z7BW-03-05-11
36. Remove bolts, washers (2) (2 used). Remove bracket 37. Remove 4 each of nuts (4), washers (5), bolts,
(1) and place it outside of the working area. washers (6) from air cooler (3). Remove plate (7).
j : 17 mm j : 17 mm
38. Remove air cooler (3). Remove bushing (9) (4 used)
and sleeves (10) (4 used).
39. Remove bolts, washers (11) (4 used) and clips (12) (4
used).
j : 17 mm
40. Remove bolts, washers (13) (2 used) and remove
breather (14).
j : 17 mm
W3-5-1-8
SECTION 3 BODY
11, 12
2
3
4
6
10
9
11, 12
5
7 13, 14, 15
1
85Z7BW-03-05-12 85Z7BW-03-05-13
41. Remove bolts (2) (4 used), washers (3) (4 used), and 43. Remove connector (10) of cable (9).
washers (4) (4 used) from frame (8). Remove radiator
44. Remove 9 each of clips (11), and bolts, washers (12)
(1).
j : 13 mm
j : 17 mm
42. Remove tubes (5) (4 used), bushes (6) (4 used), and
bushes (7) (4 used). dCAUTION: Frame (8) weight: 90 kg (198 lb)
45. Attach nylon sling to frame (8). Hoist and
temporarily hold it.
46. Remove 8 each of bolts (13), washers (14), spacers
(15). Remove frame (8).
j : 24 mm
W3-5-1-9
SECTION 3 BODY
A 11, 12
Detail A Detail B
10
15° 15°
9
9 9
a
11, 12
85Z7BW-03-05-14
13, 14, 15
a- Rear Frame
85Z7BW-03-05-13
Installation 3. Install cable (9) with 9 each of clips (11), and bolts,
washers (12) indicated by bold arrows.
dCAUTION: Frame (8) weight: 90 kg (198 lb)
j : 17 mm
1. Attach nylon sling to frame (8). Hoist and move it
onto rear frame (a).
m : 50 N·m (37 lbf·ft)
2. Install 8 each of spacers (15), bolts (13), and washers
4. Connect connector (10) .
(14) to frame (8).
j : 24 mm
m : 210 N·m (155 lbf·ft)
W3-5-1-10
SECTION 3 BODY
Detail C Detail D a
9
2
3
4 13
6
E
C
30°
11, 12
5 11, 12
D
F
Detail E
b
8 14
Detail F
7 d e
1
85Z7BW-03-05-12
c f
15 16
85Z7BW-03-05-15
a- 30 mm (1.18 in) d- 37 mm (1.46 in)
5. Install 4 each of sponges (13, 14, 15, 16), bushing (6), b- 93.5 mm (3.68 in) e- 27 mm (1.06 in)
and tubes (5) to frame (8). c- 20 mm (0.79 in) f- 35 mm (1.38 in)
6. Install radiator (1) to frame (8). Fix radiator with

washers (4) (4 used), washers (3) (4 used), and bolts
(2) (4 used).
j : 13 mm
m : 17.6 N·m (13 lbf·ft)
W3-5-1-11
SECTION 3 BODY
14
7
13
B
3 11, 12
2
11, 12
9
10 1
8
6
5 4 C
85Z7BW-03-05-11 85Z7BW-03-05-10
View A View B View C
16 17
d
7. Install breather (14) with bolts, washers (13) (2
used).
a b
j : 17 mm c
m : 50 N·m (37 lbf·ft) 11, 12
8. Install cable (15) with clips (12) (2 used) and washers a- 20 mm (0.79 in) d- 35°
85Z7BW-03-05-16
(11) (4 used). b- 30 mm (1.18 in)
c- 5 mm (0.2 in)
j : 17 mm
m : 50 N·m (37 lbf·ft)

9. Attach sponges (16, 17) to air cooler (3). Install 11. Install bracket (1) with bolts, washers (2) (2 used).
bushing (9) (4 used) and sleeves (10) (4 used) to air
cooler (3). j : 17 mm
10. Move air cooler (3) to the radiator. Install plate (7) m : 50 N·m (37 lbf·ft)
and fix with 4 each of nuts (4), washers (5), bolts,
washers (6).
j : 17 mm
m : 36 N·m (27 lbf·ft)
W3-5-1-12
SECTION 3 BODY
8 6 C
3, 4
A
2
5 B
85Z7BW-03-05-08
1
View A View B View C

2
5 6
4
7 9, 10 b
85Z7BW-03-05-09 a
1
c
3
85Z7BW-03-05-17
a- 50 mm (1.97 in) c- 60 mm (2.36 in)

b- 18 mm (0.71 in)
12. Connect hose (10) and fix with clamp (9). 15. Connect pipe (5) assembly to air cooler (b), and fix
with clamp (6).
13. Install fan motor assmbly (8). (Refer to W3-xx-xx.)
14. Connect connector (7). j : 11 mm
m : 12 N·m (8.9 lbf·ft)

17. Connect pipe (1) assembly to radiator (a), and fix
with clamp (2).
j : 8 mm
m : 20 N·m (15 lbf·ft)
W3-5-1-13
SECTION 3 BODY
a
8 1
7
6
5
4 2
85Z7BW-03-05-06
a- Radiator Assy
85Z7BW-03-05-07
18. Install hydraulic oil cooler (8) onto frame (1). Fix with
6 each of bushing (7), tubes (6), washers (5), and dCAUTION: Hydraulic oil cooler assembly (1)
bolts, washers (4).
19. Attach nylon sling to hydraulic oil cooler assembly
j : 17 mm (1), and move to radiator assembly (a).
m : 37 N·m (27 lbf·ft) 20. Install plates (3) (2 used) between hydraulic oil
cooler assembly (1) and radiator assembly (a), and
fix with bolts, washers (2) (4 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-5-1-14
SECTION 3 BODY
2, 3, 4
7
13 1
2, 3, 4, 5
14, 15
6
9, 10, 11
17
A 8
12
16
85Z7BW-03-05-04
85Z7BW-03-05-05
View A Detail B
7
16 17
a c
21. Connect hoses (16, 17) and fix with clip (15) and b
bolt, washer (14).
j : 17 mm 14, 15
m : 50 N·m (37 lbf·ft) 85Z7BW-03-05-18

a- 55° c- 40°
j : 41 mm b- 10°
m : 210 N·m (155 lbf·ft)

23. Install bushing (11) (4 used) to condenser (1) 24. Connect connector (6).
assembly. Fix condernser (1) to frame (12) with bolts
25. Install 4 each of clips (4, 5), nuts (2), and washers (3)
(9) (4 used), washers (10) (4 used).
indicated by bold arrows to hoses (7, 8).
j : 13 mm
j : 17 mm
m : 15.2 N·m (11 lbf·ft)
m : 50 N·m (37 lbf·ft)
IMPORTANT: When disassembling or assembling the
26. Fix hose (7) with clip (4), nut (2), and washer (3).
condenser (1) assembly, be sure not to damage
the core and hoses. j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-5-1-15
SECTION 3 BODY
5 D 9 3
Detail A Detail B Detail C Detail D
4 B
9
a b
13
C
1
b
2 c
A
5 4
1
2
14 85Z7BW-03-05-19
a- 60 mm (2.36 in) c- 30°
8 b- 50 mm (1.97 in)
10, 11,
12, 13 14
12
11 13
10
6, 7
85Z7BW-03-05-03
85Z7BW-03-05-20
27. Install 4 each of rubber sheet (12), tubes (13), 29. Fix hose (8) with bolt, washer (6) and clip (7).
washers (11), and bolts, washers (10) to torque
converter cooler (14). j : 17 mm
j : 17 mm m : 50 N·m (37 lbf·ft)

m : 37 N·m (27 lbf·ft)
28. Connect hoses (8, 9). j : 8 mm
j : 36 mm m : 20 N·m (15 lbf·ft)

31. Connect the both ends of hose (1) and fix with
m : 180 N·m (133 lbf·ft)
clamps (2, 3).
j : 11 mm
m : 12 N·m (9 lbf·ft)
W3-5-1-16
SECTION 3 BODY
3, 4
6
16, 17 2
7
10
9 18
1
8
11, 12
13
19
15 14
85Z7BW-03-05-02 85Z7BW-03-05-01
35°
5
3, 4
85Z7BW-03-05-21
32. Install reserve tank (18) assembly with 4 each of 36. Connect hoses (9, 10) and fix with clamps (8) (2
bolts, washers (16) and sleeves (17) indicated by used).
bold arrows.
j : 8 mm
j : 19 mm
m : 1.6 N·m (1.2 lbf·ft)
m : 90 N·m (66 lbf·ft)
38. Connect hose (5) and fix with clip (4) and bolt,
j : 8 mm washer (3).
m : 1.6 N·m (1.2 lbf·ft) j : 17 mm
34. Connect connector (13). m : 50 N·m (37 lbf·ft)

35. Fix harness (19) with bolt, washer (11) and clip (12). 39. Connect the both ends of hose (1) and fix with
clamps (2) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)

fNOTE: Fully insert hoses (1, 5).
W3-5-1-17
SECTION 3 BODY
2, 3 4
6
85Z7BW-01-05-03
40. Add coolant to the radiator. 44. Install the cover (2) assembly with bolts, washers (4)
(6 used).
fNOTE: Amount of coolant: 39 L (10.3 gal)
j : 17 mm
41. Refill transmission oil in the transmission.
m : 50 N·m (37 lbf·ft)
fNOTE: Transmission oil amount: 27 L (7.1 gal) 45. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
IMPORTANT: Check the hydraulic oil level,
fNOTE: Total amount of hydraulic oil tank (1): 180 L transmission oil level and coolant level. Start the
engine and check for any oil or water leaks.
(47.6 gal)
43. Install O-ring (3). 46. Install top cover (5), left and right side covers (6),
and rear grill assembly (7). (Refer to W3-22.)
W3-5-1-18
SECTION 3 BODY
Group 6 Hydraulic Oil Tank
Removal and Installation of Hydraulic Oil

Tank
2, 3 4
85Z7BW-01-05-03
dCAUTION: Escaping oil under pressure can

penetrate the skin and eyes causing serious injury.
Relieve the hydraulic pressure inside the piping 2. Remove bolts, washers (4) (6 used). Remove the
before removing them. Hydraulic oil becomes hot cover (2) assembly and O-ring (3).
and pressurized during operation. Severe burns
may result if skin comes in contact with escaping j : 17 mm
hydraulic oil immediately after operation. Wait for
oil to cool before starting work.
supply pump.
When removing the hose and pipe, receive oil with fNOTE: Total amount of hydraulic oil tank (1): 180 L
a container in order to avoid spilling oil. (47.6 gal)
Removal
W3-6-1-1
SECTION 3 BODY
3 2
85Z7BW-03-04-01
4. Remove engine cover (1). (Refer to W3-22-1.)

5. Remove following exterior components from left
and right side. (Refer to W3-22-1.)
 Lower Cover (2)
W3-6-1-2
SECTION 3 BODY
8, 9, 10
22
1 12
11 16, 17
15 13, 14 18, 19 23 20, 21

6, 7
85Z7BW-03-06-02
2, 3 85Z7BW-03-01-06
6. Remove bolts, washers (1) (4 used), rubber plate (2), 7. Remove bolt, washer (4) and cover (5). Remove bolt,
and plate (3). washer (6) and holder (7).
j : 17 mm j : 17 mm
8. Disconnect hoses (8, 9, 10, 11, 12). Remove hoses
(22, 23) on the machine equipped with the
emergency steering.
j : 19 mm
j : 17 mm
j : 27 mm
hose (15).
j : 17 mm
j : 36 mm
10. Remove bolt, washer (16) and air breather (17).
j : 17 mm
11. Remove bolt, washer (18) and clip (19). Remove
bolts, washers (20) (3 used) and clips (21) (3 used)
j : 17 mm
W3-6-1-3
SECTION 3 BODY
2
4
a
10
11
1
3
1 12
85Z7BW-03-06-01
5 9
7
85Z7BW-03-06-04
6
8
85Z7BW-03-06-03
12. Loosen clamps (2) (2 used) and clamps (4) (2 used). 16. Disconnect hose (9).
Disconnect hoses (1, 3).
j : 19 mm
j : 8 mm
17. Disconnect connector (10). Remove bolt, washer
13. Disconnect connector (5). (11).
14. Disconnect hose (6). j : 17 mm
j : 41 mm 18. Remove hydraulic oil level sensor (12).
15. Place a container under disconnected part of hose j : 24 mm
(8). Loosen clamps (7) (2 used). Disconnect the both
ends of hose (8).
j : 11 mm
W3-6-1-4
SECTION 3 BODY
8
1
2 a
85Z7BW-03-06-05
4 3
a- Machine Front Side b- Eyebolt Installation Point

5, 6
85Z7BW-03-06-06
19. Remove bolt, washer (3) and clip (4). 21. Remove emergency steering pump (8) assembly
(only for the machine with emergency steering).
j : 17 mm (Refer to W4-7-1.)
20. Remove bolts, washers (1) (4 used) and place
harness (2) outside of the working area. dCAUTION:
(430 lb)
Hydraulic oil tank (7) weight: 195 kg
j : 10 mm 22. Install eyebolts (4 used) to hydraulic oil tank (7) at

four positions (b). Attach nylon slings, hoist and
hold hydraulic oil tank (7).
IMPORTANT: When removing/installing hydraulic
oil tank (7) from/to the machine body, be careful
hydraulic oil tank (7) does not contact with the cab
rear glass or rear work lights.
23. Remove bolts (5) (6 used) and washers (6) (6 used)
on both sides. Remove hydraulic oil tank (7) from
the rear frame.
j : 24 mm
24. Remove the adapters with hydraulic oil tank (7)
attached if necessary.
W3-6-1-5
SECTION 3 BODY
8
1
a
2
4 3
85Z7BW-03-06-05
5, 6
85Z7BW-03-06-06
a- Machine Front Side b- Eyebolt Installation Point
Installation 5. Install harness (2) with bolts, washers (1) (4 used).

1. Install all removed adapters to hydraulic oil tank (7). j : 10 mm
dCAUTION:
(430 lb)
Hydraulic oil tank (1) weight: 195 kg m : 4 N·m (3 lbf·ft)
6. Install bolt, washer (3) and clip (4) to harness (2).
2. Install eyebolts (4 used) to hydraulic oil tank (7) at
four positions (b). Attach nylon slings, hoist and j : 17 mm
hold hydraulic oil tank (7).
m : 50 N·m (37 lbf·ft)
IMPORTANT: When removing/installing hydraulic oil
tank (7) from/to the machine body, be careful not
to contact hydraulic oil tank (7) with the cab rear
glass or rear work lights.
3. Install hydraulic oil tank (7) to the rear frame with
bolts (5) (6 used) and washers (6) (6 used).
j : 24 mm
m : 270 N·m (200 lbf·ft)

4. Install emergency steering pump (8) assembly, if
equipped. (Refer to W4-7-1.)
W3-6-1-6
SECTION 3 BODY
a
10 5
11 7
12
6
8
85Z7BW-03-06-03
b 8 b
9 c c
85Z7BW-03-06-04
a- Machine Front Side b- 34 mm

c- 3 mm
85Z7BW-03-06-07
7
7. Install hydraulic oil level sensor (12). 10. Connect the both ends of hose (8) and fix with
clamps (7) (2 used). .
j : 24 mm
j : 11 mm
m : 120 N·m (89 lbf·ft)
m : 10 N·m (7.4 lbf·ft)
8. Connect connector (10) and install bolt, washer (11).
j : 17 mm
j : 41 mm
m : 50 N·m (37 lbf·ft)
m : 210 N·m (155 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-6-1-7
SECTION 3 BODY
2
4
8, 9, 10
A B
5
1
22
3 12
11 16, 17
1
C 24
85Z7BW-03-06-01
Detail A Detail B Detail C

15 13, 14 18, 19 23 20, 21
4 2 6, 7
13
d f
85Z7BW-03-06-02
g
b c e a- Machine Front Side e- 54 mm (2.13 in)
b- 50 mm (2 in) or more f- 5 mm (0.2 in)
c- 35 mm (1.38 in) g- 25°
f
15 d- 2~3 mm (0.08~0.12 in)
3 14
1
85Z7BW-03-06-10
13. Connect hoses (1, 3) and fix with clamps (2) (2 used) 15. Fix harness (5) with bolts, washers (20) (3 used) and
and clamps (4) (2 used). clips (21) (3 used) indicated by bold arrows.
j : 8 mm j : 17 mm

14. Connect hoses (8, 9, 10, 11, 12). Connect hoses (22, 16. Fix hoses (8, 9, 10, 11, 12, 15, 24) with clips (7, 14, 19)
23) on the machine equipped with the emergency and bolts, washers (6, 13, 18), respectively.
steering.
j : 17 mm
j : 19 mm
m : 50 N·m (37 lbf·ft)
m : 30 N·m (22 lbf·ft) 17. Install breather (17) with bolt, washer (16).
j : 17 mm j : 17 mm
m : 25 N·m (18.4 lbf·ft) m : 50 N·m (37 lbf·ft)
j : 27 mm
m : 80 N·m (59 lbf·ft)
W3-6-1-8
SECTION 3 BODY
View A
9 6
a
4
8
5
7
9 85Z7BW-03-06-08
1
3
5, 6
85Z7BW-03-01-06
2
85Z7BW-03-06-09
18. Install cover (8) with bolts, washers (7) (3 used). 20. Install following exterior components to left and
right side. (Refer to W3-22-1.)
j : 17 mm
m : 50 N·m (37 lbf·ft)  Lower Cover (2)
 Engine Cover (1)
19. Install plate (6) and rubber plate (5) to hydraulic

tank (9) with bolts, washers (4) (4 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-6-1-9
SECTION 3 BODY
2, 3 4
85Z7BW-01-05-03
21. Fill hydraulic oil tank (1) with hydraulic oil. 24. Bleed air from the hydraulic system. (Refer to W1-4-
1.)
fNOTE: Total amount of hydraulic oil tank (1): 180 L
IMPORTANT: Check the hydraulic oil level. Start the
(47.6 gal)
engine and check for any oil leaks.
22. Install O-ring (3).
23. Install the cover (2) assembly with bolts, washers (4)
(6 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-6-1-10
SECTION 3 BODY
Group 7 Fuel Tank
Removal and Installation of Fuel Tank

1
1
5
6
85Z7BW-03-07-01
4 3
85Z7BW-03-07-08
5. Remove nut (5). Remove engine oil drain hose (6).

dCAUTION: Fuel is highly flammable. Never bring
a fire close to fuel. j : 41 mm
IMPORTANT: The hose and pipe contain fuel. When 6. Disconnect connector (7).
removing the hose and pipe, receive oil with a
container in order to avoid spilling fuel.
Removal
2. Open side covers (1) at the right and left sides and
rear grill (2).
3. Open the hydraulic drive fan (3) assembly.
4. Remove cap (4). Place a container. Drain off fuel by
using an oil feed pump.
fNOTE: Total fuel amount: 350 L (92.5 gal)
W3-7-1-1
SECTION 3 BODY
Group 7 Fuel Tank
4, 5 6
10
2
7
7
1 3
8
9
85Z7BW-03-04-19 85Z7BW-03-07-02
7. Remove bolt, washer (2), and disconnect connector 9. Remove bolt, washer (8) and clamp (9) from hose
(3) from fuel pump (1). (7).
j : 13 mm j : 17 mm
8. Remove bolts (4) (2 used) and washers (5) (2 used). 10. Loosen clamp (6). Disconnect hose (7) from fuel
Move fuel pump (1) to the rear. filter (10).
j : 10 mm j : 8 mm
W3-7-1-2
SECTION 3 BODY
Group 7 Fuel Tank
4
2
5
1 3
85Z7BW-03-07-03
85Z7BW-03-07-04
11. Loosen clamp (2). Disconnect hose (3) from fuel 12. Loosen hose bands (4, 6). Disconnect hoses (5, 7).
tank (1).
j : 8 mm
j : 8 mm
j : 5.5 mm
W3-7-1-3
SECTION 3 BODY
Group 7 Fuel Tank
2 4
6
7
1
85Z7BW-03-07-05
13. Loosen clamps (3, 5). Disconnect hoses (4, 6) from

fuel tank (1).
j : 8 mm
14. Loosen clamp (7) and loosen hose assembly (2).
W3-7-1-4
SECTION 3 BODY
Group 7 Fuel Tank
12
9
10
11 7, 8
6
5
5 6
3 1 a
a
4 1 85Z7BW-03-07-09
6
85Z7BW-03-07-07 a- Wooden Block

d CAUTION: Fuel tank (1) assembly weight: 265 kg
(585 lb)
hoses (9, 10).
15. Attach nylon slings onto left and right side steps j : 17 mm
(rear) (6). Hoist and hold the fuel tank (1) assembly. 19. Loosen clamp (11) and disconnect hose (12).
Hold the bottom side of fuel tank (1) assembly by
using a jack and wooden blocks (a). j : 8 mm
16. Remove bolts (3) (2 used) and washers (5) (2 used). 20. Remove left and right side steps (rear) (6) from fuel
tank (1) assembly. (Refer to W3-22-1.)
j : 36 mm
Remove fuel tank (1) assembly from rear frame (2).
j : 36 mm
W3-7-1-5
SECTION 3 BODY
Group 7 Fuel Tank
12
9
10
11 7, 8
5
b
4
6
5
6 5
1 a 3
a
85Z7BW-03-07-09 4 1
6
a- Wooden Block b- Guide 85Z7BW-03-07-07
Installation
1. Install left and right side steps (rear) (6) to fuel tank
dCAUTION:
(585 lb)
Fuel tank (1) assembly weight: 265 kg
(1). (Refer to W3-22-1.)

5. Attach nylon slings onto left and right side steps
2. Insert hose (10) through guides (b) (4 places) of fuel (rear) (6). Hoist and hold the fuel tank (1) assembly.
tank (1). Hold the bottom side of fuel tank (1) assembly by
using a jack and wooden blocks (a).
3. Connect hose (12) to fuel tank (1). Fix with clamp
(11). 6. Install fuel tank (1) assembly to rear frame (2).
Temporarily tighten bolts (4) (2 used) and washers
j : 8 mm (5) (2 used).
m : 4 N·m (3 lbf·ft) 7. Temporarily tighten bolts (3) (2 used) and washers
4. Connect hose (9), and fix with bolt, washer (7) and (5) (2 used).
clip (8). 8. Tighten bolts (4) (2 used).
j : 17 mm j : 36 mm
m : 50 N·m (37 lbf·ft) m : 700 N·m (516 lbf·ft)
9. Tighten bolts (3) (2 used).
j : 36 mm
m : 700 N·m (516 lbf·ft)
W3-7-1-6
SECTION 3 BODY
Group 7 Fuel Tank
2 4
6
7
1
85Z7BW-03-07-05
10. Install hose assembly (2) to fuel tank (1) with clamp
(7).
fNOTE: Insertion amount of hose assembly (2) is 50 mm

(1.97 in).
j : 7 mm
m : 3.4 N·m (2.5 lbf·ft)

11. Connect hose (6) to fuel tank (1) with clamp (5).
j : 8 mm
m : 1.6 N·m (1.2 lbf·ft)

12. Connect hose (4) to hose assembly (2) with clamp
(3).
j : 8 mm
m : 1.6 N·m (1.2 lbf·ft)
W3-7-1-7
SECTION 3 BODY
Group 7 Fuel Tank
2
5
a
1 3
85Z7BW-03-07-03
85Z7BW-03-07-04
a- Guide
13. Insert hose (5) through guides (a) (3 used). 15. Connect hose (3) to fuel tank (1) and fix with clamp
(2).
14. Connect hoses (5, 7) and fix with hose bands (4, 6).
j : 8 mm
j : 8 mm
m : 1.6 N·m (1.2 lbf·ft)
j : 5.5 mm
m : 1.6 N·m (1.2 lbf·ft)
fNOTE: Insertion amount of hose (7) is 18 mm (0.7 in).
W3-7-1-8
SECTION 3 BODY
Group 7 Fuel Tank
6 4, 5
10
2
7
7
1 3
8
9
85Z7BW-03-07-02 85Z7BW-03-04-19
16. Connect hose (7) to fuel filter (10) and fix with clamp 18. Return fuel pump (1) to the original position, and fix
(6). with bolts (4) (2 used) and washers (5) (2 used).
j : 8 mm j : 10 mm

17. Fix hose (7) with bolt, washer (8) and clamp (9). 19. Connect connector (3) to fuel pump (1) and fix with
bolt, washer (2).
j : 17 mm
j : 13 mm
m : 50 N·m (37 lbf·ft)
m : 10 N·m (7.4 lbf·ft)
W3-7-1-9
SECTION 3 BODY
Group 7 Fuel Tank
7
Detail A
A
5
6
5
85Z7BW-03-07-10
a- 30°
85Z7BW-03-07-01
20. Connect connector (7). 21. Connect engine oil drain hose (6) and fix with nut
(5).
j : 41 mm
m : 400 N·m (295 lbf·ft)
W3-7-1-10
SECTION 3 BODY
Group 7 Fuel Tank
1
1
4 3 85Z7BW-03-07-08
22. Fill the fuel tank with fuel. 25. Bleed air from the fuel system. (Refer to W1-4-1.)
fNOTE: Total fuel amount: 350 L (92.5 gal) IMPORTANT: Start the engine and check for any oil
leaks.
23. Install cap (4).
26. Close rear grill (2) and side covers (1) at the right
24. Close hydraulic drive fan (3) assembly. and left sides.
W3-7-1-11
SECTION 3 BODY
Group 7 Fuel Tank
(Blank)
W3-7-1-12
SECTION 3 BODY
Group 8 Pump Device
Removal and Installation of Pump Device
2, 3 4
85Z7BW-01-05-03

injury. Release the pressure before disconnecting 2. Remove bolts, washers (4) (6 used). Remove the
the hydraulic pipings or removing other cover (2) assembly and O-ring (3).
equipment. Hot hydraulic oil just after operation
may spout out and cause severe burns. Allow oil to j : 17 mm
IMPORTANT: The hose and pipe contain hydraulic oil. supply pump.
a container in order to avoid spilling oil. fNOTE: Total amount of hydraulic oil tank (1): 180 L
IMPORTANT: Cap the open ends in case the hoses (47.6 gal)
and pipes have been disconnected. In addition, 4. Remove the cab (5) assembly. (Refer to W3-1-1.)
Removal
W3-8-1-1
SECTION 3 BODY
Group 8 Pump Device
2
5
a 3
1 4 85Z7BW-03-08-01
5. Disconnect connector (1). 7. Disconnect hose (4).

6. Disconnect hose (2) and hoses (3) (3 used). j : 19 mm
j : 17 mm 8. Disconnect hose (5).
j : 22 mm
W3-8-1-2
SECTION 3 BODY
Group 8 Pump Device
5
4
3
1
a
2
85Z7BW-03-04-05
9. Disconnect hoses (4, 5). 11. Disconnect hose (3).
j : 36 mm j : 27 mm
j : 41 mm j : 36 mm
W3-8-1-3
SECTION 3 BODY
Group 8 Pump Device
2 3
1
1, 8
11
10
1, 9
85Z7BW-03-08-02
4 5 7
13. Remove bolts, washers (1) (3 used), and clips (3, 8, 15. Place a container under the disconnecting part of
9). the suction pipe (6) assembly. Loosen clamp (2).
Remove socket bolts (5) (4 used). Disconnect the
j : 17 mm both ends of the suction pipe (6) assembly. Remove
14. Disconnect hose (4). O-ring (7).
j : 36 mm j : 11 mm
l : 10 mm
W3-8-1-4
SECTION 3 BODY
Group 8 Pump Device
5
1 b
10
11
6
ST 0251
3, 4
9 8 7
a 1
85Z7BW-03-08-04
85Z7BW-03-08-03
a- Machine Front Side b- Eyebolt
17. Remove nuts (3) (2 used) and the bracket (4) 21. Remove socket bolts (9) (4 used). Remove spacer
assemblies (2 used). (10) from drive unit (5).
j : 19 mm l : 10 mm
dCAUTION: Pump device (1) weight: 95 kg (210 lb) 22. Remove O-ring (11) from spacer (10).
18. Remove reducer (2) with the bleeder valve. Install 23. Remove the adapters from pump device (1) if
special tool (ST 0251) and eyebolt (b) (M12, Pitch necessary.
1.75 mm) to the mounting hole of reducer (2) with
the bleeder valve. Attach nylon slings onto eyebolt
(b). Hoist and hold pump device (1).
j : 41 mm
19. Remove socket bolts (6, 7) (2 used for each). Remove
pump device (1) from spacer (10) and place it onto
wooden blocks.
l : 10 mm
20. Remove O-ring (8) from pump device (1).
W3-8-1-5
SECTION 3 BODY
Group 8 Pump Device
5
b 1
10
11
6
ST 0251
3, 4
9 8 7
1 a
85Z7BW-03-08-04
85Z7BW-03-08-03
b- Eyebolt a- Machine Front Side
Installation IMPORTANT: If air is accumulated inside of the pump

and if the engine starts in lacking of hydraulic oil,
1. Install all removed adapters to pump device (1).
the pump may be damaged.
2. Install O-ring (11) to spacer (10). 7. Remove eyebolt (b) (M12, Pitch 1.75 mm) and
3. Install spacer (10) to drive unit (5) with socket bolts special tool (ST 0251) (a). Add hydraulic oil to the
(9) (4 used). pump. After filling hydraulic oil in the pump, install
reducer (2) with the bleeder valve.
l : 10 mm
j : 41 mm
m : 90 N·m (66 lbf·ft)
m : 80 N·m (59 lbf·ft)
4. Install O-ring (8) to pump device (1).
IMPORTANT: Install nut (3) while securing socket
d CAUTION: Pump device (1) weight: 95 kg (210 lb) bolt (9) by using a hexagonal wrench in order not
to turn them.
5. Install eyebolt (b) (M12, Pitch 1.75 mm) and the
special tool (ST 0251) to the mounting hole of 8. Secure harness (12) to socket bolts (9) (2 used) with
reducer (2) with the bleeder valve. Attach nylon nuts (3) (2 used) and the bracket (4) assembly (2
slings onto eyebolt (b). Hoist pump device (1). used).
6. Install pump device (1) to spacer (10) with socket j : 19 mm
bolts (6, 7) (2 used for each).
m : 90 N·m (66 lbf·ft)
l : 10 mm
m : 90 N·m (66 lbf·ft)
W3-8-1-6
SECTION 3 BODY
Group 8 Pump Device
B
2 3
1
1, 8
11
C
6
A
a
10
1, 9
85Z7BW-03-08-02
4 5 7
View A
Detail B Detail C
c c c d
1, 9 e e e f
11
85Z7BW-03-04-45 85Z7BW-03-04-46
2 2
a- Machine Front Side b- 35° c- 34 mm (1.34 in) e- 3 mm (0.12 in)
d- 49 mm (1.93 in) f- 10 mm (0.39 in)
9. Install O-ring (7). Connect the both ends of the 10. Connect hose (4).
suction pipe (6) assembly with clamp (2) and socket
bolts (5) (4 used). j : 36 mm
j : 11 mm m : 180 N·m (133 lbf·ft)

11. Secure hose (4) and cable (11) with bolts, washers
m : 10 N·m (7.4 lbf·ft)
(1) (3 used), and clips (3, 8, 9).
l : 10 mm
j : 17 mm
m : 90 N·m (66 lbf·ft)
m : 50 N·m (37 lbf·ft)
W3-8-1-7
SECTION 3 BODY
Group 8 Pump Device
Detail A Detail B
A 5
4
3
1
B
1
3 30°
5°
85Z7BW-03-04-47
5
10°
a 2
85Z7BW-03-04-05
85Z7BW-03-08-05
j : 41 mm
j : 36 mm
m : 210 N·m (155 lbf·ft)
m : 180 N·m (133 lbf·ft) 15. Connect hoses (4, 5).
j : 36 mm
m : 180 N·m (133 lbf·ft)
j : 27 mm
m : 95 N·m (70 lbf·ft)
W3-8-1-8
SECTION 3 BODY
Group 8 Pump Device
2
5
a 3
1 4 85Z7BW-03-08-01

16. Connect hoses (3) (3 used) and hose (2).
j : 17 mm
m : 25 N·m (18 lbf·ft)

j : 22 mm
m : 40 N·m (30 lbf·ft)

18. Connect hose (4). 2
30°
j : 19 mm
85Z7BW-03-04-48
m : 30 N·m (22 lbf·ft)
W3-8-1-9
SECTION 3 BODY
Group 8 Pump Device
2, 3 4
85Z7BW-01-05-03
21. Install the cab (5) assembly. (Refer to W3-1-1.) 24. Install the cover (2) assembly with bolts, washers (4)
(6 used).
j : 17 mm
fNOTE: Total amount of hydraulic oil tank (1): 180 L
(47.6 gal) m : 50 N·m (37 lbf·ft)
23. Install O-ring (3).
W3-8-1-10
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Pump Device
WNEC-03-08-003
00- Main Pump 01B- Socket Bolt (4 Used) 03- O-Ring 05- Spring Washer (2 Used)
01A- Regulator 02- Pilot Pump 04- Socket Bolt (2 Used) 06- Washer (2 Used)
a- Reducer
W3-8-2-1
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Pump Device
dCAUTION: Pump Device 83 kg (185 lb)

3. Remove socket bolts (01B) (4 used) from regulator
1. Remove the reducer (with the bleeder valve (01A).
attached) at the regulator part of pump device (a).
Install the eyebolt (M12, Pitch 1.75 mm) and the l : 8 mm
special tool (ST 0251). Attach nylon slings onto the
IMPORTANT: Do not drop O-ring between regulator
eyebolt. Hoist pump device (a). Place pump device
(01A) and main pump (00).
(a) onto wooden pieces (b) of approx. 100 mm
square (3.9 in square) with the regulator up. 4. Remove regulator (01A) from main pump (00).
j : 41 mm fNOTE: Pull regulator (01A) obliquely upward as

illustrated when it floats up.
ST 0251
00 01A
W4GB-02-04-001
a- Pump Device
b- Wooden Pieces
WNEC-03-08-008
IMPORTANT: Put the matching marks on pilot pump
(02) and main pump (00) before disassembling.
2. Remove socket bolts (04) (2 used), spring washers
(05) (2 used), and washers (06) (2 used) from pilot
pump (02). Remove pilot pump (02) and O-ring (03)
from main pump (00).
l : 8 mm
W3-8-2-2
SECTION 3 BODY
Group 8 Pump Device
Assembly of Pump Device
01A 01B 00
02
04
05 06 03
T4GB-03-01-001
00- Main Pump 01B- Socket Bolt (4 Used) 03- O-Ring 05- Spring Washer (2 Used)
01A- Regulator 02- Pilot Pump 04- Socket Bolt (2 Used) 06- Washer (2 Used)
W3-8-2-3
SECTION 3 BODY
Group 8 Pump Device
Assembly of Pump Device

IMPORTANT: Check that O-rings (d) (5 used) have 5. Install O-ring (03) to pilot pump (02).
been installed in the regulator (01A) mounting
surface. 6. Fit the matching marks and install pilot pump (02)
to main pump (00) with socket bolts (04) (2 used),
1. Adjust sleeves (2 used) in regulator (01A) so that the
spring washers (05) (2 used), and washers (06) (2
grooves of sleeves are in a line.
used).
2. Place regulator (01A) on main pump (00). Insert pin
(b) of feedback link (a) into the grooves of sleeves (2 l : 8 mm
used).
m : 50 N·m (5 kgf·m, 36 lbf·ft)
3. Move regulator (01A) so that knock pins (c) (2 used)
can enter regulator (01A).
4. Install regulator (01A) to main pump (00) with
socket bolts (01B) (4 used).
l : 8 mm
m : 50 N·m (5 kgf·m, 36 lbf·ft)
01A 01B a b c d 00
W4GB-02-04-002
a- Feedback Link c- Knock Pin

b- Pin d- O-Ring
W3-8-2-4
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Main Pump
WNEC-03-08-001
00- Front Casing 14- Bushing 28- Feedback Link 38- Plug (5 Used)
01- Drive Shaft 15- Retainer 29- Link Pin 40- Spring Pin (2 Used)
02- Inner Race 17- O-Ring 30- Pin 41- O-Ring
03- Retaining Ring 18- Pump Casing 31- Spring Pin 42- O-Ring (5 Used)
04- Roller Bearing 19- Needle Bearing 32- Spring Pin 43- O-Ring
05- Retaining Ring (2 Used) 20- Knock Pin 33- Socket Bolt (8 Used) 44- Oil Seal
06- Knock Pin 22- Servo Piston (3 Used) 35A- Plug 45- Retaining Ring
07- Cradle Plate 23- Knock Pin 35B- O-Ring 46- Piston (7 Used)
08- Socket Bolt (4 Used) 24- Restrictor Pin 36A- Plug 48- Pressure Sensor
09- Swash Plate 25- Backup Ring (2 Used) 36B- O-Ring 49- Cam Plate
11- Knock Pin 26- O-Ring (2 Used) 37A- Plug 50A- Valve Plate
13- Spring (7 Used) 27- Pin 37B- O-Ring 50B- Rotor
W3-8-3-1
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Main Pump
d CAUTION: Pump device weight: 83 kg

fNOTE: When removing the front casing (00) assembly,
raise the pump casing (18) assembly side a little in order
1. Secure the main pump assembly on a workbench
to prevent the rotor (50B) assembly from falling off.
with the regulator side up.
fNOTE: The restrictor pin (24) assembly of front casing
(00) may stay in the pump casing (18) assembly.
dlb)
CAUTION: Front casing (00) weight: 36 kg (79.5
4. Place the front casing (00) assembly onto wooden
pieces (120 mm square or more) with the rotor (50B)
side up.
2. Remove socket bolts (33) (8 used) from front casing
(00).
IMPORTANT: The valve plate (50A) side of rotor (50B)
l : 12 mm is a sliding surface. Do not damage it.
IMPORTANT: Do not remove knock pin (20) of valve
IMPORTANT: Inner race (02) of the drive shaft (01) plate (50A) unless necessary.
assembly cannot be replaced. Do not damage it. 5. Remove the rotor (50B) assembly from drive shaft
IMPORTANT: Do not remove retaining ring (03) of (01). Place the rotor (50B) assembly with the valve
the drive shaft (01) assembly. plate (50A) side down.
IMPORTANT: Do not remove the restrictor pin (24)
assembly and knock pin (23) of front casing (00) 6. Remove retainer (15) and pistons (46) (7 used) from
unless necessary. rotor (50B).
3. Hoist front casing (00) by using the special tool (ST
0250). Remove the front casing (00) assembly and 7. Remove bushing (14) and springs (13) (7 used) from
O-ring (17) from the pump casing (18) assembly. the rotor (50B) assembly.
ST 0250
00
WNEC-03-08-010
W3-8-3-2
SECTION 3 BODY
Group 8 Pump Device
IMPORTANT: Do not remove knock pin (11) of cam 13. Remove retaining ring (45) and oil seal (44) from
plate (49) unless necessary. front casing (00).
8. Remove cam plate (49) from swash plate (09). IMPORTANT: Do not remove plugs (38) (2 used) of
pump casing (18).
fNOTE: When tapping the yoke part with cam plate (49) 14. Remove servo pistons (22) (3 used), O-ring (41),
up, cam plate (49) is raised. O-rings (42) (5 used), and spring pins (40) (2 used)
from pump casing (18).
IMPORTANT: Do not remove plugs (38) (3 used) of
cradle plate (07).
IMPORTANT: Do not disassemble the feedback link
IMPORTANT: Do not remove knock pin (06) of the (28) assembly unless necessary.
front casing (00) assembly unless necessary.
15. Remove the feedback link (28) assembly from pump
9. Remove socket bolts (08) (4 used) from cradle plate casing (18).
(07). Remove cradle plate (07) and O-ring (43) from
the front casing (00) assembly.
16. Remove pressure sensor (48) from pump casing
l : 6 mm (18).
j : 27 mm
10. Remove the drive shaft (01) assembly from front
casing (00).
17. Remove plug (35A) and O-ring (35B) from pump
casing (18).
IMPORTANT: When removing retaining ring (05), do
not damage the seal lip contacting surface of drive l : 5 mm
shaft (01).
11. Remove retaining rings (05) (2 used) from drive 18. Remove plug (36A) and O-ring (36B) from pump
shaft (01). casing (18).
l : 6 mm
12. Remove the roller and outer ring of roller bearing
(04).
W3-8-3-3
SECTION 3 BODY
Group 8 Pump Device
19. Remove plug (37A) and O-ring (37B) from pump

casing (18).
l : 8 mm
20. Remove needle bearing (19) from pump casing (18).
W3-8-3-4
SECTION 3 BODY
Group 8 Pump Device
Assembly of Main Pump
03 18 50A 50B 46 09 23 00 33 08 35 27 31 28 32 30 29 17 43
01 SectionBB
05
B B
02 19 20 13 14 22 15 49 11 38 07
38 41 40 42 35A, 35B 36A, 36B

05 37A, 37B 04 06 44 45
24 25 26
View C
Detail of A
48
W4GB-02-04-003
00- Front Casing 14- Bushing 28- Feedback Link 38- Plug (5 Used)
01- Drive Shaft 15- Retainer 29- Link Pin 40- Spring Pin (2 Used)
02- Inner Race 17- O-Ring 30- Pin 41- O-Ring
03- Retaining Ring 18- Pump Casing 31- Spring Pin 42- O-Ring (5 Used)
04- Roller Bearing 19- Needle Bearing 32- Spring Pin 43- O-Ring
05- Retaining Ring (2 Used) 20- Knock Pin 33- Socket Bolt (8 Used) 44- Oil Seal
06- Knock Pin 22- Servo Piston (3 Used) 35A- Plug 45- Retaining Ring
07- Cradle Plate 23- Knock Pin 35B- O-Ring 46- Piston (7 Used)
08- Socket Bolt (4 Used) 24- Restrictor Pin 36A- Plug 48- Pressure Sensor
09- Swash Plate 25- Backup Ring (2 Used) 36B- O-Ring 49- Cam Plate
11- Knock Pin 26- O-Ring (2 Used) 37A- Plug 50A- Valve Plate
13- Spring (7 Used) 27- Pin 37B- O-Ring 50B- Rotor
W3-8-3-5
SECTION 3 BODY
Group 8 Pump Device
Assembly of Main Pump IMPORTANT: Check the direction to install feedback

link (28).
IMPORTANT: Before assembling, apply hydraulic oil 5. Fit the groove for pin (27). Install the feedback link
onto parts in order to prevent them from seizing. (28) assembly to pump casing (18).
1. Install needle bearing (19) to pump casing (18) by
using the special tool and a hammer.
fNOTE: Face link pin (29) to the front casing (00) side.
2. Place pump casing (18) with the regulator mounting

fNOTE: Both surfaces of pin (27) are parallel to each
other. Fit parallel surface (a) to the groove and install pin
side up. (27).
IMPORTANT: Valve plate (50A) and rotor (50B) 27 18

28
should be replaced as an assembly.
IMPORTANT: Install valve plate (50A) of the rotor
(50B) assembly with the slotted hole (opposite
side of regulator mounting side) down.
a a W176-02-04-016
3. Apply grease onto the flat surface of valve plate
(50A). Fit valve plate (50A) to knock pin (20). Install
valve plate (50A) to pump casing (18). a- Parallel Surface
4. Install servo pistons (22) (3 used) to pump casing

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

rotor (50B) when installing bushing (14). This makes it
easy to install the shaft.
9. Install the flat surface of pistons (46) (7 used) to
retainer (15). Install the piston (46) assembly to rotor
(50B).
W3-8-3-6
SECTION 3 BODY
Group 8 Pump Device
IMPORTANT: Do not damage the sliding surface for 13. Install the inner ring plate of roller bearing (04) to
oil seal (44) of drive shaft (01). drive shaft (01) with stamped mark (d) facing to
10. Install retaining ring (05) to the groove closer to the rotor side (b).
end surface of drive shaft (01). 14. Install retaining ring (05) to drive shaft (01).
 Assembly of the front casing (00) assembly
IMPORTANT: Check the direction to install the inner 15. Place front casing (00) with the pump casing (18)
ring roller bearing (04). side down.
11. Install the inner ring of roller bearing (04) to drive
16. Apply grease onto the inner surface of oil seal (44).
shaft (01) by using the special tool (ST 7861) and a
plastic hammer. 17. Install oil seal (44) to front casing (00) by using the
special tool (ST 7860) and a plastic hammer.
04 01 18. Install retaining ring (45) to front casing (00).
a
b c
19. Turn over front casing (00). Place it on wooden
pieces (120 mm square or more).
20. Install O-ring (43) to front casing (00).
W4GB-02-04-004
21. Install the drive shaft (01) assembly to front casing
a- Inner Ring c- Input Side
(00).
b- Rotor Side
fNOTE: Roller bearing (04) can be installed by tapping

12. Install the roller and outer ring of roller bearing (04) the drive shaft (01) assembly by using a plastic hammer.
to drive shaft (01) with stamped mark (d) facing to
input side (c).
d
04
WNEC-03-08-009
d- Stamped Mark
W3-8-3-7
SECTION 3 BODY
Group 8 Pump Device
22. Fit the knock pin (06) position. Install cradle plate 25. Apply grease onto the knock pin (11) hole side of
(07) to front casing (00) with socket bolts (08) (4 cam plate (49). Fit the knock pin (11) position. Install
used). cam plate (49) to swash plate (09).
l : 6 mm
IMPORTANT: Install swash plate (09) with the
m : 20 N·m (2 kgf·m, 14.5 lbf·ft) mounting part of link pin (29) in swash plate (09)
up (facing to the regulator mounting side).
23. Install O-ring (17) to front casing (00).
26. Apply grease onto the cylindrical surface of swash
plate (09). Fit the cylindrical surface of cradle plate
IMPORTANT: Check the direction to install the (07) to that of swash plate (09). Install swash plate
restrictor pin (24) assembly. (09) to the front casing (00) assembly.
24. When restrictor pin (24) has been removed, install
backup rings (25) (2 used) and O-rings (26) (2 used)
d
to restrictor pin (24). Install the restrictor pin (24)
assembly to front casing (00).
25
W176-02-04-018
24 d- Mounting Part of Link Pin
IMPORTANT: Take care not to drop plunger (46) from

a b
the rotor (50B) assembly.
27. Install the rotor (50B) assembly to the front casing
(00) assembly.
26 c W4GB-02-04-005
a- Cradle Plate (07) Side c- Orifice

b- Front Casing (00) Side
W3-8-3-8
SECTION 3 BODY
Group 8 Pump Device
IMPORTANT: Install the front casing (00) assembly so

d CAUTION: The front casing (00) assembly weight:
36 kg (79.5 lb)
that link pin (29) can be inserted to the mouting
concave part with the feedback link (28) assembly
in swash plate (09).
28. Raise the front casing (00) assembly to the vertical 30. Install the front casing (00) assembly to pump
position and hold it. casing (18) while fitting knock pin (23) and link pin
(29).
fNOTE: Do not raise the front casing (00) assembly
excessively as swash plate (09) may come off. 31. Install front casing (00) to pump casing (18) with
socket bolts (33) (8 used).
dCAUTION: The front casing (00) assembly weight:

36 kg (79.5 lb)
l : 12 mm
m : 140 N·m (14 kgf·m, 101 lbf·ft)

IMPORTANT: Do not tilt the front casing (00)
assembly as center of gravity is at the rotor (50B) 32. Install O-ring (41), O-rings (42) (5 used), and spring
side. Rotor (50B) may come off. pins (40) (2 used) to pump casing (18).
29. Hoist the front casing assembly (00) by using the
special tool (ST 0250). 41 40 42
ST 0250
W176-02-04-014
33. Install pressure sensor (48) to pump casing (18).
j : 27 mm
m : 100 N·m (10 kgf·m, 74 lbf·ft)
00
WNEC-03-08-010
W3-8-3-9
SECTION 3 BODY
Group 8 Pump Device
34. Install O-ring (35B) to plug (35A). Install plug (35A)

to the pump casing (18) assembly.
l : 5 mm
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)

l : 6 mm
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)

l : 8 mm
m : 50 N·m (5.0 kgf·m, 37 lbf·ft)
W3-8-3-10
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Regulator
WNEC-03-08-004
00- Casing 12- Stopper 23- Cylinder 34- Lock Nut

02- Sleeve 13- O-Ring (3 Used) 24- Stopper 35- Cover
03- Spool 14- O-Ring 25- O-Ring 37- Cover
05- Cylinder 15- Lock Nut 26- Lock Nut 39- Socket Bolt (8 Used)
06- Piston 16- Lock Nut 27- Nut 41- Piston
07- O-Ring 18A- Spool 29- Spring 42- Piston
08- Backup Ring 18B- Sleeve 30- Spring 131- Plug
09- O-Ring 20- Cylinder 31- Spring 137- O-Ring
11- Stopper 21- Piston 33- Set Screw
W3-8-4-1
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Regulator
IMPORTANT: As the setting changes, do not 5. Remove springs (29, 30) from casing (00).
disassemble adjusting screws (11, 12, 15, 16, 23,
24, 26, 27, 33, and 34) of the regulator. 6. Insert a round bar into the hole on casing (00). Push
If it is disassembled, pressure should be adjusted. the end surface of spool (03). Remove the cylinder
(Refer to TROUBLESHOOTING / Operational (05) assembly, sleeve (02), and spool (03) from
Performance Test in the separated volume, T/M.) casing (00).
1. Remove socket bolts (39) (4 used) from cover (35). 7. Remove piston (06), O-ring (07), backup ring (08),
Remove the cover (35) assembly from casing (00). and O-ring (09) from cylinder (05).
l : 6 mm 8. Insert a round bar into the hole on casing (00). Push

the end surface of spool (18A). Remove the cylinder
fNOTE: The set screw (33) assembly and the stopper (11) (20) assembly, spring (31), sleeve (18B), and spool
(18A) from casing (00).
assembly are removed together with cover (35).
2. Remove O-ring (13) from stopper (12). 9. Remove piston (21) and O-ring (13) from cylinder
IMPORTANT: Do not rotate lock nut (26) and nut (27). (20).
If rotating, the setting changes.
3. Remove socket bolts (39) (4 used) from cover (37).
Remove the cover (37) assembly from casing (00).
l : 6 mm
fNOTE: The stopper (24) assembly is removed together

with cover (37).
4. Remove piston (42) and O-ring (13) from the
stopper (24) assembly.
W3-8-4-2
SECTION 3 BODY
Group 8 Pump Device
Assembly of Regulator
27 23 26 24 25 13 41 42 18B 18A 00 31 21 20 13 34 33
09 08 07 06 05 03 02 29 30 11 13 14 12 15 16
39 37 131 137 35
WNEC-03-08-007
00- Casing 12- Stopper 23- Cylinder 34- Lock Nut

02- Sleeve 13- O-Ring (3 Used) 24- Stopper 35- Cover
03- Spool 14- O-Ring 25- O-Ring 37- Cover
05- Cylinder 15- Lock Nut 26- Lock Nut 39- Socket Bolt (8 Used)
06- Piston 16- Lock Nut 27- Nut 41- Piston
07- O-Ring 18A- Spool 29- Spring 42- Piston
08- Backup Ring 18B- Sleeve 30- Spring 131- Plug
09- O-Ring 20- Cylinder 31- Spring 137- O-Ring
11- Stopper 21- Piston 33- Set Screw
W3-8-4-3
SECTION 3 BODY
Group 8 Pump Device
Assembly of Regulator
IMPORTANT: Before assembling, apply hydraulic oil 7. Install O-ring (13) and piston (42) to the stopper
onto parts in order to prevent them from seizing. (24) assembly which has installed to the cover (37)
IMPORTANT: The sleeve holes (2 places) of casing assembly. Install the cover (37) assembly to casing
(00) are the same bores. The shapes of various (00) with socket bolts (39) (4 used).
parts are very similar. Assemble it while checking
the illustration in order not to confuse. l : 6 mm
IMPORTANT: Check the direction to install sleeve m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft)
(18B) and spool (18A).
8. Install O-ring (13) and springs (29, 30) to the stopper
1. Install spool (18A) to sleeve (18B). Install the sleeve
(11) assembly which has installed to the cover (35)
(18B) assembly to casing (00) by using a round bar.
assembly. Install the cover (35) assembly to casing
2. Install O-ring (13) and spring (31) to cylinder (20). (00) with socket bolts (39) (4 used).
3. Install piston (21) to the cylinder (20) assembly. l : 6 mm
Install the cylinder (20) assembly to casing (00).
m : 19.5 N·m (2 kgf·m, 14.5 lbf·ft)
IMPORTANT: Check the direction to install sleeve
(02) and spool (03).
4. Install spool (03) to sleeve (02). Install the sleeve (02)
assembly to casing (00) by using a round bar.
5. Install O-rings (07, 09) and backup ring (08) to
cylinder (05).
6. Install piston (06) to the cylinder (05) assembly.
Install the cylinder (05) assembly to casing (00).
W3-8-4-4
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Priority Valve
WNEC-03-08-002
18- Pump Casing 64- Plug 70- Spring 75- Spring

61- Orifice 65- O-Ring 71- Screw 76- Spool
62- Orifice (2 Used) 67- Plug 72- Gasket (2 Used)
63A- Plug 68- Seat 73- Nut
63B- O-Ring 69- Poppet 74- Nut Cap
W3-8-5-1
SECTION 3 BODY
Group 8 Pump Device
Disassembly of Priority Valve

1. Remove plug (63A) and O-ring (63B) from pump IMPORTANT: Do not drop gasket (72).
casing (18). 7. Remove nut (73) from pump casing (18).
j : 41 mm j : 22 mm
2. Remove plug (64) and O-ring (65) from pump casing IMPORTANT: Do not drop spring (70) and poppet
(18). (69).
j : 50 mm 8. Remove screw (71) from pump casing (18).
3. Remove orifice (62) from spool (76). 9. Remove spring (70) and poppet (69) from screw
(71).
l : 3 mm
10. Remove seat (68) from pump casing (18).
4. Remove spool (76) and spring (75) from pump
casing (18). j : 7 mm
5. Remove orifice (62) and orifice (61) from plug (64). 11. Remove plug (67) from pump casing (18).
l : 3 mm l : 6 mm
IMPORTANT: Do not drop gasket (72).

