Work Shop Manual

PART NO.
W8R7-E-01
EH4000AC
Workshop Manual
RIGID DUMP TRUCK

WORKSHOP MANUAL
EH
4000AC
Rigid Dump Truck
URL:http://www.hitachi-c-m.com
Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TO8R7-E
Technical Manual (Troubleshooting) : Vol. No.TT8R7-E
PRINTED IN JAPAN (K) 2011. 03 Workshop Manual : Vol. No.W8R7-E
INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
ADDITIONAL REFERENCES
• Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.
MANUAL COMPOSITION
• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
W8R7-E-01(20160803) IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 0.10197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
W8R7-E-01(20160803) IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in

this manual, be alert to the potential for personal in-
jury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001 SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating the

degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situa-

tion which, if not avoided, will result in death or seri-
ous injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
• Some safety signs don’t use any of the designated
signal words above after the safety alert symbol are
occasionally used on this machine.
SA-1223
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates
a situation which, if not avoided, could result in damage
to the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
W8R7-E-01(20160803) SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine

and all safety messages in this manual.
• Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).
SA-003
• Learn how to operate the machine and its controls cor-

rectly and safely.
• Allow only trained, qualified, authorized personnel to

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may im-

pair its function and/or safety and affect machine life.
• The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operat-
ing or performing maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached
on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to cope SA-437
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near
your telephone.
004-E01A-0437
W8R7-E-01(20160803) SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment appro-

priate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438
Be sure to wear the correct equipment and clothing for

the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause impairment

or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection, be sure to cover all

points described in the “PRE-START INSPECTION”
chapter in the operator’s manual.
SA-435
007-E01A-0435
W8R7-E-01(20160803) SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work boots
the operator’s foot may slip off the pedal, possibly
resulting in a personal accident.
• Don’t leave parts and/or tools lying around the op-
erator’s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possi-
bly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives away
from the machine.
• After using the ashtray, always cover it to extinguish
the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may ex-
plode.
524-E01A-0000
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face

the machine and maintain a three-point contact with
the steps and handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps,
and handrails when leaving the machine. SA-439
• Do not step or climb on surfaces, which are not in-

tended for walking. Step only on the areas provided
with the slip resistant surfaces.
008-E01A-0439
W8R7-E-01(20160803) SA-4
SAFETY
ADJUST THE OPERATOR’S SEAT
• A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the

operator for the machine.
• The operator should be able to fully depress the ped-
als and to correctly operate the steering wheel with
his back against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the mirror position so that the best rear visibil- SA-462
ity is obtained from the operator’s seat. If the mirror is

broken, immediately replace it with a new one.
009-E01A-0378
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning ma-
chine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item
is damaged or worn, replace the seat belt or compo-
nent before operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation SA-237
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E01A-0237
W8R7-E-01(20160803) SA-5
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm

the location of bystanders before moving, or operat-
ing the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, or operating the
machine in congested areas. Coordinate hand sig- SA-1598
nals before starting the machine.

• Use appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
• Always keep the cab door closed while operating the
machine.
011-E01A-0426
HANDLE STARTING AIDS SAFELY
Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and ca-
bles.
• Remove container from machine if engine does not
need starting fluid.
SA-293
W8R7-E-01(20160803) SA-6
SAFETY
OPERATE ONLY FROM OPERATOR’S SEAT
• Inappropriate engine starting procedures may cause the

machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only from the operator’s seat.

• NEVER start the engine while standing on the plat-
form.
• Do not start engine by shorting across starter termi-
nals.
• Before starting the engine, confirm that shift lever and
hoist lever are in neutral.
• Before starting the engine, confirm the safety around
the machine and sound the horn to alert bystanders.
012-E01B-0444 SA-1599
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow

the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be in the operator’s seat so that
the machine will be under control when the engine
starts. Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway ma-

chine.
S013-E01A-0032
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the ma-
chine.
• Only allow the operator on the machine. Keep riders

off.
• Riders also obstruct the operator’s view, resulting in
the machine being operated in an unsafe manner.
• If there are riders, do not allow riders other than on
SA-1600
the trainer's seat. Riders should also have their seat
belt fastened.
014-E01B-0379
W8R7-E-01(20160803) SA-7
SAFETY
AVOID INJURY CAUSED BY HIGH TENSION
ELECTRIC SHOCK
• Never attempt to open any electrical component covers

displaying a decal with the words “HIGH VOLTAGE.”
You may receive an electric shock, possibly resulting in
personal injury or death.
• Never attempt to touch or grab any high tension electri-
cal components or the power cable with wet hands. You
may receive an electric shock, possibly resulting in per-
sonal injury or death.
SA-112
INVESTIGATE JOB SITE BEFOREHAND
• When working on a road shoulder, the machine could tip

over, possibly resulting in serious injury or death.
• Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
• Make a work plan. Use machines appropriate to the
work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder,
employ a signal person as required. SA-1601
• When the footing is weak, reinforce the ground before

starting work.
• When working on frozen ground, be extremely alert.
As ambient temperatures rise, footing becomes loose
and slippery.
• Beware the possibility of fire when operating the ma-
chine near flammable objects such as dry grass.
• Driver should try to travel the road once to under-
stand potential danger.
015-E01A-0380
PROVIDE SIGNALS FOR JOBS INVOLVING

MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, pro-

vide signals commonly known by all personnel involved.
Also, appoint a signal person to coordinate the job site.
Make sure that all personnel obey the signal person’s
directions.
018-E01A-0481
SA-481
W8R7-E-01(20160803) SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the shift

lever direction corresponds to the direction you wish to
drive.
• Be sure to detour around any obstructions.

• Avoid driving over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Don’t allow personnel to stay around the SA-1602
machine while driving.
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or overturn. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
safe operation.
019-E01C-0492 SA-1603
DRIVE ON SNOW SAFELY
• Beware of the possibility of slipping or overturning the

machine when traveling on frozen snow surfaces.
• The machine may slip more easily than expected on
frozen snow surfaces even if the inclination is small.
Reduce speed when driving. Avoid fast starts, stops
and quick turns.
• Road shoulder and/or set-up utilities covered with
snow are difficult to locate. Be sure where they are
before removing snow.
• Avoid applying the brake for quick stops on snow.
SA-1578
W8R7-E-01(20160803) SA-9
SAFETY
WHEEL MAINTENANCE
• Explosive separation of a tire and rim parts can cause

serious injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT
inflate tire above the recommended pressure.
• When inflating tires, use a clip-on chuck and exten-
sion hose long enough to allow you to stand to one
side and not in front of or over the tire assembly. Use
a safety cage if available.
• Inspect tires and wheels daily. Do not operate with
low pressure, cuts, bubbles, damaged rims, or miss-
ing lug bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. SA-249
Heat from welding could cause an increase in pres-

sure and may result in tire explosion.
521-E02A-0249
AVOID INJURY FROM ROLLAWAY

ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the dump body to the frame.
• Place the shift lever in the Neutral position and apply
the parking brake.
• Run the engine at slow idle speed without load for 5
SA-1579
minutes to cool down the engine.

• Stop the engine and remove the key from the key
switch.
• Chock the wheels if you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-1580
W8R7-E-01(20160803) SA-10
SAFETY
AVOID INJURY FROM BACK-OVER ACCI-
DENTS
• If any person is present near the machine when backing

the machine, the machine may hit or run over that per-
son, resulting in serious injury or death.
To avoid back-over accidents:

• Always look around BEFORE YOU BACK UP THE
MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING SA-1581
INTO THE WORK AREA. USE THE HORN OR

OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF
YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE
SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local regula-
tions, when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings
SA-1582
used on the job and confirm who has the responsibil-
ity for signaling.
• Keep windows, mirrors, and lights clean and in good
condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494
KEEP PERSON CLEAR FROM WORKING

AREA
• A person may be hit severely by the machine and/or

may be crushed against another object, resulting in se-
rious injury or death.
• Keep all persons clear from the area of operation and

machine movement.
• Before operating the machine, set up barriers to the
sides and rear area of the working area to prevent
anyone from entering the work area.
022-E01A-0386 SA-1583
W8R7-E-01(20160803) SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE --- SERIOUS OR FATAL CRUSHING INJU-
RIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
THEREFORE, HOLD FIRMLY ONTO THE STEERING
WHEEL IF THE MACHINE SHOULD TIP OR ROLL
OVER. DO NOT JUMP.
FASTEN YOUR SEAT BELT

• The cab is designed for the protection of the operator
and it meets the requirements for rollover protection
structures (ROPS) according to the adopted standard
for this machine.
IMPORTANT: Never make any unauthorized modifica-

tions or alterations to the Rollover Pro- SA-1584
tective Structure (ROPS) such as; weld-

ing on fire extinguisher brackets, CB
antenna brackets, or fire suppression
systems. Such unauthorized modifica-
tions will affect the structural limits of
the ROPS and will void the certification
and could result in loss of protection to
the operator.
The Rollover Protective Structure (ROPS) has been certi-

fied to meet specified requirements according to ISO
3471.
• The danger of tipping is always present when operating

on a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Keep the machine a safe distance from the edge of

cliffs and slide areas
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when driving on grades.
• Use the seat belt during operation.
• When operating the machine, both doors should be
closed at all times.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to be-
come soft and make ground travel unstable.
W8R7-E-01(20160803) SA-12
SAFETY
PROTECT AGAINST FALLING STONES AND
DEBRIS
• Stay in your cab while truck is being loaded. Stepping

out of the cab could result in possible injury.
• Do not place your head and/or arms outside of the
window.
NOTE: The cab is for the protection of the operator

and it meets the requirements for Fal-
ling-Object Protective Structure (FOPS) ac-
cording to the adopted standard for this ma-
chine.
SA-1585
OPERATE WITH CAUTION
• If the dump body (Vessel) of the machine hits against an

overhead obstacle, such as a bridge, both the machine
and the overhead obstacle will be damaged, and per-
sonal injury may result as well. Do not drive the machine
while the dump body is raising or raised.
• Take care to avoid hitting overhead obstacles with the

dump body.
SA-1604
AVOID POWER LINES
• Serious injury or death can result if the machine or

dump body are not kept a safe distance from electric
lines.
• When operating near an electric line, NEVER move

any part of the machine or load closer than 3 m plus
twice the line insulator length.
• Check and comply with any local regulations that may
apply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-1586
029-E01A-0381
W8R7-E-01(20160803) SA-13
SAFETY
PRECAUTIONS FOR LIGHTENING
• The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop
operation, and lower the dump body to the frame.
Evacuate to a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed
safety devices are found, operate the machine only
after repairing them.
SA-1798
AVOID OVERLOADING
Do not exceed the maximum payload. The overloading

raises the center of gravity position and may cause over-
turning or long braking distance. It is very dangerous and
serious injury or death may result.
SA-1797
W8R7-E-01(20160803) SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body, se-
rious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from any working area before
striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a level surface. When parking on a
grade cannot be avoided, chock blocks must also be
used for extra security.
• Lower dump body to the frame rail.
• Place shift lever in the NEUTRAL position.
• Apply the parking brake to ensure that the parking
brake is holding the machine.
• Run engine at slow idle speed without load for 5 min-
utes. SA-1587
• Make sure the hoist lever is in the Float position.

• Check that all switches and controls are in the OFF
position.
• Turn key switch to the OFF position to stop engine.
• Remove the key from the key switch.
• Turn the Battery Disconnect Switch to the OFF posi-
tion to prevent battery consumption.
• Close windows and cab doors.
• Lock all access doors and compartments.
• Park a reasonable distance from other machines.
033-E08B-0390
W8R7-E-01(20160803) SA-15
SAFETY
PREVENT UNINTENDED MACHINE MOVE-
MENT
Be careful not to accidentally actuate controls when

co-workers are present.
Ensure that the dump body is lowered during work inter-

ruptions.
Place shift lever in neutral，engage park brake and stop
engine before allowing anyone to approach the machine.
Follow these same precautions before standing up, leav- OFF ON

ing the operator's seat, or exiting the machine.
M8R8-01-054
HANDLE FLUIDS SAFELY − AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly re-
sulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flam- SA-018
mable.
• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
W8R7-E-01(20160803) SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the dump body to the frame. SA-028
3. Place shift lever in the NEUTRAL position.

4. Apply the parking brake to ensure that the parking
brake is holding the machine.
5. Run the engine at slow idle speed without load for 5
minutes.
6. Make sure the hoist lever is in the FLOAT position.
7. Check that all switches and controls are in the OFF
position.
8. Turn the key switch to the OFF position to stop en-
gine.
9. Ensure hydraulic system pressure relieves to tank.
10. Remove the key from the switch.
11. Attach a “Do Not Operate” tag to the steering wheel.
12. Allow the engine to cool.
• If a maintenance procedure must be performed with SA-527
the engine running, do not leave the machine unat-

tended.
• If the dump body must be raised, securely support the
dump body by using the prop pins.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that
part in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable de-
tergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (–) before making
adjustments to electrical systems or before perform-
ing welding on the machine.
500-E02B-0497
W8R7-E-01(20160803) SA-17
SAFETY
• Sufficiently illuminate the work site. Use a mainte-
nance work light when working under or inside the
machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious in-

jury.
• Before performing any work on the machine, attach a

“Do Not Operate” tag on the steering wheel.
This tag is available from your authorized dealer.
501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without securing

the machine first.
• Always lower the dump body to the frame before you

work on the machine. If you must work on a raised
dump body, securely support the dump body by using
the prop pins.
• If you must work on a lifted machine or dump body,
securely support the machine or dump body. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not be-
come entangled when working around rotating parts.
502-E01A-0026
SA-026
W8R7-E-01(20160803) SA-18
SAFETY
PREVENT PARTS FROM FLYING
• Accumulators and hydraulic components are under high

pressure. Failure to follow the precautions below may
result in serious injury, blindness, or death.
• Do not attempt to remove plugs or hoses until pres-

sure is fully relieved.
• As pieces may fly off, be sure to keep body and face
away from accumulator and hydraulic components to
avoid injury.
• Travel reduction gears are under pressure.
SA-344
• As pieces may fly off, be sure to keep body and face

away from AIR RELEASE PLUG to avoid injury.
GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen AIR
RELEASE PLUG to release pressure.
• Tires are under pressure.
When removing the air valve, as pieces may fly off, be
sure to keep body and face away from tires to avoid in-
jury.
503-E01B-0344
PREVENT BURNS
Hot spraying fluids:

• After operation, engine coolant is hot and under pres-
sure. Hot water or steam is contained in the engine, ra-
diator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water. DO

NOT remove the radiator cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow
all pressure to be released before removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be sure

to release all pressure before removing the cap.
Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
• Wait for the oil and components to cool before starting

any maintenance or inspection work.
SA-225
505-E01B-0498
W8R7-E-01(20160803) SA-19
SAFETY
REPLACE RUBBER HOSES PERIODICALLY
• Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspec-
tion alone.
• Periodically replace the rubber hoses. (See the page

of “Periodic replacement of parts” in the operator’s
manual).
SA-019
• Failure to periodically replace rubber hoses may cause

a fire, fluid injection into skin, or the dump body to fall on
a person nearby, which may result in severe burns, gan-
grene, or otherwise serious injury or death.
S506-E01A-0019
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under pressure

can penetrate the skin or eyes causing serious injury,
blindness or death.
• Avoid this hazard by relieving pressure before dis-

connecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care
to protect hands and body from high-pressure fluids. SA-031
Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
507-E03A-0499
SA-044
W8R7-E-01(20160803) SA-20
SAFETY
PREVENT FIRES
Check for Oil Leaks:

• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-cooler
flange bolts.
• Tighten, repair or replace any missing, loose or dam-
aged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
SA-019
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc..
Clean up Flammables:
• Spilled fuel, oil, antifreeze fluid and window washer fluid,
and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated flam-
mables immediately.
Check Key Switch:

• If fire breaks out, failure to stop the engine will escalate
fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm
that the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019
W8R7-E-01(20160803) SA-21
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air in-
side the hydraulic tank will escalate fire, hampering fire
fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that engine stops and that pressurized air
inside the hydraulic oil tank is released (a hissing
sound should be heard).
• If any abnormalities are found, be sure to repair them
before operating the machine.
Check Heat Shields:

• Damaged or missing heat shield may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the follow-

ing way:
• Stop the engine by turning the key switch to the OFF
position or pushing the emergency stop switch if there
is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab doors can not be opened,
break the left or right window panes with the emergency
evacuation hammer to escape from the cab. Refer the
explanation pages on the Emergency Evacuation
Method.
518-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe ex-
tension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the
area.
509-E01A-0016 SA-016
W8R7-E-01(20160803) SA-22
SAFETY
PRECAUTIONS FOR WELDING AND GRIND-
ING
• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grind-
ing.
• After finishing welding and grinding, recheck that there SA-818
are no abnormalities such as the area surrounding the

welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED FLUID

LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to your-
self and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable mate-
rials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem-
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc.. SA-030
AVOID APPLYING HEAT TO LINES CON-

TAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain

flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
W8R7-E-01(20160803) SA-23
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
• Remove paint before welding or heating:

SA-029
1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent
or paint stripper containers and other flammable ma-
terial from area. Allow fumes to disperse at least 15
minutes before welding or heating.
511-E01A-0029
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung
cancer.
• Depending on the work site conditions, the risk of in-

haling asbestos fiber may exist. Spray water to pre-
vent asbestos from becoming airborne. Don’t use
compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask rated SA-029
to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during opera-
tion.
• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.
W8R7-E-01(20160803) SA-24
SAFETY
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from

the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 °C (60 °F) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of SA-032
the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
• Be sure to wear eye protection when checking elec-

trolyte specific gravity.
512-E01B-0032
SERVICE AIR CONDITIONING SYSTEM

SAFELY
• If spilled onto skin, refrigerant may cause a cold contact

burn.
• Refer to the instructions described on the container

for proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
W8R7-E-01(20160803) SA-25
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides spe-

cific details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available
only in English) on chemical products used with your
machine.
515-E01A-0309
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the envi-

ronment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Air conditioning refrigerants escaping into the air can SA-226
damage the Earth’s atmosphere. Government regula-

tions may require a certified air conditioning service
center to recover and recycle used air conditioning
refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling cen-
ter, or from your authorized dealer.
516-E01A-0226
W8R7-E-01(20160803) SA-26
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Periodic Replacement of Parts
SECTION 2 BODY
Group 1 Cab
Group 2 Engine / Alternator
WORKSHOP MANUAL
Group 3 Pump Device
Group 4 Drive Device
Group 5 Front Axle
Group 6 Tire / Rim / Air Pressure
Group 7 Front Brake
Group 8 Brake Valve
Group 9 Brake Accumulator
Group 10 Steering System
Group 11 Frame Suspension
SECTION 3 HOIST DEVICE
Group 1 Hoist Control Valve
Group 2 4-Unit Proportional Control Sole-
noid Valve
Group 3 Hoist Cylinder
Group 4 Dump Body
SECTION 4 AC DRIVE CONTROL
DEVICE
Group 1 Control Cabinet
Group 2 Grid Box
All information, illustrations and speci- Group 3 Alternator Cooling Blower
fications in this manual are based on
the latest product information available
Group 4 Wheel Motor Cooling Blower
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2008
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
W8R7-E-01(20160803)
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Machine Specifications Group 1 Engine
Group 2 Component Location Group 2 Alternator
Group 3 Component Specifications Group 3 Control Cabinet
Group 4 Pump Device
SECTION 2 SYSTEM Group 5 Travel Device
Group 1 Control System Group 6 Brake Device
Group 2 Travel System Group 7 Steering Device
Group 3 Hydraulic System Group 8 Suspension Device
Group 4 Electrical System Group 9 Hoist Device
Group 5 Other System
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 PERFORMANCE TEST・ SECTION 5 TROUBLESHOOTING
Adjustment Group 1 General
Group 1 Performance Test Group 2 Component Location
Group 2 Performance Standard Group 3 Troubleshooting A
Group 3 Engine Performance Test Group 4 Troubleshooting B
Group 4 Main Performance Test Group 5 Troubleshooting C
Group 5 Hydraulic Equipment Group 6 Troubleshooting D
Group 7 Electrical System Inspection
W8R7-E-01(20160803)
SECTION 1
GENERAL
⎯ CONTENTS ⎯
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling .......................................... W1-1-1
Maintenance Standard Terminology......... W1-1-7
Group 2 Tightening
Tightening Torque Specifications ............. W1-2-1
Torque Chart............................................ W1-2-2
Piping Joint.............................................. W1-2-5
Group 3 Periodic Replacement of Parts

Periodic Replacement of Parts ................ W1-3-1
W8R7-E-01(20160803) 8R7W-1-1
(Blank)
W8R7-E-01(20160803) 8R7W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. wheel reduction device.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassembling instructed.
/ assembling procedures beforehand, to help avoid • If a part or component cannot be removed after
incorrect disassembling of components as well as removing its securing nuts and bolts, do not
personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W8R7-E-01(20160803) W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and in-
replace part. stallation of the pump, travel device cylinder is done,
• Dirt or debris on the contact or sliding surfaces bleed air from the hydraulic system in the following
may shorten the service life of the machine. Take procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the cylinder is operated with air
• Be sure that liquid-gasket-applied surfaces are
trapped in the cylinder tube, dam-
clean and dry.
age to the cylinder may result.
• If an anti-corrosive agent has been used on a
Be sure to bleed air before starting
new part, be sure to thoroughly clean the part to
remove the agent. the engine.
• Utilize matching marks when assembling.
• Be sure to use the designated tools to assemble • Bleeding Air from Hydraulic Pump
bearings, bushings and oil seals.
• Keep a record of the number of tools used for • Remove the air bleeding plug from the top of the
disassembly/assembly. After assembling is pump and fill the pump housing with hydraulic oil.
complete, count the number of tools, so as to • After the pump housing is filled with hydraulic oil,
make sure that no forgotten tools remain in the temporarily tighten the plug. Then, start the en-
assembled machine. gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.
• Bleeding Air from Front Brake, Rear Brake
• Set the wheel as the bleed valve of the brake

head will be the highest location.
• Slightly loosen the plug to bleed air from the
brake head.
• After bleeding all the air, securely tighten the
plug.
W8R7-E-01(20160803) W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating hoist cylinder, steering cylinder evenly,
operate the machine under light loads for 10 to
15 minutes. Slowly start each operation (never
fully stroke the cylinders during initial operation
stage). As the pilot oil circuit has an air bleed de-
vice, air trapped in the pilot oil circuit will be bled
while performing the above operation for approx.
5 minutes. W8DS-03-04-001
• Reposition the dump body to check hydraulic oil
level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W8R7-E-01(20160803) W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
(3) Check O-ring (B) 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.
(1) Clean the floating seal and seal mounting

bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air. Incorrect

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that
seal ring surface (A) is parallel with seal a a
mating face (C) by measuring the distances
A
(A) and (C) at point (a) and (b), as illustrated.
If these distances differ, correct the O-ring
seating. B
b b
a=b a≠b
W110-03-05-004
W8R7-E-01(20160803) W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

safely.
• Attach protectors (soft material) on the corners of Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from being damaged and the lifted load from
slipping.
• Lower the temperature of the lifted load to lower
than 100 °C (212 °F). If unavoidably lifting a load
with a temperature of 100 °C (212 °F) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal object.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W8R7-E-01(20160803) W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W8R7-E-01(20160803) W1-1-6
MAINTENANCE STANDARD TERMINOL-
OGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W8R7-E-01(20160803) W1-1-7
(Blank)
W8R7-E-01(20160803) W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATIONS
Bolt Dia. Wrench Torque

No. Descriptions Q’ty
mm Size (mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Rear axle hinge pin bolt 20 4 30 550 55 410
2 Rear axle hinge pin retaining bolt 20 1 30 550 55 410
3 Hoist shaft mounting bolt 16 8 24 270 27 200
4 Trunnion mounting bolt 33 8 60 3700 370 2730
5 Cab support mounting bolt 30 44 46 1750 175 1290
6 Alternator & engine mounting bolt 24 8 36 950 95 700
7 Engine rear mounting bolt 20 8 30 550 55 410
8 Engine mounting bolt 20 2 30 550 55 410
9 Engine front mounting bolt 36 4 55 3200 320 2360
10 Engine mounting bolt 36 2 55 3200 320 2360
11 Engine rear connecting bolt 20 8 30 550 55 410
12 Radiator mounting bolt 27 4 41 1400 140 1030
13 PTO mounting bolt 20 4 30 550 55 410
14 Main pump bracket mounting bolt 20 4 30 550 55 410
15 Fuel tank mounting bolt (upper side) 33 2 50 2600 260 1920
16 Fuel tank mounting bolt (lower side) 27 1 41 1400 140 1030
17 Hydraulic oil tank mounting bolt (upper side) 24 2 36 950 95 700
18 Hydraulic oil tank mounting bolt (lower side) 27 1 41 1400 140 1030
19 Hoist cylinder pin mounting bolt 16 8 24 270 27 200
20 Steering accumulator mounting bolt 24 2 36 950 95 70
21 Rear axle hinge pin retaining bolt 20 10 30 550 55 410
22 Cab mounting bolt (A) 45 2 70 2700 270 1990
23 Cab mounting bolt (B) 45 4 70 2700 270 1990
24 Upright mounting bolt (A) 24 5 36 950 95 700
25 Upright mounting bolt (B) 39 5 60 3200 320 2360
26 Cab bracket mounting bolt 33 10 50 2600 260 1920
27 Control cabinet mounting bolt 22 8 32 750 75 550
28 Rear wheel dagger clamp retaining bolt 33 48 50 2600 260 1920
29 Travel device mounting bolt 33 92 50 2600 260 1920
30 Travel transmission & wheel motor mounting bolt 24 24 36 950 95 700
31 Parking brake bracket mounting bolt 20 8 30 550 55 410
32 Parking brake plate mounting bolt 18 10 27 400 40 300
33 Parking brake disk mounting bolt 20 24 30 550 55 410
34 Kingpin retaining bolt 20 24 30 550 55 410
35 Front brake mounting bolt 30 48 46 1800 180 1330
36 Front wheel acroset cover mounting bolt 27 16 19★ 1400 140 1030
37 Front brake disk mounting bolt 33 64 50 2600 260 1920
38 Front wheel dagger clamp retaining bolt 24 78 36 950 95 700
39 Steering Shaft connecting bolt (A) 10 1 17 20 2 15
40 Steering Shaft connecting bolt (B) 8 1 13 10 1 7
NOTE: ★Hexagonal socket wrench
NOTE: 1.Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2.Make sure bolt and nut threads are clean
before installing.
W8R7-E-01(20160803) W1-2-1
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loos-
ening and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.
Make sure to employ correct bolts and tighten them
correctly when assembling the machine or compo- SA-040
nents.
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft) Nxm (kgfxm) (lbfxft)
M6 10 5 3 to 4 0.3 to 0.4 2.2 to 3.0
M8 13 6 30 (3.0) (22) 20 (2.0) (15) 10 (1.0) (7.4)
M10 17 8 65 (6.5) (48) 50 (5.0) (37) 20 (2.0) (15)
M12 19 10 110 (11) (81) 90 (9.0) (66) 35 (3.5) (26)
M14 22 12 180 (18) (135) 140 (14) (103) 55 (5.5) (41)
M16 24 14 270 (27) (200) 210 (21) (155) 80 (8.0) (59)
M18 27 14 400 (40) (295) 300 (30) (220) 120 (12) (89)
M20 30 17 550 (55) (410) 400 (40) (295) 170 (17) (125)
M22 32 17 750 (75) (550) 550 (55) (410) 220 (22) (162)
M24 36 19 950 (95) (700) 700 (70) (520) 280 (28) (205)
M27 41 19 1400 (140) (1030) 1050 (105) (770) 400 (40) (295)
M30 46 22 1950 (195) (1440) 1450 (145) (1070) 550 (55) (410)
M33 50 24 2600 (260) (1920) 1950 (195) (1440) 750 (75) (550)
M36 55 27 3200 (320) (2360) 2450 (245) (1810) 950 (95) (700)
W8R7-E-01(20160803) W1-2-2
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
1 12 9 4 1 6 7 14
6 3
1st, 4th
4 5
2 13 8 5 2 3 10 11
2nd, 3rd
Tighten diagonally Tighten from center and diagonally W105-01-01-003
Equally tighten upper and lower alternately
W8R7-E-01(20160803) W1-2-3
Service Recommendations for Spilt Flange
IMPORTANT: 1. Be sure to clean and Inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
nent.
W105-01-01-015
2. Be sure to use only specified WRONG
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
centered and perpendicular to
W105-01-01-016
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using
W105-01-01-008
an air wrench often causes tight-
RIGHT WRONG
ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts.
Bend along edge sharply Do not bend it round
Nut and Bolt Locking

RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
W105-01-01-009
ening, not while loosening. WRONG
RIGHT RIGHT
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W8R7-E-01(20160803) W1-2-4
PIPING JOINT
IMPORTANT: The torques given in the chart are

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication. 1 4 3 5 2
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.
M202-07-051
Joint Body
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten nut (3) to specifi- 37°
cations.
30°
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them Male Union Joint Female Union Joint
when connecting/disconnecting.
W105-01-01-017
Wrench Size Tightening Torque

Description mm
Union Nut N⋅m (kgf⋅m) (lbf⋅ft)
30°male 17 25 (2.5) (18)
19 30 (3.0) (22)
22 40 (4.0) (30)
27 80 (8.0) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
50 270 (27) (199)
55 380 (38) (280)
60 380 (38) (280)
37°female 17 25 (2.5) (18)
19 30 (3.0) (22)
22 40 (4.0) (30)
27 80 (8.0) (59)
32 140 (14) (103)
36 180 (18) (133)
41 200 (20) (148)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.
W8R7-E-01(20160803) W1-2-5
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end face of adapter (7) to

seal pressure oil.
IMPORTANT: 1. Be sue to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening nut (9), confirm
that O-ring (6) is seated correctly Hose Fittings
8 10
in O-ring groove (8). Tightening M104-07-033
nut (9) with O-ring (6) displaced

will damage O-ring (6), resulting
in oil leakage.
3. Take care not to damage O-ring
mm
groove (8) or sealing surface
(10). Union Nut N⋅m (kgf⋅m) (lbf⋅ft)
Damage to O-ring (6) will cause 19 30 (3.0) (22)
oil leakage. 22 70 (7.0) (52)
4. If nut (9) is loose and oil is leak- 27 95 (9.5) (70)
ing, do not re-tighten nut (9). Re- 32 140 (14) (103)
place O-ring (6) with a new one 36 180 (18) (133)
and check that O-ring (6) is cor- 41 200 (20) (148)
rectly seated in place, tighten nut 50 350 (35) (258)
(9).
W8R7-E-01(20160803) W1-2-6
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018
Male Tapered Thread

mm N⋅m (kgf⋅m, lbf⋅ft)
Hose Fittings FC material SS material
19 15 (1.5,11) 35 (3.5,26)
22 30 (3.0,22) 50 (5.0,37)
27 50 (5.0,37) 95 (9.5,70)
36 70 (7.0,52) 160 (16,118)
41 110 (11,81) 200 (20,148)
50 160 (16,118) 330 (33,243)
60 200 (20,148)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp.
T-Bolt Type Band Clamp: M114-07-041
4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft )

Worm Gear Type Band Clamp: T-Bolt Type Worm Gear Type
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W8R7-E-01(20160803) W1-2-7
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other 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 hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W8R7-E-01(20160803) W1-2-8
GENERAL / Periodric Replacement of Rarts
PERIODIC REPLACEMENT OF PARTS
To ensure safe operation, be sure to conduct periodic

inspection of the machine. In addition, the parts listed
below, if defective, may pose serious safety/fire haz-
ards. It is very difficult to gauge the extent of deterio-
ration, fatigue, or weakening of the parts listed below
simply by visual inspection alone. For this reason, re-
place these parts at the intervals shown in the table
below. However, if any of these parts are found to be
defective, replace before starting operation, regard-
less of the interval.
Also, when replacing hoses, check the clamps for de-
formation, cracks, or other deterioration, and replace
as necessary.
Be sure to perform periodic inspection of all hoses, as
shown below, and replace or retighten any defective
parts found, as necessary.
Consult your authorized dealer for correct replace-
ment.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to fuel pump) Every 2 years
Engine Heater hose
Every 2 years
(Heater to engine)
Brake valve seals Every 2 years
Brakes
Brake hose Every 2 years
Steering hose Every 2 years
Steering Mechanism Steering cylinder seals (Rubber parts) Every 2 years
Steering valve seals (Rubber parts) Every 2 years
Pump suction hose Every 2 years
Hydraulic Base Machine Pump delivery hose Every 2 years
System Accumlator line hose Every 2 years
Operating Device Hoist line hose Every 2 years
Seat belt Every 3 years
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W8R7-E-01(20160803) W1-3-1
GENERAL / Periodric Replacement of Rarts
(Blank)
W8R7-E-01(20160803) W1-3-2
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
SECTION 2
BODY
CONTENTS
Group 1 Cab Removal and Installation of
Removal and Installation of Cab .............. W2-1-1 Wheel Motor Assembly ...................... W2-4-36
Air Conditioner......................................... W2-1-9 Disassembly of Wheel Motor ................. W2-4-44
Inspection of Wheel Motor ..................... W2-4-52
Group 2 Engine/Alternator Assembly of Wheel Motor ...................... W2-4-54
Removal and Installation of Engine ......... W2-2-1 Disassembly of
Removal and Installation of Alternator ... W2-2-21 Wheel Reduction Device .................... W2-4-66
Disassembly of Alternator ...................... W2-2-33 Assembly of
Inspection .............................................. W2-2-43 Wheel Reduction Device .................... W2-4-93
Assembly of Alternator ......................... W2-2-49 Disassembly of
First Stage Carrier Assembly ............ W2-4-132
Assembly of
Group 3 Pump Device
First Stage Carrier Assembly ............ W2-4-136
Removal and Installation of
Disassembly of
Pump Device ....................................... W2-3-1
Second Stage Carrier Assembly ....... W2-4-144
Disassembly of Main Pump ..................... W2-3-8
Assembly of
Assembly of Main Pump ........................ W2-3-14
Second Stage Carrier Assembly ....... W2-4-148
Maintenance Standard ........................... W2-3-18
Disassembly of Brake Assembly .......... W2-4-156
Disassembly of Regulator
Assembly of Brake Assembly ............... W2-4-160
for Main Pump ................................... W2-3-20
Wheel Bearing Preload Operation
Assembly of Regulator
Management Procedures ................. W2-4-166
for Main Pump ................................... W2-3-22
Brake Clearance
Structure of Gear Pump ......................... W2-3-24
Adjustment Procedure...................... W2-4-178
Disassembly of Drive Shaft .................... W2-3-26
Friction Disc Wear
Inspection of Drive Shaft ....................... W2-3-30
Measurement Procedure .................. W2-4-180
Assembly of Drive Shaft ........................ W2-3-34
Break-in Operation of Wheel
Maintenance of Drive Shaft ................... W2-3-38
Reduction Device ............................. W2-4-182
Group 4 Drive Device

Group 5 Front Axle
Front Axle ................................................ W2-5-1
Drive Device ........................................ W2-4-1
Inspecting Front Axle Assembly Play ....... W2-5-4
Wheel Motor Assembly ...................... W2-4-10
Spindle Assembly ................................. W2-5-6
Disassembly of Parking Brake ............... W2-4-14
Inspection of Parking Brake ................... W2-4-22
Trailing Arm ........................................ W2-5-18
Assembly of Parking Brake .................... W2-4-24
Front Wheel Adjustment ......................... W2-5-30
Procedures for the 500-Hour
Maintenance Inspection ..................... W2-4-34
Front Wheel ....................................... W2-5-34
W8R7-E-01(20160803) 8R7W-2-1
Group 6 Tire and Rim Removal and Installation of
Tire / Rim / Air Pressure .......................... W2-6-1 Flow Amplifier .................................. W2-10-10
Removal and Installation of Disassembly and Assembly of
Front Tire and Rim ............................... W2-6-2 Flow Amplifier .................................. W2-10-15
Removal and Installation of Removal and Installation of
Rear Tire and Rim ............................... W2-6-6 Steering Cylinder ............................. W2-10-16
Tire Care ............................................... W2-6-12 Disassembly of Steering Cylinder
Tire Air Pressure Inspection................... W2-6-12 (Serial No.: 010001 to 010016,
010018, 010019) .............................. W2-10-20
Group 7 Front Brake Inspection of Steering Cylinder
Removal and Installation of (Serial No.: 010001 to 010016,
Front Brake .......................................... W2-7-1 010018, 010019) .............................. W2-10-24
Disassembly of Brake Head .................... W2-7-6 Assembly of Steering Cylinder
Inspection of Brake Head and (Serial No.: 010001 to 010016,
Brake Disc ............................................. W2-7-8 010018, 010019) .............................. W2-10-26
Assembly of Brake Head ....................... W2-7-10 Test of Steering Cylinder
Removal and Installation of Lining ......... W2-7-14 (Serial No.: 010001 to 010016,
Air Bleeding of Front Brake ................... W2-7-20 010018, 010019) .............................. W2-10-32
Main Accumulator ............................ W2-10-34
Group 8 Brake Valve
Disassembly and assembly of
Main Accumulator ......................... W2-10-40
Brake Valve ...................................... W2-8-1
Charging Nitrogen Gas .................... W2-10-45
Disassembly of Brake Valve .................... W2-8-6
Disassembly and assembly of
Inspection of Brake Valve ...................... W2-8-12
Steering Cylinder (Serial No.:
Assembly of Brake Valve ....................... W2-8-14
010017, Up to 010020) .................... W2-10-57
Replacement of
Brake Cartridge Seal ......................... W2-8-20
Group 9 Brake Accumulator

Rear Brake Accumulator ...................... W2-9-1
Front Brake Accumulator ..................... W2-9-3
Disassembly of Brake Accumulator ......... W2-9-6
Assembly of Brake Accumulator .............. W2-9-8
Charging Nitrogen Gas .......................... W2-9-12

Steering Column Assembly ................ W2-10-1
Disassembly and Assembly of
Driveshaft .......................................... W2-10-7
Steering Column ................................ W2-10-7
Disassembly, Assembly and Inspection of
Steering Valve .................................... W2-10-8
W8R7-E-01(20160803) 8R7W-2-2
Front Suspension Cylinder ................ W2-11-1
Disassembly of
Inspection of
Assembly of
Front Suspension Cylinder .............. W2-11-10
Charging Neocon Oil .......................... W2-11-14
Charging Helium Gas ......................... W2-11-16
Servicing Procedure of
Front Suspension Cylinder .............. W2-11-19
Suspension Cylinder Storage .............. W2-11-19
Rear Suspension Cylinder .............. W2-11-20
Disassembly of
Inspection of
Assembly of
Charging Neocon Oil .......................... W2-11-34
Charging Helium Gas ......................... W2-11-36
Servicing Procedure of
Suspension Cylinder Storage .............. W2-11-39
W8R7-E-01(20160803) 8R7W-2-3
(Blank)
W8R7-E-01(20160803) 8R7W-2-4
BODY / Cab
REMOVAL AND INSTALLATION OF CAB
Removal
1
1. Park the machine in the service position on a level
surface.
2, 3
2. Raise the dump body. Insert the body prop pins to
prevent the dump body from lowering.
4
3. Remove bolts (2) (5 used), washers (3) (5 used)

from the right side of cab (1). Remove cover (4).
: 17 mm
4. Disconnect connectors of the electronic control

Right side of cab (1) W8R7-02-01-001
system wired in the cab.
CAUTION: Before disconnecting the brake

accumulator piping, release the oil pressure 5, 6 7
in the brake system.
5. Release the oil pressure from the brake system.

Refer to REMOVAL AND INSTALLATION OF
BRAKE VALVE.
CAUTION: Floor cover (7) weight: 28 kg

(62 lb)
6. Remove bolts (5) (4 used), washers (6) (4 used).

Remove floor cover (7) from the right side of cab.
: 19 mm
W8R7-02-01-002
7. Disconnect hydraulic hoses from piping (8) and

(9) of the brake accumulator piping in cab (1).
Mark the identification number to the discon-
nected hydraulic hoses. Cap the disconnected
hydraulic hoses. 10, 11, 12 1
: 22 mm 9
8. Remove bolts (10) (8 used) and washers (11) (8 10, 11, 13

used) from cab (1). Remove clamp bracket (12), 8
and clamp brackets (13) (3 used) with manual
body down valve pipings.
Disconnect
Position
W8R7-02-01-003
W8R7-E-01(20160803) W2-1-1
BODY / Cab
9. Disconnect the hydraulic hoses (14), (15), (16),
(17) of the brake piping from base machine piping.
Mark the identification code onto the discon- 1
hydraulic hoses.
Hydraulic hoses (14, 15, 16)
: 22 mm, 19 mm
Hydraulic hose (17)
: 19 mm, 17 mm
15
14
16
17
Disconnect
Position
W8R7-02-01-004
Brake Piping
10. Disconnect the hydraulic hoses (18), (19), (20),

(21), (22) of the steering piping from base ma-
chine piping.
Mark the identification code onto the discon- 1
hydraulic hoses.
: 22 mm, 19 mm 18
21
22
19
20
Disconnect
Position
Steering Piping W8R7-02-01-005
11. Remove bolts (23) (5 used), washers (24) (5

25 1
used). Remove cover (25) from cab (1).
: 17 mm
23, 24 W8R7-02-01-006
W8R7-E-01(20160803) W2-1-2
BODY / Cab
CAUTION: Refrigerant is harmful to the en-

vironment. Do not release any refrigerant into Unit Frame
atmosphere. As for performing service, re- 27 28, 29 26
charge (charge) or discharge etc must be
done by trained and qualified service per-
sonnel.
12. Recover the refrigerant in the air conditioner sys-

tem with a recovery device.
Disconnect hose S (26) and hose L (27) from the
air conditioner unit frame. Loosen each bolt (28)
of hose S (26) and hose L (27). Remove the
hoses with clamp (29).
Cap the removed hoses. W8R7-02-01-007
: 10 mm
Unit Frame
13. Tighten both cocks of water valves (30) (2 used)

of the heater piping. Loosen clamps (33) (2 used). 31
Disconnect hoses (31) and (32) from water valves
(30) (2 used). Cock
：7 mm or
30
14. Remove washer hose (35) from washer tank (34) 32
of cab (1). Loosen bolts (36) (4 used). Remove
washer tank (34) with brackets (38) and washers 33
(37) (4 used) from cab (1) together.
: 17 mm W8R7-02-01-008
A View A
W8R7-02-01-009
34
35
36, 37
38
W8R7-02-01-010
W8R7-E-01(20160803) W2-1-3
BODY / Cab
15. Loosen bolts (39) (4 used) on cab (1). Remove
bolts (39) (4 used), washers (40) (4 used), cush-
ion rubber (41) (4 used), washers (44) (4 used)
and nuts (45) (4 used) on cab (1). Remove cush- 1
ion rubbers (41) (4 used), washers (42) (4 used),
spacers (43) (4 used), and cushion rubbers (46)
(4 used) when necessary.
: 70 mm
16. Loosen bolts (47) (2 used) on cab (1). Remove

bolts (47) (2 used), washers (40) (2 used), cush-
ion rubbers (41) (2 used), washers (44) (2 used)
and nuts (45) (2 used) on cab (1). Remove cush-
ion rubbers (41) (2 used), cushion rubbers (46) (2
used), and mounts (48) (2 used) when necessary. C B
: 70 mm
W8R7-02-01-011
47
46 40
39
41
46 40
48
41
42
43
44
44
45 45
View C View B
W8R7-02-01-012 W8R7-02-01-013
CAUTION: Cab (1) weight: 2350 kg (5180 lb)
17. Attach a lifting tool onto cab (1).

The illustration shows an example of a lifting tool. 1
18. Hoist and remove cab (1) from frame (49). When
hoisting cab (1), keep it horizontal.
49
W8DS-02-01-010
W8R7-E-01(20160803) W2-1-4
BODY / Cab
INSTALLATION
1. Set cushion rubbers (41) (2 used), cushion rub-

46
bers (46) (2 used), and mounts (48) (2 used) on 41
the front side of cab mounting position on frame 46
(49). 48
41
42
2. Set cushion rubbers (41) (4 used), washers (42) 49 43
(4 used), spacers (43) (4 used), and cushion
rubbers (46) (4 used) on the rear side of cab 49
mounting position on frame (49). Front Side Rear Side
W8R7-02-01-012 W8R7-02-01-013
CAUTION: Cab (1) weight: 2350 kg (5180 lb)

Wire Rope Chain Block
3. Attach a lifting tool onto cab (1).

The illustration shows an example of a lifting tool.
Shackle
Cab
4. Hoist and align cab (1) with the mounting position
on frame (49). When hoisting cab (1), keep it
horizontal.
W8DS-02-01-012
5. Apply lubricant onto the threads of bolts (47) (2

used). Install cab (1) to frame (49) with bolts (47)
1
(2 used), washers (40) (2 used), cushion rubbers
(41) (2 used), washers (44) (2 used) and nuts (45)
(2 used).
: 70 mm
: 2700 N·m (270 kgf·m, 1990 lbf·ft)

used). Install cab (1) to frame (49) with bolts (39)
(4 used), washers (40) (4 used), cushion rubbers
(41) (4 used), washers (44) (4 used) and nuts (45)
(4 used).
: 70 mm C B
: 2700 N·m (270 kgf·m, 1990 lbf·ft) W8R7-02-01-011
47
40
39
41 40
41
44
44
45 45
View C View B
W8R7-02-01-012 W8R7-02-01-013
W8R7-E-01(20160803) W2-1-5
BODY / Cab
7. Install washer tank (34) to cab (1) with bolts (36)
(4 used), washers (37) (4 used) and bracket (38).
Connect washer hose (35) to washer tank (34). 1
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·lb)
34
35
36, 37
38
W8R7-02-01-010
8. Connect hoses (31) and (32) of heater piping to Unit Frame

water valves (30) (2 used) with clamps (33) (2
used). Open the cock of water valves (30) (2
used). 31
：7 mm or
Cock
9. Check the radiator coolant level.

Add coolant, if necessary. 30
32
33
vironment. Do not release any refrigerant into A View A
W8R7-02-01-008 W8R7-02-01-009
atmosphere. As for performing service, re-
charge (charge) or discharge must be done
by trained and qualified service personnel.
Unit Frame
10. Connect hose S (26) and hose L (27) to the air 27 28, 29 26
conditioner unit frame with bolt (28) and clamp
(29).
Charge the refrigerant. For more information, re-
fer to Air Conditioner section.
: 10 mm
: 3.3 to 4.2 N·m (0.3 to 0.4 kgf·m, 2.4 to 3.1
lbf·ft)
W8R7-02-01-007
W8R7-E-01(20160803) W2-1-6
BODY / Cab
11. Install cover (25) to cab (1) with bolts (23) (5 used)
and washers (24) (5 used). 25 1
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
23, 24
12. Connect hydraulic hoses to pipes (8) and (9) of W8R7-02-01-006
the brake accumulator piping in cab (1) in accor-

dance with the identification codes marked when
disconnecting them. 10, 11, 12 1
: 22 mm 9
: 70 N·m (7.0 kgf·m, 52 lbf·ft)
10, 11, 13
13. Install clamp bracket (12), and clamp brackets 8
(13) (3 used) with manual body down valve pip-
ings to cab (1) with bolts (10) (8 used) and wash-
ers (11) (8 used).
Disconnect
: 17 mm Position
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
W8R7-02-01-003
14. Connect hydraulic hoses (14), (15), (16), (17) to 1

cab (1) in accordance with the identification codes
marked when disconnecting them.
Hydraulic hoses (14, 15, 16)
: 22 mm, 19 mm
: 70 N·m (7.0 kgf·m, 52 lbf·ft)
Hydraulic hose (17) 15
: 19 mm, 17 mm
: 40 N·m (4.0 kgf·m, 30 lbf·ft) 14
16
15. Connect hydraulic hoses (18), (19), (20), (21), and
(22) to cab (1) in accordance with the identifica- 17
tion codes marked when disconnecting them. Disconnect Brake Piping
: 22 mm, 19 mm Position
W8R7-02-01-004
: 95 N·m (9.5 kgf·m, 70 lbf·ft)
18
21
22
19
20
Disconnect
Position
Steering Piping
W8R7-02-01-005
W8R7-E-01(20160803) W2-1-7
BODY / Cab
CAUTION: Floor cover (7) weight: 28 kg

(62 lb) 5, 6 7
16. Install floor cover (7) to the right side of cab with
bolts (5) (4 used) and washers (6) (4 used).
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
17. Connect connectors of the electronic control sys-

tem wired in the cab.
18. Install cover (4) to the right side of cab (1) with
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft) W8R7-02-01-002
1
19. Release air from the brake and the hydraulic oil
circuit.
20. Before operating in the field, check the brake

function, steering feel and the operational condi- 2, 3
tions of hoisting device by running the machine
under constant conditions. 4
W8R7-02-01-001
Right side of cab (1)
W8R7-E-01(20160803) W2-1-8
BODY / Cab
AIR CONDITIONER
WORK AFTER REPLACING COMPO-

NENTS
The following work is required after replacing

compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is found.
1. Add compressor oil
2. Charge air conditioner with refrigerant