6. Remove nut cap (74) from screw (71).
j : 22 mm
W3-8-5-2
SECTION 3 BODY
Group 8 Pump Device
Assembly of Priority Valve
A
B
18
Section B Section A
76 63A 62 63B
69 67
68
72
73 61
71
70 64 65
74
62 75
W4GB-02-04-007
18- Pump Casing 64- Plug 70- Spring 75- Spring

61- Orifice 65- O-Ring 71- Screw 76- Spool
62- Orifice (2 Used) 67- Plug 72- Gasket (2 Used)
63A- Plug 68- Seat 73- Nut
63B- O-Ring 69- Poppet 74- Nut Cap
W3-8-5-3
SECTION 3 BODY
Group 8 Pump Device
Assembly of Priority Valve
IMPORTANT: Before assembling, apply hydraulic oil 5. Instal orifice (62) and orifice (61) to spool (76).
onto parts in order to prevent them from seizing.
l : 3 mm
1. Install plug (67) to pump casing (18).
m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
l : 6 mm
IMPORTANT: Check the direction of spool (76).
m : 15 N·m (1.5 kgf·m, 11 lbf·ft)
6. Install spool (76) and spring (75) to pump casing
2. Install seat (68) to pump casing (18). (18).
j : 7 mm 7. Install orifice (62) to plug (64).
m : 15 N·m (1.5 kgf·m, 11 lbf·ft) l : 3 mm

3. Install spring (70) and poppet (69) to screw (71). m : 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Install the screw (71) assembly to pump casing (18)
8. Install O-ring (65) to plug (64). Install plug (64) to
so that the end of poppet (69) can be inserted into
pump casing (18).
the hole on seat (68).
4. Install nut (73) and gasket (72) to screw (71). j : 50 mm
j : 22 mm m : 550 N·m (56 kgf·m, 400 lbf·ft)

m : 46 N·m (4.7 kgf·m, 34 lbf·ft)
to pump casing (18).
j : 41 mm
m : 450 N·m (46 kgf·m, 330 lbf·ft)

10. Install nut cap (74) and gasket (72) to screw (71).
j : 22 mm
m : 37 N·m (3.7 kgf·m, 27.5 lbf·ft)
fNOTE: Measure, adjust the steering relief pressure, and

install nut cap (74).
W3-8-5-4
SECTION 3 BODY
Group 8 Pump Device
Structure of Pilot Pump
WNEC-03-08-005
W3-8-6-1
SECTION 3 BODY
Group 8 Pump Device
IMPORTANT: The housing is made of aluminum. Do

not damage the housing. Take extreme care in
order to control the tightening torque.

No. Part Name Q’ty Remark
(mm) N·m kgf·m lbf·ft
2 Flange 1
Apply grease onto the lip
3 Oil Seal 1
when assembling.
5 Retaining Ring 1
6 Seal 2
when assembling.
7 Cover 1
9 Backup Ring 2
when assembling.
10 Key 2
12 O-Ring 2
when assembling.
13 Gear 1
14 Gear 1
15 Washer 4
Apply hydraulic oil when
26 Bushing 2
assembling.
Apply hydraulic oil when
27 Bushing 2
assembling.
28 Knock Pin 2
29 Bolt 4 j : 17 39 to 44 4 to 4.5 28.5 to 32.5
41 Housing 1
W3-8-6-2
SECTION 3 BODY
Group 9 Control Valve
Removal and Installation of Control Valve

1 2, 3 4
2, 3
WNEK50-03-13-001 WNEK50-03-09-001
IMPORTANT: The hoses and pipes contain hydraulic 4. Remove bolts, washers (3) (2 used) and clips (2) (2
oil. When removing the hoses and pipes, receive used).
oil with a container in order to avoid spilling oil.
j : 19 mm
Removal
inspection and maintenance. (Refer to W1-5-1.)
dCAUTION: Release any pressure from the

hydraulic oil tank. (Refer to W1-5-1.)
2. Remove cover (1). (Refer to W3-22-1.)
dCAUTION: Release any pressure in the front

attachment hydraulic circuit and the ride control
accumulator (only for the machine with ride
control device). (Refer to W1-5-1.)
j : 36 mm
W3-9-1-1
SECTION 3 BODY
6 3
5 4 85Z7BW-03-03-01
j : 19 mm j : 41 mm
6. Disconnect hoses (4) (3 used). 9. Disconnect pipe (2).
j : 19 mm j : 35 mm
j : 41 mm j : 22 mm
W3-9-1-2
SECTION 3 BODY
1 2 3 4 5
85Z7BW-03-09-01
j : 36 mm j : 41 mm
12. Disconnect hoses (3) (2 used). 15. Disconnect pipe (4).
j : 17 mm j : 35 mm
j : 36 mm j : 41 mm
W3-9-1-3
SECTION 3 BODY
1
A
85Z7BW-03-09-02 85Z7BW-03-09-03
3
Detail A
17. Remove under guard (front) (1) (only for the

machine with under guard). (Refer to W3-22-1.)
j : 17 mm 2
19. Disconnect hoses (2) (3 used). 85Z7BW-03-09-04
j : 19 mm
W3-9-1-4
SECTION 3 BODY
a 1 1
3
a- Eyebolt Mounting Hole WNEK50-03-09-007 WNEC-03-09-020
22. Remove the adapters from multiple control valve (1)

dCAUTION:

Multiple control valve (1) weight:
70 kg (155 lb)
if necessary.
20. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

eyebolt mounting holes (a) (2 places) of multiple
control valve (1). Attach nylon slings onto the
eyebolts (2 used). Hoist and hold multiple control
valve (1).
multiple control valve (1) from bracket (2).
j : 19 mm
W3-9-1-5
SECTION 3 BODY
a 1 1
3
a- Eyebolt Mounting Hole WNEK50-03-09-007 WNEC-03-09-020
Installation 3. Install multiple control valve (1) to bracket (2) with

1. Install all removed adapters to multiple control
valve (1). j : 19 mm
dCAUTION:

Multiple control valve (1) weight:
70 kg (155 lb)
m : 90 N·m (66 lbf·ft)

eyebolt mounting holes (a) (2 places) of multiple
control valve (1). Attach nylon slings onto the
eyebolts (2 used). Hoist multiple control valve (1).
W3-9-1-6
SECTION 3 BODY
Detail A
2
A 85Z7BW-03-09-04
85Z7BW-03-09-03
4. Connect hoses (2) (3 used). 5. Connect hose (3).
j : 19 mm j : 17 mm
W3-9-1-7
SECTION 3 BODY
7, 8
1 2 3 4 5
6 4
WNEK50-03-09-009
85Z7BW-03-09-01
2
a View A
a
6
1
IMPORTANT: Check the angle to install hoses (2, 5).
j : 41 mm a
b
m : 210 N·m (155 lbf·ft) 85Z7BW-03-09-05
7. Temporarily install pipe (4), clip (8), and bolt, washer a- 15 ° b- 30 °
(7).
8. Tighten pipe (4).
j : 35 mm
m : 180 N·m (133 lbf·ft)
9. Tighten bolt, washer (7). j : 17 mm
j : 19 mm m : 25 N·m (18 lbf·ft)

m : 90 N·m (66 lbf·ft)
j : 36 mm
m : 180 N·m (133 lbf·ft)
W3-9-1-8
SECTION 3 BODY
8, 9
1
2
6 3
WNEK50-03-09-011
5 4
85Z7BW-03-03-01 3
View A
b
j : 22 mm
a
m : 40 N·m (30 lbf·ft)
13. Temporarily install pipe (2), clip (9), and bolt, washer
(8). 1
85Z7BW-03-09-06
14. Tighten pipe (2). a- 25 ° b- 5°
j : 35 mm
m : 180 N·m (133 lbf·ft)

15. Tighten bolt, washer (8).
j : 19 mm 17. Connect hoses (1, 3).
m : 90 N·m (66 lbf·ft) j : 41 mm
16. Connect hoses (4) (3 used) and hose (5). m : 210 N·m (155 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-9-1-9
SECTION 3 BODY
WNEK50-03-09-001 85Z7BW-03-09-02
j : 36 mm
m : 180 N·m (133 lbf·ft)

19. Lower the lift arm. Set the machine position for
1.)
21. Install under guard (front) (5) (only for the machine
with under guard). (Refer to W3-22-1.)
22. Set the machine position (lift arm raise) for WNEK50-03-13-001
23. Install cover (1). (Refer to W3-22-1.)
W3-9-1-10
SECTION 3 BODY
Disassembly of Control Valve
67
65E
65F
43 65C
65D
37 65B
30
25D (n)
43 25E
25B
25C 65A 67
35 43
A 25B
33 59
25A
32 25J 56 60
43 31 55
(m) 2
(f) 3 57 58D
1
11D 4 5 (j) 58C
43 30 2
34 11B 1 25H 58B
06 6
11C 7 25G 58A
30 25F
11B (k)
D
C 30
11A
43 B (d) (g) 61
A
33 10D
40 (e)
39 10B
(b) 10C
33
10B (c)
42 10A
41 (a)
06
37 35 34
View A 85Z7BW-03-09-07
W3-9-2-1
SECTION 3 BODY
20
C
A 01H
B
01J
01C
(v)
01H
01J
70F
01A
01F 01D 70G
70E
70D
01E 01G 01F
76 01G 2
(t)
75 1
49 70C
4
A 77 3
B 5
61
51 6
(o) 40
(p) (s)
33 70B
(r)
(q) (x)
(w)
A 51
B
C 40
D 33 43
30
A 30
B
C
07
D 70J
70H (y)
70A 70K
70I
06 43
A
B
C
D 05
85Z7BW-03-09-08
W3-9-2-2
SECTION 3 BODY
01A- Housing 11A- Spool 34- Pilot Housing 65E- Plug

01B- Housing 11B- Spring Seat (2 Used) 35- Pilot Housing 65F- O-Ring
01C- End Plate 11C- Spring 37- Pilot Housing 67- Socket Bolt (6 Used)
01D- O-Ring (2 Used) 11D- Bolt 39- Poppet 70A- Pilot Housing
01E- O-Ring (2 Used) 20A- O-Ring 40- Spring (3 Used) 70B- Piston (2 Used)
01F- O-Ring (4 Used) 20B- O-Ring 41- Poppet 70C1- O-Ring (2 Used)
01G- O-Ring (2 Used) 20C- Pump Control Valve 42- Spring 70C2- Backup Ring (2 Used)
01H- Bolt (4 Used) 25A- Spool 43- Socket Bolt (18 Used) 70C3- O-Ring (2 Used)
01I- Washer (4 Used) 25B- Spring Seat (2 Used) 49A- O-Ring 70C4- Backup Ring (2 Used)
05A- O-Ring 25C- Spring 49B- Plug 70C5- O-Ring (2 Used)
05B- Backup Ring 25D- Bolt 51- Poppet (2 Used) 70C6- Backup Ring (2 Used)
05C- O-Ring 25E- O-Ring 55- Poppet 70C7- Sleeve (2 Used)
05D- Relief Valve 25F- Plug 56- Spring 70D- Washer (2 Used)
06A- O-Ring (2 Used) 25G- O-Ring 57- O-Ring 70E- Spring (2 Used)
06B- Backup Ring (2 Used) 25H- Spring 58A- Seat Valve 70F- Plug (2 Used)
06C- O-Ring (2 Used) 25J1- Spool 58B- Poppet 70G- O-Ring (2 Used)
06D- Overload Relief Valve (2 25J2- Check Valve 58C- Spring 70H- Ball
Used) 25J3- Plug 58D1- O-Ring 70I- Plug
07A- O-Ring 25J4- O-Ring 58D2- Plug 70J- O-Ring
07B- Backup Ring 25J5- Spring 59- Spring Guide 70K- O-Ring
07C- O-Ring 25J6- O-Ring 60- Spring 75- Valve
07D- Overload Relief Valve 25J7- Backup Ring 61- O-Ring (3 Used) 76- O-Ring
10A- Spool 30- O-Ring (7 Used) 65A- Pilot Plate 77- Nut
10B- Spring Seat (2 Used) 31- Poppet 65B- Spool
10C- Spring 32- Spring 65C- Spring
10D- Bolt 33- O-Ring (5 Used) 65D- Washer
a- Low-Pressure Relief Valve j- Load Check Valve (Bucket p- Overload Relief Valve (Bucket: v- Pump Control Valve
b- Make-Up Valve Circuit) Bottom Side) w- Bucket Anti-Drift Valve
c- Bucket Spool k- Lift Arm Flow Rate Control q- Overload Relief Valve (Lift (Selector Valve)
d- Overload Relief Valve (Bucket: Valve (Poppet Valve) Arm: Bottom Side) x- Lift Arm Anti-Drift Valve
Rod Side) m- Charge-Cut Valve r- Bucket Anti-Drift Valve (Check (Selector Valve)
e- Lift Arm Spool n- Lift Arm Flow Rate Control Valve) y- Shuttle Valve
f- Make-Up Valve (Lift Arm: Rod Valve (Selector Valve) s- Lift Arm Anti-Drift Valve
Side) o- Main Relief Valve (Check Valve)
g- Ride Control Spool t- Drain Plug
W3-9-2-3
SECTION 3 BODY
Disassembly of Control Valve  Disassembly of Bucket Anti-Drift Valve (Selector Valve)

(w) and Lift Arm Anti-Drift Valve (Selector Valve) (x)
4. Remove plugs (70F) (2 used) and O-rings (70G) (2
 Disassembly of Pump Control Valve (v)
used) from the pilot housing (70A) assembly.
IMPORTANT: The pump control valve cannot be
assembled again. Do not disassemble the pump j : 24 mm
control valve.
5. Remove springs (70E) (2 used), washers (70D) (2
1. Remove pump control valve (20C) and O-rings (20A,
used), the sleeve (70C7) assemblies (2 used), and
20B) from end plate (01C).
pistons (70B) (2 used) from the pilot housing (70A)
j : 27 mm assembly.
6. Remove backup rings (70C2, 70C4, 70C6) (2 used
 Disassembly of Overload Relief Valve (Bucket: Rod Side) for each) and O-rings (70C1, 70C3, 70C5) (2 used for
(d), and Overload Relief Valve (Bucket: Bottom Side) (p) each) from sleeves (70C7) (2 used).
IMPORTANT: Do not disassemble the overload
relief valve. If it is disassembled, pressure should  Disassembly of Shuttle Valve (y)
be adjusted. (Refer to TROUBLESHOOTING / 7. Remove plug (70I) (2 used), O-ring (70K), ball (70H),
Operational Performance Test in the separated and O-ring (70J) from the pilot housing (70A)
volume, T/M.) assembly.
2. Remove overload relief valves (06D) (2 used),
O-rings (06C) (2 used), backup rings (06B) (2 used), j : 17 mm
and O-rings (06A) (2 used) from the housing (01A)
assembly.  Disassembly of Ride Control Spool (g) and Charge-Cut
Valve (m)
j : 41 mm
8. Remove socket bolts (43) (2 used) from pilot housing
(37). Remove pilot housing (37) and O-ring (30) from
 Disassembly of Overload Relief Valve (Lift Arm: Bottom housing (01A).
Side) (q)
IMPORTANT: Do not disassemble the overload l : 8 mm
relief valve. If it is disassembled, pressure should
be adjusted. (Refer to TROUBLESHOOTING /
Operational Performance Test in the separated
volume, T/M.)
3. Remove overload relief valve (07D), O-ring (07C),
backup ring (07B), and O-ring (07A) from the
housing (01A) assembly.
j : 41 mm
W3-9-2-4
SECTION 3 BODY
9. Remove socket bolts (43) (8 used) from pilot  Disassembly of Drain Plug (t)
housing (70A). Remove pilot housing (70A), O-rings 15. Remove nut (77) from housing (01A).
(30) (3 used), O-rings (33) (2 used), and O-rings (61)
(2 used) from housing (01A). j : 13 mm
16. Remove valve (75) and O-ring (76) from housing
l : 8 mm
(01A).
10. Remove the spool (25A) assembly from housing
(01A). l : 4 mm
11. Secure spool (25A) in a vise by using wooden pieces

as illustrated. Remove bolt (25D), O-ring (25E),  Disassembly of Lift Arm Anti-Drift Valve (Check Valve)
spring seats (25B) (2 used), and spring (25C) from (s) and Bucket Anti-Drift Valve (Check Valve) (r)
the spool (25A) assembly. 17. Remove springs (40) (2 used) and poppets (51) (2
used) from housing (01A).
j : 19 mm
 Disassembly of Make-Up Valve (Lift Arm: Rod Side) (f )
18. Remove socket bolts (43) (4 used) from pilot housing
(35). Remove pilot housing (35) and O-rings (30, 33)
from housing (01A).
l : 8 mm
19. Remove spring (32) and poppet (31) from housing
(01A).
W4GB-02-05-002
12. Remove plug (25F), O-ring (25G), spring (25H), and

the spool (25J1) assembly from the spool (25A)
assembly.
j : 19 mm
13. Secure spool (25J1) in a vise by using wooden
pieces as illustrated. Remove plug (23I3), O-ring
(25J4), spring (25J5), and check valve (25J2) from
spool (25J1).
j : 10 mm
14. Remove O-ring (25J6) and backup ring (25J7) from
spool (25J1).
W3-9-2-5
SECTION 3 BODY
 Disassembly of Lift Arm Spool (e)  Disassembly of Make-Up Valve (b)

20. Remove the spool (11A) assembly from housing 25. Remove poppet (39) and spring (40) from housing
(01A). (01A).
as illustrated. Remove bolt (11D), spring seats (11B)  Disassembly of Low-Pressure Relief Valve (a)
(2 used), and spring (11C) from spool (11A). 26. Remove poppet (41) and spring (42) from housing
(01A).
j : 19 mm
 Disassembly of Main Relief Valve (o)

IMPORTANT: Do not disassemble the main relief
valve. If it is disassembled, pressure should
be adjusted. (Refer to TROUBLESHOOTING /
Operational Performance Test in the separated
volume, T/M.)
27. Remove relief valve (05D), O-ring (05C), backup ring
(05B), and O-ring (05A) from housing (01A).
W4GB-02-05-002 j : 27 mm
 Disassembly of Bucket Spool (c)  Disassembly of Plug (49B)

22. Remove socket bolts (43) (4 used) from pilot 28. Remove plug (49B) and O-ring (49A) from housing
housing (34). Remove pilot housing (34), O-ring (30), (01A).
and O-rings (33) (2 used) from housing (01A).
l : 10 mm
l : 8 mm
23. Remove the spool (10A) assembly from housing  Disassembly of Lift Arm Flow Rate Control Valve
(01A). (Selector Valve) (n)
29. Remove plug (65E) and O-ring (65F) from pilot plate
24. Secure spool (10A) in a vise by using wooden pieces (65A).
as illustrated. Remove bolt (10D), spring seats (10B)
(2 used), and spring (10C) from spool (10A). j : 36 mm
j : 19 mm 30. Remove spring (65C), washer (65D), and spool (65B)

from pilot plate (65A).
W3-9-2-6
SECTION 3 BODY
 Disassembly of Load Check Valve (Bucket Circuit) (j)  Disassembly of Housing

31. Remove socket bolts (67) (6 used) from pilot plate 36. Remove bolts (01H) (4 used) and washers (01I) (4
(65A). Remove pilot plate (65A) from housing (01A). used) from the housing (01A) assembly.
l : 10 mm j : 19 mm
32. Remove O-ring (57), poppet (55), and spring (56) 37. Remove end plate (01C), O-rings (01D), O-rings
from housing (01A). (01E), O-rings (01F) (2 used), and O-rings (01G) (2
used) from housing (01A).
 Disassembly of Lift Arm Flow Rate Control Valve
(Poppet Valve) (k)
33. Remove O-rings (30, 61), spring guide (59), spring
(60), and the seat valve (58A) assembly from
housing (01A).
34. Secure seat valve (58A) in a vise by using wooden
pieces as illustrated. Remove plug (58D2) and
O-ring (58D1) from seat valve (58A).
l : 5 mm
W4GB-02-05-002
35. Remove spring (58C) and poppet (58B) from seat

valve (58A).
W3-9-2-7
SECTION 3 BODY
Assembly of Control Valve
49A, 49B
43 43
43 43 43
67
43
67
43 43
67 43
67
43
43 43
67 43
43 43 43
43
67
43
01H, 01I
01H, 01I
01H, 01I 01H, 01I

85Z7BW-03-09-09
W3-9-2-8
SECTION 3 BODY
Section A-A
A A 06D 06C 06B 06A 39 40 33
B B
p b
C C
o a
D D
G G
H H
F F
05D 05C 05B 05A 01A 41 42 33 34
85Z7BW-03-09-10 TNED-03-02-004
Section B-B Section C-C
56 55
57 j
I K
06A 06B 06C d
06D 31
J
f
33
30
c 32 35
30
e
10A 10B 10C 10B 10D
11A 11B 11C 11B 11D
TNED-03-02-005 TNED-03-02-006
Section D-D Section F-F

t
20B
75 76 07B 07A
q 77 20A 20C
07D 07C
30 37
25E v
L
25D 01C
25A 25B 25C 25B
TNED-03-02-009
TNED-03-02-007
W3-9-2-9
SECTION 3 BODY
Section G-G Section H-H

01D 01G 01G
01F 01E 01F WNEC-03-09-003 WNEC-03-09-010
Detail I Detail J
70C7 70D 70F 70G 70C7 70D 70F 70G 70E 61 33

70E 61 33 40
w x 40
51
70C2
51
70C2 70C1 s
70C1 r 70C4
70C4 70C3 30
70C3 30 70C5
70C5 70C6
70C6 y
70B
70I
70K
70B 70J
70A 70H
WNEC-03-09-007 WNEC-03-09-006
70A
Detail K Detail L
65B 65D
65F
65A
65E 25G 25H 25J7 25J6
58D2 65C
n
58D1 59
60
58C 30
58B
58A k 70A 25J3
61
25F 30
25J1 25J2 25J5 25J4
m
WNEC-03-09-008 WNEC-03-09-009
W3-9-2-10
SECTION 3 BODY
01A- Housing 11A- Spool 34- Pilot Housing 65E- Plug

01B- Housing 11B- Spring Seat (2 Used) 35- Pilot Housing 65F- O-Ring
01C- End Plate 11C- Spring 37- Pilot Housing 67- Socket Bolt (6 Used)
01D- O-Ring (2 Used) 11D- Bolt 39- Poppet 70A- Pilot Housing
01E- O-Ring (2 Used) 20A- O-Ring 40- Spring (3 Used) 70B- Piston (2 Used)
01F- O-Ring (4 Used) 20B- O-Ring 41- Poppet 70C1- O-Ring (2 Used)
01G- O-Ring (2 Used) 20C- Pump Control Valve 42- Spring 70C2- Backup Ring (2 Used)
01H- Bolt (4 Used) 25A- Spool 43- Socket Bolt (18 Used) 70C3- O-Ring (2 Used)
01I- Washer (4 Used) 25B- Spring Seat (2 Used) 49A- O-Ring 70C4- Backup Ring (2 Used)
05A- O-Ring 25C- Spring 49B- Plug 70C5- O-Ring (2 Used)
05B- Backup Ring 25D- Bolt 51- Poppet (2 Used) 70C6- Backup Ring (2 Used)
05C- O-Ring 25E- O-Ring 55- Poppet 70C7- Sleeve (2 Used)
05D- Relief Valve 25F- Plug 56- Spring 70D- Washer (2 Used)
06A- O-Ring (2 Used) 25G- O-Ring 57- O-Ring 70E- Spring (2 Used)
06B- Backup Ring (2 Used) 25H- Spring 58A- Seat Valve 70F- Plug (2 Used)
06C- O-Ring (2 Used) 25J1- Spool 58B- Poppet 70G- O-Ring (2 Used)
06D- Overload Relief Valve (2 25J2- Check Valve 58C- Spring 70H- Ball
Used) 25J3- Plug 58D1- O-Ring 70I- Plug
07A- O-Ring 25J4- O-Ring 58D2- Plug 70J- O-Ring
07B- Backup Ring 25J5- Spring 59- Spring Guide 70K- O-Ring
07C- O-Ring 25J6- O-Ring 60- Spring 75- Valve
07D- Overload Relief Valve 25J7- Backup Ring 61- O-Ring (3 Used) 76- O-Ring
10A- Spool 30- O-Ring (7 Used) 65A- Pilot Plate 77- Nut
10B- Spring Seat (2 Used) 31- Poppet 65B- Spool
10C- Spring 32- Spring 65C- Spring
10D- Bolt 33- O-Ring (5 Used) 65D- Washer
a- Low-Pressure Relief Valve j- Load Check Valve (Bucket p- Overload Relief Valve (Bucket: v- Pump Control Valve
b- Make-Up Valve Circuit) Bottom Side) w- Bucket Anti-Drift Valve
c- Bucket Spool k- Lift Arm Flow Rate Control q- Overload Relief Valve (Lift (Selector Valve)
d- Overload Relief Valve (Bucket: Valve (Poppet Valve) Arm: Bottom Side) x- Lift Arm Anti-Drift Valve
Rod Side) m- Charge-Cut Valve r- Bucket Anti-Drift Valve (Check (Selector Valve)
e- Lift Arm Spool n- Lift Arm Flow Rate Control Valve) y- Shuttle Valve
f- Make-Up Valve (Lift Arm: Rod Valve (Selector Valve) s- Lift Arm Anti-Drift Valve
Side) o- Main Relief Valve (Check Valve)
g- Ride Control Spool t- Drain Plug
W3-9-2-11
SECTION 3 BODY
Assembly of Control Valve 5. Install the seat valve (58A) assembly, spring (60),
spring guide (59), and O-rings (30, 61) to housing
IMPORTANT: Before assembling, apply hydraulic oil
(01A).
 Assembly of Housing  Assembly of Load Check Valve (Bucket Circuit) (j)

1. Install O-rings (01G) (2 used) to end plate (01C). 6. Install poppet (55), spring (56), and O-ring (57) to
Install O-rings (01D, 01E) and O-rings (01F) (2 used) housing (01A).
to housings (01A). 7. Install pilot plate (65A) to housing (01A) with socket
2. Install housing (01B) and end plate (01C) to housing bolts (67) (6 used).
(01A) with bolts (01H) (4 used) and washers (01I) (4
l : 10 mm
used).
m : 88+50 N·m (65+3.70 lbf·ft)
j : 19 mm
m : 108+100 N·m (80+7.40 lbf·ft)  Assembly of Lift Arm Flow Rate Control Valve (Selector
Valve) (n)
 Assembly of Lift Arm Flow Rate Control Valve (Poppet 8. Install spool (65B), washer (65D), and spring (65C) to
Valve) (k) pilot plate (65A).
3. Secure seat valve (58A) in a vise by using wooden 9. Install O-ring (65F) to plug (65E). Install plug (65E) to
pieces as illustrated. Install poppet (58B) and spring pilot plate (65A).
(58C) to seat valve (58A).
j : 36 mm
4. Install O-ring (58D1) to plug (58D2). Install plug
(58D2) to seat valve (58A). m : 177+290 N·m (131+210 lbf·ft)
l : 5 mm
 Assembly of Plug (49B)
m : 15+30 N·m (11+2.20 lbf·ft) 10. Install O-ring (49A) to plug (49B). Install plug (49B)
to housing (01A).
l : 10 mm
m : 118+200 N·m (87+150 lbf·ft)
W4GB-02-05-002
W3-9-2-12
SECTION 3 BODY
 Assembly of Main Relief Valve (o)  Assembly of Bucket Anti-Drift Valve (Selector Valve) (w)
IMPORTANT: If the main relief valve has been and Lift Arm Anti-Drift Valve (Selector Valve) (x)
disassembled, pressure should be adjusted. (Refer IMPORTANT: Check the order to install O-rings
to TROUBLESHOOTING / Operational Performance (70C1, 70C3, 70C5) and backup rings (70C2, 70C4,
Test in the separated volume, T/M.) 70C6).
11. Install O-ring (05A), backup ring (05B), and O-ring 15. Install backup rings (70C2, 70C4, 70C6) (2 used for
(05C) to relief valve (05D). Install relief valve (05D) to each) and O-rings (70C1, 70C3, 70C5) (2 used for
housing (01A). each) to sleeves (70C7) (2 used).
j : 27 mm 16. Install pistons (70B) (2 used), the sleeve (70C7)

assemblies (2 used), washers (70D) (2 used), and
m : 177+290 N·m (131+210 lbf·ft) springs (70E) (2 used) to pilot housing (70A).
17. Install O-rings (70G) (2 used) to plugs (70F) (2 used).
 Assembly of Bucket Anti-Drift Valve (Check Valve) (r) Install plugs (70F) (2 used) to pilot housing (70A).
and Lift Arm Anti-Drift Valve (Check Valve) (s)
12. Install poppets (51) (2 used) and springs (40) (2 j : 24 mm
used) to housing (01A).
m : 118+200 N·m (87+150 lbf·ft)
13. Install O-rings (30) (3 used) and O-rings (33) (2 used)
to pilot housing (70A). Install O-rings (61) (2 used) to
 Assembly of Shuttle Valve (y)
housing (01A).
18. Install O-rings (70K, 70J) to plug (70I).
14. Install pilot housing (70A) to housing (01A) with
19. Install ball (70H) and plug (70I) to pilot housing
(70A).
l : 8 mm
j : 17 mm
m : 49 +5
0 N·m (36
+3.7
0 lbf·ft)
m : 34+70 N·m (25+5.20 lbf·ft)
 Assembly of Low-Pressure Relief Valve (a)

20. Install poppet (41) and spring (42) to housing (01A).
 Assembly of Make-Up Valve (b)

21. Install poppet (39) and spring (40) to housing (01A).
W3-9-2-13
SECTION 3 BODY
 Assembly of Bucket Spool (c)  Assembly of Make-Up Valve (Lift Arm: Rod Side) (f )
22. Secure spool (10A) in a vise by using wooden pieces 27. Install poppet (31) and spring (32) to housing (01A).
as illustrated. Install spring seats (10B) (2 used),
28. Install O-rings (30, 33) to pilot housing (35). Install
spring (10C), and bolt (10D) to spool (10A).
pilot housing (35) to housing (01A) with socket bolts
j : 19 mm (43) (4 used).
m : 25+50 N·m (18+3.70 lbf·ft) l : 8 mm
m : 49+50 N·m (36+3.70 lbf·ft)
 Assembly of Charge-Cut Valve (m) and Ride Control

Spool (g)
29. Install O-ring (25J4) to plug (25J3).
30. Secure spool (25J1) in a vise by using wooden pieces
as illustrated. Install check valve (25J2), spring (25J5),
and plug (25J3) to spool (25J1).
W4GB-02-05-002
j : 10 mm
m : 8+40 N·m (5.9+30 lbf·ft)

23. Apply hydraulic oil onto spool (10A). Install the
spool (10A) assembly to housing (01A).
24. Install O-ring (30) and O-rings (33) (2 used) to pilot
housing (34). Install pilot housing (34) to housing
(01A) with socket bolts (43) (4 used).
l : 8 mm
m : 49+50 N·m (36+3.70 lbf·ft)
 Assembly of Lift Arm Spool (e) W4GB-02-05-002

as illustrated. Install spring seats (11B) (2 used),
IMPORTANT: Check the order to install O-ring (25J6)
spring (11C), and bolt (11D) to spool (11A).
and backup ring (25J7).
j : 19 mm IMPORTANT: Apply grease onto O-ring (25J6) and
backup ring (25J7).
m : 25+50 N·m (18+3.70 lbf·ft)
31. Install O-ring (25J6) and backup ring (25J7) to spool
26. Apply hydraulic oil onto spool (11A). Install the (25J1).
spool (11A) assembly to housing (01A).
32. Install O-ring (25G) to plug (25F).
W3-9-2-14
SECTION 3 BODY
33. Secure spool (25A) in a vise by using wooden pieces  Assembly of Overload Relief Valve (Lift Arm: Bottom
as illustrated. Install the spool (25J1) assembly, Side) (q)
spring (25H), and plug (25F) to spool (25A). IMPORTANT: If the overload relief valve has been
disassembled, pressure should be adjusted. (Refer
j : 19 mm to TROUBLESHOOTING / Operational Performance
Test in the separated volume, T/M.)
m : 25+50 N·m (18+3.70 lbf·ft)
41. Install O-ring (07A), backup ring (07B), and O-ring
34. Install O-ring (25E) to bolt (25D). (07C) to overload relief valve (07D). Install overload
35. Secure the spool (25A) assembly in a vise by using relief valve (07D) to housing (01A).
wooden pieces as illustrated. Install spring seats
j : 41 mm
(25B) (2 used), spring (25C), and bolt (25D) to the
spool (25A) assembly. m : 93+140 N·m (69+100 lbf·ft)
j : 19 mm
 Assembly of Overload Relief Valve (Bucket: Bottom
m : 25+50 N·m (18+3.70 lbf·ft) Side) (p), Overload Relief Valve (Bucket: Rod Side) (d)
36. Apply hydraulic oil onto spool (25A). Install the IMPORTANT: If the overload relief valve has been
spool (25A) assembly to housing (01A). disassembled, pressure should be adjusted. (Refer
to TROUBLESHOOTING / Operational Performance
37. Install O-ring (30) to pilot housing (37). Install pilot Test in the separated volume, T/M.)
housing (37) to housing (01A) with socket bolts (43)
(2 used). 42. Install O-rings (06A) (2 used), backup rings (06B) (2
used), and O-rings (06C) (2 used) to overload relief
l : 8 mm valves (06D) (2 used). Install overload relief valves
(06D) (2 used) to the housing (01A) assembly.
m : 49+50 N·m (36+3.70 lbf·ft)
j : 41 mm
 Assembly of Drain Plug (t)
38. Install O-ring (76) to valve (75). m : 93+140 N·m (69+100 lbf·ft)
39. Install valve (75) to housing (01A).
 Assembly of Pump Control Valve (v)
l : 4 mm
43. Install O-rings (20A, 20B) to pump control valve
m : 7+20 N·m (5.2+1.50 lbf·ft) (20C). Install relief valve (20C) to end plate (01C).
40. Install nut (77) to valve (75). j : 27 mm
j : 13 mm m : 93+140 N·m (69+100 lbf·ft)
m : 10+20 N·m (7.4+1.50 lbf·ft)
W3-9-2-15
SECTION 3 BODY
(Blank)
W3-9-2-16
SECTION 3 BODY
Group 10 Pilot Valve
Removal and Installation of Pilot Valve

(Single Lever Type)
2
4
WNEK50-03-10-001 3 WNEK50-03-10-002
IMPORTANT: The hoses and pipes contain hydraulic 3. Remove screws (3) (5 used). Remove cover (4).
oil. When removing the hoses and pipes, receive
Removal

2. Remove screws (2) (2 used). Remove cover (1).
W3-10-1-1
SECTION 3 BODY
View A 1 2 1
WNEK50-03-10-003 1 WNEK50-03-10-004
4. Remove screws (1) (3 used). Remove cover (2). View B 3

3
6
4
5
3
WNEK50-03-10-005
W3-10-1-2
SECTION 3 BODY
Detail A
1
1
B WNEK50-03-10-010
View B
WNEK50-03-10-006
j : 19 mm
3 85Z7BW-03-10-01
8. Remove clip (3).
9. Disconnect connectors (2) (2 used).
W3-10-1-3
SECTION 3 BODY
1
4
3 WNEK50-03-10-008 WNEK50-03-10-009
10. Raise boot (1) and remove bolts, washers (4) (4

used).
j : 10 mm
11. Remove pilot valve (2) from bracket (3).
12. Remove the adapters from pilot valve (2) if
necessary.
W3-10-1-4
SECTION 3 BODY
1
4
3 WNEK50-03-10-008 WNEK50-03-10-009
Installation
1. Install all removed adapters to pilot valve (2).
2. Raise boot (1). Install pilot valve (2) to bracket (3)
with bolts, washers (4) (4 used). Lower boot (1).
j : 10 mm
m : 5 N·m (3.7 lbf·ft)
W3-10-1-5
SECTION 3 BODY
Detail A
1
1
B WNEK50-03-10-010
View B
WNEK50-03-10-006

4. Secure harness (4) (2 used) with clip (3).
5. Connect hoses (1) (6 used). 3 85Z7BW-03-10-01
j : 19 mm
m : 30 N·m (22 lbf·ft)

1.)
W3-10-1-6
SECTION 3 BODY
View A 1 2 1
WNEK50-03-10-003 1 WNEK50-03-10-004
7. Install cover (6) with screws (5) (4 used). View B 3
8. Install cover (4) with screws (3) (3 used).

3
6
4
5
3
WNEK50-03-10-005
W3-10-1-7
SECTION 3 BODY
2
4
3 WNEK50-03-10-002 WNEK50-03-10-001

W3-10-1-8
SECTION 3 BODY
Removal and Installation of Pilot Valve (Two

Lever Type)
WNEK50-03-10-020
IMPORTANT: The hoses and pipes contain hydraulic Removal

hoses, and pipes for assembling. If the clips which 2. Fully move the right console (2) assembly to the
secure the hoses have been removed, install the front by operating slide lever (1).
3. Open door (3).
W3-10-2-1
SECTION 3 BODY
WNEK50-03-10-021 3 WNEK50-03-10-022
View A 1
4. Remove screws (2) (3 used). Raise cover (1).

5. Disconnect connector (3). Remove connector (3)
from cover (4).
7. Remove cover (1).
WNEK50-03-10-023
5
W3-10-2-2
SECTION 3 BODY
1 View A 4 5
WNEK50-03-10-025
A 5
View A 6 7
1 WNEK50-03-10-024

9. Remove rubber seal (3).
13. Remove screws (10) (4 used). Remove cover (11). WNEK50-03-10-026
View B 8 9
11
10
8
WNEK50-03-10-027
W3-10-2-3
SECTION 3 BODY
View A
2
6
1
3
WNEK50-03-10-030
4
WNEK50-03-10-029
2 5 2
14. Remove clips (2) (3 used).

15. Disconnect connectors (4) (3 used) and connectors
(5) (8 used). Place harness (1) outside the work area.
16. Remove connectors (4) (3 used) from bracket (3).
17. Remove rubber seal (6).
W3-10-2-4
SECTION 3 BODY
A Detail A
2
3
WNEK50-03-10-031 WNEK50-03-10-032
Detail A
18. Lower cover (5). Pull out grip (1) harness (4) from
cover (5).
19. Loosen nut (2). Turn grip (1) counterclockwise.
Remove grip (1) from lever (3).
3
j : 17 mm
20. Remove nut (2) from lever (3).
6
j : 17 mm
21. Remove cover (5) from lever (3).
22. Loosen nut (6).
j : 19 mm
23. Remove lever (3) from pilot valve (7). Remove nut (6)
from lever (3).
7 WNEK50-03-10-033
j : 19 mm
24. Remove other lever (3) in the same way as step 18
to step 23.
W3-10-2-5
SECTION 3 BODY
1 View A
4 WNEK50-03-10-035
WNEK50-03-10-034
B View B
j : 19 mm 5
j : 19 mm
27. Remove socket bolts (3) (4 used).
l : 8 mm
28. Remove pilot valve (2) from frame (1).
29. Remove the adapters from pilot valve (2) if
necessary.
WNEK50-03-10-036
W3-10-2-6
SECTION 3 BODY
1 View A
4 WNEK50-03-10-035
WNEK50-03-10-034
B View B
Installation
1. Install all removed adapters to pilot valve (2). 5
2. Install pilot valve (2) to frame (1) with socket bolts
(3) (4 used).
l : 8 mm
m : 50 N·m (37 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft) WNEK50-03-10-036

j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-10-2-7
SECTION 3 BODY
A Detail A
WNEK50-03-10-031 7 WNEK50-03-10-033
Detail A
5. Temporarily install nut (6) to lever (3).

6. Install lever (3) to pilot valve (7). Tighten nut (6). 1
j : 19 mm
2
m : 40 N·m (29.5 lbf·ft) 3
7. Install cover (5) to lever (3).
8. Temporarily install nut (2) to lever (3). 4
IMPORTANT: Check the position to install grip (1).
9. Turn grip (1) clockwise. Install grip (1) to lever (3).
Tighten nut (2). 5
j : 17 mm
m : 20 N·m (15 lbf·ft)

WNEK50-03-10-032
10. Pass grip (1) harness (4) into cover (5). Raise cover
(5). Install cover (5) to grip (1). c
11. Install another grip (1) in the same way as step 5 to 1
step 10.
d
2
3
6
b
WNEC-03-10-020
a- 143 mm (5.63 in) c- 8 ° (Reference)
b- 223 mm (8.8 in) d- Machine Front Side
W3-10-2-8
SECTION 3 BODY
7 View A
2
6
1
8
2
9
3
WNEK50-03-10-030
4
WNEK50-03-10-029
2 5 2
12. Install rubber seal (6).

13. Install harness (1) in between grips (7) (2 used).
14. Install connectors (4) (3 used) to bracket (3).
15. Connect connectors (5) (8 used) and connectors (4)
(3 used).
16. Secure harness (1), harnesses (8) (2 used) and
harnesses (9) (3 used) with clips (2) (3 used).
W3-10-2-9
SECTION 3 BODY
1 View A 4 5
WNEK50-03-10-025
A 5
View A 6 7
1 WNEK50-03-10-024

21. Install rubber seal (3).
22. Install cover (2) with screws (1) (5 used). WNEK50-03-10-026
View B 8 9
11
10
8
WNEK50-03-10-027
W3-10-2-10
SECTION 3 BODY
6 1 View A 1
WNEK50-03-10-023
5
3 WNEK50-03-10-022
23. Install cover (1) through grips (6).

25. Install connector (3) to cover (4). Connect connector
(3).
2
1.)
engine and check for any oil leaks. WNEK50-03-10-021
W3-10-2-11
SECTION 3 BODY
WNEK50-03-10-020
28. Operate slide lever (1) and moves the right console
(2) assembly to the original position.
29. Close door (3).
W3-10-2-12
SECTION 3 BODY
Disassembly of Pilot Valve (Single Lever

Type)
WNEC-03-10-001
1- Handle 35D- Shim (Several) 51- Plate 60E- O-Ring

11A- Lever 35E- Shim (Several) 53B- Pusher (3 Used) 62- Spool
11B- Screw 35F- Shim (Several) 53C- Solenoid (3 Used) 63- Spool (3 Used)
11C- Nut 35G- Shim (Several) 53D- O-Ring (3 Used) 65- Spring (4 Used)
13- Boot 35H- Shim (Several) 60A- Guide 66A- Socket (3 Used)
35A- Nut 35I- Universal Joint 60B- Pusher 66B- Spring (3 Used)
35B- Washer 50A- Retaining Ring (3 Used) 60C- Plate 80- Casing
35C- Cam 50B- Armature (3 Used) 60D- Retaining Ring
W3-10-3-1
SECTION 3 BODY
Disassembly of Pilot Valve (Single Lever Type)

IMPORTANT: Keep the disassembled parts together 8. Remove boot (13) and nut (11C) from the lever
by each port in order not to confuse. (11A) assembly.
IMPORTANT: Casing (80) is made of aluminium. 9. Remove retaining ring (50A) and armature (50B)
Strong force deforms it. Handle it with care. from pusher (53B).
1. Remove boot (13) from plate (51). Raise boot (13).
10. Remove other retaining rings (50A) (2 used) and
2. Remove the harness of handle (1) from plate (51). armatures (50B) (2 used) in the same way as step 9.
3. Remove boot (13) from handle (1). Lower boot (13). IMPORTANT: The quantity and kind of shims (35D,
4. Remove screw (11B) from handle (1) by using a star 35E, 35F, 35G, and 35H) have been determined for
screwdriver. each pilot valve. Do not lose shims (35D, 35E, 35F,
35G, and 35H).
5. Remove handle (1) from lever (11A). 11. Remove nut (35A), washer (35B), cam (35C), and
6. Loosen nut (11C) from lever (11A). shims (35D, 35E, 35F, 35G, and 35H) from universal
joint (35I).
j : 19 mm
j : 27 mm
7. Remove the lever (11A) assembly from universal
joint (35I). fNOTE: LOCTITE #263 or equivalent has been applied to
nut (35A).
fNOTE: LOCTITE #263 or equivalent has been applied to
lever (11A).
W3-10-3-2
SECTION 3 BODY
12. Remove universal joint (35I) from casing (80) by 18. Remove spool (62) and spring (65) from hole (a) on
using a wrench. port 2 of casing (80) by using a pair of pliers.
l : 8 mm
fNOTE: LOCTITE #263 or equivalent has been applied to a

universal joint (35I).
fNOTE: Hold plate (51) against spring (65) when c
removing universal joint (35I).

13. Remove plate (51) from casing (80).
b
14. Remove plate (60C) and the guide (60A) assembly d
from casing (80) by using a screwdriver.
15. Remove the solenoid (53C) assemblies (3 used) from
casing (80) by using a screwdriver.
16. Remove pusher (60B), retaining ring (60D), and
O-ring (60E) from guide (60A). WNEC-03-10-003
17. Remove pushers (53B) (3 used) and O-rings (53D) (3 a- Hole on Port 2 c- Hole on Port 3
used) from solenoids (53C) (3 used). b- Hole on Port 1 d- Hole on Port 4
IMPORTANT: Keep the disassembled parts together

by each port in order not to confuse.
19. Remove spools (63) (3 used), springs (65) (3 used),
sockets (66A) (3 used), and springs (66B) (3 used)
from hole (b) on port 1, hole (c) on port 3, and hole
(d) on port 4 of casing (80) by using a pair of pliers.
W3-10-3-3
SECTION 3 BODY
Assembly of Pilot Valve (Single Lever Type)
Section A
11B
1
11A
11C
13 35A
35D, 35E, 35F, 35G, 35H
35I 35B
60B 35C
60C
50A
51
50B
53B
60A 53C
60E
53D
60D
66A
A
66B
62
63
65
65
80
WNEC-03-10-002
a b
1- Handle 35D- Shim (Several) 51- Plate 60E- O-Ring

11A- Lever 35E- Shim (Several) 53B- Pusher (3 Used) 62- Spool
11B- Screw 35F- Shim (Several) 53C- Solenoid (3 Used) 63- Spool (3 Used)
11C- Nut 35G- Shim (Several) 53D- O-Ring (3 Used) 65- Spring (4 Used)
13- Boot 35H- Shim (Several) 60A- Guide 66A- Socket (3 Used)
35A- Nut 35I- Universal Joint 60B- Pusher 66B- Spring (3 Used)
35B- Washer 50A- Retaining Ring (3 Used) 60C- Plate 80- Casing
35C- Cam 50B- Armature (3 Used) 60D- Retaining Ring
a- Section of Port 2 b- Sections of Port 1, 3, and 4
W3-10-3-4
SECTION 3 BODY
Assembly of Pilot Valve (Single Lever Type) 3. Install pushers (53B) (3 used) and O-rings (53D) (3
used) to solenoids (53C) (3 used).
onto parts in order to prevent them from seizing. 4. Install the solenoid (53C) assemblies (3 used) to hole
IMPORTANT: The pilot valve is the susceptible (b) on port 1, hole (c) on port 3, and hole (d) on port
hydraulic component to contamination. Keep the 4 of casing (80).
parts clean when assembling. 5. Install pusher (60B), retaining ring (60D), and O-ring
IMPORTANT: Casing (80) is made of aluminium. (60E) to guide (60A).
Strong force deforms it. Handle it with care.
6. Install the guide (60A) assembly and plate (60C) to
1. Check the port hole number and install the same hole (a) on port 2 of casing (80).
parts before disassembling. Install springs (66B) (3
used), sockets (66A) (3 used), springs (65) (3 used), 7. Fit projection (f ) on the lower surface of plate (51)
and spools (63) (3 used) to hole (b) on port 1, hole to groove (e) on the side of solenoids (53C) (3 used).
(c) on port 3, and hole (d) on port 4 of casing (80). Place plate (51) onto casing (80).
b
d
e f f, g WNEC-03-10-004
WNEC-03-10-003
e- Groove on Side of Solenoid f- Projection on Lower Surface

a- Hole on Port 2 c- Hole on Port 3 (53C) of Plate (51)
b- Hole on Port 1 d- Hole on Port 4 g- Groove on Side of Plate (60C)
2. Install spring (65) and spool (62) to hole (a) on port

2 of casing (80).
W3-10-3-5
SECTION 3 BODY
8. Apply LOCTITE #263 or equivalent to the thread part 11. Install armature (50B) between the end of cam (35C)
of casing (80). Install plate (51) to casing (80) with and pusher (53B).
universal joint (35I).
IMPORTANT: Replace retaining ring (50A) with the
l : 8 mm new one.
12. Install retaining ring (50A) to pusher (53B).
m : 50±5 N·m (37±4 lbf·ft)
13. Install other armatures (50B) (2 used) and retaining
fNOTE: Hold plate (51) against spring (65) by hand. rings (50A) (2 used) in the same way as step 11 to
9. Install shims (35D, 35E, 35F, 35G, and 35H), cam step 12.
(35C), and washer (35B) to universal joint (35I). 14. Temporarily tighten nut (11C) to the lever (11A)
assembly.
fNOTE: Insert a screwdriver into the hole on the side of
cam (35C) and tighten it to the specified torque when j : 19 mm
installing nut (35A).
IMPORTANT: Check the direction to install the lever
10. Apply LOCTITE #263 or equivalent to the thread part
(11A) assembly.
of universal joint (35I). Install nut (35A) to universal
joint (35I). 15. Apply LOCTITE #263 or equivalent to the thread
part of universal joint (35I). Install the lever (11A)
j : 27 mm assembly to universal joint (35I).
m : 30±3 N·m (22±2 lbf·ft)
W3-10-3-6
SECTION 3 BODY
16. Tighten nut (11C) to the specified torque. IMPORTANT: Install the harness of handle (1) by
winding around lever (11A). At this time, adjust
j : 19 mm the harness in order not to rub.
m : 40±4 N·m (30±3 lbf·ft) 21. Install bracket (b) of the harness of handle (1) to
groove (a) on plate (51). Secure the harness.
17. Install boot (13) to the lever (11A) assembly.
IMPORTANT: Check the direction to install handle
(1).
18. Install handle (1) to lever (11A).
IMPORTANT: The thread part of handle (1) is made
of resin. Take care not to tighten screw (11B) b a
excessively.
19. Install screw (11B) to handle (1) by using a star
screwdriver.
20. Install boot (13) to handle (1).
WNEC-03-10-005
a- Groove b- Bracket
22. Lower and install boot (13) to handle (51).
W3-10-3-7
SECTION 3 BODY
(Blank)
W3-10-3-8
SECTION 3 BODY
Disassembly of Pilot Valve (Two Lever Type)
5 5
6 2 6 2
2 3 2 3
1 1
3 4 3 4
7 9 7 9
8 8
7 7
10
10 10 11
11 11
18 12
12 12
51
13 13
51 51
14
14 13
13 15
15 14
16
14 15
17 16 17
15
16 17
19 42
17
43
20
21 21
44 22
22
21
21 22
22 24 24
23 25 23 25
26 26
24 27 24 27
28
25 25 28
29 45
26 26
30 30
27 27 28
31 46 31
28 30
29 32 31 32
30 a
c 32
31 b
32
52
53
d
50
WNEC-03-10-006
W3-10-4-1
SECTION 3 BODY
1 - Socket Bolt (8 Used) 12 - Push Rod (3 Used) 23 - Plate (2 Used) 43 - Solenoid

2 - Lock Nut (4 Used) 13 - O-Ring (4 Used) 24 - Seal (4 Used) 44 - Detent Casing
3 - Screw (4 Used) 14 - Bushing (4 Used) 25 - Plug (4 Used) 45 - Spring
4 - Lever (2 Used) 15 - Detent Bushing (4 Used) 26 - O-Ring (4 Used) 46 - Spring
5 - Boot (2 Used) 16 - Steel Ball (12 Used) 27 - Push Rod (4 Used) 50 - Casing
6 - Lock Plug (2 Used) 17 - Scraper (4 Used) 28 - Spring Seat (4 Used) 51 - Shim (3 Used)
7 - Bushing (4 Used) 18 - Push Rod 29 - Spring (2 Used) 52 - Socket Bolt
8 - Cam Shaft (2 Used) 19 - Solenoid 30 - Spring (4 Used) 53 - Band
9 - Cover (2 Used) 20 - Detent Casing 31 - Washer (4 Used)
10 - Detent Ring (3 Used) 21 - Spring Guide (4 Used) 32 - Spool (4 Used)
11 - Spring (3 Used) 22 - Spring (4 Used) 42 - Solenoid
a - Hole on Port 1 b - Hole on Port 2 c - Hole on Port 3 d - Hole on Port 4
W3-10-4-2
SECTION 3 BODY
Disassembly of Pilot Valve (Two Lever Type) 6. Remove the spring seat (28) assemblies (2 used) and
springs (30) (2 used) from the holes on port 3 and
1. Remove socket bolt (52) and band (53) from casing
port 4 of casing (50).
(50).
IMPORTANT: Do not damage the surface of spool
 Disassembly of Pilot Valve Assemblies at Port 3 Section
(32).
and Port 4 Section
IMPORTANT: Casing (50) is made of aluminium. IMPORTANT: Take care that spring seat (28) is not
Strong force deforms it. Handle it with care. lowered 6 mm or more.
2. Secure casing (50) in a vise by using wooden pieces. 7. Lower spring seat (28) of the spring seat (28)
Remove boot (5) from cover (9). assembly in the hole of port 3. Move spring seat (28)
sideways while compressing spring (45). Remove
IMPORTANT: Put the matching marks on casing the spool (32) assembly from larger hole (a) of
(50), detent casing (20), and cover (9) before spring seat (28).
disassembling.
3. Remove socket bolts (1) (2 used) from the deeper a
mounting part of cover (9). 28
l : 5 mm
4. Remove the cover (9) assembly from casing (50).
IMPORTANT: Take care that the plug (25) assembly
does not fly out due to spring (30) when removing. 32
5. Remove the plug (25) assemblies (2 used) from
casing (50) by using a screwdriver.
WNEC-03-10-008
a - Hole
8. Remove spring (45) and washer (31) from spool (32).
W3-10-4-3
SECTION 3 BODY
9. Remove spring seat (28), spring (46), washer (31), 14. Remove springs (22) (2 used), spring guides (21) (2
and spool (32) from the spring seat (28) assembly used), and shims (51) (2 used) from plate (23).
in the hole of port 4 in the same way as step 7 and
15. Remove the detent casing (20) assembly from the
step 8.
cover (9) assembly.
10. Remove push rods (27) (2 used) and O-rings (26) (2
IMPORTANT: Do not pull the lead wire when
used) from the plug (25) assemblies (2 used).
removing solenoids (42, 43).
IMPORTANT: Do not damage the inner surface of 16. Remove solenoids (42, 43) from detent casing (20).
plug (25).
17. Remove lock plug (6) from lever (4) of the cover (9)
11. Remove seals (24) (2 used) from plugs (25) (2 used).
assembly.
IMPORTANT: As the spring force is applied to the
cover (9) assembly, remove socket bolts (1) l : 3 mm
alternately. 18. Remove cam shaft (8) from cover (9).
12. Secure plate (23) of the cover (9) assembly in a vise.
19. Remove lever (4) from cover (9).
Remove socket bolts (1) (2 used) from the shallower
mounting part of cover (9). 20. Remove nuts (2) (2 used) and screws (3) (2 used)
from lever (4).
l : 5 mm
j : 13 mm
IMPORTANT: Spring guides (21) (2 used) may be
stuck to detent case (20) by grease. Do not drop
them.
13. Remove the cover (9) assembly from plate (23).
W3-10-4-4
SECTION 3 BODY
21. Remove the detent bushing (15) assemblies (2 used) 24. Remove push rods (12) (2 used) from detent
from the mounting side by using the special tools as bushings (15) (2 used).
illustrated.
25. Remove detent rings (10) (2 used) and springs (11)
(2 used) from detent bushings (15) (2 used).
a e
f IMPORTANT: Do not damage the inner surface of
detent bushing (15) when removing scraper (17).
b d
c 26. Remove scrapers (17) (2 used) from detent bushings
(15) (2 used).
W4GB-02-06-012
a - Dia. 10 mm
-0.3-0.4
d - 2 mm (0.079 in)
(Dia. 0.39-0.012-0.016 in) e - Dia. 8-0.2-0.3 mm
b - 30 mm (1.18 in) (Dia. 0.32-0.008-0.012 in)
c - 40 mm (1.58 in) f - 30°
22. Remove O-rings (13) (2 used) from cover (9).