• Purging
• Charge air conditioner with refrigerant
• Warm up operation
• Inspection
ADD COMPRESSOR OIL
Compressor oil quantity to be added after component

replacement:
• 220 mL (0.23 US qt) :
After replacement of the compressor, high
pressure hose, condenser, receiver tank, liquid
hose, or air conditioner unit.
• 100 mL (0.11 US qt) :
After replacement of the low pressure hose.
W8R7-E-01(20160803) W2-1-9
BODY / Cab
CHARGE AIR CONDITIONER WITH
REFRIGERANT
Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
1. Pressure rise in the high pressure side

Air
If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied;
however, air cannot be liquefied and remains as a
gas in the condenser because the temperature at
which air liquefies is extremely low. That is,
liquidation of the refrigerant gas in the condenser
decreases by the amount of air in the circuit, and Pressure increases if air
W115-02-10-001
the gas pressure in the high pressure side remains in the air
conditioner circuit
increases accordingly.
2. Metal corrosion
If air remains in the air conditioner circuit, a

chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid Hydrochloric acid W115-02-10-002

corrodes metals if
moisture exists
Metal corrosion
3. Plugging of the expansion valve by moisture
When high pressure refrigerant gas passes

through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the air
conditioner circuit freezes at the expansion valve
orifice, plugging refrigerant flow. Operation of the Plugged refrigerant
air conditioner becomes unstable and cooling flow
Ice produced at the
efficiency lowers. expansion valve disturbs
W115-02-10-003
refrigerant flow, lowering
cooling efficiency
Low cooling
efficiency
W8R7-E-01(20160803) W2-1-10
BODY / Cab
Purging Procedure Gauge Manifold
1. Close the high and low pressure valves on the
gauge manifold (Parts Number 4360564). Low Pressure
Connect the high-pressure-side charge hose and Valve
the low-pressure-side charge hoses to the Low Pressure
Charge Hose High Pressure
high-pressure-side charge valve (“D” marked) and
Valve
to the low-pressure-side charge valve (“S”
marked) located on the compressor, respectively. High Pressure
Connect the charge hose located on the center of Charge Hose
the manifold bottom to the vacuum pump (Parts Center Pressure
Number 4360565). Charge Hose
Vacuum Pump
NOTE: Vacuum Pump Joint Adapter (Parts

Number 4360566).
IMPORTANT: Never mistake the charge hose

connections.
W115-02-10-005
Low Pressure
Side S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open
In Operation
W115-02-10-005
W8R7-E-01(20160803) W2-1-11
BODY / Cab
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and
close the high and low pressure valves. Wait for Close
approximately five minutes and confirm that the
pointer does not return to 0. Close
IMPORTANT: If the pointer returns to 0, retighten

the line connections and perform
purging again.
In Operation
W115-02-10-005
4. With the high pressure and low pressure valves of

the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).
Refrigerant
Container
W115-02-10-007
5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the refrigerant
pressure. Loosen
Open
W115-02-10-007
W8R7-E-01(20160803) W2-1-12
BODY / Cab
6. Fully tighten the charge hose connection to the
High
gauge manifold. Open the high pressure valve Pressure
and refrigerant container valve to charge with Gauge
refrigerant (R134a). Tighten
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi). Open
NOTE: Use warm water of 40 °C (104 °F) or less to

warm the refrigerant container to aid in
charging operation.
Open
IMPORTANT: Always stop the engine when

charging the air conditioner with
refrigerant. Never position the
refrigerant container upside down
during charging operation. When
changing the refrigerant container
during charging operation, be sure
W115-02-10-007
to purge air from the charge hose,
as shown in step 10.
7. After charging, check the line connections for gas W115-02-10-008

leaks using leak tester (Parts Number 4360567).
IMPORTANT: Use the leak tester for R134a.
W8R7-E-01(20160803) W2-1-13
BODY / Cab
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:

Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
9. Open the low pressure valve in the gauge

manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear. Open
NOTE: The required refrigerant quantity is 900

g±50 g (1.98±0.11 lb).
IMPORTANT: Never open the high pressure valve

in the gauge manifold.
Open
10. If the refrigerant container becomes empty during

the charging work, replace it with a new W115-02-10-007
refrigerant container as follows:

(1) Close the high pressure and low pressure Close
valves on the manifold gauge.
(2) Replace the empty container with a new one.
(3) Tighten, then slightly loosen the refrigerant
container joint.
(4) Slightly open the low pressure valve on the
manifold gauge.
(5) When the refrigerant container joint starts to
leak, immediately tighten the refrigerant
container joint and close the low pressure Close
valve on the manifold gauge.
11. After charging, close the low pressure valve in the

gauge manifold and the refrigerant container
valve, and stop the engine.
W115-02-10-007
W8R7-E-01(20160803) W2-1-14
BODY / Cab
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver tank to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Cab Window : Fully Open Sight Glass
Cooler Switch : ON
IMPORTANT: If the air conditioner is operated with
very low refrigerant, a bad load will
be exerted on the compressor. If the
air conditioner is overcharged with
Receiver tank
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner
circuit, causing danger.
NOTE: As the bubbles in the sight glass vary
W115-02-10-009
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Checking procedures: Stop the air conditioner and wait

until refrigerant returns to the balanced pressure. Then,
start the air conditioner again.
Relation between Refrigerant Quantity and Refrigerant
Flow in Sight Glass:
Refrigerant Flow in Sight Glass
Refrigerant
(approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass
Quantity
switch is turned ON)
(immediately after) (approx. 1 mm after) Immediately after the air conditioner is turned ON, few
Adequate bubbles are seen. Then the flow becomes transparent
and shows thin milk white color.
W115-02-10-016
No bubbles are seen after the air conditioner is turned

Overcharged ON.
W115-02-10-017
Bubbles are seen continuously after the air condi-

Not Enough tioner is turned ON.
W115-02-10-018
CAUTION: Wait until the high-pressure-side

pressure drops to less than 980 kPa (10
W115-02-10-019 kgf/cm2, 142 psi) before attempting to dis-
Bubbles exist: Bubbles are seen in refrigerant flow as connect the high-pressure-side charge hose.
both liquid refrigerant and refrigerant gas exist, being Otherwise, refrigerant and compressor oil
mixed. may spout.
W115-02-10-020 13. After checking refrigerant quantity, disconnect the

Transparent: Refrigerant flow is transparent as only low-pressure-side charge hose first. Wait for the
liquid refrigerant exists. high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
high-pressure-side charge hose.
115-02-10-021
Milk white: Refrigerant flow shows thin milk white

as oil and refrigerant are separated.
W8R7-E-01(20160803) W2-1-15
BODY / Cab
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.
Operating Conditions of the Air Conditioner

Cab Window : Fully Open
Cooler Switch : ON
Inspection
After warm-up operation, carry out gas leak check
and performance check.
1. Check the air conditioner for gas leaks using a

leak tester. Leak Tester
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
connections.
(4) If any gas leaks are found, retighten the line
connections.
CAUTION: Refrigerant will produce

W115-02-10-013
poisonous material if exposed to heat of 1000
°C (1800 °F) or more. Never bring refrigerant
close to a fire.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Retighten Line
(1) Check each component for abnormalities. Connection
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance. W115-02-10-014
W8R7-E-01(20160803) W2-1-16
BODY / Cab
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal sounds.
(2) Do not remove the compressor belts during
off-season. Operate the compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.
W8R7-E-01(20160803) W2-1-17
BODY / Cab
(Blank)
W8R7-E-01(20160803) W2-1-18
BODY / Engine / Alternator
REMOVAL AND INSTALLATION OF EN-
GINE
1
Removal

surface.
2. Remove dump body (1).

BODY.
3. Turn the key switch and the battery switch OFF. M8R7-07-059
4. Remove control cabinet (2).

2
CONTROL CABINET.
W8R7-04-01-007
5. Remove grid box (3). Bind up the harnesses to the 3

frame of the grid box.
GRID BOX.
W8R7-04-02-007
W8R7-E-01(20160803) W2-2-1
6. Remove cab (4).
Refer to REMOVAL AND INSTALLATION OF 4
CAB.
M8R7-07-059
7. Remove main accumulator (5).

6
Refet to REMOVAL AND INSTALLATION OF
MAIN ACCUMULATOR.
8. Remove hoses (7) (2 used) and clamp (8) from 7

manual body down valve (6). 5
8
9. Remove bracket (9) with the brake accumulator.
W8R7-02-09-002
W8R7-E-01(20160803) W2-2-2
10. Remove grill (10) at the front of radiator.
10
W8R7-02-02-001
Unit Frame
11. Disconnect the air conditioner piping from com-
pressor (11) and condenser (12).
Receiver
Drier
11
12
Air Conditioner Piping M8R7-07-033
12. Disconnect the heater piping from engine (34).

16
13. Loosen the clamp from center deck (16). Discon-

nect heater piping from center deck (16).
34
W8R7-02-02-002
Heater Piping
W8R7-E-01(20160803) W2-2-3
14. Disconnect the hose from oil cooler (13).
13
W8R7-02-02-003
15. Remove covers (14) on the front of control cabi-

net. 16 15
16. Disconnect right and center light harness con-

nectors. Remove the clamp on support (33).
17. Remove right step (15) with the handrail and

lights.
18. Remove the clamp of radiator piping on center

deck (16).
Refer to Disconnection of Radiator Piping 14
19. Remove cushion assembly (17) and rubbers be-

33 W8R7-02-02-004
tween center deck (16) and radiator (35).
Refer to Disconnection of Radiator Piping Rubber
16
20. Remove center deck (16) with the handrail and 17

lights.
35
W8R7-02-02-015
W8R7-E-01(20160803) W2-2-4
21. Disconnect left light harness connector. Remove
the clamp on support (33).
22. Disconnect handrail on front side of cab, handrail

on reverse side of cab, and left side handrail (18).
23. Remove left step (19) with the handrail and lights.
18
33
19
W8R7-02-02-005
25 22 20 23
24. Remove the hose (21) clamp from alternator
cooling blower (20).
25. Remove air duct (22) of alternator cooling blower

(20) and air duct (24) of wheel motor cooling
blower (23).
26. Remove bracket (25) supporting the air duct.
27. Remove alternator cooling blower (20).

ALTERNATOR COLLING BLOWER.
21 24 W8R7-04-03-002
28. Remove inlet pipings (29, 30) from inlet pipings

(27, 28) of air cleaner (26) side and inlet manifold 26 26
of engine (34).
34
28
27
29 30
W8R7-02-02-006
Air Inlet Piping
W8R7-E-01(20160803) W2-2-5
29. Disconnect and remove all exhaust pipings be-
tween engine (34) and muffler (30).
30. Remove muffler (30) from support (33). 34

33
Exhaust Piping 30 W8R7-02-02-007
33
31. Disconnect all pipings and harnesses between
frame (32) and support (33).
32. Remove support (33) from frame (32).

：46 mm
32
33. Drain the engine coolant and the engine oil. Close
the shutoff valves on the fuel tank.
34. Disconnect the harness to the radiator and the W8R7-02-02-008

hoses (4 places) from the bottom of radiator.
：36 mm
W8R7-02-02-009
W8R7-E-01(20160803) W2-2-6
Disconnection of Radiator Piping
39, 41 38 42, 43, 44
34
35. Loosen hose clips (37) (6 used). Disconnect
40, 41
hoses (36) (3 used) from engine (34) and radiator
(35). 36, 37
Disconnect the parts from engine (34) and radiator
(35) in the same manner.
36. Loosen hose clamps (41) (4 used). Remove pipe 35

(38) and the rubber hoses (39, 40) assembly.
52, 57 53, 57 W8R7-02-02-010
Remove pipe clamps (42) (2 used), bolts (43) (4
used), and washers (44) (4 used) in step 18.
48, 49, 50 48, 49, 50
：17 mm
37. Loosen hose clamps (47) (8 used). Remove rub-

ber hoses (45, 46).Remove bracket (48) (2 used),
bolts (49) (4 used), and washers (50) (4 used) in 45,
47 46,
step 18. 47
：19 mm
38. Loosen hose clamps (57) (4 used), pipe clamps

(58) (4 used), bolts (59) (4 used), and washers
(60) (4 used). Remove pipe (51) (2 used), the
rubber hoses (52, 54, 55) assembly, pipe (51) (2
used), and the rubber hoses (53, 54, 56) assem-
bly.
：19 mm
39. Loosen hose clamps (64) (4 used), pipe clamp

55, 57
(65), bolts (66) (2 used) and washers (67) (2 used).
Remove pipe (61) and the rubber hoses (62, 63) 56, 57
assembly. W8R7-02-02-011
40. Loosen hose clamps (71) (4 used), pipe clamp

(72), bolts (66) (2 used) and washers (67) (2 used).
Remove pipe (68) and the rubber hoses (69, 70) 51
assembly. 58, 59, 60
54
51
63, 64
69, 71
62, 64 70, 71
61, 65, 66, 67 68, 72, 66, 67 W8R7-02-02-012
W8R7-E-01(20160803) W2-2-7
Removal of Radiator
41. Loosen bolts (77) (50 used). Remove rubbers (73,

73, 77, 74, 77,
74, 75, 76), flat bars (79) (2 used), bolts (77) (50 78 78
used), and washers (78) (50 used).
CAUTION: Radiator (35) weight: 2050 kg

(4520 lb)
42. Hoist and hold radiator (35).
43. Loosen nuts (83) (16 used). Remove cushion as-

sembly (17) (2 used) of cushion rubber (81) (8
used), screw bars (80) (2 used), plane washers
(82) (8 used), and nuts (83) (16 used).
Follow the procedure in step 19 in this operation.
：27 mm 75, 77, 78, 79 76, 77, 78, 79
W8R7-02-02-013
44. Loosen bolts (84) (4 used) and nuts (90) (4 used). 80 81 82, 83
Remove washers (85) (8 used), washers (86) (4
used), plates (87) (2 used), cushion (88) (4 used),
and plates (89) (4 used).
：41 mm
Detail A W8R7-02-02-014
45. Hoist and remove radiator (35) from frame (32). Cushion assembly (17)
A
35
32
W8R7-02-02-015
84 85
86
87
88
89
85
90
Detail B W8R7-02-02-016
W8R7-E-01(20160803) W2-2-8
Removal of Connecting Parts of Engine and Al-
ternator 34 91
46. Disconnect the fuel lines from engine (34).
47. Disconnect the connections of hydraulic lines to

engine (34) and alternator (91), lubrication pipes
and wire harnesses.
48. Install plugs to the open ends of hydraulic lines,

lubrication pipes and the inlet and exhaust piping
in order to prevent the entry of foreign matter into M8R7-07-042
the system.
49. Remove the drive shaft from the alternator. OUT

ALTERNATOR.
IN
Fuel Line W8R7-02-02-017
W8R7-E-01(20160803) W2-2-9
Removal of Engine and Alternator Assembly
34 91
CAUTION: Engine (34) + Alternator (91)

weight: 12300kg (27100 lb)
50. Hoist and hold the engine (34) and alternator (91)
assembly.
32
W8R7-02-02-018
51. Remove bolts (94) (4 used), washers (95) (8 used), 92, 93 94, 95
plates (97) (4 used) and lock nuts (98) (4 used),
which secure the brackets (92, 93) and mount (96)
(4 used) at the alternator side.
: 55 mm
96
52. Remove bolts (100) (2 used) and washers (101) (2

used) from engine (34) side bracket (99).
97
: 30 mm
95, 98
Alternator Side W8R7-02-02-019
53. Hoist and remove the engine (34) and alternator

(91) assembly from frame (32).
54. Place the engine (34) and alternator (91) assem-

bly on the proper workbench.
55. Remove alternator (91) from engine (34), if nec-

essary. 100,
ALTERNATOR.
99 Engine Side W8R7-02-02-020
W8R7-E-01(20160803) W2-2-10
Installation of Engine and Alternator Assembly
34 91
1. Install alternator (91) to engine (34).
ALTERNATOR.
CAUTION: Engine (34) + Alternator (91)

weight: 1230 kg (27100 lb)
2. Hoist the engine (34) and alternator (91) assembly.

Place the engine (34) and alternator (91) assem-
bly onto the mounting position of frame (32). 32
W8R7-02-02-018
3. Install the engine (34) and alternator (91) assem-

bly to the engine side bracket (99) with bolts (100)
(2 used) and washers (101) (2 used).
: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
100,
101
99
4. Secure brackets (92, 93) at the alternator side of Engine Side W8R7-02-02-020
the engine (34) and alternator (91) assembly to

mount (96) (4 used) on frame (32) with bolts (94) 92, 93 94, 95
(4 used), washers (95) (8 used), plates (97) (4
used) and lock nuts (98) (4 used).
: 55 mm
: 3200 N·m (320 kgf·m, 2360 lbf·ft)
96
97
95, 98
Alternator Side W8R7-02-02-019
W8R7-E-01(20160803) W2-2-11
Installation of Connecting Parts to Engine and
Alternator
34 91
5. Install the drive shaft into alternator (91).
ALTERNATOR.
6. Connect hydraulic lines, lubrication pipes, and

wire harnesses to the connecting position on en-
gine (34) and alternator (91).
7. Connect the fuel lines into engine (34).