IMPORTANT: Do not drop steel ball (16).
23. Compress springs (11) (2 used) while holding detent
rings (10) (2 used). Remove steel balls (16) (8 used)
from detent bushings (15) (2 used).
W3-10-4-5
SECTION 3 BODY
 Disassembly of Pilot Valve Assemblies at Port 1 Section

and Port 2 Section
27. Disassemble the pilot valve assemblies at port 1
section and port 2 section in the same way of step 2
to step 26.
fNOTE: Springs (45, 46), detent casing (20), solenoids

(42, 43), and push rod (12) are not equipped for the pilot
valve assembly at port 1 side. Spring (29), detent casing
(44), solenoid (19), and push rod (18) are quipped for it.
fNOTE: Detent ring (10), spring (11), shim (51), and steel
balls (16) (4 used) are not equipped for the pilot valve
assembly at port 1 side.
fNOTE: Springs (45, 46) and detent casing (20) are
not quipped for the pilot valve assembly at port 2 side.
Spring (29) and detent casing (44) are equipped for it.
fNOTE: Solenoids (42, 43) are not equipped for the pilot
valve assembly at port 2 side.
W3-10-4-6
SECTION 3 BODY
Assembly of Pilot Valve (Two Lever Type)
B B
A A
8 7
14 5
16 3
2
12
6
18 16
10 1
10
11 13
11
17 17
15 9
15
42
12
20
19 21
44 43 51
51 22
51
27 23
53
24
52
25
26
50 28
45
46
29 30
29 32
31
a Section A-A b c Section B-B d

WNEC-03-10-007
W3-10-4-7
SECTION 3 BODY
1 - Socket Bolt (8 Used) 12 - Push Rod (3 Used) 23 - Plate (2 Used) 43 - Solenoid

2 - Lock Nut (4 Used) 13 - O-Ring (4 Used) 24 - Seal (4 Used) 44 - Detent Casing
3 - Screw (4 Used) 14 - Bushing (4 Used) 25 - Plug (4 Used) 45 - Spring
4 - Lever (2 Used) 15 - Detent Bushing (4 Used) 26 - O-Ring (4 Used) 46 - Spring
5 - Boot (2 Used) 16 - Steel Ball (12 Used) 27 - Push Rod (4 Used) 50 - Casing
6 - Lock Plug (2 Used) 17 - Scraper (4 Used) 28 - Spring Seat (4 Used) 51 - Shim (3 Used)
7 - Bushing (4 Used) 18 - Push Rod 29 - Spring (2 Used) 52 - Socket Bolt
8 - Cam Shaft (2 Used) 19 - Solenoid 30 - Spring (4 Used) 53 - Band
9 - Cover (2 Used) 20 - Detent Casing 31 - Washer (4 Used)
10 - Detent Ring (3 Used) 21 - Spring Guide (4 Used) 32 - Spool (4 Used)
11 - Spring (3 Used) 22 - Spring (4 Used) 42 - Solenoid
a - Port 1 b - Port 2 c - Port 3 d - Port 4
W3-10-4-8
SECTION 3 BODY
Assembly of Pilot Valve (Two Lever Type)

dCAUTION: Take care that detent rings (10) (2
used) do not fly out due to springs (11) (2 used).
IMPORTANT: Adjust push rods (12) (2 used) so that
 Assembly of Pilot Valve Assemblies at Port 3 Section steel balls (16) (8 used) fit on the constricted parts
and Port 4 Section of push rods (12) (2 used).
IMPORTANT: Check the direction to install scraper
4. Compress springs (11) (2 used) while holding detent
(17).
rings (10) (2 used). Apply grease onto steel balls (16)
1. Apply grease onto scrapers (17) (2 used). Install (8 used). Install steel balls (16) (8 used) to the detent
scrapers (17) (2 used) to detent bushings (15) (2 bushing (15) assemblies (2 used).
used).
5. Install O-rings (13) (2 used) to cover (9).
15 6. Check the position before disassembling and install

the detent bushing (15) assemblies (2 used) to cover
17 (9).
7. Temporarily tighten screws (3) (2 used) and nuts (2)
(2 used) to lever (4).
W4GB-02-06-014
2. Apply grease onto the sliding surface of detent

bushings (15) (2 used) and detent rings (10) (2
used). Install detent rings (10) (2 used) and springs
(11) (2 used) to detent bushings (15) (2 used).
IMPORTANT: Check the direction to install push rods
(12) (2 used).
3. Install push rods (12) (2 used) to the detent bushing
(15) assemblies (2 used).
W3-10-4-9
SECTION 3 BODY
8. Apply grease onto top and bottom of push rods (12) 12. Apply grease onto the mounting surface of spring
(2 used), the sliding surface of lever (4) side surface, of spring guides (21) (2 used). Check the position
and the sliding surface of cam shaft (8). Secure before disassembling and install spring (22) (2 used)
cover (9) in a vise. Install lever (4) and cam shaft (8) and spring guides (21) (2 used) to plate (23).
to cover (9).
9. Apply LOCTITE #241 onto lock plug (6). Install lock
dCAUTION: Take care that spring (22) (2 used) do
not fly out when installing the cover (9) assembly.
plug (6) to lever (4).
13. Install the cover (9) assembly and detent casing (20)
l : 3 mm to plate (23). Temporarily tighten socket bolts (1) (2
used) to the the shallower mounting part of cover
m : 7 N·m (5.2 lbf·ft) (9).
IMPORTANT: Engage the rubber bushing of the lead l : 5 mm
wire passage position into the detent casing (20)
groove. 14. Secure plate (23) in a vise. Tighten socket bolts (1) (2
used) to cover (9) to the specified torque. Spray anti-
10. Check the position before disassembling and install
rust oil to the spring chamber of detent casing (20).
solenoids (42, 43) to detent casing (20).
IMPORTANT: Check the direction to install detent l : 5 mm
casing (20).
m : 9 N·m (6.6 lbf·ft)
11. Install shims (51) (2 used) and detent casing (20) to
push rods (12) (2 used) of the cover (9) assembly.
W3-10-4-10
SECTION 3 BODY
IMPORTANT: Check the direction to install seal (24). IMPORTANT: Take care that spring seats (28) (2 used)
15. Install O-rings (26) (2 used), seals (24) (2 used), and are not lowered 6 mm or more.
push rods (27) (2 used) to plugs (25) (2 used). 17. Install the spool (32) assembly to larger hole (a) of
spring seats (28) (2 used). Lower spring seats (28)
(2 used). Move spring seats (28) (2 used) sideways
24 while compressing springs (45, 46).
25 a
28
27
W4GB-02-06-015
16. Install springs (45, 46) and washers (31) (2 used) to 32

spools (32) (2 used).
WNEC-03-10-008
a - Hole
W3-10-4-11
SECTION 3 BODY
IMPORTANT: Do not fit bottom of spools (32) (2 IMPORTANT: The clearance between screws (3) (2
used) to casing (50) too strongly. used) and push rod (12) produces a small amount
18. Install springs (30) (2 used), the spool (32) of play when starting the lever (4) operation. After
assemblies (2 used), and the plug (25) assemblies tightening nut (2), recheck that no play is present.
(2 used) to the holes on port 3 and port 4 of casing IMPORTANT: When pushing push rods (12) (2 used)
(50). with screws (3) (2 used) too strongly, the front
attachment may be operated unexpectedly when
19. Apply grease onto top of push rods (27) (2 used).
starting the engine.
20. Secure casing (50) in a vise by using wooden pieces. 21. Adjust the height of screws (3) (4 used) so that
Install the cover (9) assembly to casing (50). Install levers (4) (2 used) are perpendicular to top of covers
socket bolts (1) (2 used) to the deeper mounting (9) (2 used). Turn the lever from side to side. Check
part of cover (9). that no play is present with the lever in neutral.
Tighten it with nuts (2) (4 used).
l : 5 mm
l : 13 mm
m : 9 N·m (6.6 lbf·ft)
m : 17 N·m (13 lbf·ft)
IMPORTANT: When boot (5) is not installed correctly,
waterproof is reduced.
22. Spray anti-rust oil to the parts inside boots (5) (2
used). Install top of boots (5) (2 used) to the grooves
of levers (4) (2 used). Install bottom of boots (5) (2
used) to the grooves of covers (9) (2 used).
W3-10-4-12
SECTION 3 BODY
 Assembly of Pilot Valve Assemblies at Port 1 Side and 24. Install socket bolt (52) and band (53) to casing (50).
Port 2 Side
23. Assemble the pilot valve assemblies at port 1 side
and port 2 side in the same way of step 1 to step 22.
fNOTE: Springs (45, 46), detent casing (20), solenoids

(42, 43), and push rod (12) are not quipped for the pilot
valve assembly at port 1 side. Spring (29), detent casing
(44), solenoid (19), and push rod (18) are equipped for it.
fNOTE: Detent ring (10), spring (11), shim (51), and steel
balls (16) (4 used) are not equipped for the pilot valve
assembly at port 1 side.
fNOTE: Springs (45, 46) and detent casing (20) are
not quipped for the pilot valve assembly at port 2 side.
Spring (29) and detent casing (44) are equipped for it.
fNOTE: Solenoids (42, 43) are not equipped for the pilot
valve assembly at port 2 side.
W3-10-4-13
SECTION 3 BODY
(Blank)
W3-10-4-14
SECTION 3 BODY
Removal and Installation of Brake Charge

Valve
1 85Z7BW-03-04-01

Removal
1. Operate the steering wheel in right to the steering
end.
dCAUTION: Operate the brake pedal more than 50


3. Remove inspection cover (1). (Refer to W3-22-1.)
W3-11-1-1
SECTION 3 BODY
View B
B 7 5 11,12,13
6 14
A
8
a 85Z7BW-03-11-03
Detail A 16
1
4 10
b
15
85Z7BW-03-11-02
a- Machine Front Side b- Rear Frame
3
2
85Z7BW-03-11-01
4. Remove clip band (4). Disconnect connector (1). 6. Disconnect hoses (5, 6).
5. Disconnect hoses (2, 3). j : 27 mm
j : 22 mm 7. Disconnect hoses (7, 8, 9, 10).
j : 19 mm
8. Remove bolts, washers (11, 15) (2 each used),
washers (12) (2 used), cushions (13) (2 used), and
washers (14) (2 used). Remove the bracket (16)
assembly from rear frame (b).
j : 17 mm
W3-11-1-2
SECTION 3 BODY
WNEK50-03-11-004
9. Remove bolt, washer (5), bolts, washers (2) (2 used)

and nut (1). Remove brake charge valve (4) from the
bracket (3) assembly.
j : 17 mm
10. Remove the adapters from brake charge valve (4) if
necessary.
W3-11-1-3
SECTION 3 BODY
WNEK50-03-11-004
Installation
1. Install all removed adapters to brake charge valve
(4).
2. Install brake charge valve (4) to the bracket (3)
assembly with nut (1), bolts, washers (2) (2 used)
and bolt, washer (5).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-11-1-4
SECTION 3 BODY
View A 7 5 11,12,13
A
6 14
A 8
a 85Z7BW-03-11-03
16
B B View B
9
5
10
e
9 c
b
d 15
10 85Z7BW-03-11-04
85Z7BW-03-11-02
a- Machine Front Side d- 45˚ b- Rear Frame

c- 30˚ e- 15˚
3. Install the bracket (16) assembly to rear frame (b) IMPORTANT: Check the angle to install hoses (9, 10).
with washers (14) (2 used), cushions (13) (2 used), 4. Connect hoses (7, 8, 9, 10).
washers (12) (2 used) and bolts, washers (11, 15) (2
each used). j : 19 mm
j : 17 mm m : 30 N·m (22 lbf·ft)

Bolt, Washer (11) IMPORTANT: Check the angle to install hose (5).
m : 20 N·m (15 lbf·ft)
Bolt, Washer (15) j : 27 mm
Hose (5)
m : 50 N·m (37 lbf·ft)
m : 95 N·m (70 lbf·ft)
Hose (6)
m : 80 N·m (59 lbf·ft)
W3-11-1-5
SECTION 3 BODY
Detail A
1
4
a
85Z7BW-03-11-03
3
2
85Z7BW-03-11-01
j : 22 mm
m : 40 N·m (29.5 lbf·ft)

7. Connect connector (1). Install clip band (4).
W3-11-1-6
SECTION 3 BODY
1 85Z7BW-03-04-01
8. Bleed air from the hydraulic system and brake (axle).

(Refer to W1-4-1.)

9. Install inspection cover (1). (Refer to W3-22-1.)
W3-11-1-7
SECTION 3 BODY
(Blank)
W3-11-1-8
SECTION 3 BODY
Structure of Brake Charge Valve
Section A-A 24
25
20
22 21
23
19 1
18
10
17
7
16
6
B B 26
5
27
10 11 13 12 8 9 2 3 4
Section B-B
C C
A A
14 15
Section C-C
TNED-03-07-017
30 29 28 31
1- Body 9- Priority Valve 17- Spring Seat 25- Lock Nut

2- Valve Seat 10- Plug 18- Spring 26- Piston
3- Check Valve 11- Orifice 19- Spring 27- Spring
4- Spring 12- Plug 20- Plug 28- Spool
5- Plug 13- O-Ring 21- O-Ring 29- Washer
6- O-Ring 14- Plug 22- Seat 30- Spring
7- Filter 15- O-Ring 23- O-Ring 31- Orifice
8- Spring 16- Pilot Piston 24- Screw
W3-11-2-1
SECTION 3 BODY
Structure of Brake Charge Valve

No. Part Name Q’ty Wrench Size Tightening Torque Remark
mm N·m (lbf·ft)
1 Body 1
2 Valve Seat 1 Do not
disassemble.
3 Check Valve 1
4 Spring 1
5 Plug 1 j : 27 50 to 85 (37 to 63)
6 O-Ring 5
7 Filter 1 10 to 15 (7.4 to 11)
8 Spring 1
9 Priority Valve 1
10 Plug 4 l : 10 50 to 85 (37 to 63)
11 Orifice 1 l:5 10 to 15 (7.4 to 11)
12 Plug 1 l:6 30 to 40 (22 to 30)
13 O-Ring 1
14 Plug 2 l:5 17 to 23 (12 to 17)
15 O-Ring 2
16 Pilot Piston 1
17 Spring Seat 1
18 Spring 1
19 Spring 1
20 Plug 1 j : 41 120 to 140 (89 to 103)
21 O-Ring 1
22 Seat 1
23 O-Ring 1
24 Screw 1 Do not
disassemble.
25 Lock Nut 1 Do not
disassemble.
26 Piston 1
27 Spring 1
28 Spool 1
29 Washer 2
30 Spring 2
31 Orifice 2 l:5 10 to 15 (7.4 to 11)
IMPORTANT: Do not disassemble valve seat (2).

IMPORTANT: If lock nut (25) and screw (24) are
loosened, the accumulated brake pressure value
changes.
Loose lock nut (25) and screw (24) and release the
spring (19) force when removing plug (20).
W3-11-2-2
SECTION 3 BODY
Removal and Installation of Brake

Accumulator
2 1 3 4
85Z7BW-03-04-01

d CAUTION: and pipes have been disconnected. In addition,
 Use only the qualified parts for the accumulator. attach identification tags onto the connectors,
 Allow only qualified personnel to handle the secure the hoses have been removed, install the
accumulator. clips after connecting the hoses.
 High-pressure nitrogen gas is enclosed in the Removal
accumulator. Pay attention to prevent fire.
 Never hit or bring a fire close to the accumulator. maintenance. (Refer to W1-5-1.)
 Do not process the accumulator directly. Do not
weld the accumulator housing. dCAUTION: Operate the brake pedal more than 50
 Be sure to release pressure before starting to
work on the piping lines. dCAUTION: Release any pressure from the
When removing the hose and pipe, receive oil with  Under Guard Rear (1) (Only for the machine with
a container in order to avoid spilling oil. under guard)
W3-11-3-1
SECTION 3 BODY
a A
4
85Z7BW-03-11-05
View A
5
2
1 3
c
85Z7BW-03-11-07
a- Machine Front Side c- Rear Frame

b- Drive Unit
5
85Z7BW-03-11-06
3. Disconnect hoses (1, 2). 4. Remove bolts, washers (5) (4 used) indicated by
bold arrows. Remove the bracket (3) assembly from
j : 19 mm rear frame (c).
dCAUTION: Remove the bracket (3) assembly

while holding it. Do not drop the bracket (3)
j : 17 mm
assembly.
IMPORTANT: When removing the bracket (3)
assembly, be sure not to contact the bracket (7)
assembly with pipe (4).
W3-11-3-2
SECTION 3 BODY
2 1
85Z7BW-03-11-08
5. Remove nuts (4) (16 used) and U-bolts (2) (4 used). 6. Remove the adapters from brake accumulators (1)
Remove brake accumulators (1) (2 used) from (2 used) if necessary.
bracket (3).
j : 17 mm
W3-11-3-3
SECTION 3 BODY
View A 1
2
2 1
85Z7BW-03-11-10
a- No clearance
1
3 View B
3
4
c
85Z7BW-03-11-08
85Z7BW-03-11-09
b- 30˚ c- 10˚
Installation IMPORTANT: Check the position to install brake

accumulators (1) (2 used).
1. Install all removed adapters to brake accumulators
(1) (2 used). 2. Install brake accumulators (1) (2 used) to bracket (3)
with nuts (4) (16 used) and U-bolts (2) (4 used).
j : 17 mm
m : 20 N·m (15 lbf·ft)
W3-11-3-4
SECTION 3 BODY
a
4
85Z7BW-03-11-05
Detail A
5
2
3 1
c
85Z7BW-03-11-07
a- Machine Front Side c- Rear Frame

b- Drive Unit
5
85Z7BW-03-11-06
IMPORTANT: When installing the bracket (3) 4. Connect hoses (1, 2).
assembly, be sure not to contact the bracket (3)
assembly with pipes (4). j : 19 mm
3. Install the bracket (3) assembly to rear frame (c) with m : 30 N·m (22 lbf·ft)
bolts, washers (5) (4 used) indicated by bold arrows.
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-11-3-5
SECTION 3 BODY
2 1 3 4
85Z7BW-03-04-01
5. Bleed air from the hydraulic system and brake (axle).

(Refer to W1-4-1.)
6. Install the following parts. (Refer to W3-22-1.)
under guard)
W3-11-3-6
SECTION 3 BODY
Group 12 Manifold Valve
Removal and Installation of Manifold Valve
1 3 2 4
85Z7BW-03-04-01
Removal
dCAUTION: 1. Set the machine position for inspection and
 Use only the qualified parts for the accumulator. maintenance. (Refer to W1-5-1.)
 Allow only qualified personnel to handle the
accumulator. dCAUTION: Release any pressure from the
 High-pressure nitrogen gas is enclosed in the
accumulator. Pay attention to prevent fire. dCAUTION: Operate the steering wheel to the
 Never hit or bring a fire close to the accumulator. pressure in the circuit.
 Do not process the accumulator directly. Do not
weld the accumulator housing.
attachment hydraulic circuit. (Refer to W1-5-1.)
 Be sure to release pressure before starting to 2. Remove the following parts. (Refer to W3-22-1.)
work on the piping lines.  Step (Front) (2)
 Deck (3)
When removing the hose and pipe, receive oil with  Rear Fender (Front) (4)
a container in order to avoid spilling oil.  Cab Under Cover (1)
W3-12-1-1
SECTION 3 BODY
Detail A B
85Z7BW-03-12-02
View B
85Z7BW-03-12-01
A

j : 19 mm
5. Disconnect hose (3). 3
j : 17 mm
4
j : 27 mm 85Z7BW-03-12-03
W3-12-1-2
SECTION 3 BODY
Detail A
2
5
A
6
a
1 5
3
85Z7BW-03-12-04 WNEC-03-12-012
a- Rear Frame
7. Disconnect hose (1) (2 used). 10. Remove bolts, washers (4) (3 used), washer (5),
rubber cushion (6), and washer (5). Remove the
j : 17 mm bracket (7) assembly and washer (5) from rear frame
8. Disconnect hose (2) (3 used). (a).
j : 19 mm j : 19 mm
j : 27 mm
W3-12-1-3
SECTION 3 BODY
2 1
6 3
WNEK50-03-12-007
5 4
11. Remove connectors (6) (7 used). 15. Remove the adapters from manifold valve (1) if
necessary.
j : 17 mm
manifold valve (1) from bracket (5).
j : 17 mm
13. Remove accumulators (2) (2 used) from manifold
valve (1).
j : 36 mm
14. Remove pressure sensor (3) from manifold valve (1).
j : 24 mm
W3-12-1-4
SECTION 3 BODY
2 1
6 3
WNEK50-03-12-007
5 4
Installation 4. Install manifold valve (1) to bracket (5) with bolts,

1. Install all removed adapters to manifold valve (1).
2. Install pressure sensor (3) to manifold valve (1). j : 17 mm
j : 24 mm m : 50 N·m (37 lbf·ft)

5. Install connectors (6) (2 used).
m : 16 N·m (12 lbf·ft)
3. Install accumulators (2) (2 used) to manifold valve j : 17 mm
(1).
m : 50 N·m (37 lbf·ft)
j : 36 mm
m : 98 N·m (72 lbf·ft)
W3-12-1-5
SECTION 3 BODY
Detail A 4
7 WNEC-03-12-012
View B
a 1
b
3 1
3
B 85Z7BW-03-12-04
a- Rear Frame b- 45°
85Z7BW-03-12-05
6. Install the bracket (7) assembly to rear frame (a) with 7. Connect hoses (1) (2 used).
3 each of washer (5), rubber cushions (6), washer (5),
and bolts, washer (4) indicated by bold arrows (A). j : 17 mm
j : 19 mm m : 25 N·m (18.5 lbf·ft)

m : 40 N·m (29.5 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)

j : 27 mm
m : 80 N·m (59 lbf·ft)
W3-12-1-6
SECTION 3 BODY
View A
1
2
85Z7BW-03-12-02
a 3
4
3
A
4
85Z7BW-03-12-03
2
a
85Z7BW-03-12-06
a- 15°
j : 19 mm
j : 27 mm
m : 30 N·m (22 lbf·ft)
m : 70 N·m (52 lbf·ft) 13. Connect connectors (1) (3 used).
IMPORTANT: Check the angle to install hose (3). 14. Bleed air from the hydraulic system. (Refer to W1-4-
11. Connect hose (3). 1.)
j : 17 mm IMPORTANT: Check the hydraulic oil level. Start the

engine. Operate the steering wheel to the steering
m : 25 N·m (18.5 lbf·ft) end several times and check for any oil leaks.
W3-12-1-7
SECTION 3 BODY
1 3 2 4
85Z7BW-03-04-01

 Deck (3)
 Step (Front) (2)
W3-12-1-8
SECTION 3 BODY
Disassembly of Manifold Valve
WNEC-03-12-001
01- Plug 12- Filter 25- Plug 36- O-Ring (2 Used)

02- Shim (Several) 13- Screw 26- Plug (2 Used) 37- O-Ring (2 Used)
03- Poppet 14- Spool 27- Plug 38- O-Ring
04- Spring 15- Stopper 28- Socket Bolt (4 Used) 39- O-Ring
05- Shim (Several) 16- Filter 29- Washer 40- O-Ring
06- Plunger 17- Solenoid 30- Nut 41- O-Ring
07- Spring 20- Spring 32- O-Ring 43A- Sleeve
08- Spring 21- Solenoid 33- O-Ring (7 Used) 43B- Spool
09- Plug 22- Body 34- O-Ring (2 Used)
10- Sleeve 24- Plug (7 Used) 35- O-Ring
W3-12-2-1
SECTION 3 BODY
Disassembly of Manifold Valve

IMPORTANT: Keep the disassembled parts together 5. Measure and record mounting dimension (a) before
by each port in order not to confuse. removing screw (13).
IMPORTANT: The quantity and kind of shims (02, 05)
have been determined for each manifold valve. Do
22
not lose shims (02, 05).
1. Remove plug (01), O-ring (37), spring (04), shims (05,
13
02), and poppet (03) from body (22).
j : 36 mm
2. Remove plug (09), O-ring (34), spring (07), and a

plunger (06) from body (22).
l : 6 mm
WNEC-03-12-005
3. Remove socket bolts (28) (2 used) from solenoid
(17). Remove solenoid (17), O-ring (41), sleeve (43A), a- Mounting Dimension
O-rings (40, 39, 38), spool (43B), and spring (20)
from body (22).
6. Remove O-ring (34) and screw (13) from body (22).
l : 4 mm
l : 6 mm
4. Remove nut (30) from body (22).

7. Remove socket bolts (28) (2 used) from solenoid
j : 17 mm (21). Remove solenoid (21), O-ring (32), and the
sleeve (10) assembly from body (22).
l : 4 mm
W3-12-2-2
SECTION 3 BODY
8. Remove spool (14) from sleeve (10).
fNOTE: Spring (08) and washer (29) cannot be

disassembled as stopper (15) has been press fitted to
sleeve (10).
9. Remove plugs (24) (7 used) and O-rings (33) (7 used)

from body (22).
l : 5 mm
10. Remove plug (25) and O-ring (35) from body (22).
l : 6 mm
11. Remove plug (27) and O-ring (37) from body (22).
l : 12 mm
12. Remove plugs (26) (2 used) and O-rings (36) (2 used)

from body (22).
l : 8 mm
fNOTE: Filters (12, 16) cannot be disassembled as they

have been press fitted to body (22).
W3-12-2-3
SECTION 3 BODY
Assembly of Manifold Valve
24, 33
Z Z
28
Y Y
X X
W
V
28
17 21
22
24, 33
WNEC-03-12-002
Section V Section W
25 35
12 43A
43B
20
30
13
34
41 40 39 38
32 10 14 29 08 15
WNEC-03-12-003 TNED-03-07-012
W3-12-2-4
SECTION 3 BODY
Section X-X Section Y-Y
07 09
34
16
06
33
24
26
36
33 24
TNED-03-07-011 TNED-03-07-010
Section Z-Z
37 01 04
27
02, 05
37
33
24
03
33 24 36 26
WNEC-03-12-004
01- Plug 12- Filter 25- Plug 36- O-Ring (2 Used)

02- Shim (Several) 13- Screw 26- Plug (2 Used) 37- O-Ring (2 Used)
03- Poppet 14- Spool 27- Plug 38- O-Ring
04- Spring 15- Stopper 28- Socket Bolt (4 Used) 39- O-Ring
05- Shim (Several) 16- Filter 29- Washer 40- O-Ring
06- Plunger 17- Solenoid 30- Nut 41- O-Ring
07- Spring 20- Spring 32- O-Ring 43A- Sleeve
08- Spring 21- Solenoid 33- O-Ring (7 Used) 43B- Spool
09- Plug 22- Body 34- O-Ring (2 Used)
10- Sleeve 24- Plug (7 Used) 35- O-Ring
W3-12-2-5
SECTION 3 BODY
Assembly of Manifold Valve 5. Install spool (14) to sleeve (10). Install the sleeve (10)
assembly to body (22). Install O-ring (32) to solenoid
(21). Install solenoid (21) to body (22) with socket
bolts (28) (2 used).
1. Install O-rings (36) (2 used) to plugs (26) (2 used).
Install plug (26) to body (22). l : 4 mm
l : 8 mm m : 3.92±0.4 N·m (2.9±0.3 lbf·ft)
m : 48.5±4.9 N·m (36±3.6 lbf·ft)

6. Install O-ring (34) to screw (13). Install screw (13)
to body (22) so that a clearance can be equal to
2. Install O-ring (37) to plug (27). Install plug (27) to mounting dimension (a) before disassembling.
body (22).
l : 6 mm
l : 12 mm
m : 98±9.8 N·m (72±7.2 lbf·ft)

22
body (22).
13
l : 6 mm
m : 26.5±2.9 N·m (20±2.1 lbf·ft)

a
Install plugs (24) (7 used) to body (22).
l : 5 mm
WNEC-03-12-005
m : 9.8±1 N·m (7.2±0.7 lbf·ft)
a- Mounting Dimension
7. Install nut (13) to screw (30).
j : 17 mm
m : 19.6±2 N·m (14±1.5 lbf·ft)
W3-12-2-6
SECTION 3 BODY
8. Install O-rings (40, 39, and 38) to sleeve (43A). Install

spool (43B) to sleeve (43A).
9. Install spring (20) and the sleeve (43A) assembly to
body (22).
10. Install O-ring (41) to solenoid (17). Install solenoid
(17) to body (22) with socket bolts (28) (2 used).
l : 4 mm
m : 3.92±0.4 N·m (2.9±0.3 lbf·ft)
11. Install O-ring (34) to plug (09). Install plunger (06),

spring (07), and plug (09) to body (22).
l : 6 mm
m : 12.0±1.2 N·m (8.9±0.9 lbf·ft)
12. Install O-ring (37) to plug (01). Install poppet (03),

spring (04), shims (02, 05), and plug (01) to body
(22).
j : 36 mm
m : 98±9.8 N·m (72±7.2 lbf·ft)
W3-12-2-7
SECTION 3 BODY
(Blank)
W3-12-2-8
SECTION 3 BODY
Group 13 Solenoid Valve
Removal and Installation of 2-Spool Solenoid

Valve Unit 4
1 3
5
2
10
6
9
8 7
WNEK50-03-13-001 85Z7BW-03-03-04
IMPORTANT: The hose and pipe contain hydraulic oil. 5. Disconnect hose (6) (only the machine with the ride
When removing the hose and pipe, receive oil with control device).
j : 17 mm
and pipes have been disconnected. In addition, 6. Disconnect hose (8).
hoses, and pipes for assembling. If the clips which j : 19 mm
secure the hoses have been removed, install the 7. Disconnect hoses (7, 9).
Removal j : 17 mm
1. Set the machine position (lift arm raise) for 8. Remove bolts, washers (2) (2 used). Remove the
inspection and maintenance. (Refer to W1-5-1.) bracket (3) assembly from front frame (10).
j : 19 mm
dCAUTION: Release any pressure in the hydraulic
oil tank. (Refer to W1-5-1.)
j : 17 mm
W3-13-1-1
SECTION 3 BODY
4
1
85Z7BW-03-13-01
9. Remove bolts, washers (4) (2 used) and nuts (1) (2

used). Remove the 2-spool solenoid valve unit (3)
from bracket (2).
j : 17 mm
10. Remove the adapters with the 2-spool solenoid
valve unit (3) attached if necessary.
W3-13-1-2
SECTION 3 BODY
4
1
85Z7BW-03-13-01
Installation
1. Install all removed adapters to the 2-spool solenoid
valve unit (3).
2. Install the 2-spool solenoid valve unit (3) to bracket
(2) with nuts (1) (2 used) and bolts, washers (4) (2
used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-13-1-3
SECTION 3 BODY
4 1
3
5
2
10
6
9
8 7
WNEK50-03-13-001
85Z7BW-03-03-04
3. Install the bracket (3) assembly to front frame (10) 7. Connect hose (4).
with bolts, washers (2) (2 used).
j : 17 mm
j : 19 mm
m : 25 N·m (18 lbf·ft)
m : 90 N·m (66 lbf·ft)
j : 17 mm inspection and maintenance. (Refer to W1-5-1.)
m : 25 N·m (18 lbf·ft)
5. Connect hose (8). 10. Set the machine position (lift arm raise) for
j : 19 mm
11. Install front cover (1). (Refer to W3-22-1.)
m : 30 N·m (22 lbf·ft)
6. Connect hose (6) (only the machine with the ride
control device).
j : 17 mm
m : 25 N·m (18 lbf·ft)
W3-13-1-4
SECTION 3 BODY
Structure of 2-Spool Solenoid Valve Unit
1 2
6 5 4 4
WLAA-03-12-001
3 7 8 9 10 11
12
16 15 14 13
WDAA-03-13-013
W3-13-2-1
SECTION 3 BODY

(mm) N·m lbf·ft
1 Body 1
2 Socket Bolt 4 l:4 5+2 3.5+1.5
3 Solenoid 2
4 Filter 2 l:6 10+3 7.4+2.2
5 Filter 1 l : 10 20+5 15+3.7
6 Plug 1 l:8 20+5 15+3.7
7 Washer 1
8 Spring 1
9 Spool 1
10 Sleeve 1
11 Plate 1
12 Wave Spring 1
13 O-Ring 1
14 O-Ring 1
15 O-Ring 1
16 O-Ring 1
W3-13-2-2
SECTION 3 BODY
Removal and Installation of Parking Brake

Solenoid Valve Unit
1
85Z7BW-03-04-01

dCAUTION: and pipes have been disconnected. In addition,
accumulator. Pay attention to prevent fire. Removal
 Never hit or bring a fire close to the accumulator. 1. Set the machine position for inspection and
 Do not process the accumulator directly. Do not maintenance. (Refer to W1-5-1.)
 Be sure to release pressure before starting to
work on the piping lines.
dCAUTION: Release any pressure from the parking
brake circuit. (Refer to W1-5-1.)
IMPORTANT: The hoses and pipes contain hydraulic 2. Remove inspection cover (1). (Refer to W3-22-1.)
W3-13-3-1
SECTION 3 BODY
Detail A 4
6
2
3
A
5
a 85Z7BW-03-11-05
3 7 9
85Z7BW-03-13-02
3. Disconnect connectors (4, 5). Remove connector (4) 5. Remove bolts, washers (7) (2 used). Remove parking
from bracket (6). brake solenoid valve unit (8) from rear frame (9).
4. Disconnect hoses (1, 2) and hoses (3) (2 used). j : 19 mm
j : 19 mm
W3-13-3-2
SECTION 3 BODY
85Z7BW-03-13-03
6. Remove accumulator (1) from the parking brake

solenoid valve unit (3) assembly.
j : 36 mm
7. Remove pressure switch (2) from parking brake
solenoid valve unit (3).
j : 27 mm
8. Remove the adapters from parking brake solenoid
valve unit (3) if necessary.
W3-13-3-3
SECTION 3 BODY
85Z7BW-03-13-03
Installation
1. Install all removed adapters to parking brake
solenoid valve unit (3).
2. Install pressure switch (2) to parking brake solenoid
valve unit (3).
j : 27 mm
m : 98 N·m (72 lbf·ft)

3. Install accumulator (1) to parking brake solenoid
valve unit (3).
j : 36 mm
m : 98 N·m (72 lbf·ft)
W3-13-3-4
SECTION 3 BODY
Detail A 4
6
2
3
A
5
a 85Z7BW-03-11-05
3 7 9 85Z7BW-03-13-02
4. Install parking brake solenoid valve unit (8) and

bracket (6) to rear frame (9) with bolts, washers (5) 1
(2 used).
j : 19 mm
m : 90 N·m (66 lbf·ft) 8

IMPORTANT: Check the angle to install hose (1). 85Z7BW-03-13-04
5. Connect hoses (1, 2) and hoses (3) (2 used).
b- 20°
j : 19 mm
m : 30 N·m (22 lbf·ft)

6. Install connector (4) to bracket (6). Connect
connectors (4, 5).
W3-13-3-5
SECTION 3 BODY
1
85Z7BW-03-04-01

1.)
8. Install inspection cover (1). (Refer to W3-22-1.)
W3-13-3-6
SECTION 3 BODY
Structure of Parking Brake Solenoid Valve

Unit
1
1
1
1
3
3
3
3
5
5 6
6
7
7
WNEJ-03-13-001

(mm) N·m lbf·ft
1 Socket Bolt 4 l: 4 5+1 3.7+0.7
2 Solenoid Valve 1
3 O-Ring 4
4 Block 1
5 O-Ring 2 Apply grease onto the
outer surface when
assembling.
6 O-Ring 2
7 Filter 2 l: 6 25+5 18.5+3.7
W3-13-4-1
SECTION 3 BODY
(Blank)
W3-13-4-2
SECTION 3 BODY
Structure of Parking Brake Solenoid Valve
20 15 24 1 2 3 4 6 11 7 12 14 13 21
W4GB-03-10-003
5 8 9 10 17 16 18 19

(mm) N·m (lbf·ft)
1 Housing 1
2 Spool 1
3 Spring Seat 2
4 Spring 2
5 O-Ring 4
6 Rod 1
7 Stopper 1
8 Plunger 1
9 Spring 1
10 Rod 1
11 Inner Housing 1
12 Coil 1
13 Spacer 1
14 Screw 1 j : 32 30 to 40 (22 to 30) Apply LOCTITE
#243 or
equivalent.
15 O-Ring 2
16 Spring 1
17 O-Ring 1
18 Washer 1
19 Retaining Ring 1
20 Plug 1 l : 14 30 to 40 (22 to 30)
21 Pipe 1
24 Socket Bolt 4 l : 2.5 5 to 6 (3.7 to 4.4)
W3-13-5-1
SECTION 3 BODY
(Blank)
W3-13-5-2
SECTION 3 BODY
Group 14 Flow Regulator Valve
Removal and Installation of Flow Regulator

Valve
2 85Z7BW-03-01-05
1
IMPORTANT: The hose and pipe contain hydraulic oil. Removal

hoses, and pipes for assembling. If the clips which 2. Remove the following parts. (Refer to W3-22-1.)
clips after connecting the hoses.  Rear Fender (Front) (2)
 Deck (3)
W3-14-1-1
SECTION 3 BODY
View A 1
6
2
10
B
A
3
4
9 5
85Z7BW-03-14-02
View B
85Z7BW-03-14-01
3. Remove clip bands (9) (3 used). Disconnect

7
connectors (6) (3 used).
j : 19 mm
85Z7BW-03-14-03
j : 19 mm
6. Disconnect hose (3). 8 Remove bolts, washers (2) (2 used). Remove flow
regulator valve (5) from bracket (4).
j : 17 mm
7. Remove bolts, washers (10) (2 used). Remove flow j : 17 mm
regulator valve (5) assembly. 9. Remove sensors (7) (3 used).
j : 19 mm j : 24 mm
10. Remove the adapters from flow regulator valve (5) if
necessary.
W3-14-1-2
SECTION 3 BODY
View A 1
6
2
10
B
A
3
4
9 5
85Z7BW-03-14-02
View B
85Z7BW-03-14-01
8
Installation
1. Install all removed adapters to flow regulator valve
(5).
2. Install sensors (7) (3 used). 7
j : 24 mm
m : 16 N·m (12 lbf·ft)

3. Install flow regulator valve (5) to bracket (4) with 85Z7BW-03-14-03
j : 17 mm
m : 50 N·m (37 lbf·ft)

4. Install flow regulator valve (5) assembly with bolts, 7. Connect hoses (1) (4 used).
j : 19 mm
j : 17 mm
m : 30 N·m (22 lbf·ft)
m : 50 N·m (37 lbf·ft)
8. Connect connectors (6) (3 used). Install clip bands
5. Connect hose (3). (9) (3 used).
j : 17 mm
m : 25 N·m (18.5 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W3-14-1-3
SECTION 3 BODY
2 85Z7BW-03-01-05
1
9. Bleed air from the hydraulic system. (Refer to W1-4- 10. Install the following parts. (Refer to W3-22-1.)
1.)
 Deck (3)
W3-14-1-4
SECTION 3 BODY
Structure of Flow Regulator Valve
W X Y Z
W X Y Z
9 12
10
13
4
2
3
14, 1
4
13
5
Section W-W Section X-X
8
10
13
4
8
7
2
3
14, 1
4
13
11 6 5
WNEC-03-14-001
Section Y-Y Section Z-Z
W3-14-2-1
SECTION 3 BODY

(mm) N·m (lbf·ft)
1 Spool 2
2 Ring 2 Do not
disassemble.
3 Orifice 2 Do not
disassemble.
4 Spring 4
5 Plug 2 l:8 50 (37)
6 Spool 1
7 Body 1
8 Plug 2 Do not
disassemble.
9 Plug 1 l:6 25 (18)
10 Plug 2 l:8 50 (37)
11 Snap Ring 1
12 O-Ring 1
13 O-Ring 4
14 Spool 2
W3-14-2-2
SECTION 3 BODY
Group 15 Cooling Fan System
Removal and Installation of Fan Valve

Detail A
2
1
2
A
85Z7BW-03-07-06
85Z7BW-03-15-01
Removal 2. Open side cover (front) (1).

IMPORTANT: The hoses and pipes contain hydraulic 3. Disconnect connectors (2) (3 used).


W3-15-1-1
SECTION 3 BODY
1, 2
8 9 7
85Z7BW-03-15-02
j : 36 mm j : 19 mm
5. Disconnect hose (4). 9. Remove socket bolts (1) (3 used) and washers (2) (3
used). Remove fan valve (6) from bracket (5).
j : 36 mm
l : 8 mm
10. Remove the adapters from fan valve (6) if necessary.
j : 27 mm
j : 17 mm
W3-15-1-2
SECTION 3 BODY
A
B
A
7
B
6
1, 2
4
8 C
b d
3
4
8 9 7 7
9
85Z7BW-03-15-02
c c
C-C
A-A B-B
85Z7BW-03-15-03
a- 60° c- 30°
b- 10° d- 35°
Installation
1. Install all removed adapters to fan valve (6). IMPORTANT: Check the angle to install hose (7).
2. Install fan valve (6) to bracket (5) with washers (2) (3
used) and socket bolts (1) (3 used). j : 27 mm
l : 8 mm m : 95 N·m (70 lbf·ft)
m : 50 N·m (37 lbf·ft) IMPORTANT: Check the angle to install hose (4).
3. Connect hose (9). j : 36 mm
j : 19 mm m : 180 N·m (133 lbf·ft)
IMPORTANT: Check the angle to install hose (8). j : 36 mm
m : 180 N·m (133 lbf·ft)
j : 17 mm
m : 25 N·m (16.5 lbf·ft)
W3-15-1-3
SECTION 3 BODY
Detail A
2
1
2
A 85Z7BW-03-07-06
85Z7BW-03-15-01

1.)
10. Close side cover (front) (1).
W3-15-1-4
SECTION 3 BODY
Structure of Fan Valve
3
2
2
1
B
A
C D WNEC-03-15-001
Section A Section C
9 17
10
11
12
7
6
5
WJBA-03-16-005
WNEC-03-15-002
Section B Section D
20
19
15 16 18
WJBA-03-16-004 WJBA-03-16-006
W3-15-2-1
SECTION 3 BODY

(mm) N·m (lbf·ft)
1 Solenoid Valve 1
2 Socket Bolt 4 l : 4 5 (3.7)
3 Solenoid Valve 1
4 Plug 2 l : 8 70 (52)
5 Relief Valve 1
6 Plug 1 l : 10 120 (89)
7 O-Ring 1
8 Spring 2
9 Check Valve 2
10 O-Ring 1
11 Spring 1
12 Plug 1 j : 30 180 (133)
15 Plug 1 l : 6 35 (26)
16 Orifice 1
17 Plug 1 l : 5 15 (11)
18 Plug 1 l : 8 35 (26)
19 O-Ring 1
20 O-Ring 1
W3-15-2-2
SECTION 3 BODY
Removal and Installation of Fan Motor

Detail A
1
A 3
85Z7BW-03-15-04 85Z7BW-03-15-05
IMPORTANT: The hoses and pipes contain hydraulic 3. Disconnect hoses (2) (2 used).
oil with a container in order to avoid spilling oil. j : 27 mm
IMPORTANT: Cap the open ends in case the hoses 4. Disconnect hose (3).
attach identification tags onto the connectors, j : 17 mm
Removal

W3-15-3-1
SECTION 3 BODY
9
1
A
3, 4, 5
85Z7BW-03-15-06 85Z7BW-03-15-07
Detail A
5. Open the hydraulic drive fan (9) assembly. 7

6. Remove bolts, washers (2) (8 used). Remove guard
(1).
j : 17 mm 8
IMPORTANT: When removing fan (6) assembly, do

not lose key (7).
7. Remove bolt (3), spring washer (4), and washer (5).
Remove fan (6) assembly from fan motor (8).
j : 17 mm
fNOTE: LOCTITE #263 or equivalent has been applied on

bolt (3).
8. Remove key (7) from fan motor (8).
85Z7BW-03-15-08
W3-15-3-2
SECTION 3 BODY
3 2 85Z7BW-03-15-09
9. Remove bolts, washers (1) (2 used). Remove fan 10. Remove the adapters from fan motor (2) if
motor (2) from bracket (3). necessary.
j : 19 mm
W3-15-3-3
SECTION 3 BODY
3 2 85Z7BW-03-15-09
Installation 2. Install fan motor (2) to bracket (3) with bolts,

1. Install all removed adapters to fan motor (2).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-15-3-4
SECTION 3 BODY
9
1
A
3, 4, 5
85Z7BW-03-15-06 85Z7BW-03-15-07
Detail A
3. Install key (7) to fan motor (8).

IMPORTANT: When installing fan (6) assembly, do
7
not drop and lose key (7).
4. Install fan (6) assembly with key (7) to fan motor (8).
5. Apply LOCTITE #263 or equivalent to bolt (3). Secure 8
fan (6) assembly to fan motor (8) with washer (5),
spring washer (4) and bolt (3).
j : 17 mm
m : 50 N·m (37 lbf·ft)

6. Install guard (1) with bolts, washers (2) (8 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)

7. Close the hydraulic drive fan (9) assembly.
85Z7BW-03-15-08
W3-15-3-5
SECTION 3 BODY
1 Detail A
4, 5
A 3
85Z7BW-03-15-04 85Z7BW-03-15-05
8. Connect hose (3). 10. Remove plug (5). Fill hydraulic oil from port (6).
Install plug (5).
j : 17 mm
l : 6 mm
m : 25 N·m (18.5 lbf·ft)
m : 23 N·m (17 lbf·ft)
j : 27 mm engine and check for any oil leaks.
m : 95 N·m (70 lbf·ft) 11. Close rear grill (1).
W3-15-3-6
SECTION 3 BODY
Structure of Fan Motor

1 2 3 4 5 6 7 8 9
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
WJBA-03-17-001
W3-15-4-1
SECTION 3 BODY

(mm) N·m (lbf·ft)
1 Roller Bearing 1
2 Pin 1
3 O-Ring 1
4 Pin 2
5 Pin 3
6 Plunger 9
7 Swash Plate 1
8 Roller Bearing 1
9 Key 1
10 Shaft 1
11 Retaining Ring 1
12 Oil Seal 1
13 Pin 1
14 Housing 1
15 Holder 1
16 Retainer 1
17 Spring seat 1
18 Rotor 1
19 Spring 1
20 Washer 1
21 Retaining Ring 1
22 Valve Plate 1
23 Socket Bolt 3 l : 10 90 (66)
24 Rear Cover 1
W3-15-4-2
SECTION 3 BODY
Removal and Installation of Pilot Pump
2
85Z7BW-03-01-05

oil. When removing the hoses and pipes, receive dCAUTION: Release any pressure from the
2. Open side cover (front) (1).
IMPORTANT: Cap the open ends in case the hoses 3. Remove lower cover (2). (Refer to W3-22-1.)
Removal
W3-15-5-1
SECTION 3 BODY
1 3
2 5 4
WNEE-03-15-040
85Z7BW-03-15-10
6. Disconnect hoses (2) (2 used). IMPORTANT: Gasket (3) cannot be reused.

8. Remove bolts, washers (5) (2 used). Remove pilot
j : 27 mm
pump (4) and gasket (3) from engine (6).
j : 17 mm
j : 41 mm
9. Remove the adapters with pilot pump (4) attached
if necessary.
W3-15-5-2
SECTION 3 BODY
5 4
WNEE-03-15-040
Installation IMPORTANT: Replace gasket (3) with the new one.

1. Install all removed adapters to pilot pump (4). 2. Install gasket (3) and pilot pump (4) to engine (6)
j : 17 mm
m : 50 N∙m (37 lbf·ft)
W3-15-5-3
SECTION 3 BODY
View A
A 4 4
B a B-B
1
View C
1
C
b
4 85Z7BW-03-15-11
85Z7BW-03-15-10 a- 20°
b- 30°
IMPORTANT: Check the angle to install hose (1). IMPORTANT: Check the angle to install hose (2).
3. Connect hose (1). 4. Connect hoses (2) (2 used).
j : 41 mm j : 27 mm
m : 210 N∙m (155 lbf·ft) m : 95 N∙m (70 lbf·ft)
W3-15-5-4
SECTION 3 BODY
2
85Z7BW-03-01-05

5. Install lower cover (2). (Refer to W3-22-1.)
W3-15-5-5
SECTION 3 BODY
(Blank)
W3-15-5-6
SECTION 3 BODY
Disassembly of Pilot Pump
7
6
5
4
2
1
6
14
13
10
12
4
5
6
11
WNEC-03-15-010
1- Retaining Ring 5- Gasket (2 Used) 10- Drive Gear 14- Bolt (4 Used)
2- Oil Seal 6- Bushing (4 Used) 11- Driven Gear
3- Front Cover 7- Side Plate (2 Used) 12- Rear Cover
4- Gasket (2 Used) 8- Body 13- Washer (4 Used)
W3-15-6-1
SECTION 3 BODY
Disassembly of Pilot Pump 5. Remove drive gear (10) from body (8).
IMPORTANT: Put the matching marks on front 6. Remove body (8) from front cover (3).
cover (3), body (8), and rear cover (12) before
IMPORTANT: Check the position and direction of side
disassembling.
plate (7) and gaskets (4, 5) for assembling.
1. Secure the front cover (3) mounting part in a vise
7. Remove gaskets (4, 5) and side plate (7) from front
with the rear cover (12) side up.
cover (3).
2. Remove bolts (14) (4 used) and washers (13) (4
8. Remove retaining ring (1) from front cover (3).
used) from rear cover (12). Remove rear cover (12)
from body (8). IMPORTANT: Do not damage the oil seal hole of front
cover (3).
l : 10 mm
9. Remove oil seal (2) from front cover (3) by using a
IMPORTANT: Check the position and direction of side screwdriver.
plate (7) and gaskets (4, 5) for assembling.
3. Remove gaskets (4, 5) from rear cover (12). Remove
2
side plate (7) from the body (8) assembly.
IMPORTANT: The front and rear shapes of driven
gear (11) are symmetrical. Put the matching marks
for assembling.
4. Remove driven gear (11) from body (8).
W4GB-02-08-012
W3-15-6-2
SECTION 3 BODY
Assembly of Pilot Pump
10 1 2 4 7 8 13 14
WNEC-03-15-011
3 6 11 5 12
1- Retaining Ring 5- Gasket (2 Used) 10- Drive Gear 14- Bolt (4 Used)
2- Oil Seal 6- Bushing (4 Used) 11- Driven Gear
3- Front Cover 7- Side Plate (2 Used) 12- Rear Cover
4- Gasket (2 Used) 8- Body 13- Washer (4 Used)
W3-15-6-3
SECTION 3 BODY
Assembly of Pilot Pump 4. Fit the matching marks and install body (8) to front
cover (3).
onto parts in order to prevent them from seizing. IMPORTANT: Check the direction to install driven
1. Secure front cover (3) in a vise with the body (8) gear (11).
mounting surface up. IMPORTANT: Drive gear (10) and driven gear (11)
have asymmetrical tooth shape. Mesh the gears
IMPORTANT: Check the direction to install gaskets
with the small notch and install them.
(4, 5).
5. Install drive gear (10) and driven gear (11) to the
2. Apply grease onto oil gaskets (4, 5). Install gaskets
body (8) assembly.
(4, 5) to front cover (3).
3 5
l
j k
h i
6 W4GB-02-08-014
3. Install side plate (7) to front cover (3) so that the

yellow surface faces the gear side and long hole (a)
WNEC-03-15-012
faces the suction side.
7 h- Delivery Side k- Small Notch (Non-Mesh Side)
i- Suction Side l- Rotation Direction of Drive
j- Large Notch (Non-Mesh Side) Gear (10)
b c
d e 6. Install side plate (7) to drive gear (10) and driven

gear (11) so that the yellow surface faces the gear
side and long hole (a) faces the suction side.
W4GB-02-08-015
b- Delivery Side d- Short Hole

c- Suction Side e- Long Hole
8 f
f
3
f
g
g 12
g WNEC-03-15-005
f- Delivery Side
g- Suction Side
W3-15-6-4
SECTION 3 BODY
IMPORTANT: Check the direction to install gaskets 11. Install oil seal (2) to front cover (3) with oil seal guide
(4, 5). (e).
7. Apply grease onto oil gaskets (4, 5). Install gaskets
(4, 5) to rear cover (12).
12 5
e
2 10
3
6 W4GB-02-08-014
8. Fit the matching marks and install rear cover (12)

to the body (8) assembly with washers (13) (4 used)
and bolts (14) (4 used). W4GB-02-08-018
l : 10 mm e- Oil Seal Guide
m : 90 to 95 N·m (66 to 70 lbf·ft)

9. Turn over the body (8) assembly. Secure front cover 12. Install retaining ring (1) to front cover (3).
(3) in a vise.
10. Apply grease between main lip (b) and dust lip (c) of
oil seal (2).
d 1
b
3
W4GB-02-08-017
b- Main Lip d- Apply grease.

c- Dust Lip
W4GB-02-08-019
W3-15-6-5
SECTION 3 BODY
(Blank)
W3-15-6-6
SECTION 3 BODY
Removal and Installation of Ride Control

Accumulator
1
WNEK50-03-13-001 85Z7BW-03-16-04

dCAUTION: and pipes have been disconnected. In addition,
accumulator. Pay attention to prevent fire.
Removal
 Never hit or bring a fire close to the accumulator.
 Do not process the accumulator directly. Do not inspection and maintenance. (Refer to W1-5-1.)
 Be sure to release pressure before starting to dCAUTION: Release any pressure from the
work on the piping lines.
2. Remove cover (1). (Refer to W3-22-1.)
dCAUTION: Release any pressure from the front
attachment hydraulic circuit and the ride control
accumulator. (Refer to W1-5-1.)
4. Remove propeller shaft (2). (Refer to W4-4-1.)
W3-16-1-1
SECTION 3 BODY
Detail A 3, 4
1
a A
3, 4
7
2
2
8 85Z7BW-03-16-02
3
85Z7BW-03-16-01 2 4
3 2
7
4
9
j : 36 mm 6
85Z7BW-03-16-05
dCAUTION: Remove ride control accumulator (5)
while holding it. Be careful not to drop ride control
accumulator (5).
6. Remove bolts, washers (2) (4 used), clamps (3) (2 8. Remove elbow (9) from ride control accumulator (5)
used), and rubber stoppers (4) (2 used). Remove ride if necessary.
control accumulator (5) from bracket (7).
j : 19 mm
7. Remove bolts, washers (6) (4 used) and remove
bracket (7) from front frame (8).
j : 19 mm
W3-16-1-2
SECTION 3 BODY
Detail A 3, 4
1
a A
3, 4
7
2
B
2
8 85Z7BW-03-16-02
3
85Z7BW-03-16-01 2 4
3 2

5
6
7
4
Installation
9
1. Install elbow (9) to ride control accumulator (5). 6
85Z7BW-03-16-05
IMPORTANT: Check the angle to install elbow (9).
2. Install bracket (7) to front frame (8) with bolts, View B b
j : 19 mm 5 9
m : 90 N·m (66 lbf·ft) 7
3. Install ride control accumulator (5) to bracket (7)

with rubber stoppers (4) (2 used), clamps (3) (2
used), and bolts, washers (2) (4 used).
j : 19 mm
85Z7BW-03-16-03
b- 20°
m : 90 N·m (66 lbf·ft)
j : 36 mm
m : 180 N·m (133 lbf·ft)
W3-16-1-3
SECTION 3 BODY
85Z7BW-03-16-04 WNEK50-03-13-001
5. Install propeller shaft (2). (Refer to W4-4-1.)

1.)
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-16-1-4
SECTION 3 BODY
Group 17 Battery Disconnect Switch
Removal and Installation of Battery

Disconnect Switch
Detail A
5 2
A
1
3 b
a
c
85Z7B-W3-22-01-38
a- Battery Box 85Z7B-W3-22-01-37 b- OFF Position

c- ON Position
IMPORTANT: When disconnecting connectors or Removal

terminals, attach an identification tag onto the
connectors or terminals for assembling. If the
clips which secure the wire harnesses have been
removed, install the clips after connecting the 2. Open cover (1).
connectors or terminals.
IMPORTANT: Set the key switch to the OFF position.
Wait 5 minutes or longer, and then set battery
disconnect switch (2) to the OFF position.
3. Set battery disconnect switch (2) to the OFF
position (b). Remove lever (3).
4. Remove nuts (4) (2 used). Remove rubber plate (5).
j : 19 mm
W3-17-1-1
SECTION 3 BODY
1, 2
5, 6
3, 4
7, 8
85Z7B-W3-22-01-39
a- Battery
b- Battery Disconnect Switch
5. Loosen nut (7). Disconnect terminal (8).
j : 10 mm
j : 10 mm
7. Loosen nuts (5, 3). Disconnect terminals (6, 4).
j : 10 mm
W3-17-1-2
SECTION 3 BODY
a
A
1
Detail A
2
a 4
10 7 5
a- Battery Box 85Z7B-W3-22-01-39 6 85Z7B-W3-17-01-01

8 7
10
8. Remove bolts, washers (1) (2 used). Remove the 11. Remove nuts (7) (2 used) and bolts, washers (10) (2
bracket (9) assembly from battery box (a). used). Remove battery disconnect switch (8) from
bracket (9).
j : 17 mm
j : 10 mm
9. Remove nut (5). Disconnect terminal (4).
j : 17 mm
10. Remove nut (6). Disconnect terminals (2, 3).
j : 17 mm
W3-17-1-3
SECTION 3 BODY
a
A
1
Detail A
2
a 4
10 7 5
a- Battery Box 85Z7B-W3-22-01-39 6 85Z7B-W3-17-01-01

8 7
10
Installation 4. Install the bracket (9) assembly to battery box (a)

1. Install battery disconnect switch (8) to bracket (9)
with nuts (7) (2 used) and bolts, washers (10) (2 j : 17 mm
used).
m : 50 N·m (37 lbf·ft)
j : 10 mm
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

2. Connect terminal (4) with nut (5).
j : 17 mm
m : 22±1.1 N·m (16.2 lbf·ft)

3. Connect terminals (2, 3) with nut (6).
j : 17 mm
m : 22±1.1 N·m (16.2 lbf·ft)
W3-17-1-4
SECTION 3 BODY
1, 2
5, 6
3, 4
7, 8
85Z7B-W3-22-01-39
a- Battery
b- Battery Disconnect Switch
5. Connect terminals (6, 4). Tighten nuts (5, 3). 7. Connect terminal (8). Tighten nut (7).
j : 10 mm j : 10 mm
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft) m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

6. Connect terminal (2). Tighten nut (1).
j : 10 mm
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)
W3-17-1-5
SECTION 3 BODY
Detail A
5 2
A
1
3 b
a
c
85Z7B-W3-22-01-38
85Z7B-W3-22-01-37
a- Battery Box b- OFF Position
c- ON Position
8. Install lever (3). Set battery disconnect switch (2) to

the ON position (c).
9. Install rubber plate (5) with nuts (4) (2 used).
j : 19 mm
m : 35 N·m (26 lbf·ft)

10. Close cover (1).
W3-17-1-6
SECTION 3 BODY
Group 18 Aftertreatment Device
Removal and Installation of Aftertreatment

Device
85Z7B-W3-18-01-01 85Z7B-W3-18-01-02
IMPORTANT: Cap the open ends in case the hoses 3. Remove engine cover (1). (Refer to W3-22-1.)
Removal
2. Release any pressure in the the reserve tank. (Refer
to W1-5-1.)
W3-18-1-1
SECTION 3 BODY
13 14 15
4, 5 4, 6
4, 7
8
9 1, 2, 3 10, 16
18 11, 12 16, 17
85Z7B-W3-18-01-03 85Z7B-W3-18-01-04
5. Remove bolt, washer (1), washer (2), and clip (3). 8. Remove bolt, washer (11) and clip (12). Remove
bolts, washers (16) (2 used) and bracket (17).
j : 10 mm Place harness (18) outside of the work area.
6. Remove bolts, washers (4) (3 used) and clips (5, 6, 7). 9. Remove clamp (15) and disconnect connectors
(13, 14).
j : 17 mm
7. Disconnect connectors (8, 9). Remove clamp (16)
and connector (10).
W3-18-1-2
SECTION 3 BODY
1, 2 5 4
a
9
3
8
6
7
8
85Z7B-W3-18-01-05
a- Machine Front Side a 85Z7B-W3-18-01-06
10. Remove bolt, washer (1) and clip (2). 13. Remove bolts, washers (8) (4 used). Remove water
tank assembly (9).
j : 17 mm
j : 17 mm
11. Remove hoses (3, 4, 5).
12. Loosen hose band (6) and remove hose (7).
j : 6.3 mm
W3-18-1-3
SECTION 3 BODY
1, 2 8 9 5 14, 17
13
1, 3
16
10, 11
4
12 15, 18
85Z7B-W3-18-01-07A 85Z7B-W3-18-01-08
14. Remove bolts, washers (1) (3 used), clips (2) (2 used), 17. Loosen clamps (14, 15). Disconnect the both ends of
and clip (3). exhaust pipe (16). Remove gaskets (17, 18).
j : 17 mm j : 11 mm
15. Remove bolts, washers (4) (4 used) and bracket (5).
Place harness (6) and hoses (7, 8, 9) outside of the
work area.
j : 17 mm
16. Remove nuts (10) (4 used), U-bolt (11), and clamp
(12). Disconnect exhaust pipe (13).
j : 17 mm
W3-18-1-4
SECTION 3 BODY
2 1 3 4
85Z7B-W3-18-01-09
18. Loosen hose band (1) and remove hose (2).
j : 6.3 mm
19. Remove hose nipple (3) and elbow (4).
j : 19 mm
W3-18-1-5
SECTION 3 BODY
2 2
85Z7B-W3-18-01-10
a- Lifting Hole
21. Remove bolts, washers (2) (8 used). Remove the

dCAUTION: The aftertreatment device (1)
assembly weight: 136 kg (300 lb)
aftertreatment device (1) assembly from frame (3).
20. Attach nylon slings onto lifting holes (a) (4 places). j : 19 mm

Hoist and hold the aftertreatment device (1)
assembly.
W3-18-1-6
SECTION 3 BODY
1 2
Detail A 9
10 11
3, 4
12
13
6
3, 4, 5
WNEK50-03-18-013
85Z7B-W3-18-01-11
22. Remove sensor (1). 25. Remove bolt, washer (8), bolts (9) (2 used), and
washers (10) (2 used). Remove clip (11), sensor unit
j : 22 mm (7), and covers (12, 13).
j : 10 mm
Remove clip (5) and sensor unit (6).
j : 10 mm
24. Remove sensors (2) (2 used).
j : 14 mm
W3-18-1-7
SECTION 3 BODY
1 2 3, 4
10, 11, 12
5
6, 7, 8 85Z7B-W3-18-01-12
26. Remove bolt (10), washer (11), and clip (12). 29. Remove sensors (5) (2 used).
j : 10 mm j : 14 mm
27. Remove sensor (9). 30. Remove bolts (3) (2 used) and washers (4) (2 used).
Remove sensor unit (2).
j : 22 mm
j : 10 mm
Remove clips (8) (2 used) and sensor unit (1).
j : 10 mm
W3-18-1-8
SECTION 3 BODY
Detail A
1 2 3
A
9 4
85Z7B-W3-18-01-13
7 5, 6 WNEK50-03-18-016
31. Remove socket bolts (9) (2 used) and guard (8).
l : 5 mm
32. Remove connectors (5) (2 used) and cover (7).
Remove O-rings (6) (2 used) from connectors (5) (2
used).
j : 15 mm
33. Remove bolts (1) (3 used) and collars (2) (3 used).
Remove dosing valve (3) and gasket (4).
j : 10 mm
W3-18-1-9
SECTION 3 BODY
1
2
3
5
6
13
7
12
11
8
10 9
85Z7B-W3-18-01-14
34. Put the matching marks on DOC (10), clamp (8), and 35. Put the matching marks on SCR (11), clamp (12),
elbow (7). Loosen clamp (8). Remove elbow (7) from and elbow (1). Loosen clamp (12). Remove elbow (1)
DOC (10). Remove gasket (9). from SCR (11). Remove gasket (13).
j : 11 mm j : 11 mm
fNOTE: DOC (Diesel Oxidation Catalyst) fNOTE: SCR (Selective Catalytic Reduction)
36. Put the matching marks on dosing module (4),

clamp (2), and elbow (1). Put the matching marks on
dosing module (4), clamp (6), and elbow (7). Loosen
clamps (2, 6). Disconnect the both ends of dosing
module (4) from elbows (1, 7). Remove gaskets (3,
5).
j : 11 mm
W3-18-1-10
SECTION 3 BODY
17
10
16 16
15
15
14
14
14
14
a- Lifting Bracket 85Z7B-W3-18-01-15

dCAUTION: DOC (10) weight: 26 kg (58 lb) and bands (17) (2 used). Remove DOC (10) from
37. Attach nylon slings onto lifting brackets (a) (2 brackets (16) (2 used).
places). Hoist and hold DOC (10).
j : 17 mm
W3-18-1-11
SECTION 3 BODY
18
18
11
21
21
19
20
20
19
20
20
85Z7B-W3-18-01-16
b- Lifting Bracket

dCAUTION: SCR (11) weight: 44 kg (98 lb) and bands (18) (2 used). Remove SCR (11) from
39. Attach nylon slings onto lifting brackets (b) (2 brackets (21) (2 used).
places). Hoist and hold SCR (11).
j : 17 mm
W3-18-1-12
SECTION 3 BODY
18
18
11
21
21
19
20
20
19
20
20
85Z7B-W3-18-01-16
b- Lifting Bracket
Installation IMPORTANT: Check the position to install SCR (11).

2. Temporary install SCR (11) to brackets (21) (2 used)
dCAUTION: SCR (11) weight: 44 kg (98 lb)
with bands (18) (2 used), washers (19) (4 used), and
1. Attach nylon slings onto lifting brackets (b) (2 nuts (20) (8 used).
places). Hoist SCR (11).
W3-18-1-13
SECTION 3 BODY
17
10
16 16
15
15
14
14
14
14
a- Lifting Bracket
85Z7B-W3-18-01-15
IMPORTANT: Check the position to install DOC (10).

dCAUTION: DOC (10) weight: 26 kg (58 lb)
4. Temporary install DOC (10) to brackets (16) (2 used)
3. Attach nylon slings onto lifting brackets (a) (2 with bands (17) (2 used), washers (15) (4 used), and
places). Hoist DOC (10). nuts (14) (8 used).
W3-18-1-14
SECTION 3 BODY
1
2
3
5
6
13
7
12
11
8
10 9
85Z7B-W3-18-01-14
IMPORTANT: Replace gaskets (3, 5) with the new IMPORTANT: Replace gasket (9) with the new one.
ones. 7. Fit the matching marks made when removing.
5. Fit the matching marks made when removing. Temporary install gasket (9), clamp (8), and elbow
Temporary install clamps (2, 6), gaskets (3, 5), and (7) to DOC (10).
the both ends of dosing module (4) to elbows (1, 7).
IMPORTANT: Replace gasket (13) with the new one.
6. Fit the matching marks made when removing.
Temporary install clamp (12), gasket (13), and elbow
(1) to SCR (11).
W3-18-1-15
SECTION 3 BODY
12 6
20
14
20 85Z7B-W3-18-01-17
14
8. Tighten clamps (2, 6, 8, 12). 9. Tighten nuts (14, 20) (8 each used).
j : 11 mm j : 17 mm
m : 13.5±0.5 N·m (10±0.4 lbf·ft) m : 20 N·m (15 lbf·ft)
W3-18-1-16
SECTION 3 BODY
Detail A 1 2 3
A
9 4
85Z7B-W3-18-01-13
7 5, 6 WNEK50-03-18-016
IMPORTANT: Replace gasket (4) with the new one. 12. Apply lubricant (Lubriplate #105 or Cummins part
10. Temporary install gasket (4) and dosing valve No. #3163086 equivalent) to O-rings (6) (2 used).
(3) with collars (2) (3 used) and bolts (1) (3 used). Install O-rings (6) (2 used) to connectors (5) (2 used).
Temporary install bolts (1) (3 used) in the order as Install cover (7) and connectors (5) (2 used).
illustrated.
j : 15 mm
3 m : 6 N·m (4.4 lbf·ft)
13. Install guard (8) with socket bolts (9) (2 used).
l : 5 mm
m : 9 N·m (6.6 lbf·ft)
2 1
WNEK50-03-18-023
11. Tighten bolts (1) (3 used) in the order as illustrated.
j : 10 mm
m : 9 N·m (6.6 lbf·ft)
2 3
WNEK50-03-18-023
W3-18-1-17
SECTION 3 BODY
1 2 3, 4
10, 11, 12
5
6, 7, 8 85Z7B-W3-18-01-12
14. Apply anti-seize (LOCTITE Silver Grade Anti-Seize, 17. Install sensor unit (1) and clips (8) (2 used) with
Anti-Seize C5-A or equivalent) to the thread part of washers (7) (2 used) and bolts (6) (2 used).
sensors (5) (2 used). Install sensors (5) (2 used).
j : 10 mm
j : 14 mm
m : 14 N·m (10.5 lbf·ft)
m : 30 N·m (22 lbf·ft)
18. Install clip (12) with washer (11) and bolt (10).
15. Install sensor unit (2) with washers (4) (2 used) and
bolts (3) (2 used). j : 10 mm
j : 10 mm m : 14 N·m (10.5 lbf·ft)
m : 14 N·m (10.5 lbf·ft)

16. Apply anti-seize (LOCTITE Silver Grade Anti-Seize or
equivalent) to the thread part of sensor (9). Install
sensor (9).
j : 22 mm
m : 50 N·m (37 lbf·ft)
W3-18-1-18
SECTION 3 BODY
1 2
Detail A 9
10 11
3, 4
12
13
6
3, 4, 5
85Z7B-W3-18-01-11 WNEK50-03-18-013
19. Apply anti-seize (LOCTITE Silver Grade Anti-Seize, 21. Apply anti-seize (LOCTITE Silver Grade Anti-Seize or
Anti-Seize C5-A or equivalent) to the thread part of equivalent) to the thread part of sensor (1). Install
sensors (2) (2 used). Install sensors (2) (2 used). sensor (1).
j : 14 mm j : 22 mm

20. Install covers (12, 13), sensor unit (7), and clip (11) 22. Install sensor unit (6) and clip (5) with washers (4) (2
with washers (10) (2 used), bolts (9) (2 used), and used) and bolts (3) (2 used).
bolt, washer (8).
j : 10 mm
j : 10 mm
m : 14 N·m (10.5 lbf·ft)
Bolt, Washer (8)
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)

Bolt (9)
m : 14 N·m (10.5 lbf·ft)
W3-18-1-19
SECTION 3 BODY
2 2
85Z7B-W3-18-01-10
a- Lifting Hole
dCAUTION: The aftertreatment device (1)

23. Attach nylon slings onto lifting holes (a) (4 places).
Hoist the aftertreatment device (1) assembly.
24. Install the aftertreatment device (1) assembly to
frame (3) with bolts, washers (2) (8 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-18-1-20
SECTION 3 BODY
2 1 3 4
85Z7B-W3-18-01-09
25. Install elbow (4) and hose nipple (3).
j : 19 mm
26. Install hose (2) and fix with hose band (1).
j : 6.3 mm
m : 1.6±0.8 N·m (1.2±0.6 lbf·ft)
W3-18-1-21
SECTION 3 BODY
A 8 5
14, 17 1, 2
13
16
10, 11
1, 3
19
15, 18 20 12 85Z7B-W3-18-01-07A
85Z7B-W3-18-01-08
a- Machine Front Side View A
12
11
27. Install exhaust pipe (16) and gaskets (17, 18). Fix 13
with clamps (14, 15).
10
j : 11 mm
28. Install exhaust pipe (13) with clamp (12), U-bolt (11),
and nuts (10) (4 used).
b c
j : 17 mm a
m : 20 N·m (15 lbf·ft) 85Z7B-W3-18-01-18
29. Connect the both ends of hose (19) with clamps (20) b- 35° c- 40°
(2 used).
j : 7 mm
30. Install bracket (5) with bolts, washers (4) (4 used). 31. Install harness (6) and hose (8) with bolts, washers
Place harness (6) and hoses (7, 8, 9) outside of the (1) (3 used), clips (2) (2 used), and clip (3).
work area. j : 17 mm
j : 17 mm m : 50 N·m (37 lbf·ft)
m : 50 N·m (37 lbf·ft)
W3-18-1-22
SECTION 3 BODY
1, 2 5 4
a
9
3
8
6
7
8
85Z7B-W3-18-01-05
a 85Z7B-W3-18-01-06
32. Install water tank assembly (9) with bolts, washers 33. Install hose (7) and fix with hose band (6).
(8) (4 used).
j : 6.3 mm
j : 17 mm
34. Install hoses (3, 4, 5).
35. Install bolt, washer (1) and clip (2).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-18-1-23
SECTION 3 BODY
13 14 15
4, 5 4, 6
4, 7
8
9 1, 2, 3 10, 16
18 11, 12 16, 17
a- Machine Front Side 85Z7B-W3-18-01-04 85Z7B-W3-18-01-03
36. Connect connectors (13, 14) and fix with clamp (15). 38. Connect connectors (8, 9, 10). Install clamp (16).
37. Install bracket (17) with bolts, washers (16) (2 used). 39. Install bolts, washers (4) (3 used) and clips (5, 6, 7).
Fix harness (18) with bolt, washer (11) and clip (12).
j : 17 mm
m : 50 N·m (37 lbf·ft)

40. Remove bolt, washer (1), washer (2), and clip (3).
j : 10 mm
m : 3~4 N·m (2.2~3 lbf·ft)
W3-18-1-24
SECTION 3 BODY
85Z7B-W3-18-01-01
IMPORTANT: Check the coolant level. Start the

engine and check for any water leaks.
IMPORTANT: Warm up the engine. Warm up the
engine and increase the SCR exhaust temperature
over 190 °C (374 °F). Check the DEF hose for DEF
leaks.
42. Install engine cover (1). (Refer to W3-22-1.)
W3-18-1-25
SECTION 3 BODY
(Blank)
W3-18-1-26
SECTION 3 BODY
Group 19 DEF Tank
Removal and Installation of DEF Tank
2
3
1
85Z7BW-03-19-01 85Z7BW-03-19-02
Removal 2. Remove bolts, washers (2) (2 used). Remove cover

(1).
and pipes have been disconnected. In addition, j : 17 mm
hoses, and pipes for assembling. If the clips which 3. Place a container under drain plug (3). Slowly loosen
secure the hoses have been removed, install the drain plug (3). Drain off DEF completely. Tighten
clips after connecting the hoses. drain plug (3).
l : 6 mm
maintenance. (Refer to W1-5-1.) m : 5 to 7 N·m (4 to 5 lbf·ft)
fNOTE: Total amount of DEF tank: 41 L (11 gal)

W3-19-1-1
SECTION 3 BODY
Group 19 DEF Tank
1 3
2
85Z7BW-03-01-02 85Z7BW-03-01-03
4. Release any pressure in the the reserve tank. (Refer 6. Place a container under hose (2). Loosen cock (3).
to W1-5-1.) Drain off coolant. Close cock (3).
5. Open side cover (1). fNOTE: Amount of coolant: 39 L (10.3 gal)
W3-19-1-2
SECTION 3 BODY
Group 19 DEF Tank
1 3
a
2
85Z7BW-03-19-03 85Z7BW-03-19-04
b
a- Machine Front Side b- DEF Tank Box
dCAUTION: Cover (2) weight: 15 kg (33 lb)

9. Remove bolts, washers (1) (6 used). Remove covers
(2, 3).
j : 17 mm
W3-19-1-3
SECTION 3 BODY
Group 19 DEF Tank
2
Detail A
10 8 9
2
11, 6
8
1
7
12
1
3
13
4 2 85Z7BW-03-19-04 85Z7BW-03-19-05
8. Disconnect connector (13). Remove connector (13) 11. Remove hose bands (8) (2 used). Disconnect hoses
from bracket (12). (5, 9).
9. Remove bolt, washer (11). Remove clip (6). 12. Remove bolts, washers (2) (4 used) and brackets (1)
(2 used). Remove DEF tank (3) from DEF tank box
j : 17 mm (4).
j : 17 mm
W3-19-1-4
SECTION 3 BODY
Group 19 DEF Tank
A
Detail A
2 10 8 9
B
11, 6
2
C 5
7
1 12
1
3
13
85Z7BW-03-19-05
4 2 85Z7BW-03-19-04 a
View B
Installation
1. Install DEF tank (3) to DEF tank box (4) with brackets View C
(1) (2 used) and bolts, washers (2) (4 used). c
j : 17 mm
b
m : 50 N·m (37 lbf·ft)
IMPORTANT: Check that hose (5) connecting surface
is dry before connecting hose (5). 85Z7BW-03-19-06
2. Connect hoses (5, 9) with clamps (8) (2 used). a- 35 ° c- 5°
3. Connect hoses (7, 10). b- 30 °
IMPORTANT: Check the angle to install clip (6).

4. Secure hose (10) with clip (6) and bolt, washer (11). 5. Install connector (13) to bracket (12). Connect
connector (13).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-19-1-5
SECTION 3 BODY
Group 19 DEF Tank
View A
1 85Z7BW-03-19-04 85Z7BW-03-19-02
A
6. Add coolant to the radiator. 7. Check that drain plug (2) is tightened.
fNOTE: Amount of coolant: 39 L (10.3 gal) 8. Fill DEF tank (1) with DEF.
fNOTE: Total amount of DEF tank (1): 41 L (11 gal)
IMPORTANT: Check the DEF level and coolant level.

Start the engine and check for any water leaks.
W3-19-1-6
SECTION 3 BODY
Group 19 DEF Tank
1 3
1 4
85Z7BW-03-19-03 85Z7BW-03-19-01
dCAUTION: Cover (2) weight: 15 kg (33 lb)

9. Install covers (2, 3, 4) with bolts, washers (1) (8 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-19-1-7
SECTION 3 BODY
Group 19 DEF Tank
85Z7BW-03-01-02
10. Close side cover (1).
W3-19-1-8
SECTION 3 BODY
Removal and Installation of Coolant Control

Valve
1
3
85Z7BW-03-01-02 85Z7BW-03-01-03
Removal 4. Place a container under hose (2). Loosen cock (3).



2. Release any pressure in the reserve tank. (Refer to
W1-5-1.)
3. Open side cover (1).
W3-20-1-1
SECTION 3 BODY
Detail A
B 1
85Z7BW-03-20-03
View B 6 4 7
1
8
7
A
85Z7BW-03-20-01
5
8
2
3
85Z7BW-03-20-02
5. Remove bolt, washer (2) and clip (3). 7. Remove bolt, washer (5) and clip (6).
j : 17 mm 8. Loosen clamps (7) (2 used). Disconnect hoses (8) (2

used).
j : 8 mm
W3-20-1-2
SECTION 3 BODY
2
a
85Z7BW-03-20-04
a- Machine Rear Side 3
9. Remove bolts, washers (2) (2 used). Remove the 10. Remove screws (3) (2 used). Remove coolant control
bracket (4) assembly from rear frame (5). valve (1) from bracket (4).
j : 17 mm
W3-20-1-3
SECTION 3 BODY
B
5
a 85Z7BW-03-20-04
a- Machine Rear Side
3
View B
1
Installation
IMPORTANT: Install coolant control valve (1) with
triangular mark (b) facing to the rear side of
machine.
1. Install coolant control valve (1) to bracket (4) with
a
screws (3) (2 used).
2. Install the bracket (4) assembly to rear frame (5) b
j : 17 mm
4
m : 50 N·m (37 lbf·ft) a- Machine Rear Side b- Triangular Mark
WNEK50-03-20-005
W3-20-1-4
SECTION 3 BODY
View A 4 7
6
1
8
7
9
5
8
a 2
A 3
85Z7BW-03-20-02
b
85Z7BW-03-20-01 6 b
9
a- Machine Rear Side 5
7
8 7 c 8
3. Connect hoses (8) (2 used) with clamps (7) (2 used).
j : 8 mm View B 8
1
4
fNOTE: Keep the end of hose (8) from clamp (7) by 3 mm
(0.12 in). c
4. Secure hose (9) with clip (6) and bolt, washer (5). 10
2 3
j : 17 mm
85Z7BW-03-20-05
m : 50 N·m (37 lbf·ft)
b- 3 mm c- 30°
5. Secure wire harness (10) with clip (3), and bolt,
washer (2).
j : 17 mm
m : 50 N·m (37 lbf·ft)

W3-20-1-5
SECTION 3 BODY
85Z7BW-03-01-02
IMPORTANT: Check the coolant level. Start the

engine and check for any water leaks.
W3-20-1-6
SECTION 3 BODY
Removal and Installation of DEF Supply

Module
WNEK50-03-19-003

Removal
2. Open side cover (1).
W3-21-1-1
SECTION 3 BODY
A Detail A
2, 3
B
4 5
85Z7BW-03-20-01 85Z7BW-03-21-01
View B
3. Lower lock (6) and disconnect connector (4).

Remove DEF supply module (5) from support (7).
j : 13 mm
TDC1-05-01-005
6
W3-21-1-2
SECTION 3 BODY
A Detail A
1
2, 3
B
4 5
85Z7BW-03-20-01 85Z7BW-03-21-01
View B
Installation
1. Install DEF supply module (5) to support (7) with
j : 13 mm
m : 16 N·m (12 lbf·ft)

2. Connect hoses (1) (3 used). WDC150-03-17-003
6
3. Connect connector (4). Raise to apply lock (6).
W3-21-1-3
SECTION 3 BODY
85Z7BW-03-01-02
IMPORTANT: Warm up the engine. Warm up the

engine over 15 minutes. Check that the SCR
exhaust temperature is over 190°C (374°F) by
using the monitor. Check the DEF hose for DEF
leaks.
W3-21-1-4
SECTION 3 BODY
Removal and Installation of Exterior

Components
101 102 103 104 105 106 107 108

85Z7B-W3-22-01-01
117
116
115
114
109 110 111 110 111 112 113

85Z7B-W3-22-01-02
118
121
113 120 119 122 85Z7B-W3-22-01-03
W3-22-1-1
SECTION 3 BODY
No. Parts Page Related Parts

1 2 3 4
101 Front Cover W3-22-1-3
102 Front Fender W3-22-1-4
103 Deck W3-22-1-5
104 Step (Front) W3-22-1-5
105 Rear Fender (Front) W3-22-1-5
106 Rear Fender (Rear) W3-22-1-7
107 Engine Cover W3-22-1-9 Rear Fender Side Cover Rear Grill (116) Rear Cover
(Rear) (106) (Front) (115) (108)
108 Rear Cover W3-22-1-21 Rear Grill (116)
109 Cab Under Cover W3-22-1-25
110 Mud Guard W3-22-1-26
111 Inspection Cover W3-22-1-28 Battery Box
(121)
112 Lower Cover W3-22-1-31
113 Step (Rear) W3-22-1-28
114 DEF Tank Box W3-22-1-28 DEF Tank
115 Side Cover (Front) W3-22-1-32
(without Rear
Fender (Rear))
W3-22-1-38 Rear Fender
(with Rear (Rear) (106)
Fender (Rear))
116 Rear Grill W3-22-1-44
117 Left Side Cover (Rear) W3-22-1-51
118 Right Side Cover (Rear) W3-22-1-55
119 Tool Box W3-22-1-5
120 Under Guard (Rear) W3-22-1-59
121 Battery Box W3-22-1-60 Rear Fender
(Front) (105)
122 Under Guard (Front) W3-22-1-70
W3-22-1-2
SECTION 3 BODY
Removal and Installation of Front Cover (101)
02
01
85Z7B-W3-22-01-04
No. Part Name Q'ty Wrench Size Tightening Torque Weight

mm N·m (lbf·ft) kg (lb)
01 Bolt, Washer 4 j : 17 50 (37)
02 Cover 1
Set the machine position for inspection and maintenance before removing/installing parts. (Refer to W1-5-1.)
W3-22-1-3
SECTION 3 BODY
Removal and Installation of Front Fender (102)
12
02
13
14
05
01 14
04 03
11
13
05 03 04
85Z7B-W3-22-01-05

01 Fender 1 20 (44)
02 Fender 1 20 (44)
03 Washer 8
04 Washer 8
05 Nut 8 j : 19 35 (2.6)
11 Cover 1
12 Cover 1
13 Screw 12
14 Plug 8
W3-22-1-4
SECTION 3 BODY
Removal and Installation of Deck (103), Step (Front)

(104), Rear Fender (Front) (105), and Tool Box (119)
18 24
37
38
20 20
19 26
25 19
26
25
21
25
25 21
22 26 26 22
31 31
30 30
33 33
14
33 33
05
07
06 27
34 32 34 32 13
14
12
02
01
08
07
08
21
02
21
22
22
09
85Z7B-W3-22-01-06
W3-22-1-5
SECTION 3 BODY

01 Deck 1
02 Bolt, Washer 6 j : 19 90 (66)
05 Fender 1 27 (60)
06 Fender 1 27 (60)
07 Bolt, Washer 12 j : 19 90 (66)
08 Bolt, Washer 6 j : 19 90 (66)
09 Tool Box 1
12 Cover 1
13 Cover 1
14 Screw 12
18 Handrail 1
19 Bolt, Washer 4 j : 19 90 (66)
20 Bolt, Washer 4 j : 19 90 (66)
21 Washer 8
22 Nut 8 j : 19 90 (66)
24 Handrail 1
25 Washer 6
26 Bolt, Washer 6 j : 19 35 (2.6)
30 Step 2 29 (64)
31 Bolt, Washer 8 j : 19 90 (66)
32 Step 2
33 Bolt, Washer 8 j : 17 50 (37)
34 Nut 8 j : 17 50 (37)
37 Handrail 1
38 Handrail 1
W3-22-1-6
SECTION 3 BODY
Removal and Installation of Rear Fender (Rear)

(106)
03
23 01
07
13
10
26
17 08
05 19
20
16
15
21
24 23
02 03
23
07
14
10
09 18 26
19 06
20
16
15
22 23
25
85Z7B-W3-22-01-07
W3-22-1-7
SECTION 3 BODY

01 Fender 1
02 Fender 1
03 Bolt, Washer 8 j : 17 50 (37)
05 Bracket 1
06 Bracket 1
07 Bolt, Washer 4 j : 19 90 (66)
08 Bracket 1
09 Bracket 1
10 Bolt, Washer 6 j : 19 90 (66)
13*1 Cover 1
14*1 Cover 1
15 Bolt 4 j : 17 50 (37)
16 Washer 4
17 Plate 1
18 Plate 1
19 Bolt, Washer 4 j : 17 20 (15)
20 Nut 4 j : 17 50 (37)
21 Plate 2
22 Plate 1
23 Bolt, Washer 12 j : 17 50 (37)
24 Plate 1
25 Plate 1
26 Rubber Sheet 2
*1: Install covers (13, 14) with the dull surface facing to the rear side of the machine.
W3-22-1-8
SECTION 3 BODY
Removal and Installation of Engine Cover (107)
115 106
108 1
106
85Z7B-W3-22-01-08 85Z7B-W3-22-01-09
Removal 3. Remove bolts, washers (1) (4 used). Remove tail pipe

(2).
maintenance. (Refer to W1-5-1.) j : 19 mm
2. Remove the following exterior components. (Refer
to W3-22-1-1.)
 Left and Right Rear Fender (Rear) (106)
 Left and Right Side Cover (Front) (115)
 Rear Cover (108)
W3-22-1-9
SECTION 3 BODY
1, 2 3, 4
LH RH
85Z7B-W3-22-01-44 85Z7B-W3-22-01-45
4. Remove bolts, washers (1) (2 used), bolts, washers

(3) (2 used), clips (2) (2 used), and clips (4) (2 used).
j : 17 mm
W3-22-1-10
SECTION 3 BODY
2 3
5
4
1
4
6 3
85Z7B-W3-22-01-10 85Z7b-W3-22-01-11
5. Remove rubber caps (1) (3 used).

6. Remove bolts, washers (2) (4 used).
dCAUTION: Engine cover (4) weight: 52 kg (115 lb)
7. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to the
j : 19 mm bolt, washer (2) mounting holes (4 places). Attach
nylon slings onto the eyebolts (4 used). Hoist and
hold engine cover (4).
8. Remove bolts, washers (3) (4 used). Remove engine
cover (4) from hydraulic tank (5) and frame (6).
j : 24 mm
W3-22-1-11
SECTION 3 BODY
3 2
5
4
1
4
6 3
85Z7b-W3-22-01-11 85Z7B-W3-22-01-10
Installation 3. Tighten bolts, washers (3) (4 used).
dCAUTION: Engine cover (4) weight: 52 kg (115 lb) j : 24 mm

m : 210 N·m (155 lbf·ft)
bolt, washer (2) mounting holes (4 places). Attach
nylon slings onto the eyebolts (4 used). Hoist engine 4. Install rubber caps (1) (3 used).
cover (4).
5. Remove eyebolts, and tighten bolts, washers (2) (4
2. Temporally install engine cover (4) to hydraulic oil used).
tank (5) and frame (6) with washers (3) (4 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-22-1-12
SECTION 3 BODY
1, 2 3, 4
LH RH
85Z7B-W3-22-01-44 85Z7B-W3-22-01-45
6. Install 2 each of bolts, washers (1, 3) and 2 each of

clips (2, 4).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-22-1-13
SECTION 3 BODY
115 106
1 108
106
85Z7B-W3-22-01-09 85Z7B-W3-22-01-08
7. Install tail pipe (2) with bolts, washers (1) (4 used). 8. Install the following exterior components. (Refer to
W3-22-1-1.)
j : 19 mm
 Rear Cover (108)
m : 90 N·m (66 lbf·ft)  Left and Right Side Cover (Front) (115)
 Left and Right Rear Fender (Rear) (106)
W3-22-1-14
SECTION 3 BODY
Removal and Installation of Rear Cover (108)
6 1
5 3
85Z7B-W3-22-01-12
Removal
dCAUTION: Rear cover (4) weight: 15 kg (33 lb)
2. Remove bolts, washers (1) (4 used). nylon slings onto the eyebolts (4 used). Hoist rear
cover (4).
j : 17 mm
6. Remove bolts, washers (5) (6 used). Remove rear
3. Remove duct (2). cover (4) from roof (6).
j : 17 mm
W3-22-1-15
SECTION 3 BODY
6 1
5 3
85Z7B-W3-22-01-12
Installation 4. Remove eyebolts, and tighten bolts, washers (3) (2

used).
dCAUTION: Rear cover (4) weight: 15 kg (33 lb)
j : 17 mm
m : 50 N·m (37 lbf·ft)
nylon slings onto the eyebolts (2 used). Hoist rear
cover (4). 5. Install duct (2) with bolts, washers (1) (4 used).
2. Temporarily install rear cover (4) to roof (6) with j : 17 mm
m : 50 N·m (37 lbf·ft)
3. Tighten bolts, washers (5) (6 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-22-1-16
SECTION 3 BODY
Removal and Installation of Cab Under Cover (109)
04
03
03
02
03
03
05
01
03
06 85Z7B-W3-22-01-13

01 Cover 1
02 Cover 1
03 Bolt, Washer 14 j : 17 50 (37)
04 Cover 1
05 Cover 1
06 Cover 1
W3-22-1-17
SECTION 3 BODY
Removal and Installation of Mud Cover (110)
05
06 06
07
04
05
06
06 02
09
07 08
06 19
03
08
09
19
15
06
01 17
09 08
16
08
09
14
85Z7B-W3-22-01-14
W3-22-1-18
SECTION 3 BODY

01*1 Cover 1
02*1 Cover 1
03 Bracket 1
04 Bracket 1
05 Bracket 2
06 Bolt, Washer 18 j : 17 50 (37)
07 Washer 6
08 Bolt 18 j : 17 50 (37)
09 Washer 18
14*2 Cover 1
15*2 Cover 1
16 Bracket 1
17 Bracket 1
19 Washer 6
*1: Install covers (01, 02) with the pearskin surface facing to the rear side of the machine.
*2: Install covers (14, 15) with the glossy surface facing to the rear side of the machine.
W3-22-1-19
SECTION 3 BODY
Removal and Installation of Inspection Cover (111),

Step (Rear) (113), and DEF Tank Box (114)
59 58
57
56
53 52
51 53 113
04
06
08
111 07
05
09 58
57
59
53
113
06
55
05
50
111 04
12 13
03 06
02 15 23 24
25
01 16 35
17
11A
21
114 10 11G
22
11F 11E 11D
11B
34
11
34 11C
12
20
85Z7B-W3-22-01-15
111- Inspection Cover 113- Step (Rear) 114- DEF Tank Box
W3-22-1-20
SECTION 3 BODY

01 Plate 1
02 Sponge 1
03 Sponge 1
04 Cover 2
05 Sponge 2
06 Bolt, Washer 20 j : 17 50 (37)
07 Plate 1
08 Sponge 1
09 Sponge 1
10*1 Box 1 56 (123.5)
11 Cover 1 12 (26.5)
11A Hinge 2
11B Catch 1
11C Screw 3
11D Screw 3
11E Washer 1
11F Spring Washer 1
11G Nut 1
12 Bolt, Washer 10 j : 17 50 (37)
13 Plate 1
15 Spacer 4
16 Washer 4
17 Bolt 4 j : 24 210 (155)
20 Cover 1
21 Plate 1
22 Rubber Sheet 2
23 Bolt, Washer 1
24 Plate 1
25 Plate 1
35 Rubber Stopper 2
50 Step 1
51 Step 1
52 Step 1
53 Bolt, Washer 6 j : 19 90 (66)
55 Step 1
56 Step 1
57 Washer 4
58 Washer 4
59 Nut 4 j : 19 35 (26)
*1: Remove the DEF tank before removing box (10). (Refer to W3-19-1.)
W3-22-1-21
SECTION 3 BODY
Removal and Installation of Lower Cover (112)
01
04
01
01
02
01
85Z7B-W3-22-01-16

01 Bolt, Washer 10 j : 17 50 (37)
02 Cover 1
04 Cover 1
W3-22-1-22
SECTION 3 BODY
Removal and Installation of Side Cover (Front) (115)

(without Rear Fender (Rear))
85Z7B-W3-22-01-17
Removal
2. Open side cover (front) (1).
W3-22-1-23
SECTION 3 BODY
Detail A
1 3
4
2
A
7
5
2 85Z7B-W3-22-01-18 85Z7B-W3-22-01-19
5. Remove nut (8). Remove the damper (2) assembly

dCAUTION:
lb)
Side cover (front) (1) weight: 30 kg (66 from bracket (7).
IMPORTANT: Attach nylon slings onto the frame side j : 13 mm

of side cover (front) (1).
3. Attach nylon slings onto side cover (front) (1). Hoist
fNOTE: When loosening nut (8), secure bolt (6) with a
wrench to fix it.
and hold side cover (front) (1).
j : 13 mm
4. Remove nut (5). Disconnect the damper (2)
assembly from bracket (4).
j : 13 mm
fNOTE: When loosening nut (5), secure bolt (3) with a

wrench to fix it.
j : 13 mm
W3-22-1-24
SECTION 3 BODY
85Z7B-W3-22-01-20
6. Remove bolts, washers (3) (4 used). Remove side 7. Remove other side cover (front) (1) in the same way
cover (front) (1) from engine roof (2). as step 2 to step 6.
j : 19 mm
W3-22-1-25
SECTION 3 BODY
85Z7B-W3-22-01-20
Installation 2. Install side cover (front) (1) to engine roof (2) with
dCAUTION:
lb)
Side cover (front) (1) weight: 30 kg (66
j : 19 mm
IMPORTANT: Attach nylon slings onto the frame side
m : 90 N·m (66 lbf·ft)
side cover (front) (1).
W3-22-1-26
SECTION 3 BODY
1
Detail A
3
4
2
A
a
7
5
2
85Z7B-W3-22-01-18 8
85Z7B-W3-22-01-19
IMPORTANT: Set the direction of part (b) of the IMPORTANT: Set the direction of part (a) of the
damper (2) assembly as illustrated. dumper (2) assembly as illustrated.
3. Install the damper (2) assembly to bracket (7) with 4. Install the damper (2) assembly to bracket (4) with
nut (8). nut (5).
j : 13 mm j : 13 mm
m : 10 N·m (7.4 lbf·ft) m : 10 N·m (7.4 lbf·ft)
fNOTE: When tightening nut (8), secure bolt (6) with a fNOTE: When tightening nut (5), secure bolt (3) with a
wrench to fix it. wrench to fix it.
j : 13 mm j : 13 mm
W3-22-1-27
SECTION 3 BODY
85Z7B-W3-22-01-17
5. Close side cover (front) (1). 6. Install other side cover (front) (1) in the same way as
step 1 to step 5.
W3-22-1-28
SECTION 3 BODY
Removal and Installation of Side Cover (Front) (115)

(with Rear Fender (Rear))
106
85Z7B-W3-22-01-08
Removal 3. Open side cover (front) (1).

to W3-22-1-1.)
 Rear Fender (Rear) (106)
W3-22-1-29
SECTION 3 BODY
1 A
Detail A
3
4
B
6 5 5 2
2
85Z7B-W3-22-01-22
Detail B
2 2 85Z7B-W3-22-01-21
2
10
dCAUTION:
lb)
8
of side cover (front) (1). 2
4. Attach nylon slings onto side cover (front) (1). Hoist 10
and hold side cover (front) (1).
5. Remove lock pin (6), washers (5) (5 used), and pin
(3). Disconnect dampers (2) (2 used) from bracket
(4).
9 7
6. Remove lock pin (9), washers (10) (3 used), and pin
(7). Remove dampers (2) (2 used) from bracket (8).
85Z7B-W3-22-01-23
10
W3-22-1-30
SECTION 3 BODY
85Z7B-W3-22-01-20
7. Remove bolts, washers (3) (4 used). Remove side 8. Remove other side cover (front) (1) in the same way
cover (front) (1) from engine roof (2). as step 2 to step 7.
j : 19 mm
W3-22-1-31
SECTION 3 BODY
85Z7B-W3-22-01-20
Installation 2. Install side cover (front) (1) to engine roof (2) with
dCAUTION:
lb)
j : 19 mm
m : 90 N·m (66 lbf·ft)
side cover (front) (1).
W3-22-1-32
SECTION 3 BODY
1 A
Detail A
3
4
B
6 5 5 2
2
85Z7B-W3-22-01-22A
Detail B
2
2 2 85Z7B-W3-22-01-21
10
b
IMPORTANT: Set the direction of part (b) of dampers 8

(2) (2 used) as illustrated. 2
3. Install dampers (2) (2 used) to bracket (8) with pin 10
(7), washers (10) (3 used), and lock pin (9).
IMPORTANT: Set the direction of part (a) of dampers
(2) (2 used) as illustrated.
4. Install dampers (2) (2 used) to bracket (4) with pin
9 7
(3), washers (5) (5 used), and lock pin (6).
10 85Z7B-W3-22-01-23B
W3-22-1-33
SECTION 3 BODY
106
85Z7B-W3-22-01-08
5. Close side cover (front) (1). 7. Install other side cover (front) (1) in the same way as
step 1 to step 6.
6. Install the following exterior components. (Refer to
W3-22-1-1.)
 Rear Fender (Rear) (106)
W3-22-1-34
SECTION 3 BODY
Removal and Installation of Rear Grill (116)
1 View A
2, 3
85Z7B-W3-22-01-24 85Z7B-W3-22-01-26
Removal 3. Remove bolt, washer (2) and clip (3).

1. Set the machine position for inspection and j : 17 mm
W3-22-1-35
SECTION 3 BODY
1
Detail A
5 6
3
A
2
4
85Z7B-W3-22-01-28
85Z7B-W3-22-01-27
6. Remove lock pin (6) and washer (5) from pin (3).
dCAUTION:
kg (101 lb)
The rear grill (1) assembly weight: 46 Disconnect damper (2) from bracket (4).
7. Remove the other damper (2) from bracket (4) in the
5. Attach nylon slings onto the rear grill (1) assembly.
same way as step 6.
Hoist and hold the rear grill (1) assembly.
W3-22-1-36
SECTION 3 BODY
1
3
6, 4
6, 4
6, 4
85Z7B-W3-22-01-29
8. Remove nuts (2) (6 used) and washers (4) (6 used).

Remove the rear grill (1) assembly from bracket (3).
j : 13 mm
W3-22-1-37
SECTION 3 BODY
1
3
6, 4
6, 4
6, 4
85Z7B-W3-22-01-29
Installation 2. Install the rear grill (1) assembly to bracket (3) with
nuts (2) (6 used) and washers (4) (6 used).
dCAUTION:
kg (101 lb)
The rear grill (1) assembly weight: 46
j : 13 mm
1. Attach nylon slings onto the rear grill (1) assembly.
m : 20 N·m (15 lbf·ft)
Hoist the rear grill (1) assembly.
W3-22-1-38
SECTION 3 BODY
Detail A
5 6
3
A
2
4
a
85Z7B-W3-22-01-27 85Z7B-W3-22-01-28A
IMPORTANT: Set the direction of part (b) of damper 4. Install the other damper (2) to bracket (4) in the
(2) as illustrated. same way as step 3.
3. Install damper (2) to pin (7) of bracket (4) with
washer (5) and lock pin (6).
W3-22-1-39
SECTION 3 BODY
1 Detail A
4
A
2, 3
85Z7B-W3-22-01-24
85Z7B-W3-22-01-26
5. Connect the connectors (4) (2 used). 7. Close rear grill (1).

6. Secure the harness with clip (3) and bolt, washer (2).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W3-22-1-40
SECTION 3 BODY
Removal and Installation of Left Side Cover (Rear)

(117)
4
1
7, 8
5, 6
85Z7B-W3-22-01-08 85Z7B-W3-22-01-30
Removal 4. Disconnect connectors (3, 4).

1. Set the machine position for inspection and 5. Remove bolt (5) and clip (6).
6. Remove connector (7) from holder (8).
2. Open left side cover (front) (2).
W3-22-1-41
SECTION 3 BODY
3 4
1
7 6
6
5
85Z7B-W3-22-01-31
j : 19 mm
dCAUTION: Left side cover (rear) (1) assembly
8. Remove bolts, washers (3, 7) (2 each used) and
bracket (2). Remove the left side cover (rear) (1)
assembly from frames (4, 5).
j : 19 mm
W3-22-1-42
SECTION 3 BODY
3 4
1
7 6
6
5
85Z7B-W3-22-01-31
dCAUTION: Left side cover (rear) (1) assembly

j : 19 mm
m : 90 N·m (66 lbf·ft)

1. Temporarily install the side cover (rear) (1) assembly
to frames (4, 5) with bracket (2) and bolts, washers
(3, 6, 7) (2 each used).
2. Tighten bolts, washers (3, 7) (2 each used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-22-1-43
SECTION 3 BODY
4
1
7, 8
5, 6
85Z7B-W3-22-01-30 85Z7B-W3-22-01-08
4. Connect connectors (3, 4). 7. Close rear grill (1).

5. Install connector (7) to holder (8). 8. Close left side cover (front) (2).
6. Install bolt (5) and clip (6).
W3-22-1-44
SECTION 3 BODY
Removal and Installation of Right Side Cover (Rear)

(118)
1
2
85Z7B-W3-22-01-32 85Z7B-W3-22-01-33
Removal 4. Disconnect connectors (3, 4).

2. Open right side cover (front) (1).
W3-22-1-45
SECTION 3 BODY
4 3
7
6
85Z7B-W3-22-01-34
j : 19 mm
dCAUTION: Right side cover (rear) (1) assembly
6. Remove bolts, washers (3, 7) (2 each used) and
bracket (2). Remove the right side cover (rear) (1)
assembly from frames (4, 5).
j : 19 mm
W3-22-1-46
SECTION 3 BODY
4 3
7
6
85Z7B-W3-22-01-34
dCAUTION: Right side cover (rear) (1) assembly

j : 19 mm
m : 90 N·m (66 lbf·ft)

1. Temporarily install the right side cover (rear) (1)
assembly to frames (4, 5) with bracket (2) and bolts,
washers (3, 6, 7) (2 each used).
2. Tighten bolts, washers (3, 7) (2 each used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W3-22-1-47
SECTION 3 BODY
1
2
85Z7B-W3-22-01-33 85Z7B-W3-22-01-32
4. Connect connectors (3, 4). 5. Close rear grill (2).