M8R7-07-042
OUT
IN
Fuel Line W8R7-02-02-017
W8R7-E-01(20160803) W2-2-12
Installation of Radiator
80 81 82, 83
CAUTION: Radiator (35) weight: 2050 kg
(4520 lb)
8. Hoist radiator (35). Place and hold radiator (35)

Detail A W8R7-02-02-014
with the mounting position on frame (32).
16 Cushion assembly(17)
9. Install radiator (35) to frame (32) with bolts (84) (4
used), nuts (90) (4 used), washers (85) (8 used), A
washers (86) (4 used), plates (87) (2 used),
cushion (88) (4 used), and plates (89) (4 used).
: 41 mm 35
: 1400 N·m (140 kgf·m, 1030 lbf·ft)
10. Install cushion assembly (17) of nuts (83) (16

used), plane washers (82) (8 used), cushion rub- B
bers (81) (8 used), and screw bars (80) (2 used) to
radiator (35) and center deck (16). Install with
compressing cushion rubber (81) thickness to be 32
W8R7-02-02-015
3 mm thinner.
Follow the procedure in step 33 in this operation. 84 85
: 27 mm 86
87
11. Install rubbers (73, 74, 75, 76) and flat bars (79) (2 88
used) to radiator (35) and the left and right fenders
with bolts (77) (50 used) and washers (78) (50
used).
89
：17 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft) 85
90
Detail B
W8R7-02-02-016
73, 77, 74, 77,

78 78
75, 77, 78, 79 76, 77, 78, 79

W8R7-02-02-013
W8R7-E-01(20160803) W2-2-13
Connection of Radiator Piping
12. Install pipe (68), the rubber hoses (69, 70) as-
sembly to engine (34) and radiator (35) with hose 51
clamps (71) (4 used), pipe clamp (72), bolts (66) 58, 59, 60
：17 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
Connect the parts to engine (34) and radiator (35) 54
in the same manner.
13. Install pipe (61), the rubber hoses (62, 63) as-
51
sembly with hose clamps (64) (4 used), pipe
clamp (65), bolts (66) (2 used) and washers (67)
(2 used). 63, 64
：17 mm 69, 71
：50 N·m (5.0 kgf·m, 37 lbf·ft)
62, 64 70, 71
14. Install pipe (51) (2 used), the rubber hoses (52, 54,
55) assembly, pipe (51) (2 used), and the rubber 68, 72, 66, 67 W8R7-02-02-012
61, 65, 66, 67
hoses (53, 54, 56) assembly with hose clamps
(57) (4 used), pipe clamps (58) (4 used), bolts (59)
39, 41 38 42, 43, 44
(4 used), and washers (60) (4 used). 34
：19 mm
40, 41
：90 N·m (9.0 kgf·m, 66 lbf·ft)
36, 37
15. Install rubber hoses (45, 46) with hose clamps
(47) (8 used). Install bracket (48) (2 used), bolts
(49) (4 used), and washers (50) (4 used) in step
34. 35
：19 mm
52, 57 53, 57 W8R7-02-02-010
：90 N·m (9.0 kgf·m, 66 lbf·ft)
48, 49, 50 48, 49, 50
16. Install pipe (38) and the rubber hoses (39, 40)
assembly with hose clamps (41) (4 used).
Install pipe clamps (42) (2 used), bolts (43) (4
used), and washers (44) (4 used) in step 34.
：17 mm 45,
47 46,
：50 N·m (5.0 kgf·m, 37 lbf·ft) 47
17. Connect hoses (36) (3 used) with hose clips (37)

(6 used).
55, 57
56, 57
W8R7-02-02-011
W8R7-E-01(20160803) W2-2-14
18. Connect hoses (4 places) and the harness to the
bottom of radiator.
：36 mm
：180 N·m (18 kgf·m, 133 lbf·ft)
19. Open the shutoff valves located at the fuel tank.

Add the engine coolant and the engine oil.
For more information, refer to the Operator’s
Manual.
Coolant capacity : 619 L (164 USgal)
20. Install support (33) to frame (32).

：46 mm W8R7-02-02-009
：1750 N·m (175 kgf·m, 1290 lbf·ft)

33
21. Connect the disconnected pipings and harnesses
between frame (32) and support (33).
22. Install muffler (30) to support (33).

32
23. Connect and install all exhaust pipings between
engine (34) and muffler (30).
W8R7-02-02-008
34
33
Exhaust Piping 30 W8R7-02-02-007
W8R7-E-01(20160803) W2-2-15
24. Install inlet pipings (29, 30) to inlet pipings (27, 28)
of air cleaner (26) side and inlet manifold of en- 26 26
gine (34).
34
28
27
29 30
W8R7-02-02-006
Air Inlet Piping
25. Install alternator cooling blower (20). 25 22 20 23

ALTERNATOR COOLING BLOWER.
26. Install bracket (25) to support the air duct.
27. Install air duct (22) of alternator cooling blower

(20) and air duct (24) of wheel motor cooling
blower (23).
28. Install the hose (21) clamp from alternator cooling

blower (20).
21 24 W8R7-04-03-002
29. Install left step (19) with the handrail and lights.
30. Connect handrail on front side of cab, handrail on

reverse side of cab, and left side handrail (18).
31. Connect left light harness connector. Install the

clamp of support (33).
18
33
19
W8R7-02-02-005
W8R7-E-01(20160803) W2-2-16
32. Install center deck (16) with the handrail and
lights.
33. Install cushion assembly (17) and rubbers be-

tween center deck (16) and radiator (35).
Refer to INSTALLATION OF RADIATOR.
34. Install the clamp of radiator piping to center deck

(16).
Refer to INSTALLATION OF RADIATOR PIPING.
35. Install right step (15) with the handrail and lights. 14
36. Connect right and center light harness connectors.

33 W8R7-02-02-004
Install the clamp of support (33).
Rubber
16
37. Install covers (14) to the front of control cabinet.
38. Connect hose to oil cooler (13). 17
35
W8R7-02-02-015
13
W8R7-02-02-003
W8R7-E-01(20160803) W2-2-17
39. Install heater piping to center deck (16) with
clamp. 16
40. Connect the heater piping to engine (34).

34
W8R7-02-02-002
Heater Piping
41. Connect air conditioner piping to compressor (11) Unit Frame
and condenser (12).
Receiver
Drier
11
12
Air Conditioner Piping M8R7-07-033
42. Install grill (10) to the front of radiator.
10
W8R7-02-02-001
W8R7-E-01(20160803) W2-2-18
43. Install bracket (9) with the brake accumulator.
6
44. Install hoses (7) (2 used) and clamp (8) to manual
body down valve (6).
7
45. Install main accumulator (5). 5
Refet to REMOVAL AND INSTALLATION OF
8
MAIN ACCUMULATOR.
W8R7-02-09-002
46. Install cab (4). 4

CAB.

vironment. Do not release any refrigerant into
atmosphere. As for performing service, re-
charge (charge) or discharge shall be done by
the trained and qualified service personnel.
M8R7-07-059
47. Charge the refrigerant in the air conditioner sys-

tem.
For more information about charging the refriger-
ant, refer to Air Conditioner section.
W8R7-E-01(20160803) W2-2-19
48. Install grid box (3).
GRID BOX. 3
W8R7-04-02-007
49. Install control cabinet (2).

CONTROL CABINET.
W8R7-04-01-007
50. Install dump body (1).

BODY.
51. Warm up the engine.

Check the cooling system, fuel system, oil filter
system, oil cooler system, engine oil circulation
system, air conditioner system, and heater system
for any oil leaks while warm-up operation. M8R7-07-059
Check all instruments for proper engine perform-

ance. Check the oil level in engine, wheel reduc-
tion device and hydraulic oil tank.
Add oil, if necessary.
W8R7-E-01(20160803) W2-2-20
Removal and Installation of Alternator
Removal
1. Park the machine on a level surface with the ser-
vice position.

3. Remove the obstructive parts for removing alter-

nator such as high-voltage cable, blower duct and
alternator cooling blower.
T8DS-04-04-005
a 2 3 5
46
b
4. Remove bolts, washers (5) (4 used). Remove
cover (3) from bracket (46).
: 17 mm

used). Remove drive shaft (2) from alternator (a)
and flange (b).
: 19 mm
47, 48 5 WQFB-02-02-048
a - Alternator
b - Flange
W8R7-E-01(20160803) W2-2-21
6. Remove bolts (6) (3 used). Remove cover (7) at
the rear right of engine.
: 21 mm
7. Remove clip (8). Push shaft (9). 6

7
WQEB-02-02-044
8 9
Detail a
WQEB-02-02-045
8. Turn the flywheel by turning shaft (9). Remove

socket bolts (11) (12 used) from rotor flange (10)
of the alternator. 11
Shaft (9). 10
: 24 mm
Socket bolt (11)
: 14 mm
WQFB-02-02-022
W8R7-E-01(20160803) W2-2-22
9. Turn rotor flange (13) so that the position of rotor 16 13 16
position adjusting plates (15) (4 used) and rotor
position adjusting bolts (4, 16) (2 used for each) A
should be set correctly.
15
4 4 WQFB-02-02-084
4, 16 4, 16
17 18 17
CAUTION: If removing the alternator from the
engine without performing following work,
19
the rotor of the alternator may fall and cause
serious injury.
10. Loosen rotor position adjusting bolts (4, 16) (2

used for each) and lock nuts (17) (4 used). Re-
move spacers (18) (4 used). Secure rotor flange
(13) with rotor position adjusting bolts (4, 16) (2
used for each) and lock nuts (17) (4 used).
Confirm that all ends (4 places) of rotor position
adjusting bolts (4, 16) (2 used for each) come in 13
contact with rotor position adjusting plates (15) (4 15
used) completely. Section A WQFB-02-02-061
W8R7-E-01(20160803) W2-2-23
CAUTION: Alternator (20) weight: 3300 kg

(7280 lb) 21 23, 24
11. Install shackles to lifting brackets (21) (2 used) of

alternator (20). Hoist and hold alternator (20).

22
used) from brackets (22) (2 used) for mounting the
engine and the alternator.
: 36 mm
20
W8R7-02-02-021
13. Remove bolts (25) (16 used) and washers (26) (16 25, 26
used) from alternator (20).
Hoist and remove alternator (20).
: 24 mm
WQFB-02-02-022
20
30 19
14. Remove bolts, washers (29) (16 used), flange (19),
29
and shim packs (30) (4 used) from engine (27).
: 19 mm
27
WQFB-02-02-049
W8R7-E-01(20160803) W2-2-24
15. Install flange (19) to alternator (20) with bolts (25)
(16 used) and washers (26) (16 used). 19 25, 26
: 24 mm
: 270 N·m (27 kgf·m, 200 lbf·ft)
16. Install transport brackets (33) (2 used) to flange

(19) of alternator (20) and rotor flange (13) with
bolts (34) (6 used) and bolts (35) (2 used).
Bolt (34)
: 17 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
Bolt (35)
: 19 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
NOTE: Store alternator (20) with transport brackets

20 WQEB-02-02-052
(33) (2 used) attached.
34
33 35
19
13
WQFB-02-02-028
W8R7-E-01(20160803) W2-2-25
Shim Adjustment Procedure
1. Install the measurement tool (ST 7964) to flange
(38) at the engine side.
ST 7964
2. Measure following two dimensions (a, b) at four
holes (A, B, C, D) of the measurement tool (ST D
7964). A
a. Dimension between the end of flywheel (39) and

outer end of the measurement tool (ST 7964) (in-
cluding thickness of the measurement tool)
Measurement Result (mm)

point 1st 2nd 3rd Average
a’
B
A C
B WQFB-02-02-063
C
D
Average a” 38
39
b. Thickness of the measurement tool (ST 7964) ST 7964
Measurement point Result (mm) a

A
B
C
c
D
Average b’ b
3. Subtract values (b’) from (a”). Calculate distance

(c) between end of flywheel (39) and extension of
end of flange (38).
a” - b’ = c WQFB-02-02-064
W8R7-E-01(20160803) W2-2-26
4. Measure following dimension (d) at four points (A,
B, C, D) at the alternator side. A
19
d. Dimension between outer end of rotor flange (13)
and outer end of flange (19) at stator side
13
Measurement point Result (mm) D
A
B B
C
D
Average d’
5. Subtract values (c) from (d’). Calculate thickness

(e) of shim packs (30) (4 used).
d’ - c = e
C W8R7-02-02-023
6. Create shim packs (30) (4 used) of the required
thickness by using shims. The tolerance of the E
shim pack (30) thickness (against calculated
thickness (e)) must be within 0.00 to +0.05 mm.
19
NOTE: There are 3 types of shims available
-thickness of 0.5 mm (24 used), 0.3 mm (8
used), 0.1 mm (8 used).
d
Wipe the surface of each shim to remove dirt and
oil. Use a micrometer to measure the thickness.
Check that the total measurement value is within
the tolerance value described above.
Lay the shims. Measure the shim pack (30)
thickness to check that it is within the tolerance
value described above.
13
Section E
WQFB-02-02-085
W8R7-E-01(20160803) W2-2-27
Installation
IMPORTANT: Create shim packs (30) (4 used) be- 17 4, 16

fore installing the alternator. Refer to
the heading "Shim adjustment pro-
cedure" (W2-2-26) for detail.
1. Confirm that the rotor is secured with rotor posi-

tion adjusting bolts (4, 16) (2 used for each) and
lock nuts (17) (4 used).
Confirm that the all ends (4 places) of rotor posi- 13 15
W8R7-02-02-025
tion adjusting bolts (4, 16) (2 used for each) come
in contact with rotor position adjusting plates (15) 34
of rotor flange (13) completely.
33
2. Remove bolts (34) (6 used), bolts (35) (2 used), 16 35
and transport brackets (33) (2 used) from flange 16
(19) of alternator (20) and rotor flange (13).
Bolt (34)
: 17 mm
Bolt (35)
: 19 mm 13

used), and flange (19) from alternator (20).
: 24 mm
19
4 4
W8R7-02-02-023
25, 26
19
WQEB-02-02-052
20
W8R7-E-01(20160803) W2-2-28
4. Install flange (19) and shim packs (30) (4 used) to
engine (27) with bolts, washers (29) (16 used). 30 19
: 19 mm 29
: 87 N·m (8.7 kgf·m, 64 lbf·ft)
27
WQFB-02-02-049
21
CAUTION: Alternator (20) weight: 3300 kg
(7280 lb)
5. Install shackles to lifting brackets (21) (2 used) of

alternator (20). Hoist and hold alternator (20).
20
W8R7-02-02-021
19 25, 26
6. Install alternator (20) to flange (19) with bolts (25)

: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft)
WQFB-02-02-022
20
W8R7-E-01(20160803) W2-2-29
7. Loosen rotor position adjusting bolts (4, 16) (2 4, 16 4, 16
used for each) and lock nuts (17) (4 used) so that
17 17
spacers (18) (4 used) can be installed. After in- 18
serting spacers (18) (4 used), secure rotor posi- 20
tion adjusting bolts (4, 16) (2 used for each) with
lock nuts (17) (4 used).
Confirm that all ends (4 places) of rotor position
adjusting bolts (4, 16) (2 used for each) are sep-
arated from rotor position adjusting plates (15)
through the observation window of alternator (20).
15
WQFB-02-02-061
8. Turn the flywheel by turning shaft (9). Install

socket bolts (11) (12 used) to rotor flange (10).
Shaft (9)
: 24 mm
Socket bolt (11)
: 14 mm
: 270 N·m (27 kgf·m, 200 lbf·ft) 9
WQEB-02-02-044
11
10
WQFB-02-02-022
W8R7-E-01(20160803) W2-2-30
9. Install alternator (20) to alternator mounting
brackets (22) at the right and left sides with bolts
(23) (8 used) and washers (24) (8 used).
: 36 mm
: 950 N·m (95 kgf·m, 700 lbf·ft) 22
23, 24 20
W8R7-02-02-021
10. Install cover (7) at the rear right of engine with

bolts (6) (3 used). 6
: 21 mm 7
: 220 N·m (22 kgf·m, 162 lbf·ft)
11. Pull out shaft (9). Install clip (8).
WQEB-02-02-044
8 9
Detail a
WQEB-02-02-045
W8R7-E-01(20160803) W2-2-31
12. Install drive shaft (2) to flange (b) and alternator
(a) with bolts (47) (8 used) and washers (48) (8 5
a 2 3 46
used).
: 19 mm b
: 110 N·m (11 kgf·m, 81 lbf·ft)
13. Install cover (3) to bracket (46) with bolts, washers

(5) (4 used).
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
14. Install the parts such as high-voltage cable, blower

duct, and alternator cooling blower that are re-
moved when removing the alternator.
47, 48 5 WQFB-02-02-048
15. Remove the body prop pins and lower the dump
body to travel position. a - Alternator
b - Flange
W8R7-E-01(20160803) W2-2-32
DISASSEMBLY OF ALTERNATOR
27 45
50 47
48, 49
46
24 25 26 27, 45 28 29 30 31 32 33 34 35
36
20 21 22 23
19
37
18
17
38
16
15 39, 40, 41
14
12, 13 1
W8R7-02-02-027
11 10 9 8 7 6 5 4 3 2
Synchronous Alternator Construction Drawing
1- Shaft 13 - Lock Washer (3 Used) 25 - Stator Frame 37 - Rotor Coil

2- Balance Weight 14 - Plate 26 - Lock Pin 38 - Plate
3- Core Holder (2 Used) 15 - Ball Bearing 27 - Terminal 39 - Bolt (12 Used)
4- Rotor Core 16 - Bolt (8 Used) 28 - Stator Coil 40 - Lock Washer (6 Used)
5- Rotor Core Key 17 - Bearing Cover 29 - Core Holder (2 Used) 41 - Knock Pin
6- Stopper Key (4 Used) 18 - Grease Fitting 30 - Temperature Sensor 45 - Collective Terminal Box
7- Wire Support 19 - Bolt (8 Used) 31 - Knock Pin (4 Used) 46 - Crimp Type Contact (3 Used)
8- Slip Ring Boss 20 - Bearing Box 32 - Stator Core 47 - Crimp Type Contact (2 Used)
9- Oil Thrower 21 - Rotor Coil 33 - Lifting Tool (2 Used) 48 - Connector
10 - Bearing Cover 22 - Rotor Core 34 - Stator Frame 49 - Connector
11 - Oil Thrower 23 - Stator Coil 35 - Bolt (16 Used) 50 - Crimp Type Contact (3 Used)
12 - Bolt (6 Used) 24 - Stator Core 36 - Flange
W8R7-E-01(20160803) W2-2-33
Main Alternator Aux. Alternator
60
59
58 63 58 63
56, 57
56, 57 59, 60
34 Aux. Alternator
61
62
20
55
10
61
Main Alternator 59, 60

W8R7-02-02-028
8- Slip Ring Boss 55 - Slip Ring (4 Used) 59 - Brush Holder (8 Used) 63 - Support
10 - Bearing Cover 56 - Washer (6 Used) 60 - Carbon Brush (16 Used)
20 - Bearing Box 57 - Bolt (6 Used) 61 - Holder Rod (8 Used)
34 - Stator Frame 58 - Support 62 - Connecting Crimp Contact
(4 Used)
W8R7-E-01(20160803) W2-2-34
60
59
58 63 58 63
56, 57
56, 57 59, 60
34 Aux. Alternator
61
62
20
55
10
61

W8R7-02-02-028
W8R7-E-01(20160803) W2-2-35
Disassembly of Alternator
1. Remove temperature sensor (30) from stator

frame (34).
If the insulation sheath of temperature sensor (30) 30
is broken, change the insulation sheath.
: 10 mm
34
W8R7-02-02-029
27 45
2. Remove inspection covers (65, 66) and terminal
box covers (27, 45) of main alternator.
: 17 mm
65 66
M8R8-07-115
3. Raise carbon brush retainer part (81) of brush

holder (59). Remove connecting terminal (82)
from brush holder (59). At this time, do not loosen 59
tightening nut (83) which secures to holder rod
(61).
Remove carbon brush (60) from brush holder
(59).
: 10 mm W8DS-02-02-018
60
4. Remove bolts (57) (6 used) and washers (56) (6 81 82
used). Remove the support (58) assembly and
the support (63) assembly from stator flame (34).
: 17 mm 60
59 83
61
W8DS-02-02-019 W8DS-02-02-020
W8R7-E-01(20160803) W2-2-36
20
17
16
14
12, 13 1
W8R7-02-02-027
11 10 9
W8R7-E-01(20160803) W2-2-37
5. Extend lock washer (13) (3 used) bend, remove
bolts (12) (6 used) and remove plate (14) from
shaft (1).
: 24 mm 72 71 70 17
6. Remove oil thrower (11) from shaft (1) by using a

special tool. Insert stud bolts (70) (4 used) into the
screw hole on oil thrower (11). Install plate (71) to
stud bolt (70) and secure with nuts (72) (4 used).
Attach cylinder (73) to shaft (1) end. Align with the
concave portion of plate (71) and install cylinder
73
(73). Tighten nuts (72) (4 used). Extend the cyl-
inder by using a hydraulic pump. Remove oil
thrower (11).
1 11 15
W8DS-02-02-014
Example: Special Tool when Pulling Out
16 20
7. Remove bolts (16) (8 used).
Stand up the pulling-out bolts into the pulling-out 10
hole. Float bearing cover (17) from bearing box
(20). Remove bearing cover (17).
Remove bearing cover (10) and oil thrower (9) 9
after removing the shaft (1) assembly.
: 19 mm 17
W8DS-02-02-015
34
8. Loosen bolts (91) (4 used) and (93) (2 used). 36
Remove transport bracket (92) from flange (36)
and plate (38). 91
Bolt (91)
：17 mm
92
Bolt (93)
：24 mm 93
38 W8R7-02-02-033
W8R7-E-01(20160803) W2-2-38
32 34
36
38
39, 40, 41
1
W8R7-02-02-027
W8R7-E-01(20160803) W2-2-39
9. Put the matching marks on plate (38) and shaft
(1) for reassembling. Hoist and hold plate (38).
87, 88
10. Loosen rotor position adjusting bolts (87) (4 used) 34
and lock nuts (88) (4 used) mounted on stator
frame (34) so that all ends of bolts (87) exceed the
inner diameter of flange (36). 36
11. Return lock washer (40) (6 used) bend, loosen

bolts (39) (12 used) and remove plate (38).
Do not remove knock pins (41) (3 used) unless
necessary. W8R7-02-02-032
: 36 mm
34 32 75 76
12. Install connecting shaft (77) onto the flange of
shaft (1) by using a lifting tool. Insert hanger (76).
Position wire rope (75) and slowly move the shaft
assembly toward the arrow direction.
Do not contact stator core (32) with rotor core (4)
while moving the shaft assembly. Place the re-
moved shaft assembly onto the suitable table with
V shaped groove in order not to damage rotor
core (4) 77
4 1 W8DS-02-02-016
Example: Special Tool When Lifting
W8R7-E-01(20160803) W2-2-40
15
1
W8R7-02-02-027
10 9
W8R7-E-01(20160803) W2-2-41
13. Install holding plate (95) to bearing cover (10) with
the bolts (4 used).
78 79 80 15
: 19 mm
14. Insert stud bolts (M16) (80) (4 used) into the 10

screw hole on holding plate (95). Install plate (79)
to stud bolt (80) and secure with nuts (78) (4
used).
Attach cylinder (73) to shaft (1) end. Align with the
concave portion of plate (79) and install cylinder
73
(73). Tighten nuts (78) (4 used).
Extend cylinder (73) by using a hydraulic pump.
Remove ball bearing (15) and bearing cover (10).
: 24 mm 1 9
W8DS-02-02-017

15. Do not remove oil thrower (9) unless necessary.
When removing oil thrower (9), remove oil thrower
(9) from shaft (1) by using a pulling-out tool.
16. Do not disassemble the rotor and the stator fur-

ther.
W8R7-E-01(20160803) W2-2-42
INSPECTION
24 28 32 34
21 22 23
37
W8R7-02-02-027
W8R7-E-01(20160803) W2-2-43
Inspection
Inspection of Rotor
1. Blow away and clean dust on rotor core (4, 22)
surface and in the air holes by using compressed
dry air. If the soil is hard in particular, remove it by
using cleaning solvent.
2. If the separation occurs on rotor core (4, 22) sur-

face after cleaning rotor core (4, 22), refinish with
varnish and dry in the dry kiln or naturally in air.
3. Check for deformation, crack or damage for rotor

coil (21, 37). Repair or replace defective parts.
4. Check for the looseness of each mounting bolt.

Retighten the loose bolt to the specified torque.
Inspection of Stator
1. Blow away and clean dust in the clearance of
stator core (24, 32) inner surface, coil end, lead
wire and stator frame (34) by using compressed
dry air. If the soil is hard in particular, remove it by
using cleaning solvent.
2. Check for internal and external crack or damage

for stator core (24, 32). Repair or replace defec-
tive parts.
3. Check for short circuit and insulation damage for

rotor coil (21, 37) and stator coil (23, 28). Repair
or replace defective parts.
4. Check for the damage of crossover and lead wire,

insulation damage and looseness of the mounting
part. Repair or replace defective parts.
W8R7-E-01(20160803) W2-2-44
15
W8R7-02-02-027
W8R7-E-01(20160803) W2-2-45
5. Measure and record the insulation resistance
between the insulation resistance testing lead
wire and a ground.
Heat the coil surface temperature from 90 to
130°C (194 to 266°F). After drying the coil for 12
hours, check that the insulation resistance is 3 M
OHM or more in high temperature state. If the
insulation resistance does not reach to 3 M OHM,
dry the coil again.
6. When disassembling and checking, if the finish

varnish come off, apply with finish varnish and dry
it.
Dry it naturally in air or heat under 130°C (266°F).
Inspection of Bearings (15)

1. When removing from the engine, turn the rotor of
alternator slowly by hand and place a mechanics
stethoscope on the bearing part. Check if the
bearing is in good condition.
Quiet and clear sound should be heard if the
bearing is in good condition. If the bearing is
damaged by flaking, pitting or a crack, it gener-
ates high-pitched harsh noise such as “chatter” or
“squeak”.
Replace bearings if it has been removed, or if it is

damaged.
W8R7-E-01(20160803) W2-2-46
60
59
60
59
55
59, 60
Aux. Alternator
61
62
55
61

W8R7-02-02-028
W8R7-E-01(20160803) W2-2-47
Inspection of Slip Ring Device
1. Check for damage of wires. Repair and replace

damaged wires.
2. Check for looseness of the terminal retaining part.

If a loose terminal is observed, tighten the part
with the specified torque.
3. Check for looseness of the brush holder (59)

mounting part. If a loose mounting part is ob- P
served, tighten the part with the specified torque. 59
P
4. Check for abnormal wear of the carbon brush (60).
In order to confirm wear of the carbon brushes
(60) (16 used), check if the stopper (84) in brush
holders (59) (8 used) contacts the brushes. If
stopper (84) contacts the carbon brush (60), dis- W8DS-02-02-018
card the carbon brush and replace with a new
one. 84 60
5. Check if excessive carbon dust and dirt adhere to

the slip ring boss (8), slip ring (55), holder rod (61)
and brush holder (59).
If dirty, blow the excessive carbon dust and dirt
away using the compressed air or remove by us-
ing a dry cloth.
6. Check if any oil adheres to the slip ring boss (8).

When adhering, remove oil by using a dry cloth.
7. Check if the slipping surface on the slip ring boss

(8) is damaged. If the slipping surface is damaged,
repair or replace the slip ring boss (8).
W8R7-E-01(20160803) W2-2-48
ASSEMBLY OF ALTERNATOR
27 45
50 47
48, 49
46
24 25 26 27, 45 28 29 30 31 32 33 34 35
36
20 21 22 23
19
37
18
17
38
16
15 39, 40, 41
14
12, 13 1
W8R7-02-02-027
11 10 9 8 7 6 5 4 3 2
1- Shaft 13 - Lock Washer (3 Used) 25 - Stator Frame 37 - Rotor Coil

2- Balance Weight 14 - Plate 26 - Lock Pin 38 - Plate
3- Core Holder (2 Used) 15 - Ball Bearing 27 - Terminal Box 39 - Bolt (12 Used)
4- Rotor Core 16 - Bolt (8 Used) 28 - Stator Coil 40 - Lock Washer (6 Used)
5- Rotor Core Key 17 - Bearing Cover 29 - Core Holder (2 Used) 41 - Knock Pin
6- Stopper Key (4 Used) 18 - Grease Fitting 30 - Temperature Sensor 45 - Collective Terminal Box
7- Wire Support 19 - Bolt (8 Used) 31 - Knock Pin (4 Used) 46 - Crimp Type Contact (3 Used)
8- Slip Ring Boss 20 - Bearing Box 32 - Stator Core 47 - Crimp Type Contact (2 Used)
9- Oil Thrower 21 - Rotor Coil 33 - Lifting Tool (2 Used) 48 - Connector
10 - Bearing Cover 22 - Rotor Core 34 - Stator Frame 49 - Connector
11 - Oil Thrower 23 - Stator Coil 35 - Bolt (16 Used) 50 - Crimp Type Contact (3 Used)
12 - Bolt (6 Used) 24 - Stator Core 36 - Flange
W8R7-E-01(20160803) W2-2-49
60
59
58 63 58 63
56, 57
56, 57 59, 60
34 Aux. Alternator
61
62
20
55
10
61

W8R7-02-02-028
8- Slip Ring Boss 55 - Slip Ring (4 Used) 59 - Brush Holder (8 Used) 63 - Support
10 - Bearing Cover 56 - Washer (6 Used) 60 - Carbon Brush (16 Used)
20 - Bearing Box 57 - Bolt (6 Used) 61 - Holder Rod (8 Used)
34 - Stator Frame 58 - Support 62 - Crimp Type Contact
(4 Used)
W8R7-E-01(20160803) W2-2-50
15
1
W8R7-02-02-027
10 9
W8R7-E-01(20160803) W2-2-51
Assembly of Alternator
1. Install oil thrower (9) to shaft (1). Apply grease to 15

clearance (B) between oil thrower (9) and bearing
cover (10). 10
Use raremax super (Kyodo Yushi) or LGHP2
(SKF) for lubrication grease. Use it for all lubricant
B
described below.
2. Fill grease 200 g (0.44 lb) into the shaded area of

bearing cover (10). 1
Install bearing cover (10) to shaft (1).
Install bearing cover (10) while holding the right
angle to shaft (1).
9
3. Heat bearing (15) to 120°C (248°F) by using a

bearing heater. Install bearing (15) to shaft (1). W8DS-02-02-021
Install shaft (1) to bearing (15) slowly to prevent

damage. Install bearing (15) while holding the 10
right angle to shaft (1).
Fill grease 200 g (0.44 lb) into bearing (15).
W8DS-02-02-022
W8R7-E-01(20160803) W2-2-52
32
20
38
15 39, 40, 41
1
W8R7-02-02-027
W8R7-E-01(20160803) W2-2-53
4. Place the stator horizontally. 34 32 75 76 4
Install connecting shaft (77) to the flange of shaft
(1). Insert into hanger (76).
Position wire rope (75). Slowly move the shaft
assembly toward the arrow direction.
Do not contact stator core (32) with rotor core (4)
77
while moving the shaft assembly.
Install stud bolts (85) (2 used) through the
mounting bolt hole immediately before inserting
bearing (15) into bearing box (20). Install nuts (86)
(2 used) to stud bolt (85). Tighten the nuts and
insert bearing (15).
1
Insert the cloth between stator core (32) and rotor W8DS-02-02-016
85, 86
core (4). Remove the lifting tool.
5. Hoist plate (38). Align the matching marks marked

on plate (38) and shaft (1) when disassembling
with knock pin (41) (3 used). Install plate (38) to
the flange of shaft (1) with bolts (39) (12 used)
and washers (40) (6 used). Bend lock washers
(40) (6 used).
Set the turning device (special tool) under plate
(38). Check that plate (38) can be turned by hand.
: 36 mm
: 340 to 410 N·m
(34 to 41 kgf·m, 250 to 302 lbf·ft)
W8DS-02-02-025
38
W8DS-02-02-023
38
W8DS-02-02-024
Turning Device
W8R7-E-01(20160803) W2-2-54
34
36
38
1
W8R7-02-02-027
W8R7-E-01(20160803) W2-2-55
6. Set the phase of the plate (38) as illustrated to
flange (36). Look at from the Engine Side
92
87、88
90
38
36
W8R7-02-02-023
7. Secure the rotor with the rotor position adjusting 88 87 89

bolts (87) (4 used) and lock nuts (88) (4 used).
Store spacers (89) (4 used) instead of throwing
away.
Confirm that the all ends (4 places) of rotor posi-
tion adjusting bolts (87) (4 used) hit rotor position
adjusting plates (90) (4 used) completely. 36
90
38
W8R7-02-02-032 W8R7-02-02-031
8. Install transport brackets (92) (2 used) to flange 36