6. Close right side cover (front) (1).
W3-22-1-48
SECTION 3 BODY
Removal and Installation of Under Guard (Front)

(122)
06
05
04
01
06
05
07 04
03
02
03 07
08 85Z7B-W3-22-01-35

01 Guard 1 82 (181)
02 Cover 1 3.5 (7.7)
03 Cover 2 2 (4.4)
04 Bolt 6 j : 24 210 (155)
05 Washer 6
06 Washer 6
07 Bolt, Washer 8 j : 17 50 (37)
08 Bolt, Washer 4 j : 17 50 (37)
d CAUTION: While removing or installing guard (01), place a stand and jack under guard (01) to hold guard
(01). Do not drop guard (01).
W3-22-1-49
SECTION 3 BODY
Removal and Installation of Under Guard (Rear)

(120)
05
01 04
05 03
04
06
03
06 02
85Z7B-W3-22-01-36

01 Guard 1 88 (194)
02 Plate 1 7 (15)
03 Bolt 6 j : 24 210 (155)
04 Washer 6
05 Washer 6
06 Bolt, Washer 4 j : 17 50 (37)
d CAUTION: While removing or installing guard (01), place a stand and jack under guard (01) to hold guard
(01). Do not drop guard (01).
W3-22-1-50
SECTION 3 BODY
Removal and Installation of Battery Box (121)
Detail A
A 1
4
3 b
85Z7B-W3-22-01-38
a- OFF Position
85Z7B-W3-22-01-37 b- ON Position
Removal IMPORTANT: Set the key switch to the OFF position.

Wait 5 minutes or longer, and then set battery
IMPORTANT: When disconnecting connectors or
disconnect switch (5) to the OFF position.
terminals, attach an identification tag onto the
connectors and terminals for assembling. If the 4. Set battery disconnect switch (4) to OFF position (a).
clips which secure the wire harnesses is removed, 5. Remove nuts (3) (2 used). Remove rubber plate (1).
install the clips after connecting the connectors or
terminals. j : 19 mm
to W3-22-1-1.)
 Right Rear Fender (Front) (105)
3. Open covers (2).
W3-22-1-51
SECTION 3 BODY
1 10 15, 16 6, 7
11, 12
2
5
5
3, 4 3, 4
2
8, 9
13, 14
17 1 17
85Z7B-W3-22-01-39
6. Remove bolt (15) and clip (16).

dCAUTION: Battery (1) weight: 46 kg (101 lb)
j : 10 mm brackets (2) (2 used), rubber sheet (17) (4 used), and
rod (5) (4 used). Remove batteries (1) (2 used).
8. Loosen nuts (8, 11). Disconnect terminals (9, 12).
j : 19 mm
j : 10 mm
11. Remove battery disconnect switch (10). (Refer to
9. Loosen nut (6). Disconnect terminal (7). W3-17-1.)
j : 10 mm
W3-22-1-52
SECTION 3 BODY
1
2
4
5 3
4
1
85Z7B-W3-22-01-40
12. Remove bolts, washers (1) (4 used) and angle (2). 13. Remove bolts, washers (3) (2 used) and bosses (4) (2
used). Remove cover (5) and angle (6).
j : 17 mm
j : 17 mm
W3-22-1-53
SECTION 3 BODY
3, 4
3, 4
5 85Z7B-W3-22-01-41
a- Hole

dCAUTION: The battery box (5) assembly weight:
61 kg (134 lb)
used). Remove the battery box (5) assembly from
rear frame (1) while pulling the wire harness (2)
14. Attach nylon slings onto the battery box (5) assembly from hole (a) on battery box (5).
assembly. Hoist and hold the battery box (5)
assembly. Hold the lower part of the battery box (5) j : 30 mm
assembly by using a jack and wooden blocks.
W3-22-1-54
SECTION 3 BODY
3, 4
3, 4
5
85Z7B-W3-22-01-41
a- Hole
Installation 2. Install the battery box (5) assembly to rear frame (1)
with washers (4) (4 used) and bolts (3) (4 used).
dCAUTION: The battery box (5) assembly weight:
61 kg (134 lb) j : 30 mm
1. Attach nylon slings onto the battery box (5)
m : 400 N·m (295 lbf·ft)
assembly. Hoist and hold the battery box (5)
assembly. Raise the lower part of the battery box (5)
assembly by using a jack and wooden blocks. Pass
through the wire harness (2) assembly to battery
box (5) via hole (a).
W3-22-1-55
SECTION 3 BODY
1
2
4
5 3
4
1
85Z7B-W3-22-01-40
3. Temporarily install cover (5) and angle (6) with bolts, 5. Tighten bolts, washers (3) (2 used) and bolts,
washers (3) (2 used) and bosses (4) (2 used). washers (1) (4 used).
j : 17 mm j : 17 mm
4. Temporarily install angle (2) with bolts, washers (1) m : 50 N·m (37 lbf·ft)
(4 used).
j : 17 mm
W3-22-1-56
SECTION 3 BODY
Detail A
1 10 15, 16 B 6, 7 1 2 1
11, 12
2
5 5 17
85Z7B-W3-22-01-42
3, 4 3, 4
5 Detail B
18
2 17
1 1
8, 9
5
13, 14
17 1 17 18
85Z7B-W3-22-01-39A 85Z7B-W3-22-01-43
8. Connect terminals (9, 12) and tighten nuts (8, 11).

d CAUTION: Battery (1) weight: 46 kg (101 lb)
j : 10 mm
IMPORTANT: Insert rubber sheet (17) between
battery (1) and bracket (2), and between bracket
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)
(2) and cable (18) as shown.
6. Install batteries (1) (2 used) with rods (5) (4 used), 9. Connect terminal (14) and tighten nut (13).
rubber sheet (17) (4 used), brackets (2) (2 used), j : 10 mm
washers (4) (4 used) and nuts (3) (4 used).
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)
j : 19 mm
10. Install battery disconnect switch (10). (Refer to W3-
m : 20 N·m (15 lbf·ft) 17-1.)
7. Connect terminal (7). Tighten nut (6).
j : 10 mm
m : 3 to 4 N·m (2.2 to 3.0 lbf·ft)
W3-22-1-57
SECTION 3 BODY
Detail A
1 4
4
b
3
85Z7B-W3-22-01-38
a- OFF Position
b- ON Position
85Z7B-W3-22-01-37
11. Install rubber plate (1) with nuts (3) (2 used). 13. Close cover (2).
j : 19 mm 14. Install the following exterior components. (Refer to

W3-22-1-1.)
m : 35 N·m (26 lbf·ft)
 Right Rear Fender (Front) (105)
12. Set battery disconnect switch (4) to ON position (b).
W3-22-1-58
MEMO
MEMO
SECTION 4
TRAVEL SYSTEM
CONTENTS
Group 1 Tire Removal and Installation of Steering
Removal and Installation of Front Tire....................W4-1-1-1 Accumulator................................................................W4-6-9-1
Removal and Installation of Rear Tire......................W4-1-2-1 Removal and Installation of Left Stop Valve....... W4-6-10-1
Removal and Installation of Right Stop Valve.... W4-6-11-1
Group 2 Drive Unit Disassembly of Stop Valve........................................ W4-6-12-1
Removal and Installation of Drive Unit...................W4-2-1-1 Assembly of Stop Valve.............................................. W4-6-12-2
Disassembly and Assembly of Drive Unit...............W4-2-2-1
Removal and Installation of Torque Converter....W4-2-3-1 Group 7 Emergency Steering Device
Disassembly and Assembly of Transmission ........W4-2-4-1 Removal and Installation of Emergency Steering
Disassembly and Assembly of Transmission Pump..............................................................................W4-7-1-1
Control Valve ..............................................................W4-2-5-1
Removal and installation of parking brake
(Replace the brake friction pad)...........................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 Pilot
Valve...............................................................................W4-6-1-1
Disassembly of Steering Pilot Valve .......................W4-6-2-1
Assembly of Steering Pilot Valve...............................W4-6-2-4
Removal and Installation of Steering Valve
(Without Emergency Steering).............................W4-6-3-1
(With Emergency Steering)....................................W4-6-4-1
Disassembly of Steering Valve...................................W4-6-5-1
Assembly of Steering Valve.........................................W4-6-5-4
Disassembly of Emergency Steering Check
Block...............................................................................W4-6-6-1
Assembly of Emergency Steering Check Block....W4-6-6-3
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
NEM50W-4-1
(Blank)
NEM50W-4-2
SECTION 4 TRAVEL SYSTEM
Group 1 Tire
Removal and Installation of Front Tire
3 2 85Z7B-W4-01-01-01
a- Wheel Stopper
Removal
dCAUTION: Perform removal and installation

of the front tires in a group more than two
personnel.
 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) (20 used) one turn.
j : 36 mm
W4-1-1-1
Group 1 Tire
1, 2 3 4 a 85Z7B-W4-01-01-02
a- Stand
d CAUTION: Machine weight: 21000 kg (46300 lb)

5. Raise the machine until tire (3) slightly gets away b
from the ground. Securely support the machine by
using stand (a).
dCAUTION: Front tire (3) weight: 700 kg (1545 lb)

2 1
6. Attach lifting tools (b) onto front tire (3). Hoist and
hold front tire (3). 3
7. Remove wheel bolts (1) (20 used) and washers (2)
(20 used). Remove front tires (3) from front axle (4).
j : 36 mm
W4GB-03-01-003
b- Lifting Tool
W4-1-1-2
Group 1 Tire
1, 2 3 4 a 85Z7B-W4-01-01-02
a- Stand
Installation
dCAUTION: Front tire (3) weight: 700 kg (1545 lb) b

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). 2 1
2. Install front tire (3) to front axle (4) with washers (2)
3
(20 used) and wheel bolts (1) (20 used).
j : 36 mm

3. Remove stand (a) from the machine. Lower the
machine and place tire (3) onto the ground.
W4GB-03-01-003
b- Lifting Tool
W4-1-1-3
Group 1 Tire
3 2 85Z7B-W4-01-01-01
a- Wheel Stopper
4. Tighten wheel bolts (3) (20 used) according to the

order as illustrated.
j : 36 mm
m : 892 N·m (658 lbf·ft)

 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.
M4GB-07-102
fNOTE: Air Pressure of Tires:
Standard Tire Standard Air Pressure
26.5-25-20PR 422~441 kPa (61~64 psi)
6. Remove wheel stoppers (a) (2 used).
W4-1-1-4
Group 1 Tire
Removal and Installation of Rear Tire
1 2
85Z7B-W4-01-02-01
4 3
Removal Detail A
a 5
dCAUTION: Perform removal and installation of
the rear tires in a group more than two personnel.
 Rear Fender (rear) (2) (only for the machine with rear
fender) 6
 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. 85Z7b-W4-01-02-02
a- Wooden Block
4. Loosen wheel bolts (3) (20 used) one turn.
j : 36 mm
W4-1-2-1
Group 1 Tire
4, 5 3 2 a
a- Stand 85Z7B-W4-01-02-03

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: 700 kg (1545 lb)

6. Attach lifting tools (b) onto rear tire (3). Hoist and
hold rear tire (3). 5 4
3
7. Remove wheel bolts (4) (20 used) and washers (5)
(20 used). Remove rear tires (3) from rear axle (2).
j : 36 mm
W4GB-03-01-003
b- Lifting Tool
W4-1-2-2
Group 1 Tire
4, 5 3 2 a
a- Stand
85Z7B-W4-01-02-03
Installation
dCAUTION: Rear tire (3) weight: 700 kg (1545 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) (20 5 4
used) and wheel bolts (4) (20 used). 3
j : 36 mm

3. Remove stand (a) from the machine. Lower the
machine and place tire (3) onto the ground.
W4GB-03-01-003
b- Lifting Tool
W4-1-2-3
Group 1 Tire
1 2
85Z7B-W4-01-02-01
4 3
Detail A
5. Tighten wheel bolts (3) (20 used) according to the a 5
order as illustrated.
j : 36 mm
m : 892 N·m (658 lbf·ft)

6. Remove wooden blocks (a) (2 used).
 Rear Fender (Front) (1) 6
 Rear Fender (rear) (2) (only for the machine with rear
fender)
 Under Guard (rear) (4) (only for the machine with
under guard)
85Z7b-W4-01-02-02
a- Wooden Block
IMPORTANT: Check air pressure of the tires. Check
for any damage to the tires.
fNOTE: Air Pressure of Tires:
Standard Tire Standard Air Pressure
26.5-25-20PR 422~441 kPa (61~64 psi)
M4GB-07-102
W4-1-2-4
Group 2 Drive Unit
Removal and Installation of Drive Unit
1
View A
3, 4, 5, 6
14
12, 13
8, 9, 10
A
11
7
8, 9, 10
b 85Z7B-W4-02-01-02
a 85Z7B-W4-02-01-01
a- Stand b- Stand
Removal 3. Remove bolt, nut (5), washer (6), clamps (3) (2 used),
and rubber (4).
1. Set the vehicle position for inspection and
maintenance. (Refer to W1-5-1.) j : 17 mm
2. Remove the engine (1) assembly from the machine 4. Disconnect hose (14).
body. (Refer to W3-4-1.)
j : 36 mm
j : 17 mm
6. Remove bolts (8) (6 used), spring washers (9) (6
used), and washers (10) (6 used). Remove brackets
(7, 11).
j : 30 mm

the thread part of bolt (8).
W4-2-1-1
Group 2 Drive Unit
3, 4
3, 4
2 2
85Z7B-W4-02-01-03
85Z7B-W4-02-01-04
7. Remove bolts, washers (3) (4 used) and clips (4) (4

used).
j : 17 mm
9. Remove pump device (1). (Refer to W3-8-1-5.)
W4-2-1-2
Group 2 Drive Unit
3 7
4
8
2
1
a
10
9
11, 12
4
85Z7B-W4-02-01-05 85Z7B-W4-02-01-06
a- Lifting Bracket
4
10. Remove bolts (9) (2 used) and bracket (10).

11. Remove bolts, washers (3) (2 used) and bolts,
washers (5) (2 used). Remove bracket (2) and cover
(1).
j : 17 mm
b
dCAUTION: Drive unit (4) weight: 545 kg (1210 lb)

12. 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). WNEK50-04-02-006
13. Remove bolts (8) (4 used) through the open part of b- Stand
cover (1). Remove drive unit (4) from engine (7).
j : 18 mm
dCAUTION: Place drive unit (4) onto stable stand

(b) in order not to fall down.
14. Remove bolts (11) (12 used) and spring washers (12)
(12 used). Remove drive unit (4) from engine (7).
j : 17 mm
15. Remove the adapters from drive unit (4) if
necessary.
W4-2-1-3
Group 2 Drive Unit
7
4
8
4
b
11, 12
85Z7B-W4-02-01-06 WNEK50-04-02-008
b- Stand
Installation
1. Install all removed adapters to drive unit (4).
dCAUTION: Place a stable stand (b) under drive
unit (4) in order not to fall down drive unit (4).
dCAUTION: Drive unit (4) weight: 545 kg (1210 lb) 3. Install drive unit (4) to engine (7) with spring
washers (12) (12 used) and bolts (11) (12 used).
2. Install the shackles (2 used) to lifting brackets (a) (2
places). Attach the nylon slings onto the shackles (2 j : 17 mm
used). Hoist drive unit (4).
m : 36±3.6 N·m (26.5±2.7 lbf·ft)
4. Install drive unit (4) to engine (7). Tighten bolts (8) (4
used) through the open part of cover (1).
j : 18 mm
m : 115 N·m (85 lbf·ft)
W4-2-1-4
Group 2 Drive Unit
1
a
10
9
4
85Z7B-W4-02-01-05
a- Lifting Bracket
5. Install bracket (2) and cover (1) with bolts, washers

(3) (2 used) and bolts, washers (5) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)

6. Install bracket (10) with bolts (9) (2 used).
j : 19 mm
m : 90 N·m (66 lbf·ft)
W4-2-1-5
Group 2 Drive Unit
3, 4
3, 4
2
2
85Z7B-W4-02-01-03 85Z7B-W4-02-01-04
7. Install pump device (1). (Refer to W3-8-1-5.)

9. Secure the harness with bolts, washers (3) (4 used)
and clips (4) (4 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W4-2-1-6
Group 2 Drive Unit
1 View A
3, 4, 5, 6
14
12, 13
8, 9, 10
A
11
7
8, 9, 10
b 85Z7B-W4-02-01-02
a 85Z7B-W4-02-01-01
a- Stand b- Stand
10. Apply LOCTITE #263 or equivalent onto the thread 11. Install clamp (12) with bolt, washer (13).
part of bolts (8) (6 used). Install brackets (7, 11) with
washers (10) (6 used), spring washers (9) (6 used), j : 17 mm
and bolts (8) (6 used).
m : 50 N·m (37 lbf·ft)
j : 30 mm
m : 401 N·m (300 lbf·ft)
W4-2-1-7
Group 2 Drive Unit
View B
B
D
3, 4, 5, 6
14
C
c WNEK50-03-08-012
12, 13 c- 25° 14
8, 9, 10 14
View C
d
11
7
8, 9, 10
85Z7B-W4-02-01-02 WNEK50-03-08-013
d- 10°
View D

j : 36 mm
e
85Z7B-W4-02-01-07
m : 180 N·m (133 lbf·ft)
e- 15°
13. Secure hose (14) with bolt, nut (5), washer (6),
clamps (3) (2 used), and rubber (4).
j : 17 mm
m : 50 N·m (37 lbf·ft)

14. Install the engine (1) assembly to the body. (Refer to
W3-4-1.)
W4-2-1-8
Group 2 Drive Unit
Disassembly and Assembly of Drive Unit

Drive Unit Assembly
1 2
3 4
85Z7B-W4-02-02-01
1- Torque Converter 3- Oil Filter 5- Parking Brake

2- Transmission 4- Transmission Control Valve
W4-2-2-1
Group 2 Drive Unit
Detail of Transmission Assembly (2)
2 6 4 3
2
4
7
5
1
8
6
7 9
8 T106954
T4GB-03-09-004
1- First Speed Clutch (K1) 3- Reverse Clutch (KR) 6- Slow-Speed Forward Clutch 8- Third Speed Clutch (K3)
2- Fast-Speed Forward Clutch 4- Input Shaft (AN) (KV) 9- Output Shaft (AB)
(K4) 5- Hydraulic Pump Drive 7- Second Speed Clutch (K2)
W4-2-2-2
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. (W4-2-
2-4)
 Torque Converter (1)
 Refer to Removal and Installation of Torque
Converter. (W4-2-3-1)
 Transmission (2)
 Refer to Removal and Installation of Hydraulic Pump
Drive. (W4-2-4-1)
 Refer to Removal and Installation of Clutch. (W4-2-4-
10)
 Refer to Disassembly and Assembly of Clutch. (W4-2-
4-25)
 Transmission Control Valve (4)
 Refer to Removal and Installation of Transmission
Control Valve. (W4-2-5-1)
 Refer to Removal and Installation of Duct Plate. (W4-
2-5-4)
 Refer to Disassembly and Assembly of Transmission
Control Valve. (W4-2-5-7)
 Parking Brake (5)
 Refer to Removal and Installation of Parking Brake
(Replace the brake friction pad). (W4-2-6-1)
W4-2-2-3
Group 2 Drive Unit
Removal and Installation of Oil Filter
WNEC-04-02-011
1- O-Ring (2 Used) 3- Socket Bolt (2 Used) 5- Duct Plate

2- Filter Head 4- Oil Filter
W4-2-2-4
Group 2 Drive Unit
Removal of Oil Filter

1. Remove oil filter (4) from filter head (2) by using a
filter wrench. 2
4 W4GB-03-02-008
2. Remove socket bolts (3) (2 used) by using a star key
wrench. Remove filter head (2) and O-rings (1) (2 5 1, 2
3
used) from duct plate (5).
l : T40 (Star Key Wrench)
W4GB-03-02-009
W4-2-2-5
Group 2 Drive Unit
Installation of Oil Filter

1. Apply oil onto O-rings (1) (2 used). Install O-rings
5 1, 2
(1) (2 used) to filter head (2). Install filter head (2) to
duct plate (5) with socket bolts (3) (2 used) by using
a star key wrench.
l : T40 (Star Key Wrench) 3
m : 34 N·m (25 lbf·ft)
W4GB-03-02-010
IMPORTANT: Take care not to tighten oil filter (4) too
2
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 3/4 turn by using a filter wrench after it has come
into contact with seal surface.
4 W4GB-03-02-011
W4-2-2-6
Group 2 Drive Unit
Removal and Installation of Torque Converter

Removal of Torque Converter
85Z7B-W4-02-03-01
7- Torque Converter Assembly 9- Torque Converter Housing 11- O-Ring

8- Bolt (18 Used) 10- Oil Feeder Housing 12- Torque Converter Input Speed Sensor
IMPORTANT: When the torque converter side faces 3. Remove bolts (8) (18 used). Remove torque
down with torque converter assembly (7) attached converter housing (9) from oil feeder housing (10).
on the transmission, torque converter assembly
(7) comes off. j : 19 mm
1. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to the 4. Remove torque converter input speed sensor (12)
bolt holes (a) of torque converter assembly (7) in from torque converter housing (9). Remove O-ring
diagonal position. (11) from torque converter input speed sensor (12).
dCAUTION:
30 kg (66 lb)
Torque converter assembly (7) weight: j : 22 mm
2. Attach nylon slings onto the eyebolts. Hoist and

remove torque converter assembly (7).
W4-2-3-1
Group 2 Drive Unit
Installation of Torque Converter
10
85Z7B-W4-02-03-02
7- Torque Converter Assembly 9- Torque Converter Housing 11- *O-Ring

8- Bolt (18 Used) 10- Oil Feeder Housing 12- *Torque Converter Input Speed Sensor
fNOTE: As for the item with mark *, refer to W4-2-3-1.
W4-2-3-2
Group 2 Drive Unit
d c
a- Turbine c- Drive Tube 85Z7B-W4-02-03-03

b- Turbine Shaft d- Hydraulic Pump
1. Install torque converter housing (9) to oil feeder 2. Attach nylon slings onto the eyebolts. Hoist and
housing (10) with bolts (8) (18 used). install torque converter assembly (7) to oil feeder
housing (10).
j : 17 mm
m : 68 N·m (50 lbf·ft)
dCAUTION:
30 kg (66 lb)
Torque converter assembly (7) weight:
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).
W4-2-3-3
Group 2 Drive Unit
e
d c
85Z7B-W4-02-03-03
c- Drive Tube e- Mounting Hole for Torque Converter Input f- Pickup Disc
d- Hydraulic Pump Speed Sensor (12)
IMPORTANT: Check that pickup disc (f) can be seen 3. Install O-ring (11) to torque converter input speed
through the center of mounting hole (e) for torque sensor (12). Install torque converter input speed
converter input speed sensor (12) in torque sensor (12) to torque converter housing (9).
converter housing (9).
j : 22 mm
IMPORTANT: Apply grease onto the lip part in order
not to damage the oil seal of hydraulic pump (d) m : 30 N·m (22 lbf·ft)
due to the spline joint of drive tube (c).
W4-2-3-4
Group 2 Drive Unit
Disassembly and Assembly of Transmission

Disassembly and Assembly of Hydraulic Pump Drive
WNEC-04-02-009
W4-2-4-1
Group 2 Drive Unit
Portion a
WNEC-04-02-010
1- Socket Bolt (15 Used) 8- O-Ring 15- Hydraulic Pump Drive Shaft 22- Tab Washer
2- Socket Bolt (21 Used) 9- Hydraulic Pump 16- Ball Bearing
3- Socket Bolt (4 Used) 10- Socket Bolt (10 Used) 17- Transmission Case Cover
4- Socket Bolt (2 Used) 11- O-Ring (10 Used) 18- Retaining Ring
5- Plate 12- Stator Shaft 19- Pressure Plate
6- Oil Feeder Housing 13- Transmission Case 20- Spring
7- Gasket 14- Piston Ring 21- Piston
W4-2-4-2
Group 2 Drive Unit
Removal of Hydraulic Pump Drive

1. Remove socket bolts (2) (21 used) at bolt mounting 3. Remove socket bolts (3) (4 used) at bolt mounting
position (a) by using a star key wrench. position (c) by using a star key wrench.
l : T40 (Star Key Wrench) l : T40 (Star Key Wrench)
a- Bolt Mounting Position c- Bolt Mounting Position

WNEC-04-02-012 WNEC-04-02-012
2. Remove socket bolts (1) (15 used) at bolt mounting 4. Remove socket bolts (4) (2 used). Remove plate (5).
position (b) by using a star key wrench.
l : 8 mm
b- Bolt Mounting Position

WNEC-04-02-012
W4-2-4-3
Group 2 Drive Unit
5. Remove socket bolts (10) (10 used). Remove the oil 8. Remove stator shaft (12) from transmission case
feeder housing (6) assembly and gasket (7) from (13).
transmission case (13). Remove O-rings (11) (10
used) from socket bolts (10) (10 used).
l : 8 mm
13
6. Remove hydraulic pump (9) from oil feeder housing
(6) by using a plastic hammer. Remove O-ring (8)
12
from hydraulic pump (9).
6 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
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
Group 2 Drive Unit
Assembly of Hydraulic Pump Drive

1. Install ball bearing (16) to hydraulic pump drive
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
Group 2 Drive Unit
5. Install piston (21), spring (20), and pressure plate 7. Apply grease onto gasket (7). Install special tools (a)
(19) to oil feeder housing (6). (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
6. Push pressure plate (19) with the bolt (M6). Secure 7

pressure plate (19) with tab washer (22).
a- Special Tool
W4GB-03-02-047
22 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).
6 6 a
W4GB-03-02-046
a
13
a- Special Tool
W4GB-03-02-048
W4-2-4-7
Group 2 Drive Unit
IMPORTANT: Do not tilt stator shaft (12) when IMPORTANT: Check that pump housing (c) and cam
installing. disc (d) of hydraulic pump (9) have been installed
9. Install special tools (b) (ZF No.: 5870 204 007) (2 as illustrated.
used) to oil feeder housing (6). Fit stator shaft (12)
to special tools (b) (ZF No.: 5870 204 007) (2 used). d
Install stator shaft (12) to oil feeder housing (6).
b
c- Pump Housing
b 12 d- Cam Disc
W4GB-03-02-057
6
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).
b- Special Tool
W4GB-03-02-049
9
10. Install O-ring (8) to hydraulic pump (9). Apply oil 6
onto O-ring (8).
9
W4GB-03-02-058
12. Apply oil onto O-ring (11). Install O-ring (11) to

W4GB-03-02-057 socket bolts (10) (10 used).
11 10
W4GB-03-02-059
W4-2-4-8
Group 2 Drive Unit
13. Install socket bolts (10) (8 used) to oil feeder 15. Install socket bolts (1) (15 used) to bolt mounting
housing (6). Remove special tools (b) (ZF No.: 5870 position (f ) by using a star key wrench.
204 007) (2 used). Install socket bolts (10) (2 used) to
the positions for removed special tools (b) (ZF No.: l : 40 (Star Key Wrench)
5870 204 007) (2 used).
m : 23 N·m (17 lbf·ft)
l : 8 mm
m : 46 N·m (34 lbf·ft) f
9 10
6
W4GB-03-02-060
f- Bolt Mounting Position
14. Install socket bolts (2) (21 used) to bolt mounting WNEC-04-02-012
position (e) by using a star key wrench.
l : T40 (Star Key Wrench) 16. Install socket bolts (3) (4 used) to bolt mounting
position (g) by using a star key wrench.
m : 23 N·m (17 lbf·ft)
e m : 23 N·m (17 lbf·ft)
e- Bolt Mounting Position

WNEC-04-02-012
g- Bolt Mounting Position
WNEC-04-02-012
W4-2-4-9
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
Group 2 Drive Unit
Removal and Installation of Clutch 3. Remove socket bolts (5) (5 used). Remove the
output shaft (6) assembly and screen sheets (7, 8)
Removal of Clutch, Input Shaft, and Output Shaft
from transmission case (3).
dCAUTION:
kg (185 lb)
Transmission case cover (1) weight: 83
l : 6 mm

6
transmission case cover (1) as illustrated. Attach
nylon slings onto the eyebolts. Hoist and hold
7, 8
5
3
1
W4GB-03-02-075
4. Remove taper roller bearings (9) (2 used) at both

sides of output shaft (6) by using a puller.
W4GB-03-02-074
2. Remove socket bolts (2) (42 used). Remove 6

9
transmission case cover (1) and plate (4) from
transmission case (3).
l : 14 mm
WNEC-04-02-025
1 2
W4GB-03-02-073
W4-2-4-11
Group 2 Drive Unit
5. Remove piston rings (10) (6 used) from the clutch

shafts (6 used). dCAUTION: The transmission case cover (1)
10
10 7. Hoist and hold the transmission case cover (1)
assembly. Remove the transmission case cover (1)
10 assembly from transmission case (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 W4GB-03-02-079
clutch shafts.
fNOTE: The flat washer and hexagon nut (M10) can be

8. Remove oil pipes (11) (2 used) from transmission
used in place of special tool (a) (ZF No.: 5870 204 011) as
illustrated. case (3). Remove O-rings (12) (2 used for each) from
both sides of oil pipes (11) (2 used).
1
11
12
a
3
12
a- Special Tool
W4GB-03-02-078 11
3
WNEC-04-02-026
W4-2-4-12
Group 2 Drive Unit
9. Install the transmission case cover (1) assembly to 11. The following figure shows the layout of clutches
the maintenance stand. which are left in transmission case cover (1). The
numbers at the clutch shaft end correspond to the
1 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
Group 2 Drive Unit
12. Remove piston rings (13) (6 used) from the clutch 14. Remove second speed clutch (K2) from transmission
shafts (6 used). case cover (1).
K2
13
13
KR
KV
K4
K2 1
1
K1 K3
13 W4GB-03-02-106 W4GB-03-02-084
15. Remove third speed clutch (K3) from transmission

13. Raise fast-speed forward clutch (K4) a little from case cover (1).
transmission case cover (1) and hold it. Remove first
speed clutch (K1) from transmission case cover (1).
Return fast-speed forward clutch (K4).
K4
W4GB-03-02-085
K3
W4GB-03-02-083
K1 1
W4-2-4-14
Group 2 Drive Unit
16. Raise slow-speed forward clutch (KV) and reverse IMPORTANT: Do not change any combinations of
clutch (KR) a little from transmission case cover (1) the outer ring and inner ring of the taper roller
and hold them. Remove fast-speed forward clutch bearing, which are used for each clutch and input
(K4) from transmission case cover (1). 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).
K4 W4GB-03-02-086
17. Raise slow-speed forward clutch (KV), reverse clutch

(KR), and input shaft (14) (AN) at the same time and W4GB-03-02-088
remove them from transmission case cover (1).
KR
KV
14
W4GB-03-02-087
W4-2-4-15
Group 2 Drive Unit
19. Remove piston rings (15) (2 used) from input shaft IMPORTANT: As the movement of turbine shaft (17)
(14). 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

15 necessary.
14
17, 18
15
W4GB-03-02-089 AN
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
Group 2 Drive Unit
Installation of Clutch, Input Shaft, and Output Shaft

fNOTE: Install turbine shaft in the same way as step 3 to
fNOTE: Install input gear (AN) in the same way as step 1 step 4 when it has been removed.
to step 2 when it has been removed. 3. Install snap ring (18) to turbine shaft (17).
dCAUTION: Put heat-resisting gloves when

installing input gear (AN).
1. Cool input shaft (14) to about -80 °C (-112 °F). Heat
18
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 17
2. Install retaining ring (19) to input shaft (14). 14
19
W4GB-03-02-096
14
W4GB-03-02-093
W4-2-4-17
Group 2 Drive Unit

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
Group 2 Drive Unit
IMPORTANT: Refer to the following figure for 8. Install reverse clutch (KR), input shaft (14), and
the mounting position. Do not change the slow-speed forward clutch (KV) to transmission case
combinations of the outer rings and the inner cover (1) at the same time.
rings of bearings.
7. Install the outer ring corresponding to the 14
taper roller bearing at each clutch shaft end to
transmission case (3) and transmission case cover
(1).
KR
KV
3 AN
KR
KV
K2 K4 1
W4GB-03-02-101
K3 K1
9. Raise input shaft (14) a little and install fast-speed
AB forward clutch (K4) to transmission case cover (1).
W4GB-03-02-099
14
AN 1
KR KV
K4 K2
K4
K1 AB K3
W4GB-03-02-102
W4GB-03-02-100
W4-2-4-19
Group 2 Drive Unit
10. Install third speed clutch (K3) to transmission case 12. Raise fast-speed forward clutch (K4) a little and
cover (1). install first speed clutch (K1) to transmission case
cover (1).
K1
K3
1
W4GB-03-02-103 W4GB-03-02-105
11. Install second speed clutch (K2) to transmission case 13. Check that each gear engages securely and that
cover (1). 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
K2 13
KR
1 KV
K4
K2
1
K1 K3
W4GB-03-02-104
W4GB-03-02-106
13
W4-2-4-20
Group 2 Drive Unit
14. Install special tools (a) (ZF No.: 5870 260 010) to all 18. Install transmission case cover (1) to transmission
clutch shafts. case (3).
19. Remove special tools (a) (ZF No.: 5870 260 010) from
all clutches.
a
a- Special Tool
W4GB-03-02-107
a- Special Tool
dCAUTION: The transmission case cover (1)

W4GB-03-02-109
15. Turn over the transmission case cover (1) assembly.

Install eyebolts (M20, Pitch 2.5 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.
dCAUTION:
(210 lb)
Transmission case (3) weight: 94 kg
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
Group 2 Drive Unit
22. Install screen sheet (7) to transmission case (3).

d CAUTION: Transmission case cover (1) weight: 83
kg (185 lb)
20. Hoist and remove transmission case cover (1) from
3
transmission case (3).
3 W4GB-03-02-111
W4GB-03-02-109 23. Install output shaft (6) to transmission case (3). Fit
the mounting hole of screen sheet (8) to that of
installing the inner ring of taper roller bearing (9).
screen sheet (7). Install screen sheet (8) to screen
sheet (7) with socket bolts (5) (5 used).
21. Heat the inner ring of taper roller bearing (9) to l : 6 mm
about +120 °C (248 °F). Install screen sheet (8)
through output shaft (6) and install the inner ring of m : 23 N·m (17 lbf·ft)
taper roller bearing (9) by using a press. Install the
inner ring of taper roller bearing (9) at the opposite
side.
7, 8
3 5 W4GB-03-02-112
W4GB-03-02-110
W4-2-4-22
Group 2 Drive Unit
24. Install O-rings (12) (4 used) to both ends of oil pipes 27. Apply Form-In-Place Gasket (LOCTITE #574) onto
(11) (2 used). the cover mating surface of transmission case (3).
12 11 12
W4GB-03-02-113
3
25. Install oil pipes (11) (2 used) to transmission case
cover (3) .
W4GB-03-02-116
3
11
11 dCAUTION:
kg (185 lb)
Transmission case cover (1) weight: 83
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.
W4GB-03-02-114 28. Install transmission case cover (1) to transmission

case (3).
26. Install piston rings (10) (6 used) to all clutch shaft

ends. Apply grease onto piston rings (10) (6 used).
1
10
W4GB-03-02-117
10 W4GB-03-02-115
W4-2-4-23
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) (42 used) to
l : 14 mm
m : 46 N·m (34 lbf·ft)
2 1
W4GB-03-02-120
W4-2-4-24
Group 2 Drive Unit
Disassembly and Assembly of Clutch

First Speed Clutch (K1)
WNEC-04-02-003
1- Taper Roller Bearing 8- O-Ring 17- End Shim 24- Axial Washer
2- Piston Ring 10- Piston 18- Snap Ring 25- Axial Needle Cage
3- Shaft 11- Cup Spring (7 Used) 19- Running Disc 26- Running Disc
4- Stud 13- Snap Ring 20- Axial Needle Cage 27- Retaining Ring
5- Piston Ring 14- Disc 21- Axial Washer 28- Taper Roller Bearing
6- Disc Carrier 15- Inner Clutch Disc (9 Used) 22- Idler
7- O-Ring 16- Outer Clutch Disc (9 Used) 23- Needle Cage
W4-2-4-25
Group 2 Drive Unit
Second Speed Clutch (K2)
WNEC-04-02-004
4- Stud 13- Snap Ring 20- Axial Needle Cage 27- Retaining Ring
5- Piston Ring 14- Disc 21- Axial Washer 28- Taper Roller Bearing
W4-2-4-26
Group 2 Drive Unit
Third Speed Clutch (K3)
WNEC-04-02-005
4- Stud 13- Snap Ring 20- Axial Needle Cage 28- Taper Roller Bearing
5- Piston Ring 14- Disc 21- Axial Washer
W4-2-4-27
Group 2 Drive Unit
Disassembly of First Speed Clutch (K1), Second

Speed Clutch (K2), and Third Speed Clutch (K3)
1. Remove piston rings (2, 5) from shaft (3). 8. Compress cup spring (11) by using special tool (a)
(ZF No.: 5870 345 088). Remove snap ring (13) from
2. Remove stud (4) from shaft (3). Remove taper roller
disc carrier (6). Release cup spring (11). Remove cup
bearings (1, 28) from shaft (3) by using the special
springs (11) ( 7 used) from disc carrier (6).
tools (ZF No.: 5870 026 100, 5873 001 059, 5873 002
001, and 5873 002 038).
3. Remove retaining ring (27) (only K1 and K2),
running disc (26), axial needle cage (25), and axial a
washer (24) from disc carrier (6).
4. Remove idler (22) from disc carrier (6).
5. Remove needle cage (23), axial washer (21), axial
needle cage (20), and running disc (19) from idler
(22).
6
6. Remove disc carrier (6) from shaft (3) by using a
puller.
7. Remove snap ring (18) from disc carrier (6). Remove
end shim (17), outer clutch discs (16) (9 used), inner a- Special Tool
W4GB-03-02-124
clutch discs (15) (9 used), and disc (14) from disc
carrier (6).
fNOTE: Number of inner clutch disc (15): 7 used (K2, K3) 9. Supply low-pressure air through the oil hole of disc
Number of outer clutch disc (16): 7 used (K2, K3) carrier (6) and remove piston (10) from disc carrier
(6).
W4GB-03-02-125
10. Remove O-rings (7, 8) from piston (10).
W4-2-4-28
Group 2 Drive Unit
First Speed Clutch (K1)
14 16
18
6
17
10
15
WNEC-04-02-021
1- *Taper Roller Bearing 8- *O-Ring 17- End Shim 24- *Axial Washer
2- *Piston Ring 10- Piston 18- Snap Ring 25- *Axial Needle Cage
3- *Shaft 11- *Cup Spring (7 Used) 19- *Running Disc 26- *Running Disc
4- *Stud 13- *Snap Ring 20- *Axial Needle Cage 27- *Retaining Ring
5- *Piston Ring 14- Disc 21- *Axial Washer 28- *Taper Roller Bearing
6- Disc Carrier 15- Inner Clutch Disc (9 Used) 22- *Idler
7- *O-Ring 16- Outer Clutch Disc (9 Used) 23- *Needle Cage
W4-2-4-29
Group 2 Drive Unit
Second Speed Clutch) (K2) and Third Speed Clutch (K3)
14 16
18
6
17
10
15
WNEC-04-02-022
1- *Taper Roller Bearing 10- Piston 19- *Running Disc 27- *Retaining Ring (Second
2- *Piston Ring 11- *Cup Spring (7 Used) 20- *Axial Needle Cage Speed Clutch) (K2)
3- *Shaft 13- *Snap Ring 21- *Axial Washer 28- *Taper Roller Bearing
4- *Stud 14- Disc 22- *Idler
5- *Piston Ring 15- Inner Clutch Disc (7 Used) 23- *Needle Cage
6- Disc Carrier 16- Outer Clutch Disc (7 Used) 24- *Axial Washer
7- *O-Ring 17- End Shim 25- *Axial Needle Cage
8- *O-Ring 18- Snap Ring 26- *Running Disc
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
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 cup springs (11) (7 used) to disc carrier (6).
and third speed clutch (K3) are similar. Therefore, third 4. Compress cup spring (11) by using special tool (b)
speed clutch (K3) is explained here. (ZF No.: 5870 345 088) and special tool (c) (ZF No.:
5870 345 124). Install snap ring (13) to disc carrier
IMPORTANT: Check that the ball part of valve (a) in (6).
piston (10) is not clogged.
1. Apply oil onto O-rings (7, 8). Install O-rings (7, 8) to
piston (10).
b, c
10 8 a
13
7 6
a- Valve
W4GB-03-02-126
b, c- Special Tool
W4GB-03-02-129
2. Install piston (10) to disc carrier (6) by using special

tool (b) (ZF No.: 5870 345 088). Check the direction
of piston (10) in the figure.
10
W4GB-03-02-127
W4-2-4-31
Group 2 Drive Unit
IMPORTANT: Install disc (14) with the non-coating IMPORTANT: Select snap ring (18) so that the disc
surface facing to the piston (10) side. Do not apply clearance is correct.
oil onto each disc in order to set the disc clearance 7. Set a dial gauge to end shim (17). Set the dial gauge
correctly. to 0 (zero) when pressure of about 100 N (22.5 lbf )
5. Install inner clutch discs (15) (7 used), outer clutch is applied to end shim (17).
discs (16) (7 used), and disc (14) to disc carrier (6).
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): 9 used (K1)
16
15
W4GB-03-02-134
14
8. Record the value of the dial gauge when end shim

6
(17) is raised by using screwdriver (d). If the disc
clearance value is different from the specification,
replace snap ring (18) with that of different
W4GB-03-02-132 thickness.
fNOTE:
6. Install end shim (17) to disc carrier (6). Install snap  Disc clearance specification (first speed clutch) (K1):

ring (18) to disc carrier (6). 2.4 to 2.6 mm (0.094 to 0.1 in)
f NOTE: Thickness of snap ring (18): 2.65 mm (0.1 in)  Disc clearance specification (second speed clutch) (K2)

(Standard) and (third speed clutch) (K3): 1.75 to 2.05 mm (0.069
to 0.081 in)
fNOTE: Selected thickness of snap ring (18): 2.1 to 4.2
mm (0.083 to 0.17 in)
17
6 d
W4GB-03-02-133
d- Screwdriver
WNEC-04-02-027
W4-2-4-32
Group 2 Drive Unit
9. After adjustment of the disc clearance, remove all IMPORTANT: Install running disc (19) with the
discs. Apply oil to each disc. Install them again. chamfered surface facing to the idler (22) side.
13. Install running disc (19), axial needle cage (20), and
axial washer (21) to shaft (3).

about +120 °C (248 °F). Install the inner ring of taper 21
roller bearing (1) to shaft (3).
20
11. Heat the center of disc carrier (6) to about +120 °C
(248 °F). 19
W4GB-03-02-138
6
14. Install needle cage (23) to shaft (3).
W4GB-03-02-136

installing disc carrier (6).
12. Install disc carrier (6) to shaft (3).
W4GB-03-02-137
W4-2-4-33
Group 2 Drive Unit
15. In order to engage the spline of idler (22) and the

gear teeth of inner clutch disc (15) with shaft (3), dCAUTION: Put heat-resisting gloves when
install idler (22) to shaft (3) by turning it right and
left. (28).
about +120 °C (248 °F). Install the inner ring of taper
28
22
3
3
W4GB-03-02-139
IMPORTANT: Install running disc (26) with the

chamfered surface facing to the axial needle cage
(25) side. W4GB-03-02-142
16. Install axial washer (24), axial needle cage (25),

running disc (26), and retaining ring (27) (only K1
and K2) to idler (22).
26
25
24
22
W4GB-03-02-141
fNOTE: When the parts have been installed correctly in

step 16, the level difference of upper surface of running
disc (26) and shaft (3) are the same. If running disc (26)
is higher, check the engagement of idler (22) and inner
clutch disc (15).
W4-2-4-34
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 (12.5 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
Group 2 Drive Unit
Slow-Speed Forward Clutch (KV) and Reverse Clutch

(KR)
WNEC-04-02-006
1- Taper Roller Bearing 8- Ball Bearing 15- Snap Ring 23- Disc Carrier
2- Piston Ring 9- Snap Ring 16- Guide Ring 24- Snap Ring
3- Shaft 10- Snap Ring 17- Coil Spring 25- Taper Roller Bearing
4- Stud 11- End Shim 18- Washer
5- Piston Ring 12- Inner Clutch Disc (10 Used) 19- Piston
6- Needle Cage 13- Outer Clutch Disc (10 Used) 21- O-Ring
7- Idler 14- Disc 22- O-Ring
W4-2-4-36
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 (17) by using special tool (a)
disc carrier (23). Release coil spring (17). Remove
guide ring (16), coil spring (17), and washer (18)
tools (ZF No.: 5870 026 100, 5873 001 059, and 5873
from disc carrier (23).
001 057).
3. Remove snap ring (24) from shaft (3). Remove disc
carrier (23) from shaft (3) by using a puller.
a
4. Remove idler (7) from shaft (3) by using a press.
5. Remove needle cage (6) from shaft (3).
6. Remove snap ring (9) from idler (7). Remove ball
bearing (8) from idler (7).
23
7. Remove snap ring (10) from disc carrier (23).
Remove end shim (11), outer clutch discs (13) (10
used), inner clutch discs (12) (10 used), and disc (14)
a- Special Tool
W4GB-03-02-124
9. Supply low-pressure air through the oil hole of disc

carrier (23) and remove piston (19) from disc carrier
(23).
W4GB-03-02-125
W4-2-4-37
Group 2 Drive Unit
Slow-Speed Forward Clutch (KV) and Reverse Clutch

(KR)
14 13
10
23
11
19
12
W4GB-03-02-147
1- *Taper Roller Bearing 8- *Ball Bearing 15- *Snap Ring 23- Disc Carrier
2- *Piston Ring 9- *Snap Ring 16- *Guide Ring 24- *Snap Ring
3- *Shaft 10- Snap Ring 17- *Coil Spring 25- *Taper Roller Bearing
4- *Stud 11- End Shim 18- *Washer
5- *Piston Ring 12- Inner Clutch Disc (10 Used) 19- Piston
6- *Needle Cage 13- Outer Clutch Disc (10 Used) 21- *O-Ring
7- *Idler 14- Disc 22- *O-Ring
W4-2-4-38
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 3. Install washer (18), coil spring (17), and guide ring
piston (19) is not clogged. (16) to disc carrier (23).
1. Apply oil onto O-rings (21, 22). Install O-rings (21,
22) to piston (19).
16
19 17
21
b
18
23
22
W4GB-03-02-146
a- Valve
W4GB-03-02-126
4. Compress coil spring (17) by using special tool (b)
(ZF No.: 5870 345 088) and special tool (c) (ZF No.:
2. Install piston (19) to disc carrier (23) by using special 5870 345 124). Install snap ring (15) to disc carrier
tool (b) (ZF No.: 5870 345 088). Check the direction (23).
b, c
19
23
15
23
W4GB-03-02-127
b, c- Special Tool
W4GB-03-02-129
W4-2-4-39
Group 2 Drive Unit
IMPORTANT: Install disc (14) with the non-coating IMPORTANT: Select snap ring (10) so that the disc
surface facing to the piston (19) side. Do not apply clearance is correct.
oil onto each disc in order to set the disc clearance 7. Set a dial gauge to end shim (11). Set the dial gauge
correctly. to 0 (zero) when pressure of about 100 N (22.5 lbf )
5. Install inner clutch discs (12) (10 used), outer clutch is applied to end shim (11).
discs (13) (10 used), and disc (14) to disc carrier (23).

13
12
14
W4GB-03-02-134
23
8. Record the value of the dial gauge when end shim

W4GB-03-02-132 (11) is raised by using screwdriver (d). If the disc
replace snap ring (10) with that of different
thickness.
6. Install end shim (11) and snap ring (10) to disc
carrier (23). fNOTE: Disc clearance specification: 2.7 to 2.9 mm
(0.106 to 0.114 in)
fNOTE: Thickness of snap ring (10): 2.65 mm (0.1 in)
(Standard) fNOTE: Selected thickness of snap ring (10): 2.1 to 4.2
mm (0.083 to 0.17 in)
11
23
W4GB-03-02-133 d- Screwdriver
WNEC-04-02-027
W4-2-4-40
Group 2 Drive Unit
9. After adjustment of the disc clearance, remove all 14. Install idler (7) to shaft (3) by using a press.
discs. Apply oil onto each disc. Install them again.
10. Engage idler (7) with inner discs (12) (10 used) and
install it to disc carrier (23) by turning it right and
left. This work is done in order to arrange inner disc
(12) and outer disc (13). After this work, remove idler
(7).
7
7
W4GB-03-02-152
23

W4GB-03-02-148 (248 °F).

about +120 °C (248 °F). Install the inner ring of
taper roller bearing (1) to shaft (3).
13. Install ball bearing (8) to idler (7). Install snap ring
(9) to idler (7).
W4GB-03-02-153
W4GB-03-02-151
W4-2-4-41
Group 2 Drive Unit

IMPORTANT: Engage the gear teeth of idler (7) and (25).
clutch disc (12) carefully when installing. 18. Heat the inner ring of taper roller bearing (25) to
16. Install disc carrier (23) to shaft (3). about +120 °C (248 °F). Install the inner ring of taper
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 (12.5 lbf·ft)

23
7
3
W4GB-03-02-154 clutch operation sound can be heard.
17. Install retaining ring (24) to shaft (3).
24
W4GB-03-02-156
3
W4GB-03-02-155 20. Install piston rings (2, 5) to shaft (3).
W4-2-4-42
Group 2 Drive Unit
Fast-Speed Forward Clutch (K4)
WNEC-04-02-007
1- Taper Roller Bearing 9- Axial Needle Cage 17- End Shim 27- O-Ring
2- Piston Ring 10- Axial Washer 18- Inner Clutch Disc (6 Used) 28- Disc Carrier
3- Shaft 11- Needle Cage 19- Outer Clutch Disc (6 Used) 29- Snap Ring
4- Stud 12- Idler 20- Disc 30- Taper Roller Bearing
5- Piston Ring 13- Axial Washer 21- Snap Ring
6- Gear 14- Axial Needle Cage 23- Cup Spring (7 Used)
7- Snap Ring 15- Running Disc 24- Piston
8- Axial Washer 16- Snap Ring 26- O-Ring
W4-2-4-43
Group 2 Drive Unit
Disassembly of Fast-Speed Forward Clutch (K4)

1. Remove piston rings (2, 5) from shaft (3). 9. Compress cup spring (23) by using special tool (a)
disc carrier (28). Release cup spring (23). Remove
cup springs (23) (7 used) from disc carrier (28).
tools (ZF No.: 5870 026 100, 5873 001 057, and 5873
001 059).
3. Remove snap ring (29) from shaft (3). Remove disc a
carrier (28) 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).
6. Remove needle cage (11), axial washer (10), axial
needle cage (9), and axial washer (8) from shaft (3). 28
7. Remove snap ring (7) from shaft (3). Remove gear
(6) from shaft (3).
8. Remove snap ring (16) from disc carrier (28). a- Special Tool
Remove end shim (17), outer clutch discs (19) (6 W4GB-03-02-124
used), inner clutch discs (18) (6 used), and disc (20)
10. Supply low-pressure air through the oil hole of disc
carrier (28) and remove piston (24)from disc carrier
(28).
W4GB-03-02-125
W4-2-4-44
Group 2 Drive Unit
Fast-Speed Forward Clutch (K4)
20 19
28 16
17
24
18
WNEC-04-02-023
1- *Taper Roller Bearing 9- *Axial Needle Cage 17- End Shim 27- *O-Ring
2- *Piston Ring 10- *Axial Washer 18- Inner Clutch Disc (6 Used) 28- Disc Carrier
3- *Shaft 11- *Needle Cage 19- Outer Clutch Disc (6 Used) 29- *Snap Ring
4- *Stud 12- *Idler 20- Disc 30- *Taper Roller Bearing
5- *Piston Ring 13- *Axial Washer 21- *Snap Ring
6- *Gear 14- *Axial Needle Cage 23- *Cup Spring (7 Used)
7- *Snap Ring 15- *Running Disc 24- Piston
8- *Axial Washer 16- Snap Ring 26- *O-Ring
W4-2-4-45
Group 2 Drive Unit
Assembly of Fast-Speed Forward Clutch (K4) 4. Compress cup spring (23) by using special tool (b)
(ZF No.: 5870 345 088) and special tool (c) (ZF No.:
IMPORTANT: Check that the ball part of valve (a) in
5870 345 124). Install snap ring (21) to disc carrier
piston (24) is not clogged.
(28).
1. Apply oil onto O-rings (26, 27). Install O-rings (26,
27) to piston (24).
b, c
24
26 a
21
27
28
a- Valve
W4GB-03-02-126
b, c- Special Tool
2. Install piston (24) to disc carrier (28) by using special W4GB-03-02-129
tool (a) (ZF No.: 5870 345 088). Check the direction
IMPORTANT: Install disc (20) with the non-coating

surface facing to the piston (24) side. Do not apply
24
oil onto each disc in order to set the disc clearance
correctly.
5. Install inner clutch discs (18) (6 used), outer clutch
28 discs (19) (6 used), and disc (20) to disc carrier (28).

W4GB-03-02-127
3. Install cup springs (23) (7 used) to disc carrier (28).
19
18
20
28
W4GB-03-02-132
W4-2-4-46
Group 2 Drive Unit
6. Install end shim (17) to disc carrier (28). Install snap 8. Record the value of the dial gauge when end shim
ring (16) to disc carrier (28). (17) is raised by using screwdriver (d). If the disc
fNOTE: Thickness of snap ring (16): 3.35 mm (0.13 in) replace snap ring (16) with that of different
(Standard) thickness.
fNOTE: Disc clearance specification: 1.4 to 1.6 mm

(0.055 to 0.063 in)
17 fNOTE: Selected thickness of snap ring (16): 2.1 to 4.2
mm (0.083 to 0.17 in)
28
d
W4GB-03-02-133
IMPORTANT: Select snap ring (16) so that the disc

d- Screwdriver
clearance is correct. WNEC-04-02-027
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). 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 (18) (6 used) and
install it to disc carrier (28) by turning it right and
left.This work is done in order to arrange inner disc
(18) and outer disc (19). After this work, remove idler
(12).
W4GB-03-02-134
12
28
W4GB-03-02-148
W4-2-4-47
Group 2 Drive Unit
14. Install axial washer (8), axial needle cage (9), and
d CAUTION: Put heat-resisting gloves when
axial washer (10) to shaft (3).

about +120 °C (248 °F). Install the inner ring of
taper roller bearing (1) to shaft (3).
3
installing gear (6).
10
12. Cool shaft (3) to about -80 °C (-112 °F). Heat gear (6)
9
to about +120 °C (248 °F). Install gear (6) to shaft (3).
fNOTE: Install gear (6) with the longer hub up.

8
W4GB-03-02-163
3
6
W4GB-03-02-160 11
13. Install snap ring (7) to shaft (3).
W4GB-03-02-164
W4GB-03-02-161
W4-2-4-48
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 (18) with shaft (3),
install idler (12) to shaft (3) by turning it right and
3
left.
12
3
12
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. 20. Install retaining ring (29) to shaft (3).
17. Install axial washer (13), axial needle cage (14), and
running disc (15) to idler (12).
15
14 3
13 29
12
W4GB-03-02-168
W4GB-03-02-166

(248 °F).
W4-2-4-49
Group 2 Drive Unit

installing the inner ring of taper roller bearing fNOTE: Install nuts (M10) (2 used) to the top of stud
(30). (4) and secure it. Then, install stud (4) to shaft (3). After
21. Heat the inner ring of taper roller bearing (30) to installing stud (4), remove nuts (M10) (2 used) from stud
about +120 °C (248 °F). Install the inner ring of taper (4).
roller bearing (30) to shaft (3). m : 17 N·m (12.5 lbf·ft)
23. Install piston rings (2, 5) to shaft (3).
30
W4GB-03-02-170

clutch operation sound can be heard.
W4GB-03-02-169
W4-2-4-50
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 4- Socket Bolt (23 Used)
W4-2-5-1
Group 2 Drive Unit
Removal of Transmission Control Valve

1. Remove socket bolts (4) (23 used) by using a star
key wrench. Remove control valve (3) and plate (2)
from duct plate (1).
W4-2-5-2
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 star key
wrench.
m : 9.5 N·m (7 lbf·ft)
W4-2-5-3
Group 2 Drive Unit
Removal and Installation of Duct Plate
1 2 3
8 1 7 6 4, 5
W4GB-03-02-012
1- Nut (14 Used) 4- Switch 7- Spring 10- *Transmission Case Cover

2- Duct Plate 5- O-Ring 8- Gasket
3- Socket Bolt (36 Used) 6- Piston 9- Safety Valve
W4-2-5-4
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
key wrench. Remove duct plate (2) and gasket (8)
from transmission case cover (10) .

4. Remove safety valve (9) from transmission case
cover (10).
W4-2-5-5
Group 2 Drive Unit
Assembly of Duct Plate 3. Apply LOCTITE #243 onto socket bolts (3) (36 used).
Install duct plate (2) to transmission case cover (10)
1. Install safety valve (9) to transmission case cover
with socket bolts (3) (36 used) by using a star key
(10).
wrench.

10
m : 23 N·m (17 lbf·ft)
9
10
W4GB-03-02-014
2
2. Apply grease onto gasket (8). Install gasket (8) to W4GB-03-02-016
4. Apply LOCTITE #243 onto the mounting part of

10 nuts (1) (14 used). Install nuts (1) (14 used) to
transmission case cover (10) .
j : 13 mm
m : 15 N·m (11.1 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
8 m : 30 N·m (22.1 lbf·ft)
W4GB-03-02-015
7
6
4, 5 W4GB-03-02-013
W4-2-5-6
Group 2 Drive Unit
(Blank)
W4-2-5-7
Group 2 Drive Unit
Disassembly and Assembly of Transmission Control

Valve
36 2
3 37
4
38
34 6
7
35 8
39
31
9
41
33 30 10
40
32
11
12
29
WNEC-04-02-013
28
13
14
25 15
27
16
26
24
17 1- Cover 24- Piston (3 Used)
2- Gasket 25- Spring (3 Used)
18 3- Pressure Regulator (3 Used) 26- Spring
4- Socket Bolt (18 Used) 27- Piston
19 5- Housing Cover 28- O-Ring
23
6- Piston (3 Used) 29- Plug
7- Spring (3 Used) 30- Spring (3 Used)
8- Gasket 31- Piston (3 Used)
9- Valve Block Assembly 32- Spring
10- Orifice (6 Used) 33- Control Piston
11- Spring (3 Used) 34- Socket Bolt (3 Used)
12- Piston (3 Used) 35- Fixing Plate (3 Used)
13- Gasket 36- Socket Bolt (14 Used)
14- Housing Cover 37- Socket Bolt (18 Used)
15- Socket Bolt (18 Used) 38- Duct Plate
16- Fixing Plate (3 Used) 39- Middle Sheet
20 17- Pressure Regulator (3 Used) 40- Housing
18- Gasket 41- Screen (6 Used)
21 19- Wire Harness
20- Cover
21- Socket Bolt (14 Used)
22- Retaining Clamp
22
85Z7B-W4-02-05-01 23- Socket Bolt (3 Used)
W4-2-5-8
Group 2 Drive Unit
Disassembly of Transmission Control Valve

1. Put the matching marks on the wire harness (19) 10. Remove socket bolts (4) (2 used) in diagonal
mounting part of valve block assembly (9). position by using a star key wrench. Install the
2. Remove retaining clamp (22) from cover (20). special tools (ZF No.: 5870 204 036) (2 used) to the
positions for removed socket bolts (4) (2 used).
3. Remove socket bolts (21) (14 used) by using a star Evenly loosen socket bolts (4) (16 used) by using
key wrench. Remove cover (20) and gasket (18) from a star key wrench. Remove housing cover (5) and
housing cover (14). gasket (8) from housing (40) without tilting housing
cover (5). Remove the special tools (ZF No.: 5870 204
l : T27 (Star Key Wrench) 036) (2 used).
key wrench. Remove cover (1) and gasket (2) from l : T27 (Star Key Wrench)
housing cover (5). 11. Remove pistons (6, 31) (3 used for each), springs (7,
30) (3 used for each), control piston (33), and spring
l : T27 (Star Key Wrench) (32) from housing (40).
5. Remove wire harness (19) from housing covers (5, 12. Remove socket bolts (37) (18 used) by using a star
14). key wrench. Remove duct plate (38) and middle
6. Remove socket bolts (23) (3 used) by using a star sheet (39) from housing (40).
key wrench. Remove fixing plates (16) (3 used) and
pressure regulators (17) (3 used) from housing cover l : T27 (Star Key Wrench)
(14). 13. Remove screens (41) (6 used) from middle sheet
(39).
14. Remove plug (29) from housing (40). Remove O-ring
7. Remove socket bolts (15) (2 used) in diagonal (28) from plug (29).
position by using a star key wrench. Install the
special tools (ZF No.: 5870 204 036) (2 used) to the l : 5 mm
positions for removed socket bolts (15) (2 used).
Evenly loosen socket bolts (15) (16 used) by using 15. Remove orifices (10) (6 used) from housing (40).
a star key 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).

8. Remove pistons (12, 24) (3 used for each), springs
(11, 25) (3 used for each), spring (26), and piston (27)
from housing (40).
key wrench. Remove fixing plates (35) (3 used) and
pressure regulators (3) (3 used) from housing cover
(5).
W4-2-5-9
Group 2 Drive Unit
1
5
6
3
2
F20
Removal of Lockup Solenoid Valve

1. Put the matching marks on the mounting part of
housing (4) and valve block (5).
2. Remove screws (6) (2 used) and remove valve (1).
j : 10 mm
3. Remove sleeves (2) (2 used) with O-rings (2 used).
j : 19 mm
4. Remove screws (3) (14 used). Remove housing (4)
from block (5).
W4-2-5-10
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
IMPORTANT: Check all disassembled parts and
(12) (3 used) to housing (40).
replace any defective parts if necessary. Check
that each piston moves smoothly after it has
been installed in housing (40). Replace defective 12
pistons.
1. Install orifices (10) (6 used) to position (a) in housing

(40) with the hollow up.
40
a
40
b W4GB-03-02-021
b- Pin Mounting Position
4. Install special tools (c) (ZF No.: 5870 204 036) (2

used) to housing (40). Fit gasket (13) and housing
a W4GB-03-02-019 cover (14) to special tools (c) (ZF No.: 5870 204 036)
a- Mounting Position of Orifice (2 used). Install gasket (13) and housing cover (14)
(10) to housing (40).
2. Apply oil onto pistons (12, 24) (3 used for each) and
piston (27). Place housing (40) in the direction as 14
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).
c c
40
40
11
WNEC-04-02-015
25 c- Special Tool
27
24 24
12 12
26
W4GB-03-02-020
W4-2-5-11
Group 2 Drive Unit
5. Install socket bolts (15) (16 used) to housing cover 7. Install pressure regulators (17) (3 used) to housing
(14) by using a star key wrench. Remove special cover (14) in the direction as illustrated. Turn the
tools (c) (ZF No.: 5870 204 036) (2 used). Install claws of fixing plates (16) (3 used) down. Install
socket bolts (15) (2 used) to the positions for fixing plates (16) (3 used) with socket bolts (23) (3
removed special tools (c) (ZF No.: 5870 204 036) (2 used) by using a star key wrench..
used) by using a star key wrench.
m : 5.5 N·m (4.1 lbf·ft)
m : 5.5 N·m (4.1 lbf·ft)
16
17
14 14
W4GB-03-02-026
W4GB-03-02-025
6. Push pistons (12) (3 used). Remove pins (dia. 5 mm)

(3 used) from housing (40).
W4-2-5-12
Group 2 Drive Unit
8. Apply oil onto pistons (6, 31) (3 used for each) and 10. Install special tools (e) (ZF No.: 5870 204 036) (2
piston (33). Install pistons (6, 31) (3 used for each) used) to housing (40). Fit gasket (8) and housing
and piston (33) to housing (40) with springs (7, 30) cover (5) to special tools (e) (ZF No.: 5870 204 036)
(3 used for each) and spring (32). (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
W4GB-03-02-028
9. Push pistons (6) (3 used). Install pins (dia. 5 mm) (3
e- Special Tool
used) to position (d) in housing (40). Secure pistons
(6) (3 used) to housing (40).
11. Install socket bolts (4) (16 used) to housing cover (5)
by using a star key wrench. Remove special tools (e)
(ZF No.: 5870 204 036) (2 used). Install socket bolts
6 (4) (2 used) to the positions for removed special
tools (e) (ZF No.: 5870 204 036) (2 used) by using a
star key wrench.
40 l : T27 (Star Key Wrench)
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 WNEC-04-02-016
d- Pin Mounting Position
W4-2-5-13
Group 2 Drive Unit
13. Install pressure regulators (3) (3 used) to housing 15. Install gasket (18) to housing cover (14). Fit the pin
cover (5) in the direction as illustrated. Turn the of the wire harness (19) socket to the groove on
claws of fixing plates (35) (3 used) down. Install cover (20). Install cover (20) to housing cover (14)
fixing plates (35) (3 used) with socket bolts (34) (3 with socket bolts (21) (14 used) by using a star key
used) by using a star key wrench. wrench.
l : T27 (Star Key Wrench) l : T27 (Star Key Wrench)
m : 5.5 N·m (4.1 lbf·ft) m : 5.5 N·m (4.1 lbf·ft)
20
3 14
W4GB-03-02-029
W4GB-03-02-031
14. Fit the matching marks made when disassembling
and connect wire harness (19) to pressure 16. Secure the wire harness (19) socket to cover (20)
regulators (3, 17) (3 used for each). 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
m : 5.5 N·m (4.1 lbf·ft)
W4-2-5-14
Group 2 Drive Unit
IMPORTANT: Install screens (41) (6 used) with them 20. Fit duct plate (38) to special tools (f ) (ZF No.: 5870
facing to the duct plate (38) side. 204 063) (2 used). Install duct plate (38) to housing
18. Install screens (41) (6 used) to middle sheet (39). (40). Install socket bolts (37) (16 used) to duct
plate (38) by using a star key 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
e e
m : 11 N·m (8.1 lbf·ft)
f
38
40
W4GB-03-02-034
e- 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
W4GB-03-02-037
40
f- Special Tool

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
W4-2-5-15
Group 2 Drive Unit
Installation of Lockup Solenoid Valve
3
1
2
4
10
11
F31
F29
1. Install gasket (1) to valve block (4). Align the match 5. Install pipe (11) with screw (9), O-ring, and nut (10).
marks on housing (2) and valve block (4) and
tighten screws (3) (14 used). j (9) : 22 mm
l : T27 (Star Key Wrench) m : 45 N·m (33 lbf·ft)
m : 5.5 N·m (4 lbf·ft) j (10) : 19 mm
m : 35 N·m (26 lbf·ft)
5
7
15
6
12
8
13
14
F30
F32
2. Install valve (5) with screws (6) (2 used).
j : 10 mm 6. Apply LOCTITE #243 and install sleeve (12).
m : 10 N·m (7.4 lbf·ft) j : 22 mm

3. Install sleeves (7) (2 used) with O-rings (2 used). m : 45 N·m (33 lbf·ft)
j : 19 mm 7. Install pipe (13) with nuts (14, 15).
m : 25 N·m (18.4 lbf·ft) j (14) : 19 mm

4. Install plug (8). m : 35 N·m (26 lbf·ft)
l : 5 mm j (15) : 22 mm
m : 10 N·m (7.4 lbf·ft) m : 45 N·m (33 lbf·ft)
W4-2-5-16
Group 2 Drive Unit
Removal and installation of parking brake

(Replace the brake friction pad)
a
1
Section A-A
2 1 3 a
A A
5 WNEC-04-02-045
6, 7
a- Transmission
WNEC-04-02-046
Removal
1. Release parking brake (1) manually. (Refer to W4-2- 4. Remove bolts (6) (6 used) and washers (7) (6 used).
6-6.) Remove brake disc (4) from flange (5).
2. Loosen nuts (3) (2 used). j : 17 mm
j : 30 mm
3. Remove bolts (2) (2 used). Remove the parking
brake (1) assembly from transmission (a).
j : 30 mm
W4-2-6-1
Group 2 Drive Unit
1 2 3 4
5 b 5 a WNEC-04-02-047
a- Transmission b- Brake Disc
7. Remove brake pads (5) (2 used) from the parking

dCAUTION: Spring force of lining spring (3) is
applied to adjusting screw (2).
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
Group 2 Drive Unit
1 2 3 4
5 b 5 a WNEC-04-02-047
a- Transmission b- 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.
dCAUTION: Spring force of lining spring (3) is

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
Group 2 Drive Unit
a
1
Section A-A
2 1 3 a
A A
5 WNEC-04-02-045
6, 7
a- Transmission
WNEC-04-02-046
5. Install brake disc (4) to flange (5) with bolts (6) (6 8. Adjust the parking brake (1). (Refer to W4-2-6-5.)
used) and washers (7) (6 used).
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 : 30 mm
m : 46 N·m (34 lbf·ft)

7. Tighten nuts (3) (2 used).
j : 30 mm
m : 230 N·m (170 lbf·ft)
W4-2-6-4
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

activated normally before adjusting the parking
brake.
1. Set the machine position for inspection and a
2. Remove cap (4) from the parking brake (2)
assembly. 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 1 7
7. Install lock nut (6).
j : 24 mm
m : 80 N·m (59 lbf·ft)

8. Install cap (4).
b b
WNEC-04-02-047
W4-2-6-5
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 (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.
6 2
4 5
MNEC-06-005
W4-2-6-6
Group 2 Drive Unit
Removal and Installation of Flange at Output Shaft Detail A

Side
1 2 3 4 5 6
13
WNEC-04-02-050
B
A
15 Detail B
7 8 9 10 11 12
4 14 WNEC-04-02-052
Removal
1. Remove bolts (1) (2 used), washer (2), and O-ring (3).
j : 17 mm
2. Remove flange (4) and screen (5).
3. Remove shaft seal (6) from transmission case (14).
4. Remove the parking brake assembly and brake disc
WNEC-04-02-051
(13). (Refer to W4-2-6-1.) 13
5. Remove bolts (12) (2 used), washer (11), and O-ring
(10).
j : 17 mm
6. Remove flange (9) and screen (8).
7. Remove shaft seal (7) from transmission case cover
(15).
W4-2-6-7
Group 2 Drive Unit
Detail A
1 2 3 4 5 6
WNEC-04-02-050
a
4 14 WNEC-04-02-052
Installation
1. Apply grease onto shaft seal (6). Install shaft seal (6) 14
to transmission case (14) by using special tool (a)
(ZF NO.:5870-048-237).
2. Install screen (5) to flange (4).
3. Install flange (4) to the input shaft.
4. Install O-ring (3) and washer (2) to flange (4) with
bolts (1) (2 used).
WNEC-04-02-054
j : 17 mm
m : 46 N·m (34 lbf·ft)
W4-2-6-8
Group 2 Drive Unit
Detail B
7 8 9 10 11 12
13
WNEC-04-02-051
B 13
15
WNEC-04-02-052
a 15
1. Apply grease onto shaft seal (7). Install shaft seal (7)
to transmission case cover (15) by using special tool
(a) (ZF No. : 5870-048-237).
2. Install screen (8) to flange (9).
3. Install flange (9) to the input shaft.
4. Install O-ring (10) and washer (11) to flange (9) with
WNEC-04-02-053
j : 17 mm
m : 46 N·m (34 lbf·ft)

5. Install brake disc (13) and the parking brake
assembly. (Refer to W4-2-6-3.)
W4-2-6-9
Group 2 Drive Unit
(Blank)
W4-2-6-10
Group 3 Axle
Removal and Installation of Front Axle
3
WNEK50-03-13-001 WNEK50-04-03-001
2
IMPORTANT: The hoses and pipes contain hydraulic 2. Remove front cover (1). (Refer to W3-22-1.)
IMPORTANT: Cap the open ends in case the hoses j : 8 mm
secure the hoses have been removed, install the 5. Remove front tires (2) (2 used) from front axle (3).
clips after connecting the hoses. (Refer to W4-1-1.)
Removal


W4-3-1-1
Group 3 Axle
6, 7
4 3 2 WNEK50-04-03-002 5 WNEK50-04-03-003
6. Remove propeller shaft (1) from front axle (4). (Refer

to W4-4-1.)
(2).
j : 17 mm
j : 17 mm
W4-3-1-2
Group 3 Axle
A Detail A
1
WNEK50-04-03-004 WNEK50-04-03-005
j : 22 mm
W4-3-1-3
Group 3 Axle
5
W4GB-03-03-104
2
5 4 5
WNEK50-04-03-006
dCAUTION:
lb)
Front axle (5) weight: 1185 kg (2610 a
11. Attach nylon slings onto front axle (5). Hoist and W4GB-03-03-106
hold front axle (5).
a- Stand
12. Place stand (a) under front axle (5).
IMPORTANT: Take care not to damage the sensor at
the bottom of front axle (5).
nuts (4) (8 used). Remove front axle (5) from front
frame (3). Place it on stand (a).
j : 46 mm
W4-3-1-4
Group 3 Axle
1 2 3
WNEK50-04-03-007
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
Group 3 Axle
1 2 3
WNEK50-04-03-007
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 (30 lbf·ft)
W4-3-1-6
Group 3 Axle
2
5 4
WNEK50-04-03-006 W4GB-03-03-104
4. Set the front axle (5) assembly under the mounting

position of front axle (5).
dCAUTION:
lb)
Front axle (5) weight: 1185 kg (2610
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 : 46 mm
m : 1579 N·m (1165 lbf·ft)
W4-3-1-7
Group 3 Axle
A Detail A
1
WNEK50-04-03-004 WNEK50-04-03-005
j : 22 mm
m : 40 N·m (30 lbf·ft)
W4-3-1-8
Group 3 Axle
6, 7
5 WNEK50-04-03-003 4 3 2 WNEK50-04-03-002
8. Connect connectors (5) (2 used). 11. Install propeller shaft (1) to front axle (4). (Refer to
W4-4-1.)
9. Secure harness (8) with clip (7) and bolt, washer (6).
j : 17 mm
m : 50 N·m (37 lbf·ft)

10. Install guard (2) with bolts, washers (3) (2 used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W4-3-1-9
Group 3 Axle
3
WNEK50-04-03-001 WNEK50-03-13-001
2
12. Set the machine position (lift arm raise) for 17. Set the machine position (lift arm raise) for
inspection and maintenance. (Refer to W1-5-1.) 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 : 8 mm
m : 4±1 N·m (3±0.7 lbf·ft)

15. Set the machine position (lift arm lower) for
16. Install front tires (2) (2 used) to front axle (3). (Refer
to W4-1-1.)
W4-3-1-10
Group 3 Axle
Removal and Installation of Rear Axle
1 85Z7B-W4-03-02-01
85Z7BW-03-02-01
Detail A

When removing the hose and pipe, receive oil with a
4, 5
Removal
1. Set the Machine position for inspection and
maintenance. (Refer to W1-5-1.) 85Z7B-W4-03-02-02
a- Air Breather


hydraulic oil tank. (Refer to W1-5-1.) 3. Open side cover (front) (2).
2. Remove rear tires (1) (2 used) from rear axle (3). 4. Loosen clamp (4). Disconnect hose (5).
(Refer to W4-1-2.)
j : 8 mm
W4-3-2-1
Group 3 Axle
Detail A
A 2
3
1
WNEK50-04-03-010 85Z7B-W4-03-02-03
5. Remove propeller shaft (1). (Refer to W4-4-1.)

6. Disconnect pipe (3).
j : 17 mm
j : 22 mm
W4-3-2-2
Group 3 Axle
1
a
a- Machine Front Side 85Z7B-W4-03-02-04
8. Disconnect pipe (1).
j : 17 mm
W4-3-2-3
Group 3 Axle
5
W4GB-03-03-111
6
7, 8
W4GB-03-03-113
a- Stand
5 9 2
4
85Z7B-W4-03-02-05
11. Remove nuts (4) (8 used) and washers (2) (8 used).

dCAUTION: The rear axle (5) assembly weight:
1360 kg (3000 lb)
Remove the rear axle (5) assembly from rear frame
(3). Place it onto stand (a).
9. Secure support (6, 9) to rear axle (5) by using wires.
12. Remove the stand (a) under the Machine.
Attach nylon slings onto the rear axle (5) assembly.
Hoist and hold the rear axle (5) assembly. fNOTE: Disassemble the rear axle (5) on the stand (a).
10. Place stand (a) under rear axle (5). 13. Loosen clamp (7). Disconnect hose (8).
j : 8 mm
W4-3-2-4
Group 3 Axle
3
2 1
1
5
7
6 5
4
85Z7B-W4-03-02-06
14. Disconnect the both ends of pipes (1) (2 used). 17. Remove support (6) from rear axle (4).
j : 22 mm 18. Remove dust seals (5) (2 used) and bushing (7) from
support (6).
15. Remove bolt, washer (2). Remove block (3) from rear
axle (4).
j : 17 mm
dCAUTION: Support (6) weight: 100 kg (220 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
Group 3 Axle
11
12
11
8 10
9
8
13
4
85Z7B-W4-03-02-07
22. Remove bolts (8) (8 used). Remove thrust plate (12)

d CAUTION: Support (13) weight: 122 kg (270 lb) from rear axle (4).
19. Attach nylon slings onto support (13). Hoist and
hold support (13). Remove the wires for fasting j : 24 mm
support (13) that have been installed in step 9.
20. Remove bolts (8) (8 used) and washers (9) (8 used). the thread part of bolt (8).
Remove cover (10) from support (13). 23. Remove thrust washer (11) from support (13).
j : 24 mm

the thread part of bolt (8).
21. Remove thrust washer (11) from thrust plate (12).
W4-3-2-6
Group 3 Axle
15
4
13
14
85Z7B-W4-03-02-08
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
Group 3 Axle
15
4
13
14
85Z7B-W4-03-02-08
a
Installation
1. Install all removed adapters to rear axle (4).
IMPORTANT: Check the direction to install dust seal b
(15) and bushing (14).
2. Install bushing (14) and dust seal (15) to support
(13).
dCAUTION: Support (13) weight: 122 kg (270 lb) 4 15 13 14

3. Apply grease onto the inner circumference of 85Z7B-W4-03-02-09
bushing (14). Attach nylon slings onto support (13).
Hoist support (13). Install support (13) to rear axle
a- Direction to Install b- Groove
(4).
4. Secure support (13) to rear axle (4) by using wires.
W4-3-2-8
Group 3 Axle
11
12
11
8 10
9
8
13
4
85Z7B-W4-03-02-07
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 13 11 12 8 11
4
bolts (8) (8 used). WNEK50-04-03-018
j : 24 mm a- Direction to Install b- Groove
m : 223 N·m (164 lbf·ft)

IMPORTANT: Check the direction to install thrust IMPORTANT: When installing cover (10), do not drop
washer (11). thrust washer (11).
7. Apply grease onto the mounting surface of thrust 8. Apply LOCTITE #263 or equivalent onto bolts (8) (8
washer (11) for glue. Install thrust washer (11) to used). Install cover (10) to support (13) with washers
thrust plate (12). (9) (8 used) and bolts (8) (8 used).
j : 24 mm
m : 223 N·m (164 lbf·ft)
W4-3-2-9
Group 3 Axle
3
2 1
1
5
7
6 5
4
85Z7B-W4-03-02-06
IMPORTANT: Check the direction to install dust seal a

a
(5) and bushing (7).
a
IMPORTANT: Install bushing (7) with slit (b) up.
9. Install bushing (7) and dust seals (5) (2 used) to
support (6).
dCAUTION: Support (6) weight: 100 kg (220 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 7 6 5 4
11. Secure support (6) to rear axle (4) by using wires. WNEK50-04-03-019
a- Direction to Install
12. Install block (3) to rear axle (4) with bolt, washer (2).
b- Slit
j : 17 mm
m : 50 N·m (37 lbf·ft)

13. Connect the both ends of pipes (1) (2 used).
j : 22 mm
m : 40 N·m (30 lbf·ft)
W4-3-2-10
Group 3 Axle
W4GB-03-03-113
a- Stand
7, 8
85Z7B-W4-03-02-05
14. Place the rear axle (5) assembly on stand (a). 16. Set the rear axle (5) assembly under the mounting
position of rear axle (5).
j : 8 mm
W4-3-2-11
Group 3 Axle
5
W4GB-03-03-111
5 10 2
4
85Z7B-W4-03-02-05
18. Install the rear axle (5) assembly to rear frame (3)
dCAUTION: The rear axle (5) assembly weight:
1360 kg (3000 lb)
with washers (2) (8 used) and nuts (3) (8 used). At
this time, lock bolt (1) by engaging hexagonal head
17. Attach nylon slings onto the rear axle (5) assembly. of bolt (1) and square hole of lock plate (9). Remove
Hoist the rear axle (5) assembly. the wires for fasting support (6, 10) that have been
installed in step 4 and step 11.
j : 41 mm
m : 1128 N·m (832 lbf·ft)
W4-3-2-12
Group 3 Axle
1
a
19. Connect pipe (1).
j : 17 mm
m : 25 N·m (18 lbf·ft)
W4-3-2-13
Group 3 Axle
Detail A
2
3
1
WNEK50-04-03-010
85Z7B-W4-03-02-03
j : 22 mm
m : 40 N·m (30 lbf·ft)

21. Connect pipe (3). Apply grease onto grease fittings
4
(4) (2 used).
j : 17 mm
MNEC-07-009
m : 25 N·m (18 lbf·ft)
22. Install propeller shaft (1). (Refer to W4-4-1.)
W4-3-2-14
Group 3 Axle
Detail A
A
4, 5
3
85Z7B-W4-03-02-02
85Z7B-W4-03-02-01
a- Air Breather
j : 8 mm
24. Install rear tires (1) (2 used) to rear axle (3). (Refer to
W4-1-2.)
1 85Z7BW-03-02-01
W4-3-2-15
Group 3 Axle
(Blank)
W4-3-2-16
Group 3 Axle
Disassembly of Axle
WNEE-04-03-010
W4-3-3-1
Group 3 Axle
 Axle Equipped with TPD
WNEC-04-03-004
W4-3-3-2
Group 3 Axle
 Axle Equipped with LSD
WNEC-04-03-023
W4-3-3-3
Group 3 Axle
 Planetary Carrier Assembly (70)
WNEC-04-03-005
W4-3-3-4
Group 3 Axle
1- Level Gauge 28- Brake Piston (2 Used) 54- Dust Cover 79- Side Gear (2 Used)
2- Housing 29- D-Ring (2 Used) 55- Oil Seal 80- Plate (4 Used)
3- Pin (8 Used) 30- Bolt (20 Used) 56- O-Ring 81- Disc (4 Used)
4- Plug (4 Used) 31- Washer (20 Used) 57- Pinion 82- Plate (2 Used)
5- Case 32- Differential Case A 58- Shim 83- Spider
6- Bleeder Valve (2 Used) 33- Ring Gear 59- Bolt 84- Pinion (4 Used)
7- Housing 34- Bolt (12 Used) 60- Washer 85- Planetary Carrier (2 Used)
8- Bolt (Front Axle) (13 Used) 35- Washer (12 Used) 61- Yoke 86- Retaining Ring (6 Used)
9- Washer (Front Axle) (13 Used) 36- Differential Case B 62- Bearing Cage 87- Retainer Plate (2 Used)
10- Drain Plug 37- Thrust Washer (2 Used) 63- O-Ring 88- Steel Ball (6 Used)
11- Bolt (40 Used) 38- Side Gear (2 Used) 64- Shim 89- Thrust Washer (12 Used)
12- Washer (40 Used) 39- Spring (16 Used) 65- Pinion (4 Used) 90- Bearing (12 Used)
13- Plug (2 Used) 40- Adapter (16 Used) 66- Thrust Washer (4 Used) 91- Retaining Ring (12 Used)
15- Plug 41- Button Head Bolt (16 Used) 67- Pin (16 Used) 92- Planetary Gear (6 Used)
16- Cover 42- Shaft (2 Used) 68- Lock Plate (2 Used) 93- Collar (6 Used)
17- Bolt (28 Used) 43- Retaining Ring (4 Used) 69- Adjusting Nut (2 Used) 94- Spacer (12 Used)
18- Washer (28 Used) 44- Disc Hub (2 Used) 70- Planetary Carrier Assembly (2 95- Planetary Shaft (6 Used)
19- Shim 45- Bearing Retainer (2 Used) Used) 96- Plug (4 Used)
20- Bearing (2 Used) 46- Bolt (24 Used) 71- Bolt (2 Used) 97- Thermometer Sensor (Front
21- Brake Disc (4 Used) 47- Washer (24 Used) 72- Bearing (2 Used) Axle)
22- Brake Ring (2 Used) 48- Dowel Pin (4 Used) 73- Axle Shaft (2 Used) 98- Packing (Front Axle)
23- Ring Gear (2 Used) 49- Spider 74- Bearing (2 Used) 99- Bolt (Rear Axle) (14 Used)
24- Brake Ring (2 Used) 50- Bearing 75- Oil Seal (2 Used) 100- Washer (Rear Axle) (14 Used)
25- End Plate (2 Used) 51- Spacer 76- Differential Case A
26- Pin (4 Used) 52- Spacer 77- Differential Case B
27- D-Ring (2 Used) 53- Bearing 78- Pressure Ring (2 Used)
fNOTE: The quantity of parts is the quantity per one

axle.
W4-3-3-5
Group 3 Axle
Disassembly of Axle
dCAUTION: The axle assembly weight: Front/rear:

1190 kg/1360 kg (2630 lb/3000 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 : 14 mm
fNOTE: Gear oil amount: 43 L (11.4 gal)
dCAUTION: The housing (2) assembly weight:

Front/rear: 380 kg/330 kg (840 lb/730 lb)
2. Attach nylon slings onto the housing (2) assembly.
Hoist and hold the housing (2) assembly. Place the
housing (2) assembly on a stand. 42
W4GB-03-03-005
7
2 6. Remove retaining ring (43) from the shaft (42)

assembly. Remove disc hub (44) from the spline part
of shaft (42).
W4GB-03-03-004
43
44
used) from housing (2).
j : 24 mm
W4GB-03-03-006
7. Remove housing (7) and the shaft (42) assembly at

the opposite side in the same way.
W4-3-3-6
Group 3 Axle
Disassembly of Housings (2, 7)

dCAUTION: Housing (2) weight: Front/rear: 190
kg/150 kg (420 lb/330 lb)
d CAUTION: The housing (2) assembly weight:
Front/rear: 380 kg/330 kg (840 lb/730 lb) 10. Remove axle shaft (73) from housing (2) by using a
8. Place the housing (2) assembly with the differential press.
gear mounting side up. Secure axle shaft (73) with
the plate and bolt.
WNEC-04-03-014 73
73 WNEC-04-03-015
a- Bolt
b- Plate 11. Remove the inner race of bearing (72) from housing
(2).
dCAUTION: Planetary carrier assembly (70)

9. 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
W4-3-3-7
Group 3 Axle
12. Remove the inner race of bearing (74) from axle 15. Disassemble housing (7) in the same way.
shaft (73) by using a bearing separator. Remove oil
seal (75).
73
74
75
W4GB-03-03-010
13. 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.
dCAUTION: Ring gear (23) weight: 22 kg (48.5 lb)

14. When replacing ring gear (23), remove it from
housing (2) by using a gear puller. Insert a plate into
housing (2) and support the shaft of gear puller. At
this time, take care not to lose pins (3) (4 used).
23
W4GB-03-03-011
W4-3-3-8
Group 3 Axle
Disassembly of Planetary Carrier Assembly (70)

16. Remove retaining ring (86) from planetary carrier 19. Remove bearings (90) (2 used) and collar (93) from
(85). planetary gear (92). Remove retaining rings (91) (2
used).
86 90 91
85
92
W4GB-03-03-012
W4GB-03-03-014
17. Tap and remove planetary shaft (95) and steel ball
(88) from the opposite side of planetary carrier (85). 20. Disassemble other planetary gears (92) (2 used) in
the same way.
21. Remove retainer plate (87) from planetary carrier

(85).
85
87
92
W4GB-03-03-013
18. Remove the planetary gear (92) assembly, spacers

(94) (2 used), and thrust washers (89) (2 used). W4GB-03-03-015
fNOTE: If spacer (94) and bearing (90) is reused, mark

them for assembling.
W4-3-3-9
Group 3 Axle
Removal of Brake
22. Remove end plate (25), brake ring (24), brake disc 26. Remove D-rings (27, 29) from brake piston (28).
(21), brake ring (22), brake disc (21), and brake ring
27. Remove the brake at the opposite side in the same
(24) from case (5) in sequence. Remove pins (67) (8
way.
used) from case (5).
23. Remove button head bolts (41) (8 used), adapters
(40) (8 used), and springs (39) (8 used) from brake
piston (28).
l : 6 mm
39
40
41
W4GB-03-03-016
24. Install the special tool (ST 7790) with bolts (M16) (2
used) by using the housing (2) mounting surface of
case (5).
25. Supply compressed air through the hydraulic
pressure port slowly and remove brake piston (28)
from case (5).
ST 7790
W4GB-03-03-017
W4-3-3-10
Group 3 Axle
Removal of Bearing Cage (62) Assembly

used). Remove cover (16) from case (5).
j : 17 mm
29. Record gear teeth contact state and backlash of ring C
gear (33) at this time. C
dCAUTION: The bearing cage (62) assembly

weight: Front/rear: 38 kg/42 kg (84 lb/93 lb)
30. Attach nylon slings onto the bearing cage (62) 62 8, 9
assembly. Hoist and hold the bearing cage (62)
W4GB-03-03-018
assembly.
C- Thread Part for Pullers
used) from bearing cage (62) in case of the front
axle. Remove bolts (99) (14 used) and washers (100)
(14 used) from bearing cage (62) in case of the rear 32. Install bolts (8) (2 used) which have been removed
axle. at step 40 to thread part (C) for pullers of bearing
cage (62) in case of the front axle. Tighten bolts (8)
j : 24 mm (2 used) evenly. Remove bearing cage (62), pinion
gear (57), and shim (64). Install bolts (99) (2 used)
which have been removed at step 40 to thread part
(C) for pullers of bearing cage (62) in case of the
rear axle. Tighten bolts (99) (2 used) evenly. Remove
bearing cage (62), pinion gear (57), and shim (64).
j : 24 mm
W4-3-3-11
Group 3 Axle
Disassembly of Bearing Cage (62) Assembly

33. Place bearing cage (62) onto a stand with the yoke 39. Remove oil seal (55) from bearing cage (62).
(61) side up. Remove bolt (59) and washer (60) from
40. Remove the inner race of bearing (53) from bearing
flange (61).
cage (62).
j : 30 mm 41. Remove the outer races of bearings (50, 53) from
34. Remove O-ring (56). bearing cage (62) by tapping each outer surface
evenly.
35. Remove yoke (61) from pinion (57). Remove dust
cover (54) and shim (58) from yoke (61). 42. Remove O-ring (63) from bearing cage (62).
36. Remove pinion (57) from bearing cage (62) by using

a press.
57
62
W4GB-03-03-019
37. Remove spacers (51, 52) from pinion (57).

38. Remove the inner race of bearing (50) from pinion
(57) by using a separator.
50
57
W4GB-03-03-020
W4-3-3-12
Group 3 Axle
Removal of Differential Case Assembly 46. Remove adjusting nut (69) from bearing retainer
(45). Remove the outer race of bearing (20) at the
dCAUTION: The differential case assembly weight:
TPD/LSD: 91 kg/98 kg (201 lb/216 lb)
opposite side.
47. Remove bearing retainer (45) at the opposite side in
43. Attach the nylon slings onto the differential case
the same way.
assembly. Hoist and hold the differential case
assembly.
TPD/LSD: 91 kg/98 kg (201 lb/216 lb)
44. Remove bolts (46) (12 used), washers (47) (12 used),
and lock plate (68) from bearing retainer (45).
IMPORTANT: When removing and installing the
j : 17 mm differential case assembly, take care not to contact
45. Install bolts (46) (2 used) which have been removed the inner race of bearing (20) with case (5).
at step 53 to the screw hole for pullers of bearing 48. Remove the differential case assembly from case (5).
retainer (45). Tighten them evenly. Remove bearing
retainer (45).
j : 17 mm
45 5
W4GB-03-03-023
W4GB-03-03-022
W4-3-3-13
Group 3 Axle
Disassembly of Differential Case (only Axle

equipped with TPD)
dCAUTION: Ring gear (33) weight: 25 kg (56 lb) 52. Remove side gears (38) (2 used), spider (49), pinions
dCAUTION: Do not drop ring gear (33). (65) (4 used), thrust washers (37) (2 used), and thrust
washers (66) (4 used) from differential case B (36)
and differential case A (32).
used) from differential case A (32). Remove ring gear
(33) from differential case A (32).
36 38 65
j : 24 mm
30, 31
33
32
32 49
W4GB-03-03-026
53. Remove the inner races of bearings (20) (2 used)

W4GB-03-03-024 from differential case B (36) and differential case A
(32) by using a bearing puller.
50. 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 : 22 mm
20
36
34, 35
36
W4GB-03-03-027
32
W4GB-03-03-025
dCAUTION:
(64 lb)
Differential case A (32) weight: 29 kg
51. Tap the center of spider (49) and remove differential

case A (32) from differential case B (36).
W4-3-3-14
Group 3 Axle
Disassembly of Differential Case

(only Axle equipped with LSD)
dCAUTION: Ring gear (33) weight: 25 kg (56 lb) 56. Remove plate (82), plates (80) (2 used), discs (81)
(2 used), pressure ring (78), and side gear (79) from
dCAUTION: Do not drop ring gear (33). differential case B (77).
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
57. 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).
W4GB-03-03-028
55. Install the bolts (M12, Pitch 1.25 mm) (2 used) to 84

pulling-out bolt holes (E) (2 places) of differential
case A (76). Tighten them evenly. Remove 83
differential case A (76) from differential case B (77).
76 77
E
E
W4GB-03-03-031
77
W4GB-03-03-029
E- Pulling-Out Bolt Hole
W4-3-3-15
Group 3 Axle
dCAUTION:
(53 lb)
Differential case B (77) weight: 24 kg
58. Remove the inner race of bearing (20) from

differential case B (77) by using a bearing puller.
20
77
W4GB-03-03-032
59. 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
Group 3 Axle
Assembly of Axle 3 4 5 A 6 7
1 2
WNEC-04-03-006
View A 11, 12 96 97, 98 10 8, 9
13
15
16
17, 18
W4GB-03-03-082
30, 31 34, 35
 Axle equipped with TPD 32 33
25 26 27 28 29 36 37 38 39 40
24
23
22 41
21
20
19
42
43
44
45
69
75 74 73 72 71 70 46, 47
68 50
67 66 65 49 48
51
64 63 52
53
62
54
61
W4GB-03-03-083
60 59 58 57 56 55
W4-3-3-17
Group 3 Axle
 Axle equipped with LSD 30, 31 76 33 77 78

25 26 27 28 29 79 80 81 82 39
40
24
23
22 41
21
20
19
42
43
44
45
69
75 74 73 72 71 70 46, 47
68 67 50 84 83
51
64 63 52
53
62
54
61
60 59 58 57 56 55 W4GB-03-03-002
 Planetary Carrier Assembly (70)

88 89 90 91 92 93 94 95
85 86 87
W4GB-03-03-003
W4-3-3-18
Group 3 Axle
1- Level Gauge 28- Brake Piston (2 Used) 54- Dust Cover 79- Side Gear (2 Used)
2- Housing 29- D-Ring (2 Used) 55- Oil Seal 80- Plate (4 Used)
3- Pin (8 Used) 30- Bolt (20 Used) 56- O-Ring 81- Disc (4 Used)
4- Plug (4 Used) 31- Washer (20 Used) 57- Pinion 82- Plate (2 Used)
5- Case 32- Differential Case A 58- Shim 83- Spider
6- Bleeder Valve (2 Used) 33- Ring Gear 59- Bolt 84- Pinion (4 Used)
7- Housing 34- Bolt (12 Used) 60- Washer 85- Planetary Carrier (2 Used)
8- Bolt (Front Axle) (13 Used) 35- Washer (12 Used) 61- Yoke 86- Retaining Ring (6 Used)
9- Washer (Front Axle) (13 Used) 36- Differential Case B 62- Bearing Cage 87- Retainer Plate (2 Used)
10- Drain Plug 37- Thrust Washer (2 Used) 63- O-Ring 88- Steel Ball (6 Used)
11- Bolt (40 Used) 38- Side Gear (2 Used) 64- Shim 89- Thrust Washer (12 Used)
12- Washer (40 Used) 39- Spring (16 Used) 65- Pinion (4 Used) 90- Bearing (12 Used)
13- Plug (2 Used) 40- Adapter (16 Used) 66- Thrust Washer (4 Used) 91- Retaining Ring (12 Used)
15- Plug 41- Button Head Bolt (16 Used) 67- Pin (16 Used) 92- Planetary Gear (6 Used)
16- Cover 42- Shaft (2 Used) 68- Lock Plate (2 Used) 93- Collar (6 Used)
17- Bolt (28 Used) 43- Retaining Ring (4 Used) 69- Adjusting Nut (2 Used) 94- Spacer (12 Used)
18- Washer (28 Used) 44- Disc Hub (2 Used) 70- Planetary Carrier Assembly (2 95- Planetary Shaft (6 Used)
19- Shim 45- Bearing Retainer (2 Used) Used) 96- Plug (4 Used)
20- Bearing (2 Used) 46- Bolt (24 Used) 71- Bolt (2 Used) 97- Thermometer Sensor (Front
21- Brake Disc (4 Used) 47- Washer (24 Used) 72- Bearing (2 Used) Axle)
22- Brake Ring (2 Used) 48- Dowel Pin (4 Used) 73- Axle Shaft (2 Used) 98- Packing (Front Axle)
23- Ring Gear (2 Used) 49- Spider 74- Bearing (2 Used) 99- Bolt (Rear Axle) (14 Used)
24- Brake Ring (2 Used) 50- Bearing 75- Oil Seal (2 Used) 100- Washer (Rear Axle) (14 Used)
25- End Plate (2 Used) 51- Spacer 76- Differential Case A
26- Pin (4 Used) 52- Spacer 77- Differential Case B
27- D-Ring (2 Used) 53- Bearing 78- Pressure Ring (2 Used)
fNOTE: The quantity of parts is the quantity per one

axle.
W4-3-3-19
Group 3 Axle
Assembly of Axle
Assembly of Differential Case (only Axle equipped 4. Install the inner race of bearing (20) to differential
with TPD) case B (36) by using a press or a plastic hammer.
5. Turn over differential case B (36). After checking
dCAUTION:
(64 lb)
Differential case A (32) weight: 29 kg
dowel pins (48) (2 used), apply grease onto thrust
washer (37). Install thrust washer (37) to differential
1. Install the inner race of bearing (20) to differential case B (36).
case A (32) by using a press or a plastic hammer.
6. Fit side gear (38) to pinion (65) of differential
2. Turn over differential case A (32). After checking case A (32). Fit the matching marks made when
dowel pins (48) (2 used), fit the hole positions (2 disassembling and install differential case B (36)
places) of thrust washer (37) to dowel pin (48). to differential case A (32). Tap differential case B
Install thrust washer (37) to differential case A (32). (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 W4GB-03-03-035
(65) (4 used) and thrust washers (66) (4 used)
attached. 7. Apply LOCTITE #262 onto the thread part of bolts
(34) (12 used). Install differential case B (36) to
fNOTE: Install spider (49) to the mounting hole of
differential case A (32) in diagonal order with bolts
differential case A (32) by using a plastic hammer.
(34) (12 used) and washers (35) (12 used).
j : 22 mm
m : 150 N·m (111 lbf·ft)
65 66 49 32 W4GB-03-03-034
W4-3-3-20
Group 3 Axle
dCAUTION: Ring gear (33) weight: 25 kg (55 lb)

20
1
3
8. Install ring gear (33) to differential case A (32) with
the gear surface up. Contact ring gear (33) to the 18 5
flange surface of differential case A (32) by using
a plastic hammer. Temporary tighten bolts (30) (2 16 7
used) and washers (31) (2 used) from the bottom
side of differential case A (32). 14 9
j : 24 mm
12 11
10 13
8 15
6 17
33
4 19
2
WNEC-04-03-021
W4GB-03-03-036
9. Turn over the differential case A (32) assembly.

Apply LOCTITE #262 onto the thread part of bolts
(30) (20 used). Install ring gear (33) with bolts (30)
(20 used) and washers (31) (20 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
Group 3 Axle
Assembly of Differential Case (only Axle equipped

with LSD)
dCAUTION:
(53 lb)
Differential case B (77) weight: 24 kg 14. Install pressure ring (78) to differential case B (77).
Install disc (81), plate (80), disc (81), and plate (80)
10. Install the inner races of bearings (20) (2 used) to in sequence. At this time, fit disc (81) to the spline
differential case A (76) and differential case B (77) by of side gear (79), and install disc (81) to differential
using a press or a plastic hammer. case B (77).
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 78
fitting the spline part.
fNOTE: Fit the convex part of plate (82) to the concave 77

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). W4GB-03-03-030
84 15. Install discs (81) (2 used) and plates (80) (2 used)

to differential case B (77). Measure level difference
83
(X) between plate (80) and differential case B (77).
When level difference (X) is 18.3 mm (0.72 in) or
more, replace last-installed plate (80) with plate (80)
5 mm (0.20 in) thick.
77
fNOTE: Thickness of plate (80): 4.5 mm (0.18 in)
(Standard)
80 81 77
W4GB-03-03-031
13. Engage side gear (79) with pinion (84). Install it.
W4GB-03-03-038
W4-3-3-22
Group 3 Axle
16. Apply grease onto plate (82). Install plate (82) to 18. Turn over differential case B (77) which has been
differential case A (76). temporarily installed. Install ring gear (33) to
differential case B (77) with the gear surface up.
fNOTE: Fit the convex part of plate (82) to the concave Contact ring gear (33) to the flange surface of
groove (4 places) of differential case B (77). Install it. In differential case B (77) by using a plastic hammer.
addition, install the groove surface of plate (82) to the Temporary tighten bolts (30) (2 used) and washers
side gear (79) side. (31) (2 used) from the differential case A (76) side.
76 77
82
30, 31
30, 31
33
W4GB-03-03-039 W4GB-03-03-041
17. Turn over differential case A (76). Temporarily install

differential case A (76) with bolts (F) (M12, Pitch 1.25
mm) (2 used).
76
W4GB-03-03-040
F- Bolt for Temporary
Installation
W4-3-3-23
Group 3 Axle
19. Turn over the differential case assembly. Remove

bolts (F) (M12, Pitch 1.25 mm) (2 used) which have 1
20 3
been temporarily installed in step 17.
18 5
20. Apply LOCTITE #263 or equivalent to the thread
part of bolts (30) (20 used). Install ring gear (33) with 16 7
fNOTE: Refer to the illustration for the order to tighten 14 9

bolts (30).
j : 24 mm 12 11
m : 225 N·m (166 lbf·ft)

10 13
8 15
33
6 17
30, 31 4 19
2
WNEC-04-03-021
77
W4GB-03-03-042
W4-3-3-24
Group 3 Axle
Assembly of Bearing Cage

21. Install the outer races of bearings (50, 53) to bearing 26. Apply load to the inner race of bearing (53) by using
cage (62) by using a press. a press. Measure the rotation resistance by using
a spring balance. Use thread part (C) for pullers for
22. Apply grease onto O-ring (63). Install O-ring (63) to
measurement.
bearing cage (62).
23. Install the inner race of bearing (50) to pinion (57). j : 24 mm
24. Install spacers (51, 52) to pinion (57). fNOTE: Use a press which can provide at approx. 93 kN
(21000 lbf).
52
51
a
57
W4GB-03-03-043
W4GB-03-03-045
25. Install bearing cage (62) to pinion (57). Install the a- Thread Part (C)
inner race of bearing (53) to pinion (57).
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 : 30 mm
m : 324 N·m (240 lbf·ft)
62 27. If rotation resistance is lower than the standard

value, remove pinion (57) and grind spacer (52) for
adjustment.
57 fNOTE: Rotational resistance standard value: 14.7 to

26.5 N (3.3 to 5.9 lbf)
W4GB-03-03-044
W4-3-3-25
Group 3 Axle
28. Apply LOCTITE #263 or equivalent to the outer 32. Insert O-ring (56) to the groove between yoke (61)
surface of oil seal (55). Install oil seal (55) to bearing and pinion (57). Install washer (60) to yoke (61).
cage (62).
33. Apply LOCTITE #263 or equivalent to the thread part
29. Apply grease onto the lip part of oil seal (55). of bolt (59). Install yoke (61) to pinion (57) with bolt
(59) and washer (60). Check that pinion (57) rotates
30. Apply LOCTITE #263 or equivalent to the inner
smoothly.
surface of dust cover (54). Install dust cover (54)
to yoke (61). Fit yoke (61) to the spline of pinion j : 30 mm
(57). Install it. Up and down yoke (61) and fix any
deformations on the seal-lip part of oil seal (55). m : 680 N·m (500 lbf·ft)
61
54
62
W4GB-03-03-046
31. Measure distance (x) between yoke (61) and the

end of pinion (57). Adjust shim (58) so that level
difference (x) is 0.05 to 0.1 mm (0.002 to 0.004 in).
57
61
x
54
W4GB-03-03-081
x- Level Difference
W4-3-3-26
Group 3 Axle
Installation of Differential Case

34. Install the outer races (2 used) of bearing (20) to 37. Apply LOCTITE #263 or equivalent to bolts (46) (12
bearing retainers (45) (2 used). used).Support the differential case assembly and
install bearing retainers (45) (2 used) to case (5) with
35. 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

TPD/LSD: 91 kg/98 kg (201 lb/216 lb)
46
45
W4GB-03-03-049
IMPORTANT: When removing and installing the
differential case assembly, take care not to touch
the inner race of bearing (20) with case (5).
36. 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
W4GB-03-03-048
W4-3-3-27
Group 3 Axle
Installation of Bearing Cage (62) Assembly

38. Install shim (64) between case (5) and bearing cage 41. Tighten adjusting nuts (69) on both sides by using
(62). the special tool (ST 7791).
dCAUTION: The bearing cage (62) assembly

weight: Front/rear: 38 kg/42 kg (84 lb/93 lb)
m : 120 N·m (89 lbf·ft)
39. Attach nylon slings onto the bearing cage (62)

assembly. Hoist and hold the bearing cage (62)
ST 7791
assembly.
40. Apply LOCTITE #263 or equivalent to bolts (8) (13
used) in case of the front axle. Install the bearing
cage (62) assembly to case (5) with bolts (8) (13
used) and washers (9) (13 used). Apply LOCTITE
#262 to bolts (99) (14 used) in case of the rear axle.
Install bearing cage (62) to case (5) with bolts (99) 69
(14 used) and washers (100) (14 used).
j : 24 mm
m : 225 N·m (166 lbf·ft) W4GB-03-03-051
5 9
8 62
W4GB-03-03-050
W4-3-3-28
Group 3 Axle
Adjustment of Ring Gear Backlash and Adjustment

of Ring Gear Teeth Engagement
42. Secure adjusting nut (69) with lock plate (68), bolt 46. Apply a film of red lead primer onto 3 to 4 teeth
(46), and washer (47). of ring gear (33). Turn ring gear (33) forward and
backward by hand and check engagement of teeth.
69 68
W4GB-03-03-052
W4GB-03-03-054
43. Install a dial gauge to the tooth outer end of ring

gear (33). 47. For adjustment of engagement of teeth, refer to (A)
to (E) in the following. After adjusting engagement
44. Secure pinion (57), turn ring gear (33) forward and
of teeth, check backlash again.
backward, and measure backlash.
W4GB-03-03-055
W4GB-03-03-053
a- Tow Part (Small End) c- Flank
b- Face d- Heel Part (Big End)
45. 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: 0.31 to 0.40 mm (0.012

to 0.016 in)
W4-3-3-29
Group 3 Axle
A. Normal Engagement C. Contact of Heel Part

Normal engagement of the tooth surface is 40 % or For adjustment, loosen adjusting nut (69) at the
more around the center of the tooth. The adjustments differential case B (36) side, tighten adjusting nut (69)
of (B) to (E) are the checking method for the convexity at the differential case A (32) side, and move ring gear
of the teeth. Be careful as the engagement is reverse (33) close to pinion (57). Next, increase the thickness
for the concave side. of shim (64) of bearing cage (62) and move pinion (57)
away from ring gear (33).
57 33
33
W4GB-03-03-056
B. Contact of Tow Part

W4GB-03-03-058
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).
57 33
W4GB-03-03-057
W4-3-3-30
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).
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).
57 33
W4GB-03-03-060
W4-3-3-31
Group 3 Axle
Adjustment of Brake Disc Clearance
dCAUTION: If the clearance of brake disc is not

correct, the performance of service brake may be
48. Measure dimension (b) (1 place) between the brake
piston (28) mounting part and the housing (2) end
reduced and the service brake may be broken. surface of case (5). Record it.
 Large clearance: The response of service brake 5
becomes slow.
 Small clearance: The early wear and seizure of
brake disc may occur.
For adjustment of clearance (x) of brake disc, measure

dimensions (a, b, and c) inside the axle and combine two-
type brake ring (24) on the thickness.
fNOTE: Thickness of brake ring (24): 6.5 mm, 6.9 mm

(026 in, 0.27 in)
b
A WNEC-04-03-018
49. Measure dimension (a) (4 place toward

circumference of a circle) between the housing (2)
end surface and the ring gear (23) end surface with
ring gear (23) attached to housing (2). Calculate the
mean value and record it.
fNOTE: Refer to W4-3-3-29 for installation of ring gear

(23).
WNEC-04-03-016
a
Detail A
5 a b
24
2 23
WNEC-04-03-019
28
x
WNEC-04-03-017
W4-3-3-32
Group 3 Axle
53. Record clearance (x) (calculated value) of the brake

d CAUTION: Special tool (ST 7880) weight: 20 kg
(44 lb)
disc and the combination of brake rings (24) (2
used).
50. Set end plate (25), brake rings (24) (6.5 mm, 6.9 mm,
54. Adjust the clearances (4 places) of all brake discs for
0.26 in, 0.27 in), brake discs (21) (2 used), brake ring
front and rear axles.
(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.
ST 7880
c
WNEC-04-03-020
51. Calculate clearance (x) of the brake disc in the

following formula.
Clearance (x) (calculated value) of brake disc = a +
b - c (unit: mm, in)
52. If clearance (x) (calculated value) of the brake disc
is not within the standard, change combination of
brake rings (24) (2 used).
(1) If clearance (x) (calculated value) of the brake
disc is 1.3 mm (0.051 in) or more and 1.9 mm
(0.075 in) or less, select the original combination
of brake rings (24) (2 used).
disc is less than 1.3 mm (0.051 in), change the
combination and select brake rings (24) (6.5 mm,
0.26 in) (2 used).
disc is over 1.9 mm (0.075 in), change the
combination and select brake rings (24) (6.9 mm,
0.27 in) (2 used).
fNOTE: Clearance (x) (standard) of brake disc: 1.3 mm

(0.051 in) (lower limit), 1.9 mm (0.075 in) (upper limit)
W4-3-3-33
Group 3 Axle
Installation of Brake
dCAUTION: Use the parts which are used

for adjustment of brake disc clearance when
58. Install retaining ring (43), disc hub (44), and
retaining ring (43) to shaft (42) in sequence. At this
installing the brake. time, install disc hub (44) with the side with lug
directed to small spline.
55. Install D-rings (27, 29) to the groove of the outer
surface of brake piston (28). Apply grease onto 59. Install shaft (42) to the spline of side gear (38) in
D-rings (27, 29). case (5).
56. Install brake piston (28) to case (5) by using the
special tool (ST 7790).
dCAUTION: Select the thickness of brake ring (24)
which has been selected for adjustment of brake
disc clearance.
60. Install two pieces of pins (67) (8 used) to the bottom
a
of case (5). Then, install brake ring (24).
ST 7790
5
28 W4GB-03-03-061
a- Thrust Bolt (M16, Pitch 2.0 mm, Thread part length: 50 mm or more)
67
57. Apply LOCTITE #262 onto button head bolt (41). 24

Install springs (39) (8 used), adapters (40) (8 used),
and button head bolts (41) (8 used) to case (5)
W4GB-03-03-062
through the piston hole of brake piston (28).
l : 6 mm
m : 49 N·m (36 lbf·ft)
m (a) : 41 N·m (30 lbf·ft)
39
40
41
W4GB-03-03-016
W4-3-3-34
Group 3 Axle
61. Install brake disc (21) to the spline of disc hub (44).
Install brake ring (22).
62. Install second brake disc (21) so that the open hole
fits to that of first brake disc (21).
dCAUTION: Select the thickness of brake ring (24)

which has been selected for adjustment of brake
disc clearance.
63. Install brake ring (24) and end plate (25) to case (5).
64. Install other pins (67) (6 used) by using a plastic
hammer.
67
W4GB-03-03-063
65. Install the brake at opposite side in the same way.
W4-3-3-35
Group 3 Axle
Assembly of Housings (2, 7)
dCAUTION: Ring gear (23) weight: 21 kg (46 lb) 69. Turn over housing (2). Hoist housing (2) with the
differential gear side up. Install housing (2) to axle
66. 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).

kg/160 kg (441 lb/353 lb)
67. Attach nylon slings onto housing (2). Hoist and hold
housing (2) with the wheel side up. Install the outer 2
race and inner race of bearing (74) to housing (2).
IMPORTANT: Oil seal (75) is a separate-type
parts. Install oil seal (75) to housing (2) without
disassembling.
68. 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
70. Install the outer race of bearing (72) to housing (2).