(36) and plate (38) with bolts (91) (4 used) and 91
(93) (2 used).
: 17 mm 92
: 24 to 28 N·m (2.4 to 2.8 kgf·m, 18 to 21
lbf·ft) 93
: 24 mm
: 100 to 110 N·m (10 to 11 kgf·m, 74 to 81 38
lbf·ft) W8R7-02-02-033
W8R7-E-01(20160803) W2-2-56
20
17
16
15
14
12, 13 1
W8R7-02-02-027
11 10
W8R7-E-01(20160803) W2-2-57
9. Fill grease into lubrication hole of bearing box (20).
Fill grease 200 g (0.44 lb) into bearing cover (17). 20
(shaded area in the figure)
Install bearing cover (17) to bearing box (20) and
bearing cover (10) with bolts (16) (8 used).
: 19 mm
: 35Nm (3.5 kgf·m, 66 lbf·ft)
W8DS-02-02-026
10. pply grease slightly into clearance (c) between
bearing cover (17) and oil thrower (11). 17
Install oil thrower (11) to the shaft (1).
W8DS-02-02-027
11. Install plate (14) to shaft (1) with bolts (12) (6

20 10
used) and lock washers (13) (3 used). Bend lock 16
washers (13) (3 used).
: 24 mm 17
: 270 Nm (27 kgf·m, 199 lbf·ft)
c
1
11
W8DS-02-02-021
W8R7-E-01(20160803) W2-2-58
60
59
58 63 58 63
56, 57
56, 57 59, 60
34 Aux. Alternator
61
62
20
55
10
61
W8R7-02-02-028
W8R7-E-01(20160803) W2-2-59
12. Install the support (58) assembly and the support
(63) assembly to stator flame (34) with bolts (57)
: 17 mm 59
: 20 Nm (2 kgf·m, 15 lbf·ft)
13. Install new carbon brushes (60) (16 used) onto

brush holders (59) (8 used). Install terminals (82)
(4 used) of brush holders (59) (8 used). 60 W8DS-02-02-018
Push carbon brush holder portion (81) in brush 81 82

holders (59) (8 used) downward. 60
: 10 mm
: 5 Nm (0.5 kgf·m, 3.7 lbf·ft)
59
W8DS-02-02-019
61 W8DS-02-02-020
14. Install inspection covers (65, 66) and terminal box 27 45

covers (27, 45) of main alternator.
: 17 mm
: 20 Nm (2 kgf·m, 15 lbf·ft) 65 66
15. Measure the coil insulation from the wiring in al-

ternator terminal box (27, 45) by using a insulat-
ing-resistance tester (megohm tester). Check for
the insulation resistance as follows. If any defect
is found, repair or replace the coil.
Main coil (U, V, W): 3 M OHM or more
Auxiliary coil (U, V, W): 3 M OHM or more
M8R8-07-115
16. Install temperature sensor (30) to stator frame

(34).
: 10 mm 30
: 6 Nm (0.6 kgf·m, 4.4 lbf·ft)
34
W8R7-02-02-029
W8R7-E-01(20160803) W2-2-60
BODY / Pump Device
REMOVAL AND INSTALLATJON OF PUMP
DEVICE
Removal

surface.

3. After the engine is stopped, operate the hoist lever

several times to release remaining pressure in the
circuit. T8DS-04-04-005
1 2 3, 54 Bracket
4. Remove the alternator cooling blower.

used). Remove cover (2) of driveshaft (1) from
bracket.
: 17 mm

used). Remove driveshaft (1) from the pump de-
vice and the alternator. Pump Device
Alternator 5, 43 4
: 19 mm W8R7-02-03-001
7. Remove bolt (6) and washer (7). Remove flange

4
(4), plates (8, 10), and retaining ring (9) from the 8
pump device. 6, 7
: 24 mm
8. Remove clips (46) (2 used), bolts (47) (2 used),

and washers (48) (2 used) securing harness from
bracket C (25).
: 17 mm 10 9 W8DS-02-03-001
9. Disconnect harnesses from the pump device.

Harness 25 46, 47, 48 Harness
Harness W8R7-02-03-002
W8R7-E-01(20160803) W2-3-1
BODY / Pump Device
10. Remove bolts (23) (2 used), bolts (24) (3 used),
and washers (58) (5 used). Remove bracket C 30
(25) from bracket A (30).
23, 58 25
: 19 mm
11. Loosen socket bolts (15) (4 used). Remove suc-

tion pipe (14) from the main pump assembly. In-
stall a cover to removed suction pipe (14).
：14 mm
12. Remove split flanges (41) (4 used) and socket

bolts (16) (8 used). Remove delivery hoses (11,
12) from the main pump assembly. Install a cap to
24, 58 W8R7-02-03-003
removed delivery hoses (11, 12).
：10 mm
20 13 19 15 14
13. Remove hydraulic piping (13, 19, 20, 21, 22) and
22
from the pump assembly. Install a cap to removed
hydraulic piping. 21
: 17 mm, 19 mm
30 mm, 36 mm
36 mm, 41 mm
14. Remove socket bolts (51) (8 used) and split

flanges (49, 50) (2 each used). Remove reduction 11
gear cooling hoses (17, 18) from the gear pump.
Install a cap to removed hydraulic piping.
：10 mm 12
16, 41 T8R7-02-03-004
CAUTION: Pump device weight: 222 kg Gear Pump

(489 lb) 50, 51 49, 51
15. Attach a nylon sling onto the pump device. Hoist 17

18
and hold the pump device.

used) from bracket A (30).
: 30 mm
W8R7-02-03-005
Pump
31, 32 Device
30
W8R7-02-03-006
W8R7-E-01(20160803) W2-3-2
BODY / Pump Device
17. Remove bolts (27) (3 used), washers (28) (3 used),
socket bolts (29) (2 used), and washers (55) (2 Pump Device
used) from bracket B (26) with the pump device.
Remove bracket B (26) from the pump device.
: 36 mm 29, 55
CAUTION: Pump device weight: 222 kg 27, 28

(489 lb)
26
18. Hoist and remove the pump device from bracket A
(30). W8R7-02-03-005
30
used). Remove the gear pump from the main
pump. 44
: 19 mm
20. Remove socket bolts (33) (4 used) and washers

(34) (4 used). Remove manifold (35) from main
pump 1.
：10 mm
45
Main Pump Gear Pump
21. Remove socket bolts (36) (4 used) and washers
(37) (4 used). Remove manifold (38) from main
pump 2.
：10 mm
22. Remove elbow S (44) and tee S (45) from the

39, 56
main pump.
：32 mm
35 33, 34 36, 37 38
W8R7-02-03-007
Main Pump 1 Main Pump 2
W8R7-E-01(20160803) W2-3-3
BODY / Pump Device
Installation
1. Install elbow S (44) and tee S (45) to the main
44 45
pump.
: 32 mm
: 140 N·m (14 kgf·m, 103 lbf·ft)
2. Install manifold (38) and O-ring (40) to the main

pump 2 with socket bots (36) (4 used) and wash-
ers (37) (4 used).
：10 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
Main Pump Gear Pump
3. Install manifold (35) and O-ring (40) to main pump

1 with socket bolts (33) (4 used) and washers (34)
(4 used).
：10 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
39, 56
4. Apply a slight amount of grease onto an O-ring.
33, 34 36, 37
Install the O-ring on a face of the main pump. In- 38, 40
35, 40
stall the gear pump to the main pump with bolts
: 19 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
CAUTION: Pump device weight: 222 kg

(489 lb) Main pump 1 Main pump 2
W8R7-02-03-007
5. Attach a nylon sling to the pump device. Hoist the
pump device and align to the bracket A (30) in- Pump Device
30 31, 32
stallation position.
6. Install the pump device to bracket A (30) with bolts

: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
W8R7-02-03-006
W8R7-E-01(20160803) W2-3-4
BODY / Pump Device
7. Install bracket B (26) to the pump device and
bracket A (30) with bolts (27) (3 used), washers Pump Device
(28) (3 used), socket bolts (29) (2 used), and
washer (55) (2 used). 29, 55
：19 mm
26
：110 N·m (11 kgf·m, 81 lbf·ft)
：14 mm 27, 28
：210 N·m (21 kgf·m, 155 lbf·ft) 30
8. Install suction pipe (14) to the main pump assem-

bly with O-ring (57) and socket bolts (15) (4 used). W8R7-02-03-005
：14 mm
：210 N·m (21 kgf·m, 155 lbf·ft)
20 13 19 15 14, 57
9. Install delivery hoses (11, 12) to the main pump 22
assembly with split flanges (41) (4 used), socket
bolts (16) (8 used), and O-rings (42) (2 used).
：10 mm 21
：110 N·m (11 kgf·m, 81 lbf·ft)
10. Install hydraulic piping (13, 19, 20, 21, 22) re-
moved during disassembly to the main pump as-
sembly.
: 17 mm, 19 mm
: 30 N·m (3 kgf·m, 22 lbf·ft)
: 30 mm, 36 mm 11
: 180 N·m (18 kgf·m, 133 lbf·ft) W8R7-02-03-004
: 36 mm, 41 mm 16, 41, 42 12

: 200 N·m (20 kgf·m, 148 lbf·ft)
50, 51 Gear Pump 49, 51
11. Install brake cooling hoses (17, 18) and O-rings
(52, 53) to gear pump with split flanges (49) (2 18, 53 17, 52
used), split flanges (50) (2 used), and socket bolts
(51) (8 used).
：10 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-02-03-005
W8R7-E-01(20160803) W2-3-5
BODY / Pump Device
12. Install bracket C (25) to bracket A (30) with bolts 30 25
(23) (2 used), bolts (24) (3 used), and washers
(58) (5 used).
23, 58
: 19 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
13. Connect harnesses disconnected during disas-

sembly to the pump device.
14. Install clips (46) (2 used), bolts (47) (2 used), and

washers (48) (2 used) to bracket C (25), and se-
cure the harness.
: 17 mm 24, 58 W8R7-02-03-003
: 20 N·m (2.0 kgf·m, 15 lbf·ft)
15. Apply grease on to shaft and spine of pump de- 25 46, 47, 48
vice. Install flange (4), plates (8, 10), and retaining
Harness Harness
ring (9) to the pump device and secure with bolt
(6) and washer (7).
: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft)
16. Install drive shaft (1) to the pump device and the
alternator with bolts (5) (8 used) and washers (43)
(8 used).
: 19 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
Harness W8R7-02-03-002
17. Install cover (2) of driveshaft (1) to the bracket with

: 17 mm 1 2 3, 54 Bracket
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
18. Install alternator cooling blower.

19. Remove body prop pins from the dump body.

Lower the dump body.
4 Pump Device
Alternator 5, 43
W8R7-02-03-001
4
8
6, 7
10 9 W8DS-02-03-001
W8R7-E-01(20160803) W2-3-6
BODY / Pump Device
IMPORTANT: After installing the pump device,
perform break-in operation for pre- 45 44
venting the pump device from initial
seizuring.
20. Release any pressure in the pump device.

1. Fill the pump casing with hydraulic oil.
When filling oil, remove hose (13) and elbow S
(44), and tee S (45).
Hose (13)
: 30 mm, 36 mm
: 180N m (18 kgf·m, 132 lbf·ft)
Elbow S (44), Tee S (45) W8R7-02-03-003
: 32 mm 13
: 140N m (14 kgf·m, 103 lbf·ft)
2. Start the engine and run at low idling speed for
20 minutes. During idling, check for any oil
leaks.
3. Accelerate the engine to its maximum speed.
Operate the hoist cylinder up and down for 20
minutes. When operating the lever, slowly
move the lever for a full stroke.
W8R7-E-01(20160803) W2-3-7
BODY / Pump Device
DISASSEMBLY OF MAIN PUMP
21 22
20 26
25
31 24
32 19
18 23
17
16
15
14
13
28 12
29
11
10
9
8
7
46 50
27
5 49
4 48
3
2 47
1
45
44
43
42
41 51
40
38
37 52
64
54 63
36 62
34 35
33
61
55 60
59
48
58
57
49 65
76
66
67
68
70
75 74 71
73 72
W8R7-02-03-008
W8R7-E-01(20160803) W2-3-8
BODY / Pump Device
1- Socket Bolt (4 Used) 21 - Regulator (2 Used) 40 - Spring (18 Used) 59 - O-Ring

2- Cover 22 - Socket Bolt (12 Used) 41 - Cylinder Block (2 Used) 60 - O-Ring (6 Used)
3- O-Ring 23 - Servo Piston (2 Used) 42 - Valve Plate 61 - Housing
4- Oil Seal 24 - O-Ring (2 Used) 43 - Bearing 62 - O-Ring
5- Shaft 25 - Backup Ring (2 Used) 44 - O-Ring 63 - Cover
7- Bearing (2 Used) 26 - Stopper (2 Used) 45 - Cover 64 - Socket Bolt (4 Used)
8- Spacer (3 Used) 27 - O-Ring (4 Used) 46 - Plug (2 Used) 65 - Cover
9- Retaining Ring (2 Used) 28 - Taper Screw (4 Used) 47 - O-Ring (2 Used) 66 - Socket Bolt (4 Used)
10 - Socket Bolt (4 Used) 29 - Plug (4 Used) 48 - Screw (2 Used) 67 - Shaft
11 - Cover 31 - O-Ring (2 Used) 49 - Nut (2 Used) 68 - Pin
12 - Nut (2 Used) 32 - Plug (2 Used) 50 - Booster 70 - Spring Pin
13 - Screw (2 Used) 33 - Swash Plate (2 Used) 51 - Coupling 71 - Cover
14 - Spring Pin (2 Used) 34 - Bushing (2Used) 52 - Spring Pin (2 Used) 72 - O-Ring (2 Used)
15 - O-Ring (2 Used) 35 - Shoe (18 Used) 54 - Pin 73 - Plug (2 Used)
16 - Stopper (2 Used) 36 - Plunger (18 Used) 55 - Shoe Plate (2 Used) 74 - O-Ring
17 - Backup Ring (2 Used) 37 - Retainer (2 Used) 57 - Bearing 75 - O-Ring
18 - O-Ring (2 Used) 38 - Spherical Bushing (2 Used) 58 - Valve Plate 76 - O-Ring (3 Used)
19 - Housing
20 - Tilt Pin (2 Used)
NOTE: Parts (7 to 9, 12 to 18, 20 to 41, and 55) in

housing (61) are the same as those used
in housing (19).
W8R7-E-01(20160803) W2-3-9
BODY / Pump Device
21 22
20 26
25
31 24
32 19
18 23
17
16
15
14
13
28 12
29
11
10
9
8
7
46 50
27
5 49
4 48
3
2 47
1
45
44
43
42
41 51
40
38
37 52
64
54 63
36 62
34 35
33
61
55 60
59
48
58
57
49 65
76
66
67
68
70
75 74 71
73 72
W8R7-02-03-008
W8R7-E-01(20160803) W2-3-10
BODY / Pump Device
Disassembly of Main Pump
• Before starting any repair work, thoroughly read 5. Remove cylinder blocks (41) (2 used), springs
all “Precautions for Disassembling and Assem- (40), (18 used), spherical bushings (38) (2 used),
bling” (W1-1-1). retainers (37) (2 used), plungers (36) (18 used),
and shoes (35) (18 used) from housings (19 and
IMPORTANT: Do not remove screws (13 and 48) 61), respectively.
and nuts (12 and 49). If removed, the
set flow rate will changed. 6. Remove socket bolts (1 and 64) (4 each used),
covers (2 and 63) and O-rings (3 and 62).
1. Remove plugs (32) (2 used) and O-rings (31) (2 Remove oil seal (4) from cover (2).
used) to drain hydraulic oil from the pump. : 6 mm
: 36 mm
7. While tapping covers (11 and 65) with a plastic
2. Remove socket bolts (22) (12 used) and hammer, remove the covers from housings (19
regulator (21)(2 used). and 61). Remove O-rings (15 (2 used) and 27 (4
: 6 mm used)) and spring pins (14) (2 used).
IMPORTANT: Take care not to allow valve plates 8. Remove swash plates (33) (2 used) and shoe
(42 and 58) to drop when separating plates (55) (2 used) from housings (19 and 61).
housing (19), cover (45), cover (71),
and housing (61) into each respec-
tive sub-assembly.
3. Insert pipes through bolt holes on covers (11 and