71. Install the inner race of bearing (72) to axle shaft
(73).
75
72. Assemble housing (7) at the opposite side in the
2 same way.
W4GB-03-03-064
W4-3-3-36
Group 3 Axle
Preload Adjustment of Axle Shaft Bearing (Shim

Adjustment)
dCAUTION:
(104 lb)
Planetary carrier (85) weight: 47 kg 76. Install selected shim (19) and retainer plate (87) to
the end of axle shaft (73) with bolt (71).
73. Attach nylon slings onto planetary carrier (85).
j : 36 mm
Hoist and hold planetary carrier (85). In order to
adjust preload, install planetary carrier (85) without m : 49 N·m (36 lbf·ft)
installing the gear to axle shaft (73).
77. Attach a a spring balance onto pin (26) of housing
74. Install retainer plate (87) to planetary carrier (85). (2). Measure rotation resistance of the bearing by
Tighten bolt (71). Push the inner race of bearing (72) pulling the top of mounting pitch circle. If measured
in axle shaft (73). At this time, turn housing (2). values are out of 20 to 39 N (2 to 4 kgf, 4.5 to 8.78
lbf ), adjust the shim again. If the value is small,
j : 36 mm
reduce the thickness of shim (19). If the value is big,
m : 49 N·m (36 lbf·ft) increase the thickness of shim (19).
75. Loosen bolt (71). Remove retainer plate (87).

Measure level difference (Y) between the axle shaft 26
(73) end surface and planetary carrier (85). Select
shim (19) that is 0.03 to 0.10 mm (0.001 to 0.004 in)
thicker than level difference (Y).
j : 36 mm
2
Y
W4GB-03-03-068
dCAUTION:
(104 lb)
Planetary carrier (85) weight: 47 kg
73 70
78. Attach nylon slings onto planetary carrier (85). Hoist
and hold planetary carrier (85). Remove bolt (71).
Remove retainer plate (87), shim (19), and planetary
carrier (85).
W4GB-03-03-067
j : 36 mm
Y- Level Difference
W4-3-3-37
Group 3 Axle
Assembly and Installation of Planetary Carrier 82. Install planetary gear (92) and spacers (94) (2 used)
Assembly (70) between thrust washers (89). At this time, adjust the
thickness of spacer (94) so that clearance (T) is less
79. Install retaining rings (91) (2 used) to planetary gear
than 0.5 mm (0.02 in).
(92).
fNOTE: Thickness of spacer (94): 2 mm, 2.5 mm, 3 mm
(0.079 in, 0.098 in, 0.12 in)
91 89
T
92 94
92
W4GB-03-03-069
IMPORTANT: When installing the outer race of

bearing (90), do not push it to retaining ring (91) W4GB-03-03-071
too strongly.
80. Install the outer race of bearings (90) (2 used) to T- Clearance
both sides of planetary gear (92). Install collar (93)
into the center of planetary gear (92). Install the
inner race of bearing (90) to both sides. 83. Install steel ball (88) to planetary shaft (95). Install
planetary shaft (95) to planetary carrier (85).
92 91 93 90
85
95
W4GB-03-03-070
81. Install thrust washers (89) (2 used) to planetary

carrier (85). At this time, install stoppers of thrust W4GB-03-03-072
washer (89) to the groove of the outer surface of
planetary carrier (85).
W4-3-3-38
Group 3 Axle
IMPORTANT: Fit the notch of retaining ring (86) to

the mounting groove for steel ball (88). dCAUTION: Planetary carrier assembly (70)
View S 86. Attach nylon slings onto planetary carrier assembly

86 a (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).
87. 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
m : 1590 N·m (1173 lbf·ft)

W4GB-03-03-074
a- Steel Ball Mounting Groove
84. Install retaining ring (86) to planetary carrier (85).

85. 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.
W4GB-03-03-075
W4-3-3-39
Group 3 Axle
Installation of Housings (2, 7)

88. Apply LOCTITE #5127 onto the mating surface of 90. Install drain plug (10) to case (5). Add oil to case (5).
case (5) and housing (2). Apply LOCTITE so that
there is no bead missed on the inside of bolt-hole l : 0.5 in
lines
fNOTE: Gear oil amount: 43 L (11.4 gal)
fNOTE: Bead width: 2 to 3 mm (0.079 to 0.12 in)
W4GB-03-03-079
W4GB-03-03-076

kg/330 kg (840 lb/730 lb)

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) (20 used) and washers (12) (20 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
Group 3 Axle
91. Apply LOCTITE #5127 onto the cover (16) mounting

surface of case (5). Apply LOCTITE so that there is no
bead missed on the inside of bolt-hole lines
W4GB-03-03-078
92. Install cover (16) to case (5) with bolts (17) (28 used)
and washers (18) (28 used).
j : 17 mm
m : 98 N·m (72 lbf·ft)
16
17,18
W4GB-03-03-080
W4-3-3-41
Group 3 Axle
(Blank)
W4-3-3-42
Removal and Installation of Propeller Shaft
1 2
85Z7B-W4-04-01-01

Removal
1. Set the Machine position for inspection and
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
1 A
a
85Z7B-W4-04-01-02
3. Remove clip (2) and disconnect the both ends of Detail A

pipe (1).
j : 17 mm
1
85Z7B-W4-04-01-03
W4-4-1-2
85Z7B-W4-04-01-04
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
A
2
85Z7B-W4-04-01-04
Detail A
d CAUTION: Remove propeller shaft (4) while
holding it. Do not drop propeller shaft (4).
5 4a 6 4b
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. WNEK50-04-04-002
dCAUTION: The propeller shaft (4) assembly

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). 8. Remove bolts (1) (4 used). Remove propeller shaft
(4) from propeller shaft (5).
7. Remove bolts (2) (4 used). Disconnect propeller
shaft (4) from drive unit (3). j : 17 mm
j : 3/4 in. fNOTE: LOCTITE #263 or equivalent has been applied to
bolt (1).
bolt (2).
W4-4-1-4
7 1
A
6
5
4
2
3
Detail A
d CAUTION: Remove propeller shaft (1) while
1

propeller shaft (1). 8
WNEK50-04-04-002
shaft (1) from front axle (7).
j : 17 mm

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
a
3
A
2
4

85Z7B-W4-04-01-06
12. Remove grease fitting (6). Detail A

4b 7 6 4a
j : 10 mm
fNOTE: Remove grease fitting (6) in order to drain

grease.
dCAUTION: Remove propeller shaft (4) while

IMPORTANT: Propeller shaft (4) consists of two WNEK50-04-04-003
parts. If propeller shafts (4a, 4b) are removed
Propeller shaft (4) should be removed as an
assembly.
shaft (4) from drive unit (5).
j : 3/4 in
14. Remove bolts (2) (4 used). Remove propeller shaft
(4) from rear axle (1).
bolt (3).
j : 17 mm

bolt (2).
W4-4-1-6
a
3
A
2
4
Detail A
Installation 4b 7 6 4a
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
Propeller shaft (4) should be installed as an WNEK50-04-04-003
assembly.
used). Install propeller shaft (4) to drive unit (5) with
bolts (3) (4 used).
j : 3/4 in.
m : 143 N·m (105 lbf·ft)

used). Install propeller shaft (4) to rear axle (1) with
bolts (2) (4 used). 3. Install grease fitting (6). Apply grease.
j : 17 mm j : 7 mm
W4-4-1-7
7 1
A
6
5
4
2
3
85Z7B-W4-04-01-05
Detail A
1
5. Install propeller shaft (1) to support (8) with bolts (5) 8
WNEK50-04-04-002
(2 used), washers (4) (4 used), spring washers (2) (2
used) and nuts (3) (2 used).
j : 30 mm
m : 206±10 N·m (152±7.4 lbf·ft)

used). Install propeller shaft (1) to front axle (7) with
bolts (6) (4 used).
j : 17 mm
m : 143 N·m (105 lbf·ft)
W4-4-1-8
A
2
Detail A
d CAUTION: The propeller shaft (4) assembly
weight: 50 kg (110 lbf·ft)
5 4a 6 4b

fNOTE: When installing propeller shaft (4), its grease

fitting shall be in the same direction with propeller shaft WNEK50-04-04-002
(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
used). Fit the matching marks made when removing
shaft (5) side.
and install propeller shaft (4) to propeller shaft (5)
IMPORTANT: Propeller shaft (4) consists of two with bolts (1) (4 used).
parts. If propeller shafts (4a, 4b) are installed
individually, spline seal (6) may be damaged. j : 17 mm
Propeller shaft (4) should be installed as an
assembly. m : 143 N·m (105 lbf·ft)
used). Install propeller shaft (4) to drive unit (3) with
bolts (2) (4 used).
j : 3/4 in.
m : 143 N·m (105 lbf·ft)
W4-4-1-9
10. Install grease fitting (1). Apply grease. Detail A

1
j : 7 mm
WNEK50-04-04-002
W4-4-1-10
1 A
a
85Z7B-W4-04-01-02
11. Connect the both ends of pipe (1) and fix with clip Detail A
(2).
j : 17 mm 1
m (1) : 25 N·m (18.5 lbf·ft)
m (2) : 50 N·m (37 lbf·ft)

12. Apply grease.
85Z7B-W4-04-01-03
W4-4-1-11
1 2 85Z7B-W4-04-01-01
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
Group 5 Brake Valve
Removal and Installation of Brake Valve
1 85Z7B-W4-04-01-01

When removing the hose and pipe, receive oil with dCAUTION: Operate the brake pedal more than 50
attach identification tags onto the connectors, 2. Remove cab under cover (1). (Refer to W3-22-1.)
Removal
W4-5-1-1
Group 5 Brake Valve
View A
2
1
A 4 3
85Z7B-W4-05-01-01 85Z7B-W4-05-01-02
3. Disconnect hose (1) (2 used) and hoses (3, 4).
j : 22 mm
j : 27 mm
W4-5-1-2
Group 5 Brake Valve
Detail A
1
2
9
A
85Z7B-W4-05-01-01 3
7 6 8 5 4
85Z7B-W4-05-01-03
5. Secure the hexagonal part of ball joint (5) by using 7. Remove bolts (1) (4 used) and washers (2) (4 used).
a wrench. Remove nut (7) and washer (6). Remove Remove brake valve (3) from floor (9).
ball joint (5) from bell crank (8).
j : 12 mm
Hexagonal Part of Ball Joint (5)
8. Remove the adapters from brake valve (3) if
j : 14 mm necessary.
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
W4-5-1-3
Group 5 Brake Valve
Detail A
1
2
9
A
85Z7B-W4-05-01-01 3
7 6 8 5 4
B
85Z7B-W4-05-01-03
Installation
1. Install all removed adapters to brake valve (3). View B
9
2. Install brake valve (3) to floor (9) with washers (2) (4
used) and bolts (1) (4 used).
j : 12 mm c
m : 20 N·m (15 lbf·ft)

b
3. Install nut (4) and ball joint (5) to brake valve (3). 8
j : 17 mm
a
5 4
3
IMPORTANT: Check dimension (a) to install ball joint
85Z7B-W4-05-01-06
(5) and nut (4).
a- 113 mm (4.4 in) b- 30°
4. Secure the across flat of ball joint (5) by using a c- 50°
wrench. Secure ball joint (5) with nut (4).
j : 17 mm 5. Secure the hexagonal part of ball joint (5) by using

m : 20 N·m (15 lbf·ft) a wrench. Install ball joint (5) to bell crank (8) with
washer (6) and nut (7).
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
Group 5 Brake Valve
View A
C 2
1
A 4 3 B
85Z7B-W4-05-01-01
85Z7B-W4-05-01-02
View B
j : 27 mm
m : 80 N·m (59 lbf·ft) a

b
7. Connect hoses (3, 4) and hoses (1) (2 used).
85Z7B-W4-05-01-04
j : 22 mm
a- 35° b- 55°
m : 40 N·m (29.5 lbf·ft)
IMPORTANT: Check the hydraulic oil level. Start the View C
85Z7B-W4-05-01-05
c- 60°
W4-5-1-5
Group 5 Brake Valve
1
85Z7B-W4-04-01-01
9. Install cab under cover (1). (Refer to W3-22-1.)
W4-5-1-6
Group 5 Brake Valve
Disassembly of Brake Valve
WNEC-04-05-004
1- Flange 8- O-Ring 15- Boot 23- Spring

2- Cylinder 9- O-Ring 16- Spring 24- Retaining Ring
3- Cylinder 10- O-Ring (2 Used) 17- Spring 26- Plug (2 Used)
4- Spool (2 Used) 11- Holder 18- Spring 27- O-Ring (2 Used)
5- Plug 12- Rod 20- Packing 28- Push Rod
6- Stopper 13- Retainer 21- Scraper 31- Plug
7- Spring 14- Piston 22- Socket Bolt (2 Used) 32- O-Ring
W4-5-2-1
Group 5 Brake Valve
Disassembly of Brake Valve IMPORTANT: The reaction force of spring (16) is

applied to socket bolt (22). Slowly remove socket
IMPORTANT: Put the matching marks on flange (1), bolt (22) while holding cylinders (2, 3).
cylinder (2), and cylinder (3) before disassembling. 6. Remove socket bolts (22) (2 used) from cylinder (3).
1. Remove push rod (28) and boot (15) from flange (1).
l : 6 mm
IMPORTANT: Strong force deforms flange (1). Handle
it with care. 7. Remove cylinder (3) and O-ring (10) from the
cylinder (2) assembly.
2. Secure the flange (1) part in a vise with the cylinder
(3) side up. 8. Remove spring (23), spool (4), and O-ring (9) from
cylinder (2).
by each cylinder in order not to confuse. 9. Remove cylinder (2) and O-ring (10) from flange (1).
3. Remove plugs (26) (2 used) and O-rings (27) (2 used) 10. Remove spring (16), holder (11), rod (12), springs
from cylinders (2, 3). (17, 18), and retainer (13) from flange (1).
j : 19 mm 11. Remove retaining ring (24) from flange (1).
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
Group 5 Brake Valve
Assembly of Brake Valve
A a B b 22
15 24 16 17 18 23
28
5
6
8
1 11
2 10 9 3 4 7
14 21 20 13 12 10 32 22
4 31 A C B
WNEC-04-05-001
Section A-A Section B-B
d
e
27 26
27 26
WNEC-04-05-002 WNEC-04-05-003
1- Flange 8- O-Ring 15- Boot 23- Spring

2- Cylinder 9- O-Ring 16- Spring 24- Retaining Ring
3- Cylinder 10- O-Ring (2 Used) 17- Spring 26- Plug (2 Used)
4- Spool (2 Used) 11- Holder 18- Spring 27- O-Ring (2 Used)
5- Plug 12- Rod 20- Packing 28- Push Rod
6- Stopper 13- Retainer 21- Scraper 31- Plug
7- Spring 14- Piston 22- Socket Bolt (2 Used) 32- O-Ring
a- Port PA d- Port A
b- Port PB e- Port B
c- Port T
W4-5-2-3
Group 5 Brake Valve
Assembly of Brake Valve IMPORTANT: Strong force deforms flange (1). Handle
it with care.
IMPORTANT: Before assembling, apply hydraulic oil 3. Secure flange (1) in a vise with the piston (14) side
onto parts in order to prevent them from seizing. down.
IMPORTANT: The brake valve is the susceptible 4. Apply grease onto O-ring (10). Install O-ring (10) to
hydraulic component to contamination. Keep the flange (1).
parts clean when assembling.
IMPORTANT: Check the direction to install packing IMPORTANT: Install tip (a) of rod (12) to hole (b) of
(20) and scraper (21). retainer (13) in order not to drop retainer (13)
from rod (12).
1. Apply hydraulic oil onto packing (20), scraper (21),
and piston (14). Install packing (20), scraper (21), 5. Install springs (16, 17, 18), holder (11), and rod (12)
and piston (14) to flange (1). to retainer (13). Install tip (a) of rod (12) to hole (b) of
retainer (13).
1 20 a
21
13
WNEC-04-05-005
A
b
IMPORTANT: Replace retaining ring (24) with the
new one. View A
2. Install retaining ring (24) to piston (14). WNEC-04-05-007
a- Tip of Rod (12)

b- Hole
W4-5-2-4
Group 5 Brake Valve
6. Install the retainer (13) assembly to flange (1). 13. Install the cylinder (2) assembly and the cylinder
(3) assembly to the flange (1) assembly with socket
7. Fit the matching marks and install cylinder (2) to the
flange (1) assembly.
8. Apply hydraulic oil onto O-rings (9, 10) and spool l : 6 mm
(4). Install O-rings (9, 10), spool (4), and spring (23)
m : 30+4.3-5.5 N·m (22+3.2-4.1 lbf·ft)
to cylinder (2).
14. Tighten plug (5) to the specified torque.
9. Fit the matching marks and install cylinder (3) to
cylinder (2). j : 32 mm
10. Apply grease onto O-ring (8).
m : 68+10.4-9.2 N·m (50+7.7-6.8 lbf·ft)
11. Install O-ring (8) to plug (5).
12. Install spool (4), spring (7), and stopper (6) to Install plugs (26) (2 used) to cylinders (2, 3).
cylinder (3). Temporarily tighten plug (5).
j : 19 mm
j : 32 mm
m : 22+2.5-2.4 N·m (16+1.8-1.8 lbf·ft)
cylinder (2).
j : 22 mm
m : 39+8.1-7.6 N·m (29+6-5.6 lbf·ft)
W4-5-2-5
Group 5 Brake Valve
17. Install boot (15) to the flange (1) assembly with hole
(a) facing to the (b) side of port PA.
15 1
WNEC-04-05-006
a- Hole
b- Port PA
18. Install push rod (28) to the flange (1) assembly.
W4-5-2-6
Removal and Installation of Steering Pilot

Valve
1 85Z7B-W4-04-01-01

When removing the hose and pipe, receive oil with dCAUTION: Release any pressure in the the
IMPORTANT: Cap the open ends in case the hoses 2. Remove cab under cover (1). (Refer to W3-22-1.)
Removal
dCAUTION: Operate the steering wheel in right

and left several times, and release any pressure in
the circuit.
W4-6-1-1
View A
1
2
A
85Z7B-W4-05-01-01 85Z7B-W4-06-01-01
j : 22 mm
j : 19 mm
W4-6-1-2
7
2
4
1 3 WNEK50-04-06-016 85Z7B-W4-06-01-02
5. Remove floor mat (3). 7. Remove bolts, washers (4) (4 used). Remove steering
pilot valve (6) from steering column (7).
j : 17 mm
dCAUTION: Remove steering pilot valve (6) while
holding it. Do not drop steering pilot valve (6). 8. Remove the adapters from steering pilot valve (6) if
necessary.
W4-6-1-3
7
2
4
85Z7B-W4-06-01-02 1 3 WNEK50-04-06-016
Installation
1. Install all removed adapters to steering pilot valve 3. Install cover (2) with screws (1) (6 used).
(6).
4. Install floor mat (3).
2. Install steering pilot valve (6) to steering column (7)
j : 17 mm
m : 39 N·m (29 lbf·ft)
W4-6-1-4
View A
1
2
A
85Z7B-W4-05-01-01 85Z7B-W4-06-01-01
j : 19 mm
m : 30 N·m (22 lbf·ft)

j : 22 mm
m : 40 N·m (29.5 lbf·ft)

end several times and check for any oil leaks.
W4-6-1-5
1 85Z7B-W4-04-01-01
W4-6-1-6
Disassembly of Steering Pilot Valve
2
13
3
14
4
15
5
16
6
7
17
6
18
19 8
20
16
21 10
22
9
23
25
24
25
11
12
11
WNEC-04-06-005
1- Dust Seal 8- Housing 15- Plate 22- Ball

2- Retaining Ring 9- Sleeve 16- O-Ring (2 Used) 23- Adapter Screw
3- Bushing 10- Pin 17- Drive 24- Spring Pin
4- O-Ring 11- Centering Spring (4 used) 18- Rotor 25- Screw (7 Used)
5- Seal 12- Flat Springs (2 used) 19- Star
6- Bearing Race (2 Used) 13- Spool 20- Spacer
7- Thrust Needle 14- O-Ring 21- Cap
W4-6-2-1
Disassembly of Steering Pilot Valve

IMPORTANT: Strong force deforms housing (8). IMPORTANT: As the retaining ring (2) may fly out
Handle it with care. from housing (8), always wear safety glasses.
1. Secure housing (8) in a vise (a) with the cap (21) side IMPORTANT: Do not drop or lose the ball (22).
up. IMPORTANT: Check the position of the holes where
the ball was placed.
21 5. Remove housing (8) from vise (a). Turn over housing
(8). Remove ball (22) and spring pin (24). Place
a
housing (8) on a clean cloth in order not to damage
the finished side. Remove retaining ring (2) from
housing (8) by using a screwdriver.
a- Vise W202-02-14-002
2. Remove screws (25) (7 used) from cap (21). Remove

cap (21) from housing (8). Remove O-ring (16) from
cap (21). 2
W202-02-14-006
j : 8 mm
IMPORTANT: When removing rotor (18), do not drop 6. Turn spool (13) and sleeve (9) to set pin (10)
star (19). horizontally. Push spool (13) and sleeve (9) from
3. Remove rotor (18) and star (19) from housing (8). the cap (21) side and remove bushing (3) from the
Remove spacer (20) from rotor (18). housing (8).
4. Remove drive (17), plate (15), and O-rings (16, 14)
from housing (8). Remove adapter screw (23) from
housing (8) by using a screwdriver.
W4-6-2-2
IMPORTANT: When removing seal (5), do not IMPORTANT: As the centering spring (11) and flat
damage bushing (3). spring (12) may fly out, always wear safety glasses.
7. Remove seal (5) and dust seal (1) from bushing (3). 11. Push spool (13) forward. Remove centering springs
(11) (4 used) and flat springs (12) (2 used) from
8. Remove bearing races (6) (2 used) and thrust needle
spool (13).
(7) from spool (13).
9. Remove spool (13) and sleeve (9) from housing (8).
fNOTE: Turn slowly and remove sleeve (9) from housing

(8) so that the sleeve (9) assembly does not stick to
housing (8). 12
IMPORTANT: Put the matching marks (a) on sleeve

(9) and spool (13) before disassembling.
10. Remove pin (10) from the sleeve (9) assembly.
11
13 9
10
13
W4GB-03-07-002
9
a W202-02-14-021
a- Matching Mark
12. Slowly turn and remove spool (13) from sleeve (9).
13. Remove O-ring (4) from housing (8).
W4-6-2-3
Assembly of Steering Pilot Valve
9 8 22 24 23 14 18 20
21
6
25
5
17
1
25
16
2 3 4 7 12 11 10 13 15 16 19 T1F3-03-07-002
1- Dust Seal 8- Housing 15- Plate 22- Ball

2- Retaining Ring 9- Sleeve 16- O-Ring (2 Used) 23- Adapter Screw
3- Bushing 10- Pin 17- Drive 24- Spring Pin
4- O-Ring 11- Centering Spring (4 Used) 18- Rotor 25- Screw (7 Used)
5- Seal 12- Flat Spring (2 used) 19- Star
6- Bearing Race (2 used) 13- Spool 20- Spacer
7- Thrust Needle 14- O-Ring 21- Cap
W4-6-2-4
Assembly of Steering Pilot Valve

IMPORTANT: Before assembling, apply hydraulic oil 13
1. Install spool (13) into sleeve (9) while turning. Fit
ST2497
matching marks (a) on spool (13) and sleeve (9).
13
b
9
9
11
12
11
W4GB-03-07-003
a W202-02-14-019
a- Matching Mark 3. Install pins (10) in the holes of spool (13) and sleeve
b- Spring Grooves (9). Align the ends of the pins (10) and the outer
diameter surface of sleeve (9).
IMPORTANT: As the centering spring (11) and flat
9
spring (12) may fly out, always wear safety glasses.
13
2. Align the spring groove (b) positions of spool (13)
and sleeve (9), and place them on a flat plate. Align 10
two centering springs (11) back to back, and two
flat springs (12) in the center, and install them to a
special tool (ST 2497). Install centering springs (11)
(4 used) and flat springs (12) (2 used) to the spring W202-02-14-021
grooves (b) of spool (13) and sleeve (9) by using a
special tool.
4. Install the sleeve (9) assembly from the cap (21) side
of housing (8).
fNOTE: When installing the sleeve (9) assembly, prevent

binding. Keeping the pin horizontal, turn the pin right
and left little by little. Insert the pin until the ends behind
the sleeve (9) assembly and housing (8) come to the
same position.
W4-6-2-5
5. Install O-ring (4), bearing races (6) (2 used), and IMPORTANT: As retaining ring (2) may fly out from
thrust needle (7) to housing (8). housing (8), always wear safety glasses.
8. Install retaining ring (2) to cover (8).
fNOTE: After installing retaining ring (2), extend the bore

of retaining ring (2) with a screwdriver so that it enters
7 6 the groove on housing (8) correctly.
4 IMPORTANT: Strong force deforms housing (8).

Handle it with care.
8 9. Secure housing (8) in a vise.
IMPORTANT: Do not drop or lose ball (22) and spring
pin (24).
10. Install O-ring (14) to housing (8). Install ball (22),
W202-02-14-023 adapter screw (23), and spring pin (24) to housing
(8) at the position as illustrated below. Place plate
(15) on housing (8).
6. Install dust seal (1) and seal (5) to bushing (3).
IMPORTANT: Check that bushing (3) and bearing 23
race (6) is contacting each other horizontally.
24
7. Tap slightly with a plastic hammer and install
22
bushing (3) to spool (13).
a
8
1 2
8
5
6 4
3 WNEC-04-06-006
W212-02-14-002
a- Screwdriver
W4-6-2-6
11. Turn the sleeve (9) assembly and set pin (10) and 13. Face the O-ring (16) side of rotor (18) to the plate
port side (d) of housing (8) in parallel. Draw a line (15) side. Install star (19) while aligning the splines
(a) onto the spline side end so that line (a) is parallel of star (19) and drive (17) so that line (j) connecting
to line (b) on yoke part (c) of drive (17). Install drive concave parts (i) of star (19) is parallel to line (a) on
(17). Assemble yoke part (c) of drive (17) and pin the spline side end of drive (17). Check that line (j)
(10). Set line (a) of the spline side edge of drive (17) connecting concave parts (i) of star (19), line (a) on
and port side (d) of housing (8) in parallel position. the spline side end, line (b) on yoke part (c) of drive
(17) and line (g) connecting the centers of port L
and port T, are parallel. Fit the bolt holes (k) on rotor
a
(18) to holes on plate (15) while mating drive (17)
b and star (19).
17
18
j
c i
W487-03-08-006 19
a
e d
k
f
17 b
17
g
15
10 b
c 8
W487-03-08-007
a- Line at the Spline Side End e- Port L

b- Line on the York f- Port T
c- Yoke Part g- Line Connecting the Centers
d- Port Side of Port L and Port T
10
12. Install O-ring (16) to rotor (18). d
W202-02-14-031
i- Concave Part k- Bolt Holes

j- Line Connecting the Concave
Parts
W4-6-2-7
14. Install spacer (20) to rotor (18). Install O-ring (16) to

cap (21). Place cap (21) on rotor (18).
15. Install cap (21) to housing (8) with screws (25) (7
used).
j : 8 mm
m : 23 N·m (17 lbf·ft)
W4-6-2-8

(Without Emergency Steering)
1
WNEK50-03-13-001

IMPORTANT: Cap the open ends in case the hoses 2. Remove cover (1). (Refer to W3-22-1.)
Removal

pressure in the circuit.
W4-6-3-1
A
Detail A
1 2
WNEK50-04-06-005 3 WNEK50-04-06-012
3. Disconnect hoses (1) (2 used). 5. Disconnect hose (2).
j : 19 mm j : 36 mm
j : 36 mm
W4-6-3-2
Detail A
1
A
WNEK50-04-06-013
85Z7B-W4-06-03-01
j : 19 mm
W4-6-3-3
A
Detail A
1 2
9
3
8
4, 5
7 5, 6
WNEK50-04-06-009 WNEK50-04-06-014
7. Remove bolts, washers (3, 9) and nut (8). Remove 9. Remove the adapters from steering valve (1) if
plate (7). necessary.
j : 17 mm
dCAUTION: Steering valve (1) weight: 22 kg (49 lb)

dCAUTION: Remove steering valve (1) while
holding it. Do not drop steering valve (1).
8. Remove socket bolts (4) (2 used), socket bolt (6),
and washers (5) (3 used). Remove steering valve (1)
from bracket (2).
l : 10 mm
W4-6-3-4
A
Detail A
1 2
9
3
8
4, 5
7 5, 6
WNEK50-04-06-009 WNEK50-04-06-014
a
Installation a
1. Install all removed adapters to steering valve (1).

2. Install steering valve (1) to bracket (2) with socket
bolts (4) (2 used), socket bolt (6), and washers (5) (3 b
used).
l : 10 mm d
m : 90 N·m (66 lbf·ft)

3. Install plate (7) with nut (8) and bolts, washers (3, 9).
j : 17 mm
m : 50 N·m (37 lbf·ft) 85Z7B-W4-06-03-03
a- 45 ° c- 20 °
b- 25 ° c- 50 °
W4-6-3-5
Detail A
WNEK50-04-06-013
85Z7B-W4-06-03-01
j : 19 mm
m : 30 N·m (22 lbf·ft)
W4-6-3-6
A
Detail A
1 2
WNEK50-04-06-005 3 WNEK50-04-06-012
View B
IMPORTANT: Check the angle to connect hose (2).

a
j : 36 mm
m : 180 N·m (133 lbf·ft)

85Z7B-W4-06-03-02
6. Connect hoses (3) (3 used). a- 40°
j : 36 mm
m : 180 N·m (133 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W4-6-3-7
WNEK50-03-13-001

W4-6-3-8

(With Emergency Steering)
WNEK50-03-13-001

IMPORTANT: Cap the open ends in case the hoses 2. Remove cover (1). (Refer to W3-22-1.)
Removal

the circuit.
W4-6-4-1
A
Detail A
2 1 3
WNEK50-04-06-005
3 85Z7B-W4-06-04-02
j : 19 mm
j : 36 mm
j : 17 mm
W4-6-4-2
Detail A
2
1 3
A
4
6 5
85Z7B-W4-06-04-03
85Z7B-W4-06-03-01
6. Remove connector (3) from bracket (2). Disconnect 8. Disconnect hose (5).
connectors (1, 3).
j : 36 mm
j : 19 mm
j : 22 mm
W4-6-4-3
A
Detail A
1 2 3
9
4, 5
7 5, 6
WNEK50-04-06-009 WNEK50-04-06-010
10. Remove bolts, washers (3, 9) and nut (8). Remove 12. Remove the adapters from steering valve (1) if
plate (7). necessary.
j : 17 mm

dCAUTION: Remove steering valve (1) while
holding it. Do not drop steering valve (1).
11. Remove socket bolts (4) (2 used), socket bolt (6) and
washers (5) (3 used). Remove steering valve (1) from
bracket (2).
l : 10 mm
W4-6-4-4
A
Detail A
1 2 3
9
4, 5
7 5, 6
WNEK50-04-06-009 WNEK50-04-06-010
Installation c
A
1. Install all removed adapters to steering valve (1). a
a

2. Install steering valve (1) to bracket (2) with socket
bolts (4) (2 used), socket bolt (6) and washers (5) (3
used).
b
l : 10 mm A
a
m : 90 N·m (66 lbf·ft)
3. Install plate (7) with nut (8) and bolts, washers (3, 9).
j : 17 mm
m : 50 N·m (37 lbf·ft)

a
A-A
85Z7B-W4-06-04-01
a- 45 ° c- 20 °
b- 25 °
W4-6-4-5
Detail A
2
1 3
6 5
85Z7B-W4-06-04-03
85Z7B-W4-06-03-01
4. Connect hose (4). 6. Connect hose (6).
j : 22 mm j : 19 mm

5. Connect hose (5). 7. Connect connectors (1, 3). Install connector (3) to
bracket (2).
j : 36 mm
m : 180 N·m (133 lbf·ft)
W4-6-4-6
A Detail A
2 1 3
WNEK50-04-06-005 3 85Z7B-W4-06-04-02
View B
j : 17 mm
a
m : 25 N·m (18 lbf·ft)
85Z7B-W4-06-03-02
j : 36 mm a- 40°
m : 180 N·m (133 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W4-6-4-7
WNEK50-03-13-001
W4-6-4-8
Disassembly of Steering Valve
WNEC-04-07-004
01- Valve Housing 07- Spring (2 Used) 13- O-Ring 24- O-Ring (2 Used)
02- Spool 08- Cap 14- O-Ring (2 Used) 34A- Plug
03- Poppet (2 Used) 09- Socket Bolt (4 Used) 15- O-Ring (2 Used) 34B- O-Ring
04- Spring (2 Used) 10- O-Ring (2 Used) 16- Sleeve
05- Cap Screw (2 Used) 11- Cap 17- Overload Relief Valve (2 Used)
06- Spring Seat (2 Used) 12- Plug 23- Backup Ring (2 Used)
W4-6-5-1
Disassembly of Steering Valve IMPORTANT: Spring (07) may fly out due to the
spring force when removing cap (11).
IMPORTANT: Do not disassemble the overload
relief valve. If it has been disassembled, pressure 4. Remove socket bolts (09) (2 used) from cap (11).
should be adjusted. (Refer to TROUBLESHOOTING/ Remove spring (07) and spring seat (06) from valve
Operational Performance Test in the separated housing (01). Remove O-rings (10, 14, and 15) and
volume, Technical Manual.) sleeve (16) from cap (11).
1. Remove overload relief valves (17) (2 used) from l : 8 mm
valve housing (01).
IMPORTANT: Put the matching marks on valve
j : 32 mm housing (01) and spool (02) before disassembling.
2. Remove plug (12) and O-ring (13) from valve 5. Remove the spool (02) assembly from valve housing
housing (01). (01).
j : 36 mm
IMPORTANT: Spring (07) may fly out due to the
spring force when removing cap (08).
3. Remove socket bolts (09) (2 used) from cap (08).
Remove spring (07) and spring seat (06) from valve
housing (01). Remove O-rings (10, 14, and 15) from
cap (08).
l : 8 mm
W4-6-5-2
6. Secure the spool (02) assembly in a vise by using

wooden pieces as illustrated. Remove cap screws
(05) (2 used), springs (04) (2 used), and poppets (03)
(2 used) from the spool (02) assembly.
j : 17 mm
a
b
W4GB-03-08-002
a- 30 to 40 mm c- 70 to 100 mm
b- 10.5 to 12 mm
7. Remove O-rings (24) (2 used) and backup rings (23)

(2 used) from cap screws (05) (2 used).
8. Remove plug (34A) and O-ring (34B) from valve
housing (01).
l : 6 mm
W4-6-5-3
Assembly of Steering Valve
A B
C C
View A View B D
F
E
05 23 24 04 03 02 01
09
11
Section DD
D
Section F 08 07 06 16 Section E
10 15
14
34A, 34B
15 12 13 14
17 17
Section CC
WNEC-04-07-006
01- Valve Housing 07- Spring (2 Used) 13- O-Ring 24- O-Ring (2 Used)
02- Spool 08- Cap 14- O-Ring (2 Used) 34A- Plug
03- Poppet (2 Used) 09- Socket Bolt (4 Used) 15- O-Ring (2 Used) 34B- O-Ring
04- Spring (2 Used) 10- O-Ring (2 Used) 16- Sleeve
05- Cap Screw (2 Used) 11- Cap 17- Overload Relief Valve (2 Used)
06- Spring Seat (2 Used) 12- Plug 23- Backup Ring (2 Used)
W4-6-5-4
Assembly of Steering Valve 3. Install O-ring (13) to plug (12). Install plug (12) to
valve housing (01).
onto parts in order to prevent them from seizing. j : 36 mm
IMPORTANT: The steering valve is the susceptible
hydraulic component to contamination. Keep the m : 206 to 226 N·m (152 to 166 lbf·ft)
parts clean when assembling. 4. Install overload relief valves (17) (2 used) to valve
1. Install backup rings (23) (2 used) and O-rings (24) (2 housing (01).
used) to cap screws (05) (2 used).
j : 32 mm
2. Secure spool (02) in a vise by using wooden pieces
as illustrated. Install poppets (03) (2 used), springs m : 78 to 88 N·m (58 to 65 lbf·ft)
(04) (2 used), and cap screws (05) (2 used) to spool IMPORTANT: Check the direction to install the spool
(02). (02) assembly.
j : 17 mm 5. Install the spool (02) assembly to valve housing (01).
m : 39.2 to 41.2 N·m (29 to 30 lbf·ft) 6. Install sleeve (16) to cap (11).
a
b
W4GB-03-08-002
a- 30 to 40 mm c- 70 to 100 mm
b- 10.5 to 12 mm
W4-6-5-5
7. Install O-rings (10, 14, and 15) to cap (08). Install

spring seat (06), spring (07), and cap (08) to valve
housing (01) with socket bolts (09) (2 used).
j : 8 mm
m : 50 N·m (37 lbf·ft)

8. Install O-rings (10, 14, and 15) to the cap (11)
assembly. Install spring seat (06), spring (07), and
the cap (11) assembly to valve housing (01) with
j : 8 mm
m : 50 N·m (37 lbf·ft)

to valve housing (01).
l : 6 mm
m : 21.6 to 23.6 N·m (16 to 17 lbf·ft)
W4-6-5-6
Disassembly of Emergency Steering Check

Block
WNEC-04-07-005
4- Spring 27- Spring 30- Poppet 33- O-Ring

25- Valve Housing 28- O-Ring 31- O-Ring 35- Socket Bolt (3 Used)
26- Poppet 29- Plug 32- Plug
a- Steering Valve
W4-6-6-1
Disassembly of Emergency Steering Check Block

1. Remove socket bolts (35) (3 used) from valve
housing (25).
l : 8 mm
2. Remove valve housing (25) and O-ring (33) from
steering valve (a).
3. Remove plug (32), O-ring (31), spring (4), and
poppet (30) from valve housing (25).
j : 27 mm
IMPORTANT: Record the direction to install spring
(27).
4. Remove plug (29), O-ring (28), spring (27), and
poppet (26) from valve housing (25).
j : 24 mm
W4-6-6-2
Assembly of Emergency Steering Check

Block
A A
Section BB
30 B B
32
31 35
29 27 26
28 25
33 a
Section AA
WNEC-04-07-007
4- Spring 27- Spring 30- Poppet 33- O-Ring

25- Valve Housing 28- O-Ring 31- O-Ring 35- Socket Bolt (3 Used)
26- Poppet 29- Plug 32- Plug
a- Steering Valve
W4-6-6-3
Assembly of Emergency Steering Check Block

IMPORTANT: The emergency steering check
block is the susceptible hydraulic component
to contamination. Keep the parts clean when
assembling.
IMPORTANT: Check the direction to install spring
(27).
1. Install O-ring (28) to plug (29). Install plug (29),
spring (27), and poppet (26) to valve housing (25).
j : 24 mm
m : 88 to 98 N·m (65 to 72 lbf·ft)

2. Install O-ring (31) to plug (32). Install plug (32),
spring (4), and poppet (30) to valve housing (25).
j : 27 mm
m : 103 to 113 N·m (76 to 83 lbf·ft)

3. Install valve housing (25) and O-ring (33) to steering
valve (a) with socket bolts (35) (3 used).
l : 8 mm
m : 58 to 64 N·m (43 to 47 lbf·ft)
W4-6-6-4
Removal and Installation of Steering Cylinder
1 85Z7B-W4-04-01-01
IMPORTANT: The hose and pipe contain hydraulic oil. 2. Remove under guard (front) (1) (only for the
When removing the hose and pipe, receive oil with machine with under guard). (Refer to W3-22-1.)
Removal

pressure in the circuit.

W4-6-7-1
a View A
1
2
3, 4
85Z7B-W4-06-07-21
85Z7B-W4-06-07-01
Removal of Steering Cylinder (Left)

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
85Z7B-W4-06-07-02
j : 19 mm
j : 27 mm
j : 36 mm
W4-6-7-3
1
85Z7B-W4-06-07-05
9. Remove grease fitting (1).
j : 10 mm
W4-6-7-4
Detail A
3 5 4
6
1 2
6
85Z7B-W4-06-07-07
2
85Z7B-W4-06-07-05
13. Disconnect steering cylinder (2) from rear frame (1).

dCAUTION:
lb)
Steering cylinder (2) weight: 27 kg (60
14. Retract steering cylinder (2).
10. Attach nylon slings onto steering cylinder (2). Hoist 15. In order not to extend the rod, pass the wires
and hold steering cylinder (2). through the rod hole of steering cylinder (2) and
secure the rod to the cylinder tube.
dCAUTION: 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.
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
A
Detail A
3 4
1 2 5
2
1
85Z7B-W4-06-07-08
85Z7B-W4-06-07-03

a hammer is used. Wear necessary protection, 18. Remove steering cylinder (1) from front frame (2).
such as goggles, hard hat, etc. in order to prevent 19. Remove the adapters from steering cylinder (1) if
personal injury. necessary.
j : 19 mm
W4-6-7-6
4 3 1, 2 85Z7B-W4-06-07-09
Removal of Steering Cylinder (Right)

j : 17 mm
j : 17 mm
j : 14 mm
W4-6-7-7
4 85Z7B-W4-06-07-10
j : 19 mm
j : 36 mm
j : 27 mm
W4-6-7-8
85Z7B-W4-06-07-12
1
j : 10 mm
W4-6-7-9
1
Detail A
4 5 1
3
a
6
85Z7B-W4-06-07-14
2
dCAUTION:
lb)
Steering cylinder (2) weight: 24 kg (53 dCAUTION: Metal fragments may fly off when
27. Attach nylon slings onto steering cylinder (2). Hoist such as goggles, hard hat, etc. in order to prevent
and hold steering cylinder (2). personal injury.
j : 19 mm
30. Disconnect steering cylinder (2) from rear frame (1).
31. Retract steering cylinder (2).
32. 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.
W4-6-7-10
Detail A
3 4 5
2
1
A
85Z7B-W4-06-07-15
1
85Z7B-W4-06-07-11
34. Remove shim (6).

a hammer is used. Wear necessary protection, 35. Remove steering cylinder (1) from front frame (2).
such as goggles, hard hat, etc. in order to prevent 36. Remove the adapters from steering cylinder (1) if
personal injury. necessary.
j : 19 mm
W4-6-7-11
Detail A
3 4 5
2
1
A
85Z7B-W4-06-07-15
1
85Z7B-W4-06-07-11
Installation
Installation of Steering Cylinder (Right)
1. Install all removed adapters to steering cylinder (1). such as goggles, hard hat, etc. in order to prevent
personal injury.
dCAUTION:
lb)
Steering cylinder (1) weight: 27 kg (60 4. Install pin (5) by using a hammer.
5. Install washer (4) and bolt, washer (3).
2. Attach nylon slings onto steering cylinder (1). Hoist
steering cylinder (1). Fit the hole at cylinder bottom j : 19 mm
side to the cylinder mounting hole of front frame
(2). m : 90 N·m (66 lbf·ft)
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: 1 mm (0.039 in)
W4-6-7-12
Detail A
4 5 1
3
a
6
2 85Z7B-W4-06-07-14

85Z7B-W4-06-07-12
6. Remove the wires from the rod holes of steering

cylinder (2). Extend steering cylinder (2) and fit the dCAUTION: Metal fragments may fly off when
cylinder rod hole to the mounting hole of rear frame
(1). such as goggles, hard hat, etc. in order to prevent
personal injury.
8. Install pin (5) by using a hammer.
7. Fit shims (6) to the top and bottom sides of the 9. Install washer (3) and bolt, washer (4).
cylinder rod hole. Adjust the total clearance at the
j : 19 mm
top and bottom sides of steering cylinder (2) and
rear frame (1) within 1 mm (0.039 in.). m : 90 N·m (66 lbf·ft)
fNOTE: Shim (6) thickness: 0.5 mm (0.02 in.), 1 mm

(0.039 in.)
W4-6-7-13
View A
1 a
85Z7B-W4-06-07-16
a- 60 °
1 A
85Z7B-W4-06-07-12
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
1 Detail A
b
2
a a 2 4
85Z7B-W4-06-07-17
3
a- 20°
b- 25°

85Z7B-W4-06-07-10
4
j : 36 mm
j : 27 mm
m : 180 N·m (133 lbf·ft)
j : 19 mm
m : 30 N·m (22 lbf·ft)
W4-6-7-15
85Z7B-W4-06-07-19
4 3 1, 2 85Z7B-W4-06-07-09
14. Install elbow (4). 16. Secure pipe (3) with clip (2) and bolt, washer (1).
Apply grease onto grease fitting (5).
j : 14 mm
j : 17 mm
15. Connect the both ends of pipe (3).
m : 50 N·m (37 lbf·ft)
j : 17 mm
m : 25 N·m (18 lbf·ft)
W4-6-7-16
A a Detail A
3 4
5
1 2
2
1
85Z7B-W4-06-07-08
Installation of Steering Cylinder (Left)

1. Install all removed adapters to steering cylinder (1).
dCAUTION:
lb)
Steering cylinder (1) weight: 27 kg (60
personal injury.
2. Attach nylon slings onto steering cylinder (1). Hoist
steering cylinder (1). Fit the hole at cylinder bottom 5. Install washer (5) and bolt, washer (4).
(2). j : 19 mm
IMPORTANT: Use one or more shims (6) respectively m : 90 N·m (66 lbf·ft)
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).
W4-6-7-17
A
Detail A
3 5 4
1
6
2
6
85Z7B-W4-06-07-07
2 85Z7B-W4-06-07-05
6. Remove the wires from the rod holes of the steering

cylinder (2). Extend steering cylinder (2) and fit the dCAUTION: Metal fragments may fly off when
cylinder rod hole to the mounting hole of rear frame
(1). such as goggles, hard hat, etc. in order to prevent
personal injury.
7. Fit shims (6) to the top and bottom sides of the 9. Install washer (5) and bolt, washer (4).
cylinder rod hole. Adjust the total clearance at the
j : 19 mm
top and bottom sides of steering cylinder (2) and
rear frame (1) within 1 mm (0.039 in). m : 90 N·m (66 lbf·ft)
W4-6-7-18
View A
85Z7B-W4-06-07-20
A 1 a- 60 °
85Z7B-W4-06-07-05
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
Detail A
2
a
3
A
85Z7B-W4-06-07-18
a- 25 °
85Z7B-W4-06-07-02
j : 36 mm
m : 180 N·m (133 lbf·ft)

j : 27 mm
m : 95 N·m (70 lbf·ft)

j : 19 mm
m : 30 N·m (22 lbf·ft)
W4-6-7-20
a View A
1
2
3, 4
85Z7B-W4-06-07-21
2
85Z7B-W4-06-07-01
14. Install elbow (1).

a
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). 5
j : 17 mm
m : 50 N·m (37 lbf·ft) 85Z7B-W4-06-07-19
W4-6-7-21
1 85Z7B-W4-04-01-01

engine. Operate the steering cylinder to the stroke
17. Install under guard (front) (1) (only for the machine
with under guard). (Refer to W3-22-1.)
W4-6-7-22
Disassembly of Steering Cylinder
20
18
17
16
15
14
12
13
12
19
11
10
9
8
7
6
5
4
3
2
1
WNDB-04-06-001
1- Cylinder Rod 6- Washer 11- Retaining Ring 16- Piston

2- Dust Seal 7- O-Ring 12- Backup Ring (2 Used) 17- Wear Ring
3- U-Ring 8- O-Ring 13- O-Ring 18- Nut
4- Buffer Ring 9- Backup Ring 14- Dust Seal 19- Set Screw
5- Cylinder Head 10- Bushing 15- Seal Ring 20- Cylinder Tube
W4-6-8-1
Disassembly of Steering Cylinder 4. Loosen cylinder head (5) by using hook wrench (b).
dCAUTION: Steering cylinder weight: 27 kg (60 lb) Diameter of cylinder head (5): 84 mm (3.3 in)
1. Hoist the cylinder. Secure the cylinder on a
workbench horizontally. Drain off hydraulic oil from b
the cylinder.
20
W102-04-02-027
1 5 W506-04-02-004
2. Install a protective cover to cylinder rod (1). b- Hook Wrench

such as goggles, helmets, etc in order to prevent 5. Remove the cylinder rod (1) assembly from cylinder
personal injury. tube (20). Secure it on the special tool (ST 5908) for
IMPORTANT: Do not damage the sliding surface of cylinder.
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 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
fNOTE: Set screw (19) has been crimped by using a
WNDB-04-06-002 punch (2 places) after installing.
a- Stopper
fNOTE: LOCTITE #243 or equivalent has been applied on
set screw (19).
W4-6-8-2
7. Remove nut (18) by using the special tool (ST 5908) 9. Remove cylinder head (5) from cylinder rod (1) by
for cylinder and the special tool for nut. using a plastic hammer.
Special Tool for Nut: 10. Remove wear ring (17) and dust seal (14) from
piston (16).
ST 3394: 58 mm (2.3 in)
such as goggles, helmets, etc in order to prevent
personal injury.
IMPORTANT: Do not damage the seal groove.

11. Remove backup rings (15a) (2 used) from piston
Special Tool for Cylinder: ST 5908 (16). Cut seal ring (15b) and ring (15c) by using a
screwdriver and a hammer. Remove seal ring (15b)
W158-04-02-022 and ring (15c) from piston (16).
8. Remove piston (16) by using the special tool (ST 16 a b a 15

5908) for cylinder and the special tool for piston.
Special Tool for Piston:
ST 3395: 52 mm (2 in)
WDBE-05-02-006
a- Backup Ring c- Ring

b- Seal Ring
W158-04-02-022
W4-6-8-3
12. Remove backup rings (12) (2 used) and O-ring (13)

from piston (16) by using a spatula. dCAUTION: Metal fragments may fly off when
13. Remove backup ring (9) and O-rings (7, 8) from such as goggles, helmets, etc in order to prevent
cylinder head (5) by using a spatula. personal injury.
14. Remove U-ring (3), backup ring (4a), and buffer ring
(4b) from cylinder head (5) by using an awl. IMPORTANT: Do not damage cylinder head (5).
15. Secure cylinder head (5) in a vise. Remove dust seal
(2) from cylinder head (5) by using a screwdriver
3 5
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

from cylinder head (5). Cut off bushing (10) by using a
lathe. Insert a screwdriver strongly and remove busing
A WNDB-04-06-005
4 (10).
Detail A
a b
4
WDBE-05-02-008
a- Backup Ring b- Buffer Ring
W4-6-8-4
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
1- Cylinder Rod 6- Washer 11- Retaining Ring 16- Piston

2- Dust Seal 7- O-Ring 12- Backup Ring (2 Used) 17- Wear Ring
3- U-Ring 8- O-Ring 13- O-Ring 18- Nut
4- Buffer Ring 9- Backup Ring 14- Dust Seal 19- Set Screw
5- Cylinder Head 10- Bushing 15- Seal Ring 20- Cylinder Tube
W4-6-8-5
Assembly of Steering Cylinder IMPORTANT: Check the direction to install backup

ring (4a).
onto parts in order to prevent them from seizing. 4. Install U-ring (3), buffer ring (4b), and backup ring
(4a) to cylinder head (5).
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. 3 5
Special Tool for Bushing (Rod Outer Diameter):
ST 3398: 45 mm
2. Install retaining ring (11) to cylinder head (5).

A WNDB-04-06-005
personal injury. 4
3. Install dust seal (2) to cylinder head (5) by using the
special tool for dust seal.
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
8. Hoist and secure cylinder rod (1) on the special tool

installing seal ring (15b).
(ST 5908) for cylinder.
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. W158-04-02-022
After installing seal ring (15b), adjust it by using the
special tool for seal ring. Install backup rings (15a) (2
9. Install the cylinder head (5) assembly to cylinder rod
used) to piston (16).
(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
ST 3397: 70 mm using the special tool (ST 5908) for cylinder and the
special tool for piston.
16 a b a 15
ST 3395: 52 mm
m : 491±49 N·m (360±36 lbf·ft)
WDBE-05-02-006
a- Backup Ring c- Ring

b- Seal 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
11. Install nut (18) to cylinder rod (1) by using the IMPORTANT: Fit the cylinder rod (1) assembly to the
special tool (ST 5908) for cylinder and the special center of cylinder tube (20) and install it straight
tool for nut. in order not to damage the rings.
Special Tool for Nut:
14. Secure cylinder tube (20) on a workbench
ST 3394: 58 mm (2.3 in) horizontally. Install washer (6) and the cylinder rod
(1) assembly to cylinder tube (20). At this time, fit
m : 491±49 N·m (360±36 lbf·ft)
the bent part of washer (6) to notch (a) of cylinder
tube (20) and install washer (6).
fNOTE: New washer (6) is not bent. The position

adjustment of washer (6) is not necessary.

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- Notch
W4-6-8-8
IMPORTANT: Do not damage the sliding surface of

cylinder rod (1). dCAUTION: Metal fragments may fly off when
15. Tighten cylinder head (5) to cylinder tube (20) by
personal injury.
using hook wrench (a).
16. Bend washer (6) by using a chisel and a hammer in
Diameter of cylinder head (5): 84 mm order not to loosen cylinder head (5). At this time,
bend one of three notches (c) for the hook wrench
m : 491±49 N·m (360±36 lbf·ft)
of cylinder head (5) in order not to loosen. (In case
of new washer (6), bend notch (b) of cylinder tube
a (20) in order not to loosen.)
1 5 6 20
20
1 5 W506-04-02-004
a- Hook Wrench
c WNDB-04-06-004
b- Notch c- Notch
W4-6-8-9
(Blank)
W4-6-8-10
Removal and Installation of Steering

Accumulator
1
1
2
3 2
3
1
2
3
85Z7B-W4-06-10-01
Removal IMPORTANT: Remove guard (4) while holding it. Do

not drop guard (4).
attach an identification tag onto the connectors,
dCAUTION: Guard (4) weight: 91 kg (200 lb)
2. Set a stand and a jack under guard (4). Hold guard
hoses, and pipes for assembling. Connect the (4).
hoses and install the clips in case the clips which
secure the hoses have been removed. 3. Remove bolts (3) (6 used) and washers (1, 2) (6 used
for each). Remove guard (4).
1. Set the machine position for inspection and j : 24 mm
dCAUTION: Bleed air from the hydraulic oil tank.

(Refer to W1-4-1.)
dCAUTION: Operate the steering wheel right and

left several times, and release any pressure in the
circuit.
W4-6-9-1
1
2
1
2
2 2
3 4
4
6
4
5 5
4
5
5
WNEC-04-08-007
4. Place a container under steering accumulator (3). 7. Remove steering accumulator (3) from frame (6).
5. Disconnect hose (1) from steering accumulator (3). 8. Remove other steering accumulator (3) in the same
way as step 4 to step 7.
j : 19 mm
6. Remove nuts (5) (4 used) and washers (4) (4 used)
from U-bolts (2) (2 used). Remove U-bolts (2) (2
used) from frame (6).
j : 17 mm
W4-6-9-2
1
2
1
2
2 2
3 4
4
6
4
5 5
4
5
5
WNEC-04-08-007
Installation
1. Install steering accumulator (3) to frame (6) with 3. Install other steering accumulator (3) in the same
U-bolts (2) (2 used), washers (4) (4 used), and nuts way as step 1 to step 2.
(5) (4 used).
j : 17 mm 1.)
m : 20 N·m (2 kgf·m, 15 lbf·ft) IMPORTANT: Check the hydraulic oil level. Start the
2. Connect hose (1) to steering accumulator (3).
j : 19 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
W4-6-9-3
1
1
2
3 2
3
1
2
3
85Z7B-W4-06-10-01
dCAUTION: Guard (4) weight: 91 kg (200 lb)

5. Set a stand and a jack under guard (4). Hold guard
(4).
6. Install guard (4) with washers (1, 2) (6 used for each)
and bolts (3) (6 used).
j : 24 mm
m : 210 N·m (21 kgf·m, 155 lbf·ft)
W4-6-9-4
Removal and Installation of Left Stop Valve
1
85Z7B-W4-04-01-01

When removing the hose and pipe, receive oil with dCAUTION: Release any pressure in the hydraulic
Removal
1. Operate the steering wheel in right to the steering
end.

the circuit.
W4-6-10-1
Detail A
1 2
4
3
85Z7B-W4-06-10-02 85Z7B-W4-06-10-03
4. Disconnect hoses (1) (2 used). 6. Remove bolts, washers (3) (3 used). Remove stop
valve (6) from rear frame (4).
j : 19 mm
j : 13 mm
7. Remove the adapters with stop valve (6) attached if
W4-6-10-2
Detail A
1 2
4
3
85Z7B-W4-06-10-03
85Z7B-W4-06-10-02
c 6
Installation
a
1. Install all removed adapters to stop valve (6).
IMPORTANT: Face air bleed hole (d) of boot (c) down.
2. Install stop valve (6) to rear frame (4) with bolts,
washers (3) (3 used). b
85Z7B-W4-06-10-04
j : 13 mm d
m : 10 N·m (7.4 lbf·ft) a- Up c- Boot

b- Down d- Air Bleed Hole
j : 17 mm 4. Connect hoses (1) (2 used).

m : 25 N·m (18.5 lbf·ft) j : 19 mm
m : 30 N·m (22 lbf·ft)

engine. Slowly operate the steering wheel to the
steering end several times, and check for any oil
leaks.
W4-6-10-3
Front Frame
2.5 mm
(0.1 in)
Stopper (bolt) Stop valve (LH) Rear Frame
Articulation
angle
36º~38º
Front chassis
(Plate) Stopper length
20.7~25.5 mm Clearance between
(0.8~1.0 in) chassis and stopper
10~24 mm (0.4~0.94 in)
85Z7B-W4-06-10-05 85Z7B-W4-06-10-06
fNOTE: The stop valve works when the spool is pushed

6. After adjustment, turn the steering wheel slowly at
in 2.5 mm (0.1 in). Adjust the stopper bolt by using the
a rate of 5 seconds or more per turn, and confirm
following procedure.
the clearance between the machine body and the
stopper.
5. Adjust the stopper (bolt) length so that the
clearance between the machine body and the 7. When adjustment is completed, tighten the lock nut
stopper becomes the reference dimension shown in of the stopper (bolt).
the following table. j : 19 mm
Reference dimension m : 26.5~31.4 N·m (20~23 lbf·ft)
Articulation angle 38º 37º 36º

Clearance between 10 mm 17 mm 24 mm
machine body and (0.39 in) (0.67 in) (0.94 in)
stopper
Stopper (bolt) length 20.7 mm 23.1 mm 25.5 mm
(0.81 in) (0.91 in) (1.0 in)
fNOTE: The target articulation angle should be "37º".
W4-6-10-4
1 85Z7B-W4-04-01-01
W4-6-10-5
(Blank)
W4-6-10-6
Removal and Installation of Right Stop Valve
1
85Z7BW-03-01-05

When removing the hose and pipe, receive oil with dCAUTION: Release any pressure in the hydraulic
Removal
1. Operate the steering wheel in left to the steering
end.

the circuit.
W4-6-11-1
Detail A
A
2
85Z7B-W4-06-11-01 4 85Z7B-W4-06-11-02
4. Disconnect hoses (3) (2 used). 6. Remove bolts, washers (3) (3 used). Remove stop
valve (6) from rear frame (4).
j : 19 mm
j : 13 mm
7. Remove the adapters with stop valve (6) attached if
W4-6-11-2
Detail A
A
2
85Z7B-W4-06-11-01 4 85Z7B-W4-06-11-02
c
6
Installation
1. Install all removed adapters to stop valve (6).
b
IMPORTANT: Face air bleed hole (d) of boot (c) down. d
e
2. Install stop valve (6) to rear frame (4) with bolts, 85Z7B-W4-06-11-03
a- Up d- Air Bleed Hole
j : 13 mm b- Down e- 30º
c- Boot
m : 10 N·m (7.4 lbf·ft)
j : 17 mm 4. Connect hoses (1) (2 used).

m : 25 N·m (18 lbf·ft) j : 19 mm
m : 30 N·m (22 lbf·ft)

engine. Slowly operate the steering wheel to the
steering end several times, and check for any oil
leaks.
W4-6-11-3
Rear Frame
2.5 mm Front Frame

(0.1 in)
Stop valve (RH)
Stopper (bolt)
Articulation
angle
36º~38º
Front chassis
Stopper length (Plate)
20.7~25.5 mm
(0.8~1.0 in)
Clearance between
85Z7B-W4-06-11-04 chassis and stopper
10~24 mm (0.4~0.94 in)
85Z7B-W4-06-11-05
fNOTE: The stop valve works when the spool is pushed

6. After adjustment, turn the steering wheel slowly at
in 2.5 mm (0.1 in). Adjust the stopper bolt by using the
a rate of 5 seconds or more per turn, and confirm
following procedure.
the clearance between the machine body and the
stopper.
5. Adjust the stopper (bolt) length so that the
clearance between the machine body and the 7. When adjustment is completed, tighten the lock nut
stopper becomes the reference dimension shown in of the stopper (bolt).
the following table. j : 19 mm
Reference dimension m : 26.5~31.4 N·m (20~23 lbf·ft)
Articulation angle 38º 37º 36º

Clearance between 10 mm 17 mm 24 mm
machine body and (0.39 in) (0.67 in) (0.94 in)
stopper
Stopper (bolt) length 20.7 mm 23.1 mm 25.5 mm
(0.81 in) (0.91 in) (1.0 in)
fNOTE: The target articulation angle should be "37º".
W4-6-11-4
85Z7BW-03-01-05
W4-6-11-5
(Blank)
W4-6-11-6
Disassembly of Stop Valve
15
13
12
11
10
1
5
6
2
7
8
14
9
3
4
Spool Assembly
90WNEC-04-11-05
1- Boot 6- Washer 11- Dust Seal

2- Plug 7- Spring 12- Spacer
3- Spring 8- Poppet 13- U-Packing
4- Spool 9- Screw 14- O-Ring
5- Plug 10- Flange 15- Housing
Disassembly of Stop Valve
dWARNING: The inner spring may spring out

causing injury. Do not point the spring toward
3. Vise spool (4) assembly at the bottom side and
remove plug (5) using a screwdriver.
your face. 4. Remove washer (6), spring (7) and poppet (8) from
1. Remove boot (1), and plug (2) with O-ring (14). the spool.
j : 38 mm 5. Remove screw (9) and remove flange (10), dust seal

(11), spacer (12), and U-packing (13).
2. Remove spring (3) and pull out spool (4) assembly.
W4-6-12-1
Assembly of Stop Valve
16±0.5 mm
(0.63±0.02 in)
A A
16
1 9, 10 7 4 15 2
8
11 12 13 6 5 14 3
90WNEC-04-11-06
A-A
1- Boot 6- Washer 11- Dust Seal 16- Air vent hole

2- Plug 7- Spring 12- Spacer
3- Spring 8- Poppet 13- U-Packing
4- Spool 9- Screw 14- O-Ring
5- Plug 10- Flange 15- Housing
Assembly of Stop Valve

IMPORTANT: Before assembling, apply a thin coat of 3. Install spool (4) assembly and spring (3) to housing
hydraulic oil to the parts in order to prevent them (15).
from seizing.
4. Install O-ring (14) and plug (2) to housing (15).
1. U-packing (13), spacer (12), dust seal (11), and j : 38 mm

flange (10) to housing (15) with screws (9) (2 used).
m : 186.3 N·m (137.4 lbf·ft)
m : 0.4 N·m (0.3 lbf·ft)
IMPORTANT: Install boot (1) so that the air vent hole
2. Vise spool (4) at the bottom side and install poppet (16) comes down.
(8), spring (7), washer (6), and plug (5). 5. Install boot (1) to housing (15).
m : 3.92 N·m (2.9 lbf·ft)
W4-6-12-2
Group 7 Emergency Steering Device
Removal and Installation of Emergency

Steering Pump
Detail A
b
1
c
a
85Z7B-W4-07-01-04
85Z7B-W4-07-01-03

c- ON Position
IMPORTANT: The hose and pipe contain hydraulic oil. IMPORTANT: Turn the key switch to the OFF position,
When removing the hose and pipe, receive oil with wait 5 minutes or longer, and then turn battery
a container in order to avoid spilling oil. disconnect switch (2) to the OFF position.
IMPORTANT: Cap the open ends in case the hoses 3. Set battery disconnect switch (2) to OFF position
and pipes have been disconnected. In addition, (b).
Removal

2. Open cover (1).
W4-7-1-1
3 2
85Z7B-W4-04-01-01
4. Open side covers (front) (1) at left and right sides.

 Lower Cover (2)
W4-7-1-2
2 85Z7B-W4-07-01-01
6. Remove bolts, washers (1) (2 used). Place rubber

plate (2) outside of the work area.
j : 17 mm
W4-7-1-3
View A
1 2
6
5
B
85Z7B-W4-07-01-05
4
85Z7B-W4-07-01-02
Detail B 8 7
7. Remove nut (6). Disconnect terminal (5).
j : 12 mm
j : 22 mm
j : 27 mm
emergency steering pump (1) and ground (9) from
bracket (8). 9 7
85Z7B-W4-07-01-06
j : 17 mm
12. Remove the adapters from emergency steering
pump (1) if necessary.
W4-7-1-4
View A
1 2
B
5
85Z7B-W4-07-01-05
4
85Z7B-W4-07-01-02
Detail B
8 7
Installation
1. Install all removed adapters to emergency steering
pump (1).
2. Install emergency 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)

j : 27 mm
9 7
m : 80 N·m (59 lbf·ft)
85Z7B-W4-07-01-06
j : 22 mm
m : 40 N·m (30 lbf·ft)

6. Connect terminal (5) with nut (6).
j : 12 mm
m : 8.2 to 9.8 N·m (6 to 7.2 lbf·ft)
W4-7-1-5
Detail A
1
b
a
c
85Z7B-W4-07-01-04
85Z7B-W4-07-01-03

c- ON Position
7. Set battery disconnect switch (2) to ON position (c).

8. Close cover (1).
W4-7-1-6
2 85Z7B-W4-07-01-01

9. Install rubber plate (2) with bolts, washers (1) (2
used).
j : 17 mm
m : 50 N·m (37 lbf·ft)
W4-7-1-7
3 2 85Z7B-W4-04-01-01

 Lower Cover (2)
11. Close left and right side covers (front) (1).
W4-7-1-8
MEMO
MEMO
SECTION 5
FRONT ATTACHMENT
CONTENTS
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
NEM50W-5-1
(Blank)
NEM50W-5-2
SECTION 5 FRONT ATTACHMENT
Removal and Installation of Front

Attachment
1 2 3
85Z7B-W5-01-01-01
a
a- Stand
IMPORTANT: The hoses and pipes contain hydraulic 2. Start the engine. Raise lift arm (1). Set lift arm
oil. When removing the hoses and pipes, receive cylinder (2) in the horizontal position. Operate
oil with a container in order to avoid spilling oil. bucket cylinder (3). Dump and place bucket (4) on
IMPORTANT: Cap the open ends in case the hoses stand (a). Stop the engine.
Removal
W5-1-1-1
View A
A
4
85Z7B-W5-01-01-03
85Z7B-W5-01-01-02
3. Disconnect connector (3). 6. Remove another headlight (1) assembly in the same
4. Remove connector (3) from bracket (4).
headlight (1) assembly.
j : 19 mm
W5-1-1-2
1, 2
5
a 9
3
4
85Z7B-W5-01-01-04 8 85Z7B-W5-01-01-05

8. Remove bolt, washer (1) and washer (2).
j : 17 mm dCAUTION: Release any pressure in the front
angle sensor (3) assembly.
IMPORTANT: After removing bucket cylinder (8), do
j : 17 mm not operate the bucket.
10. Disconnect terminals (7) (2 used). 13. Remove bucket cylinder (8). (Refer to W5-2-2.)
horn (6) assembly.
j : 19 mm
12. Remove another horn (6) assembly in the same way
as step 10 to step 11.
W5-1-1-3
Section A
A 5
6
2
85Z7B-W5-01-01-06 85Z7B-W5-01-01-07
18. Remove another lift arm cylinder (1) from lift arm (3)
d CAUTION: Lift arm cylinder (1) weight: 172 kg
(380 lb)
in the same way as step 14 to step 18.
19. Start the engine. Retract lift arm cylinders (2).
14. Attach nylon slings onto lift arm cylinder (1). Hoist
and hold lift arm cylinder (1). 20. 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.

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 lift arm cylinder (1) from lift arm (3).
17. Set wooden blocks in between lift arm cylinder (1)
and front frame (2). Support lift arm cylinder (1).
W5-1-1-4
A
Section A
5 5
1
3
2
3
8
9
4
85Z7B-W5-01-01-08 85Z7B-W5-01-01-09
26. Remove other pin (6) in the same way as step 23 to

d CAUTION: The front attachment assembly
step 26.
IMPORTANT: Slowly move the machine in reverse
21. Attach nylon slings onto lift arm (4). Hoist and hold
direction while taking care not to contact the lift
the front attachment assembly.
arm (4) mounting part of front frame (3) and lift
22. Disconnect the both ends of pipe (2). arm (4).
27. Start the engine. Move the machine in reverse
j : 17 mm
direction and remove the front attachment
23. Remove elbow (1). assembly from front frame (3). Stop the engine.
j : 14 mm 28. Remove the front attachment assembly from front
frame (3). Place it onto wooden blocks.
dCAUTION: Pin (6) weight: 30 kg (66 lb)
personal injury.
j : 24 mm
25. Remove shims (5) (2 used).
W5-1-1-5
A
Section A
3
3
4
4 85Z7B-W5-01-01-09
85Z7B-W5-01-01-08
Installation
IMPORTANT: Check outer diameter, inner diameter,
dCAUTION: The front attachment assembly
wear, and damage of all pins and bushings before
1. Attach nylon slings onto lift arm (4). Hoist the front
installing the front attachment. Replace them if
attachment assembly.
any defect is observed. (Refer to W2-2-1.)
IMPORTANT: Check the pins and bushings. Replace if 2. Start the engine. Move the machine forward. Fit
necessary. (Refer to W5-1-4.) the lift arm (4) mounting hole to the front frame (3)
mounting hole. Stop the engine.
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.
W5-1-1-6
A 1
Section A
5 5
3
2
6
4
10 7
3
8
9
4 85Z7B-W5-01-01-09
85Z7B-W5-01-01-08
IMPORTANT: Apply shims (5) one or more each at 5. Install washers (7, 9) and bolt (8).
both right and left sides evenly.
j : 24 mm
3. Install shims (5) (2 used) to the left and right side of
the lift arm (4) mounting hole. Adjust total clearance m : 210 N·m (155 lbf·ft)
of right and left between lift arm (4) and front frame
(3) within 1.5 mm (0.059 in.). 6. Install elbow (1).
j : 14 mm
fNOTE: Shim (5) thickness: 1.6 mm (0.063 in.)
dCAUTION: Pin (6) weight: 30 kg (66 lb) m : 13 to 18 N·m (9.6 to 13.5 lbf·ft)

7. Connect the both ends of pipe (2). Apply grease
onto grease fitting (10).
personal injury. j : 17 mm
4. Install pin (6) by using a hammer. m : 25 N·m (18.5 lbf·ft)
8. Install another pin (6) in the same way as step 3 to
step 7.
W5-1-1-7
Section A
A
5
6
2
7
3
3
8
85Z7B-W5-01-01-06 85Z7B-W5-01-01-07
9. Remove the wires from the rod holes of lift arm

cylinder (1). Start the engine. Extend lift arm dCAUTION: Metal fragments may fly off when
cylinder (1) and fit the cylinder rod side hole to the
lift arm (3) mounting hole. Stop the engine. such as goggles, hard hat, etc. in order to prevent
personal injury.
10. Remove wooden blocks set in step 18.
12. Install washers (4, 6) and bolt (5).
j : 24 mm
m : 210 N·m (155 lbf·ft)

13. Apply grease to grease fitting (8).
14. Install another lift arm cylinder (1) in the same way
W5-1-1-8
1, 2
5
9 a
3
4
8 85Z7B-W5-01-01-05 85Z7B-W5-01-01-04
15. Install bucket cylinder (8). (Refer to W5-2-2.) 19. Install the angle sensor (3) assembly with bolts,
16. Install the horn (6) assembly with bolts, washers (9)
(2 used). j : 17 mm
j : 19 mm m : 50 N·m (37 lbf·ft)
m : 90 N·m (66 lbf·ft) 20. Install washer (2) and bolt, washer (1).
17. Connect terminals (7) (2 used). j : 17 mm
18. Install another horn (6) assembly in the same way as
m : 50 N·m (37 lbf·ft)
step 17 to step 18.
W5-1-1-9
View A
A
4
85Z7B-W5-01-01-03
85Z7B-W5-01-01-02
22. Install the headlight (1) assembly with bolts, 26. Bleed air from the hydraulic system. (Refer to W1-4-
washers (2) (4 used). 1.)
j : 19 mm IMPORTANT: Check the hydraulic oil level. Start the

m : 90 N·m (66 lbf·ft)
23. Install connector (3) to bracket (4).
25. Install another headlight (1) assembly in the same
W5-1-1-10
Removal and Installation of Bell Crank
Section A
1 7
1 3
4
5
6
A
2
85Z7B-W5-01-02-02
2
85Z7B-W5-01-02-01

oil. When removing the hoses and pipes, receive dCAUTION: Pin (6) weight: 21 kg (46 lb)
and pipes have been disconnected. In addition, such as goggles, hard hat, etc. in order to prevent
attach identification tags onto the connectors, personal injury.
hoses, and pipes for assembling. If the clips which 3. Remove bolt (4) and washers (3, 5). Remove pin (6)
secure the hoses have been removed, install the by using a round bar and a hammer.
j : 24 mm
Removal 4. Remove shims (7).
maintenance. (Refer to W1-5-1.) dCAUTION: Release any pressure from the
dCAUTION: Bucket link (2) weight: 81 kg (180 lb)
2. Attach nylon slings onto bucket link (2). Hoist and attachment hydraulic circuit. (Refer to W1-5-1.)
hold bucket link (2).
W5-1-2-1
2 Section A
3
A
4
5
6
1
1
85Z7B-W5-01-02-04
85Z7B-W5-01-02-03
dCAUTION: When removing bucket cylinder (2),

bell crank (1) may move. Do not allow any person
to stand in front of bell crank (1) moving direction. dCAUTION: Metal fragments may fly off when
IMPORTANT: After removing bucket cylinder (2), do such as goggles, hard hat, etc. in order to prevent
not operate the bucket. personal injury.
5. Remove bucket cylinder (2). (Refer to W5-2-2.) 6. 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.
W5-1-2-2
3 Section A
1 4
A 2
6
2
1
8
85Z7B-W5-01-02-06
85Z7B-W5-01-02-05

d CAUTION: Bell crank (1) weight: 330 kg (728 lb)
10. Remove bell crank (1) from lift arm (2). Place it onto
7. Attach nylon slings onto pin (3) which has been
wooden blocks.
installed in step 6. Hoist and hold bell crank (1).

personal injury.
j : 24 mm
W5-1-2-3
Section A
1 1
A
2
3
4
5
85Z7B-W5-01-02-07
85Z7B-W5-01-02-04

personal injury.
11. 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
W5-1-2-4
Section A
1 1
A
2
3
4
5
85Z7B-W5-01-02-07
85Z7B-W5-01-02-04
Installation 1. Install pin (2) to bell crank (1) by using a hammer.

Install washers (3, 5) and bolt (4).
wear, and damage of all pins and bushings before j : 24 mm
installing bell crank (1). (Refer to W2-2-1.)
IMPORTANT: Check pins and bushings. If any m : 210 N·m (155 lbf·ft)
damage is observed, replace it. (Refer to W5-1-4.)
fNOTE: Use pin (2), washers (3, 5) and bolt (4) which are
used for the bucket cylinder rod mounting parts.
installing the pin. In addition, apply anti-rust oil to
the inner circumference of the boss.

personal injury.
W5-1-2-5
3 Section A
1 4
A 2
6
2 9
1
8
85Z7B-W5-01-02-06
85Z7B-W5-01-02-05
dCAUTION: Bell crank (1) weight: 330 kg (728 lb) dCAUTION: Pin (7) weight: 50 kg (110 lb)
dCAUTION: Pin (2) weight: 20 kg (45 lb) dCAUTION: Metal fragments may fly off when
2. Attach nylon slings onto pin (3) which has been
installed in step 1. Hoist bell crank (1). Fit the such as goggles, hard hat, etc. in order to prevent
mounting hole of bell crank (1) to the mounting personal injury.
hole of lift arm (2). 4. Install pin (7) by using a hammer.
IMPORTANT: Apply shims (8) two or more each at 5. Install washers (4, 6) and bolt (5).
j : 24 mm
3. Install shims (8) to both sides of the bell crank (1)
mounting hole. Adjust the total clearance at the m : 210 N·m (155 lbf·ft)
left and right sides of bell crank (1) and lift arm (2)
within 1.5 mm (0.059 in.). 6. Apply grease to the grease fitting (9).
fNOTE: Shim (8) thickness: 1.6 mm (0.063 in.)
W5-1-2-6
Section A
A
2
3
4
5
1
1
85Z7B-W5-01-02-04
85Z7B-W5-01-02-05

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
W5-1-2-7
8
Section A
2
1 1 9
3
4
5
A 6
2
7 7
85Z7B-W5-01-02-02
85Z7B-W5-01-02-01
8. Install bucket cylinder (8). (Refer to W5-2-2.)

9. Attach nylon slings onto bucket link (2). Hoist a hammer is used. Wear necessary protection,
bucket link (2). Fit the mounting hole of bucket link such as goggles, hard hat, etc. in order to prevent
(2) to the mounting hole of bell crank (1). personal injury.
IMPORTANT: Apply shims (7) one or more each at 11. Install pin (6) by using a hammer.
12. Install bolt (4) and washers (3, 5).
10. Install shims (7) to both sides of the bell crank (1)
mounting hole. Adjust the total clearance at the left j : 24 mm
and right sides of bell crank (1) and bucket link (3)
within 1.5 mm. m : 210 N·m (155 lbf·ft)
13. Apply grease to the grease fitting (9).
fNOTE: Shim (7) thickness: 1.6 mm (0.063 in)
1.)
W5-1-2-8
Removal and Installation of Bucket
Section A 1
4
A
3
9
4
3 2
85Z7B-W5-01-03-01
8 6
5
7 85Z7B-W5-01-03-02
Removal 5. Remove shims (9).

1. Set the vehicle position for inspection and 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.

3. Attach nylon slings onto bucket link (3). Hoist and
hold bucket link (3).

personal injury.
j : 24 mm
W5-1-3-1
Section A
1
3
2
8
A
1
2
7 6 5 4
85Z7B-W5-01-03-03
85Z7B-W5-01-03-04
10. Remove spacers (8).

d CAUTION: Bucket (1) weight: 1530 kg (3375 lb)
11. Remove other pin (4) in the same way as step 9 to
fNOTE: The weight of bucket depends on the bucket step 10.
type.
12. Remove bucket (1) and O-rings (3) (4 used) from lift
8. Attach nylon slings onto bucket (1). Hoist and hold
arm (2).
bucket (1).

personal injury.
j : 24 mm
W5-1-3-2
Section A a
9
2
8
A
a 1
85Z7B-W5-01-03-03 7 6 5 4
85Z7B-W5-01-03-06
a- Boss Part
Installation
wear, and damage of all pins and bushings before
installing the bucket. (Refer to W2-2-1.)
IMPORTANT: Check pins and bushings. If any such as goggles, hard hat, etc. in order to prevent
damage is observed, replace it. (Refer to W5-1-4.) personal injury.
IMPORTANT: Apply grease onto the inner surface of 4. Install pin (4) by using a hammer.
bushings and dust seals when installing the pin. In 5. Install washers (5, 7) and bolt (6).
addition, apply anti-rust oil onto the inner surface
of the boss. j : 24 mm
1. Install O-rings (3) (4 used) to the boss part (a) (4 m : 210 N·m (155 lbf·ft)
places) of bucket (1).
d CAUTION: Bucket (1) weight: 1530 kg (3375 lb)
7. Install other pin (4) in the same way as step 3 to step
fNOTE: The weight of bucket depends on the bucket 6.
type.
8. Move O-rings (3) (4 used) which are installed in step
2. Attach nylon slings onto bucket (1). Hoist bucket (1). 1 to the connecting part of bucket (1) and lift arm
Fit the mounting hole of bucket (1) to the mounting (2).
hole of lift arm (1).
IMPORTANT: Apply shims (8) one or more each at
3. Install shims (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).
W5-1-3-3
Section A a
10
1
4
9
A
3
11
4
a
1
85Z7B-W5-01-03-01
8 7 6 5 85Z7B-W5-01-03-05
a- Boss Part
9. Install O-rings (4) (4 used) to the boss part (a) (2

places) of bucket (1). dCAUTION: Metal fragments may fly off when
dCAUTION: Bucket link (3) weight: 81 kg (180 lb) such as goggles, hard hat, etc. in order to prevent
personal injury.
10. Attach nylon slings onto bucket link (3). Hoist
bucket link (3). 13. Install pin (5) by using a hammer.
11. Start the engine. Fit the mounting hole of bucket 14. Install washers (6, 8) and bolt (7).
link (3) to the mounting hole of bucket (1) by
operating bucket cylinder (10). j : 24 mm
IMPORTANT: Apply shims (9) one or more each at m : 210 N·m (155 lbf·ft)
12. Install shims (9) to both sides of the bucket (1)
mounting hole. Adjust the total clearance at the 16. Move O-rings (4) (2 used) which are installed in step
left and right sides of bucket (1) and bucket link (3) 9 to the connecting part of bucket (1) and bucket
within 1.5 mm (0.059 in.). link (3).
W5-1-3-4
Removal and Installation of Bushing

H E
G
I
A
D
B
C
85Z7B-W5-01-04-01
Part Part Number of Pieces Bushings (2, 3) Cross section

Dust Seal Bushing Bushing
(1) (2) (3)
A Bucket 2 2 - a: 100 mm a
1 2
Link (3.94 in)
85Z7B-W5-01-04-02
B Bucket 2 2 - b: 100 mm b
1 2
Link (3.94 in)
85Z7B-W5-01-04-03
C Lift Arm 4 4 - c: 100 mm 1 c 2

(3.94 in)
outside 85Z7B-W5-01-04-04
D Lift Arm 4 4 - d: 100 mm 1 d 2

(3.94 in)
85Z7B-W5-01-04-05
E Lift Arm 4 4 - e: 115 mm 1 e

2
(4.53 in)
85Z7B-W5-01-04-06
W5-1-4-1
H E
G
I
A
D
B
C
85Z7B-W5-01-04-01
Part Part Number of Pieces Bushings (2, 3) Cross section

Dust Seal Bushing Bushing mounting tool
(1) (2) (3)
F Bell Crank 2 4 - f: 130 mm 1 f
(5.12 in) 2
85Z7B-W5-01-04-07
G Bucket 2 2 - g: 100 mm 1 g
2
Cylinder (3.94 in)
85Z7B-W5-01-04-08
H Bucket 2 2 - h: 100 mm
Cylinder (3.94 in) 1 2
h
85Z7B-W5-01-04-09
I Lift Arm 4 4 - i: 100 mm

Cylinder (3.94 in) 1 2
i
85Z7B-W5-01-04-10
W5-1-4-2
Removal Bushings (2, 3) mounting direction

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 NH 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
WNEC-05-01-028
may be damaged. Use a press when installing the
bushing. a- 2.5 mm (0.098 in) b- 15 °
Precautions when reinforcing the lift arm

The heat when welding in order to reinforce the lift
arm may cause oil leakage and decrease lubrication Bushing (2) mounting direction at lift arm part (c)
performance. When lubrication oil leaks, replace the
bushing.
IMPORTANT: Check the direction to install bushings c 2 c

(2, 3).
1. Install bushings (2, 3) by using a press, or the special
tool if available.
2. Install dust seal (1).
WNEC-05-01-025
c- Groove
W5-1-4-3
(Blank)
W5-1-4-4
Group 2 Cylinder
Removal and Installation of Lift Arm Cylinder
1 2 3
4
4
a- Stand
85Z7B-W5-01-01-01
a
IMPORTANT: The hoses and pipes contain hydraulic 2. Start the engine. Raise lift arm (1). Set lift arm
oil. When removing the hoses and pipes, receive cylinder (2) in the horizontal position. Dump bucket
oil with a container in order to avoid spilling oil. (5) and place it on stand (a) by operating the bucket
IMPORTANT: Cap the open ends in case the hoses cylinder. Stop the engine.
and pipes have been disconnected. In addition, 3. Remove front fender (4). (Refer to W3-22-1.)
Removal
W5-2-1-1
Group 2 Cylinder
Section A 1
6
4
2
5
3
85Z7B-W5-02-01-01 85Z7B-W5-02-01-02
9. Disconnect another lift arm cylinder (1) from lift arm

d CAUTION: Lift arm cylinder (1) weight: 175 kg
(386 lb)
(3) in the same way as step 4 to step 7.
10. Start the engine. Retract lift arm cylinders (1) (2
4. Attach nylon slings onto lift arm cylinder (1). Hoist
used).
and hold lift arm cylinder (1).
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.
personal injury.
j : 10 mm
j : 24 mm
fNOTE: Pin (7) weight: 17 kg (37 lb)
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
Group 2 Cylinder
2, 3, 4
85Z7B-W5-02-01-03


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
Group 2 Cylinder
1 Section A
1
7
2
2 6
5
A
4
85Z7B-W5-02-01-05
85Z7B-W5-02-01-04
14. Remove grease fitting (4). 16. Remove lift arm cylinder (1) from front frame (2).
j : 10 mm 17. Remove another lift arm cylinder (1) in the same

personal injury.
j : 24 mm
W5-2-1-4
Group 2 Cylinder
1 Section A
1
7
2
2 6
5
A
4
85Z7B-W5-02-01-05
85Z7B-W5-02-01-04
Installation
wear, and damage of all pins and bushings before dCAUTION: Metal fragments may fly off when
installing lift arm cylinder (1). (Refer to W2-2-1.)
personal injury.
installing the pin. In addition, apply anti-rust oil to 2. Install pin (3) by using a hammer.
the inner circumference of the boss. 3. Install washers (5, 7) and bolt (6).
IMPORTANT: Check pins and bushings. If any
damage is observed, replace it. (Refer to W5-1-4.) j : 24 mm
dCAUTION:
(386 lb)
Lift arm cylinder (1) weight: 175 kg m : 210 N·m (155 lbf·ft)
4. Install grease fitting (4). Apply grease to the grease
1. Attach nylon slings onto lift arm cylinder (1). Hoist fitting (4).
lift arm cylinder (1). Fit the hole at cylinder bottom
side to the cylinder mounting hole of front frame j : 10 mm
(2).
5. Set wooden blocks between lift arm cylinder (1) and
front frame (2). Support lift arm cylinder (1).
W5-2-1-5
Group 2 Cylinder
2, 3, 4
85Z7B-W5-02-01-03
7. 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)

8. Connect other hoses (1) (2 used) in the same way as
step 8.
W5-2-1-6
Group 2 Cylinder
Section A 1
6
4
2
5
3
85Z7B-W5-02-01-01 85Z7B-W5-02-01-02
9. Remove the wires from the rod holes of the lift

arm cylinder (1). Start the engine. Extend lift arm dCAUTION: Metal fragments may fly off when
cylinder (1) and fit the cylinder rod hole to the
mounting hole of lift arm cylinder (3). Stop the such as goggles, hard hat, etc. in order to prevent
engine. personal injury.
10. Remove wooden blocks installed in step 5.
j : 24 mm
m : 210 N·m (155 lbf·ft)

13. Install grease fitting (8). Apply grease to grease
fitting (8) before installing.
j : 10 mm
W5-2-1-7
Group 2 Cylinder
1 2 3
4
4
a- Stand
85Z7B-W5-01-01-01
a
14. Install front fender (4). (Refer to W3-22-1.)

as step 9 thru step 14.
1.)
W5-2-1-8
Group 2 Cylinder
Removal and Installation of Bucket Cylinder
Detail A 1 2 3
WNEK50-05-02-008
WNEK50-05-02-007

Removal
(3) and shim (2) from bucket cylinder (4).
j : 19 mm
W5-2-2-1
Group 2 Cylinder
View A
3 4 2
85Z7B-W5-02-02-01
WNEK50-05-02-009
View B
9 6, 7
3. Remove bolts, washers (3) (2 used) and nuts (4) (2

used). Remove bracket (2) from bucket cylinder (1).
j : 17 mm
4. Remove bolt, washer (10), nut (11), and clip (12). 10, 11, 12 5
j : 17 mm
8
5. Disconnect connectors (13) (2 used). 13
85Z7B-W5-02-02-02
and U-bolts (8) (2 used). Remove proximity switch
assembly (5) from pipe (9).
j : 17 mm
W5-2-2-2
Group 2 Cylinder
Section A
3
4
A
2
5
2
6
85Z7B-W5-02-02-03
WNEK50-05-02-012

d CAUTION: Bucket cylinder (1) weight: 175 kg
(386 lb) 10. Remove bucket cylinder (1) from bell crank (2).
7. Attach nylon slings onto bucket cylinder (1). Hoist 11. Start the engine. Retract bucket cylinder (1).
and hold bucket cylinder (1).
12. Stop the engine. In order not to extend the rod, pass
d CAUTION: Pin (4) weight: 20 kg (45 lb) wires through the rod hole of bucket cylinder (1)
and secure the rod to the cylinder tube.
personal injury.
j : 24 mm
W5-2-2-3
Group 2 Cylinder
3, 4, 5
2 WNEK50-05-02-014


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
Group 2 Cylinder
2, 3
WNEK50-05-02-015
j : 17 mm
j : 17 mm
j : 14 mm
W5-2-2-5
Group 2 Cylinder
Section A
1 2
1 3 2
A
7
85Z7B-W5-02-02-04
WNEK50-05-02-016

personal injury.
j : 24 mm
20. Remove bucket cylinder (1) from front frame (2).
W5-2-2-6
Group 2 Cylinder
1 2
Section A
A
1 3 2
7
WNEK50-05-02-016 85Z7B-W5-02-02-04
Installation
wear, and damage of all pins and bushings before such as goggles, hard hat, etc. in order to prevent
installing bucket cylinder (1). (Refer to W2-2-1.) personal injury.
IMPORTANT: Check pins and bushings. If any 3. Install pin (4) by using a hammer.
damage is observed, replace it. (Refer to W5-1-4.)
circumference of bushings and dust seals when j : 24 mm
installing the pin. In addition, apply anti-rust oil to
the inner circumference of the boss. m : 210 N·m (155 lbf·ft)
dCAUTION:
(386 lb)
Bucket cylinder (1) weight: 175 kg
1. Attach nylon slings onto bucket cylinder (1). Hoist

bucket cylinder (1). Fit the hole at cylinder bottom
(2).
2. Install shims (3) to the cylinder bottom hole. Adjust
the clearance between bucket cylinder (1) and front
frame (2) within 1.5 mm (0.059 in.).
W5-2-2-7
Group 2 Cylinder
2, 3
5 WNEK50-05-02-015
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
Group 2 Cylinder
B 1
View A 2
3, 4, 5
a- 35 ° WNEK50-05-02-018
2
View B 1
b
A
WNEK50-05-02-014
b- 25 ° WNEK50-05-02-019

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)

11. Connect hose (1) in the same way as step 10.
W5-2-2-9
Group 2 Cylinder
1 Section A
A
9
1
5
2 2
6
85Z7B-W5-02-02-03
WNEK50-05-02-012
12. Remove the wires from the rod holes of bucket

cylinder (1). Start the engine. Extend bucket dCAUTION: Metal fragments may fly off when
cylinder (1) and fit the cylinder rod hole to the
mounting hole of bell crank (2). Stop the engine. such as goggles, hard hat, etc. in order to prevent
personal injury.
13. Install shims (3) to the cylinder bottom hole. Adjust
the clearance between bucket cylinder (1) and bell
crank (2) within 1.5 mm (0.059 in.). 15. Install washers (5, 7) and bolt (6).
j : 24 mm
m : 210 N·m (155 lbf·ft)

W5-2-2-10
Group 2 Cylinder
View A
3 4 2
85Z7B-W5-02-02-01
WNEK50-05-02-009
View B
9 6, 7
17. Temporary install the proximity switch assembly (5)

to pipe (9) with U-bolts (8) (2 used), washers (7) (4
used), and nuts (6) (4 used).
10, 11, 12 5
19. Secure harness (14) with clip (12), bolt, washer (10),
and nut (11). 8
14 13
j : 17 mm 85Z7B-W5-02-02-02
m : 50 N·m (37 lbf·ft)

20. Install bracket (2) to bucket cylinder (1) with nuts (4) 5
(2 used) and bolts, washers (3) (2 used).
5
j : 17 mm
m : 50 N·m (37 lbf·ft)

a b
21. Adjust the mounting position of proximity switch
assembly (5). (Refer to Operator's Manual.) After 2 2 WNDB-05-02-003
adjustment, tighten nuts (6) (4 used). a- 5 to 10 mm (0.2 to 0.4 in.) b- 100 mm (3.9 in.) (When the
bucket is horizontal on the
j : 17 mm ground) (Reference)
m : 20 N·m (15 lbf·ft)
W5-2-2-11
Group 2 Cylinder
Detail A
A 1 2 3
5
6
WNEK50-05-02-008
WNEK50-05-02-007
22. Install shim (2) and guard (3) to bucket cylinder (4) 26. Adjust the number of shims (2) and washers (5) to
with bolts, washers (1) (4 used). be installed according to the clearance between
bucket cylinder (4) and rubber cushion (6).
j : 19 mm
m : 90 N·m (66 lbf·ft)

fNOTE: Shim (2) thickness: 0.5 mm (0.02 in.), Washer (5)
thickness: 2.3 mm (0.091 in.)
23. Ensure that the clearance between bucket cylinder 27. Install washer (5) and rubber cushion (6) to guard
(4) and cushion rubber (6) is 5 to 10 mm (0.2 to 0.4 (3) with screw (7).
in.). If clearance is not 5 to 10 mm (0.2 to 0.4 in.),
adjust the clearance by following steps 24 to 28. 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)
(3) and shim (2) from bucket cylinder (4).
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)
1.)
W5-2-2-12
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
5
4
3
2
WNEC-05-02-025
W5-2-3-1
Group 2 Cylinder
Bucket Cylinder
21
19
15
18
17
16
15
13
14
13
20
11
10
9
8
7
6
4 5
3 12
2
1
WNEC-05-02-026
1- Cylinder Rod 7- O-Ring 12- Set Screw 17- Piston

2- Dust Seal 8- Backup Ring 13- Backup Ring (2 Used) 18- Wear Ring
3- U-Ring 9- Bushing 14- O-Ring 19- Nut
4- Buffer Seal 10- Retaining Ring 15- Piston Ring (2 Used) (Lift Arm 20- Set Screw
5- Cylinder Head 11- Socket Bolt (14 Used) (Lift Arm Cylinder: 1 Used) 21- Cylinder Tube
6- O-Ring Cylinder: 12 Used) 16- Seal Ring
W5-2-3-2
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.
f NOTE: The bucket cylinder is explained here. 4. Secure cylinder rod (1) on the special tool (ST 5908)
for cylinder. Put the matching marks on the ends of
dlb)
CAUTION: Lift arm cylinder weight: 175 kg (386
cylinder rod (1), piston (17), and nut (19).
Bucket cylinder weight: 175 kg (386 lb)

1. Hoist the cylinder. Secure the cylinder on a
workbench horizontally. Drain hydraulic oil from the
cylinder.

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).
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
Group 2 Cylinder
5. Cut away the crimped part by using a hand drill. 7. Remove the piston (17) assembly from cylinder rod
Remove set screw (20). (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
using a punch at two places after installing them.
l : 4 mm ST 3386: 96 mm (3.78 in) (Lift arm cylinder)
6. Remove nut (19) from cylinder rod (1) by using the ST 3380: 130 mm (5.12 in) (Bucket cylinder)
special tool (ST 5908) for cylinder and the special 8. Remove piston rings (15) (2 used) (lift arm cylinder:
tool for nut. 1 used), wear ring (18), seal ring (16), backup rings
Special Tool for Nut: (13) (2 used), and O-ring (14) from piston (17).
ST 3393: 97 mm (3.82 in) (Lift arm cylinder) 9. Remove the cylinder head (5) assembly from
cylinder rod (1).
ST 3392: 111 mm (4.37 in) (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).

W158-04-02-022
W5-2-3-4
Group 2 Cylinder
Assembly of Lift Arm Cylinder and Bucket Cylinder
Lift Arm Cylinder
11
12
5
21 1
A
B
4 6 7, 8 15 16 18 13, 14, 13
3
2 9 17 19, 20
10
Detail A Detail B
W4GD-04-02-004
W5-2-3-5
Group 2 Cylinder
Bucket Cylinder
5 21 1
4 6 7, 8 13, 14, 13
3 9
11 2
10 15 16 18 15 19 20
12
17
Detail D Detail E
View C
WNEC-05-02-035
1- Cylinder Rod 7- O-Ring 12- Set Screw 17- Piston

2- Dust Seal 8- Backup Ring 13- Backup Ring (2 Used) 18- Wear Ring
3- U-Ring 9- Bushing 14- O-Ring 19- Nut
4- Buffer Seal 10- Retaining Ring 15- Piston Ring (2 Used) (Lift Arm 20- Set Screw
5- Cylinder Head 11- Socket Bolt (14 Used) (Lift Arm Cylinder: 1 Used) 21- Cylinder Tube
6- O-Ring Cylinder: 12 Used) 16- Seal Ring
W5-2-3-6
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
Special Tool for Bushing (Rod Outer Diameter):
using the special tool B.
ST 3389: 85 mm (3.35 in) (Lift arm cylinder)
Special Tool A (Tube Inner Diameter):
IMPORTANT: Check the direction to install.
2. Install U-ring (3) and buffer seal (4) to cylinder head
(5). Special Tool B (Tube Inner Diameter):
3. Install dust seal (2) to cylinder head (5) by using the ST 3388: 130 mm (5.12 in) (Lift arm cylinder)
special tool and a plastic hammer. ST 3382: 165 mm (6.50 in) (Bucket cylinder)
Special Tool for Dust Seal (Rod Outer Diameter): 6. Install wear ring (18), piston rings (15) (2 used) (lift
ST 3390: 85 mm (3.35 in) (Lift arm cylinder) arm cylinder: 1 used), O-ring (14), and backup rings
(13) (2 used) to piston (17).
7. Install the cylinder head (5) assembly to cylinder rod
4. Install O-rings (6, 7), backup ring (8), and retaining (1).
ring (10) to cylinder head (5).
Special Tool for Cylinder Head (Rod Outer Diameter):
W5-2-3-7
Group 2 Cylinder
8. Fit the matching marks before disassembling and 10. Apply LOCTITE #243 or equivalent to set screw (20).
install the piston (17) assembly to cylinder rod (1) by Install set screw (20) to nut (19). Crimp set screw (20)
using the special tool (ST 5908) for cylinder and the by using a punch (2 places).
special tool for piston.
l : 4 mm
m : 15±1.5 N·m (11±1.1 lbf·ft)
ST 3380: 130 mm (5.12 in) (Bucket cylinder) dcenter
CAUTION: Fit the cylinder rod (1) assembly to the
of cylinder tube (24) and install it in order
m : 980±98 N·m (720±72 lbf·ft) not to damage the rings.
9. Fit the matching marks before disassembling and 11. Secure cylinder tube (21) on a workbench
install nut (19) to cylinder rod (1) by using the horizontally. Install the cylinder rod (1) assembly
special tool (ST 5908) for cylinder and the special into cylinder tube (21).
tool for nut: 12. Apply LOCTITE #243 or equivalent to socket bolts
Special Tool for Nut: (11) (14 used) (lift arm cylinder: 12 used). Install
cylinder head (5) to cylinder tube (21) with socket
ST 3393: 97 mm (3.82 in) (Lift arm cylinder) bolts (11) (14 used) (lift arm cylinder: 12 used).
l : 14 mm
m : 1860±186 N·m (1380±138 lbf·ft)
m : 344 to 363 N·m (254 to 268 lbf·ft)

W158-04-02-022
W5-2-3-8
MEMO
MEMO

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PART NO.

Service Manual consists of the following separate Part No.

Precautions for Disassembling and  If a part or component cannot be removed after

Precautions for Using Floating Seal 1

1. In general, replace the floating seal with a new one

2. If incorrectly assembled, oil leakage or damage

a - Correct e - Sliding Surface

Precautions for Using Nylon Sling

dCAUTION: If a load is lifted with a damaged

2. Before using a nylon sling, visually check the nylon

a - Broken Sewing Thread

Maintenance Standard Terminology

Tightening Bolts and Nuts

dCAUTION: Use tools appropriate for the work

Specified Tightening Torque Chart

IMPORTANT: The following items are applied to both

a - Equally tighten upper and b - Tighten diagonally c - Tighten from center

Precautions for Spilt Flange

Nut and Bolt Locking

a- Bend along edge sharply b- Do not bend it round

b - Male Union Joint c - Female Union Joint

Wrench Size Tightening Torque

fNOTE: Tightening torque of 37 ° male coupling without

 Precautions for use

O-ring Seal Joint

IMPORTANT: Check that the thread pitch and thread

Wrench Size Tightening Torque

T-Bolt Type Band Clamp:

Worm Gear Type Band Clamp:

dCAUTION: When replacing the hoses, use only

than genuine Hitachi hoses may cause oil leaks,

a - Rubbing Against Each Other

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Surfaces to Be Painted Painting Colour

Bleed Air from the Hydraulic System.

Bleed Air from the Fuel System

1. Loosen air bleed plug (1), operate feed pump (2)

Bleeding Air from Brake (Axle)

dCAUTION: If air is mixed in the service brake

fNOTE: Perform this work on all wheels (4 places) by two

1. Set the parking brake switch of front console to the

5. Repeat steps 3 to 4 until flesh hydraulic oil without

m : 10 N·m (7.4 lbf·ft)

dCAUTION: After completing above air bleeding

Preparations for Inspection and Maintenance

dCAUTION: If ride control switch (2) is in the AUTO

dCAUTION: If the machine is unexpectedly moved,

Securing work place and work staffs MNEC-07-001

Before starting work, park the machine in a firm and large

Inspection and Maintenance Position

1. Park the machine on a level and solid surface.

3. Set the control lever lock switch to the lock position.

9. Turn key switch (6) to the OFF position. Stop the