65) and hold the pipes not to allow the pump to
rotate. Then, remove socket bolts (10 and 66) (4
each used). Separate housing (19), cover (45),
cover (71) and housing (61) into each respective
sub-assembly. Remove O-rings (44, 59, 60, 74 to
76) and spring pins (52 and 70) .
: 17 mm
4. Remove booster (50), coupling (51), valve plate

(42) and pin (54) from cover (45). Remove valve
plate (58) and pin (68) from cover (71).
NOTE: Do not remove bearings (43 and 57)

unless required.
W8R7-E-01(20160803) W2-3-11
BODY / Pump Device
20 26
25
24
19
18 23
17
16
11
9
8
7
61
65
67
W8R7-02-03-008
W8R7-E-01(20160803) W2-3-12
BODY / Pump Device
9. While tapping shafts (5 and 67) with a plastic
hammer, remove shafts (5 and 67) from covers
(11 and 65).
10. Remove retaining rings (9) (2 used), spacers (8)

(3 used), bearings (7) (2 used) from shafts (5 and
67).
IMPORTANT: The joint between servo piston (23)

and tilt pin (20) is applied LOCTITE.
Take care not to damage servo
piston (23) when disassembling.
11. Remove stoppers (16 and 26) (2 each used),

servo pistons (23) (2 used), and tilt pins (20) (2
used) from housings (19 and 61).
12. Remove O-ring (18) and backup ring (17) from

stopper (16), and O-ring (24) and backup ring
(25) from stopper (26) respectively.
W8R7-E-01(20160803) W2-3-13
BODY / Pump Device
ASSEMBLY OF MAIN PUMP
46, 47 49 24, 25
14 33 55 35 19 34 44 60 48 75 57 26 60 23 59 20 61 16 17, 18
12 74 65
13
63
11
1 62
64
2
5
67
9
4
3 8
10
66
15
27
37 38 36 41 40 42 52 54 43 45 51 50 71 68 70 58 7
31, 32 72, 73 28, 29
W8R7-02-03-011
1- Socket Bolt (4 Used) 21 - Regulator (2 Used) 40 - Spring (18 Used) 59 - O-Ring

2- Cover 22 - Socket Bolt (12 Used) 41 - Cylinder Block (2 Used) 60 - O-Ring (6 Used)
3- O-Ring 23 - Servo Piston (2 Used) 42 - Valve Plate 61 - Housing
4- Oil Seal 24 - O-Ring (2 Used) 43 - Bearing 62 - O-Ring
5- Shaft 25 - Backup Ring (2 Used) 44 - O-Ring 63 - Cover
7- Bearing (2 Used) 26 - Stopper (2 Used) 45 - Cover 64 - Socket Bolt (4 Used)
8- Spacer (3 Used) 27 - O-Ring (4 Used) 46 - Plug (2 Used) 65 - Cover
9- Retaining Ring (2 Used) 28 - Taper Screw (4 Used) 47 - O-Ring (2 Used) 66 - Socket Bolt (4 Used)
10 - Socket Bolt (4 Used) 29 - Plug (4 Used) 48 - Screw (2 Used) 67 - Shaft
11 - Cover 31 - O-Ring (2 Used) 49 - Nut (2 Used) 68 - Pin
12 - Nut (2 Used) 32 - Plug (2 Used) 50 - Booster 70 - Spring Pin
13 - Screw (2 Used) 33 - Swash Plate (2 Used) 51 - Coupling 71 - Cover
14 - Spring Pin (2 Used) 34 - Bushing (2 Used) 52 - Spring Pin (2 Used) 72 - O-Ring (2 Used)
15 - O-Ring (2 Used) 35 - Shoe (18 Used) 54 - Pin 73 - Plug (2 Used)
16 - Stopper (2 Used) 36 - Plunger (18 Used) 55 - Shoe Plate (2 Used) 74 - O-Ring
17 - Backup Ring (2 Used) 37 - Retainer (2 Used) 57 - Bearing 75 - O-Ring
18 - O-Ring (2 Used) 38 - Spherical Bushing (2 Used) 58 - Valve Plate 76 - O-Ring (3 Used)
19 - Housing
20 - Tilt Pin (2 Used)
NOTE: Parts (7 to 9, 12 to 18, 20 to 41, and 55) in

housing (61) are the same as those used
in housing (19).
Refer to page W2-3-8 about parts (21, 22,
and 76) position.
W8R7-E-01(20160803) W2-3-14
BODY / Pump Device
Assemble of Main Pump
1. Install O-rings (24) and backup rings (25) onto 7. Install springs (40) (9 used), spherical bushing
stoppers (26), O-rings (18) and backup rings (17) (38), plungers (36) (9 used), retainers (37) and
onto stoppers (16), respectively. shoes (35) (9 used) to cylinder block (41). Install
the cylinder blocks onto shafts (5 and 67) while
IMPORTANT: Apply LOCTITE (medium adhesive) aligning splines.
to the joint between servo piston
(23) and tilt pin (20). IMPORTANT: Apply grease to the valve plate (42).
2. Install tilt pins (20) (2 used), servo pistons (23) (2 8. Install spring pins (52) (2 used), pin (54), valve
used), stoppers (26) (2 used), and stoppers (16) plate (42) and O-rings (44) to cover (45).
(2 used) into housings (19 and 61).
NOTE: When installing valve plate (42), align the
3. Heat bearing (7). Install bearings (7) (2 used), pin hole position with pin (54).
spacers (8) (3 used), and retaining rings (9) (2
used) onto shafts (5 and 67). 9. Install O-rings (60) (3 used) to housing (19)
assembly. Secure housing (19) assembly to
4. Install spring pins (14), O-ring (15), and O-ring cover (45) with socket bolts (10) (4 used).
(27) (2 used) to covers (11 and 65) respectively. : 17 mm
Install covers (11 and 65) to housings (19 and 61) : 430 Nxm (43 kgfxm, 317 lbfxft)
respectively.
10. Install coupling (51) and booster (50) to cover
5. Install shoe plate (55) to swash plate (33). Install (45).
swash plates (33) to housings (19 and 61)
respectively while installing the swash plate onto
tilt pin (20).
NOTE: After installing swash plate (33), make sure

that the swash plate can be moved
smoothly by hand.
6. Install oil seal (4) and O-ring (3) to covers (2).

Install O-ring (62) to cover (63). Press shafts (5
and 67) in covers (11 and 65). Secure covers (2
and 63) to covers (11 and 65) with socket bolts (1
and 64) (4 each used).
: 6 mm
: 30 Nxm (3 kgfxm, 22 lbfxft)
W8R7-E-01(20160803) W2-3-15
BODY / Pump Device
19 74 75 60 59 20 61
66
31, 32 71 68 70 58
W8R7-02-04-011
NOTE: Refer to page W2-3-8 about parts (21, 22,

76) position.
W8R7-E-01(20160803) W2-3-16
BODY / Pump Device
IMPORTANT: Apply grease to valve plate (58).
11. Install spring pin (70), pin (68), valve plate (58),
O-ring (59), O-rings (60) (3 used), O-rings (74,
75), and O-rings (76) (3 used) to cover (71).
NOTE: When installing valve plate (58), align the

pin hole position with pin (68).
12. Install cover (71) to housing (61). Then, secure

the housing (61) assembly to housing (19)
assembly with socket bolts (66) (4 used).
：17 mm
：430 Nxm (43 kgfxm, 317 lbfxft)
13. Secure regulator (21) onto housing (19) with

socket bolts (22) (6 used) so that the regulator
feedback lever joints with tilt pin (20).
：6 mm
：30 Nxm (3.0 kgfxm, 22 lbfxft)
14. Install O-rings (31) (2 used) and plugs (32) (2

used).
：36 mm
：150 Nxm (15 kgfxm, 110 lbfxft)
W8R7-E-01(20160803) W2-3-17
BODY / Pump Device
MAINTENANCE STANDARD
1. Clearance between plunger (36) outer diameter

(d) and cylinder block (41) bore diameter (D).
d D
D-d Unit : mm(in)
Standard Allowable Limit
0.038 (0.001) 0.078 (0.003)

W117-02-02-009
2. Free length (L) of spring (40)
L Unit : mm(in)
40.9 (1.610) 40.1 (1.579)
W117-02-02-010
3. Clearance (e) between plunger (36) and shoe

(35) and thickness (t) of shoe (35).
e Unit : mm(in)
0 to 0.1(0 to 0.004) 0.35 (0.014)
t Unit : mm(in) e
t
W117-02-02-011
5.4(0.213) 5.0 (0.197)
4. Height from the reverse face of retainer (37) to

the top of spherical bushing (38)
Base
H-h Unit : mm(in)
Standard Allowable Limit H

h
13.5 (0.531) 12.5 (0.492)

W117-02-02-012
W8R7-E-01(20160803) W2-3-18
BODY / Pump Device
(Blank)
W8R7-E-01(20160803) W2-3-19
BODY / Pump Device
DISASSEMBLY OF REGULATOR FOR MAIN PUMP
30 31 32 33 2 1 3 4 5 23 24 25
6
7
9 34
8 35
28、29 10
11 27
26
21
22
20 15 19 16 18 17 12 13 14
W8R7-02-03-009
1- Casing 10 - O-Ring 19 - Sleeve 28 - O-Ring

2- Spring Seat 11 - Plug 20 - Pilot Piston 29 - Plug
3- Spring 12 - Pin 21 - Sleeve 30 - O-Ring
4- Stopper 13 - O-Ring 22 - O-Ring 31 - Valve Seat
5- O-Ring 14 - O-Ring 23 - Socket Bolt (2 Used) 32 - Steel Ball
6- Cover 15 - O-Ring 24 - Pump Control Solenoid Valve 33 - Stopper
7- Socket Bolt (4 Used) 16 - Spool 25 - Valve Cover 34 - Socket Bolt (6 Used)
8- Screw 17 - Pin 26 - Socket Bolt (4 Used) 35 - Plug
9- Nut 18 - Feedback Lever 27 - Plug
W8R7-E-01(20160803) W2-3-20
BODY / Pump Device
Disassembly of Regulator for Main Pamp
• Before starting any repair work, thoroughly read

all “Precautions for Disassembling and Assem-
bling” (W1-1-1).
1. Remove socket bolts (23) (2 used) and remove

pump control solenoid valve (24).
：4 mm

valve cover (25).
：4 mm
3. Remove O-ring (30), valve seat (31), steel ball

(32) and stopper (33) from casing (1).
4. Remove O-ring (22), sleeve (21) and pilot piston

(20) from casing (1).
5. Remove plug (11), feedback lever (18), pin (17),

sleeve (19), and spool (16).
：6 mm
NOTE: Feedback lever (18) and pin (17) will come

off at the same time .
6. Remove socket bolts (7) (4 used) and cover (6).

：4 mm
IMPORTANT: Do not remove screw (8) and nut (9).

If removed, the pump flow rate
setting will be changed.
7. Using a bolt (M4), remove stopper (4). Then,

remove spring (3) and spring seat (2).
W8R7-E-01(20160803) W2-3-21
BODY / Pump Device
ASSEMBLY OF REGULATOR FOR MAIN PUMP
30 31 32 33 2 1 3 4 5 23 24 25
6
7
9 34
8 35
28、29 10
11 27
26
21
22
20 15 19 16 18 17 12 13 14
W8R7-02-03-009
1- Casing 10 - O-Ring 19 - Sleeve 28 - O-Ring

2- Spring Seat 11 - Plug 20 - Pilot Piston 29 - Plug
3- Spring 12 - Pin 21 - Sleeve 30 - O-Ring
4- Stopper 13 - O-Ring 22 - O-Ring 31 - Valve Seat
5- O-Ring 14 - O-Ring 23 - Socket Bolt (2 Used) 32 - Steel Ball
6- Cover 15 - O-Ring 24 - Pump Control Solenoid Valve 33 - Stopper
7- Socket Bolt (4 Used) 16 - Spool 25 - Valve Cover 34 - Socket Bolt (6 Used)
8- Screw 17 - Pin 26 - Socket Bolt (4 Used) 35 - Plug
9- Nut 18 - Feedback Lever 27 - Plug
W8R7-E-01(20160803) W2-3-22
BODY / Pump Device
Assembly of Regulator for Main Pump
1. Install sleeve (19) and spool (16) into casing (1).

Then, install feedback lever (18) to sleeve (19)
with pin (17).
NOTE: Take care not to mistake the direction of

sleeve (19) and spool (16) when installing.
2. Install O-ring (10) to plug (11). Align the pin holes

of feed back lever (18) and casing (1). Then,
install plug (11) into casing (1).
: 6 mm
: 20 Nxm (2.0 kgfxm, 15 lbfxft)
NOTE: After installing plug (11), check that the

feedback lever (18) moves smoothly.
3. Install spring seat (2), spring (3), stopper (4), and

O-ring (5) into casing (1). Secure cover (6) with
socket bolts (7) (4 used).
: 4 mm
4. Install pilot piston (20), sleeve (21), and O-ring

(22) into casing (1).
5. Install stopper (33), steel ball (32), valve seat (31),

and O-ring (30) into casing (1).
6. Install pump control solenoid valve (24) to valve

cover (25) with socket bolts (23) (2 used). Secure
valve cover (25) to casing (1) with socket bolts
(26) (4 used).
: 4 mm
W8R7-E-01(20160803) W2-3-23
BODY / Pump Device
STRUCTURE OF GEAR PUMP
Details C
Details D
View B – B View A – A W8R7-02-03-010
W8R7-E-01(20160803) W2-3-24
BODY / Pump Device
Structure of Gear Pump
Part Name Q’ty Remark
1 Gear plate 1
2 Drive gear 1 Supplied in combination of 2 and 3. Apply hydraulic oil during
assembly.
3 Driven gear 1 Supplied in combination of 2 and 3. Apply hydraulic oil during
assembly.
4 Mounting flange 1
5 Cover 1
6 Pressure plate 2
7 Plate seal 2 Supplied as a repair kit. Apply grease during assembly.
8 Backup ring 2 Supplied as a repair kit. Apply grease during assembly.
9 Isolation plate 2
10 Knock pin 4
11 O-ring 2 Supplied as a repair kit. Apply grease during assembly.
12 Oil seal 2 Supplied as a repair kit. Apply grease during assembly.
13 Retaining ring 1 Supplied as a repair kit.
14 Bolt 4 Wrench size : 17 mm, Tightening torque : 40 to 45 N⋅m (4 to 4.5
kgf⋅m 30 to 33 lbf⋅ft)
15 Bolt 4 Wrench size : 17 mm, Tightening torque : 40 to 45 N⋅m (4 to 4.5
kgf⋅m 30 to 33 lbf⋅ft)
16 Spring washer 8
17 Special washer 1
W8R7-E-01(20160803) W2-3-25
BODY / Pump Device
DISASSEMBLY OF DRIVE SHAFT
5 3 1
2
4
11
10
9
8
7
6
3
2
1
5
W8DS-02-03-009
Drive Shaft Assembly Exploded Diagram
1- Flange Yoke (2 Used) 4- Needle Bearing (8 Used) 7- Grease Fitting 10 - Seal Retainer
2- Journal Cross Assembly 5- Snap Ring (8 Used) 8- Seal 11 - Shaft Assembly
(2 Used)
3- Grease Fitting (2 Used) 6- Sleeve Assembly 9- Washer
W8R7-E-01(20160803) W2-3-26
BODY / Pump Device
Disassembly of Drive Shaft
• Slip Joint 8 9 10
IMPORTANT: Before disassembling the drive shaft, 11
inspect the run out by following the
procedure provided in “Inspection”
in this chapter.
1. If the arrow mark (A) shown in the illustration is

not provided, make punch marks on sleeve
assembly (6) and shaft assembly (11) for A
indicating proper positions of components.
Slip Joint W8DS-04-51-001
2. Loosen seal retainer (10). Draw out shaft

assembly (11) from sleeve assembly (6). Remove
seal (8), washer (9), and seal retainer (10). 5
11
• Universal Joint
NOTE: Take the following procedure to remove the
journal cross assembly from the drive shaft. 2
First, remove the journal cross assembly
from the universal joint of shaft assembly
(11). Secondly, remove sleeve assembly
(6). Lastly, remove flange yoke (1).
Loosening Method of Needle Bearing W8DS-04-51-002
CAUTION: Do not tighten a balancing weight
section welded to sleeve assembly (6).
3. Lightly secure shaft assembly (11) by using a vise 5

with a soft base.
4. Move needle bearing (4) until snap ring (5) can be

removed by hitting the needle bearing (4) end
with a hammer and a brass-made round bar.
5. Remove snap ring (5). Similarly, remove snap ring

(5) at the other side.
Removal of Snap Ring W8DS-04-51-003
W8R7-E-01(20160803) W2-3-27
BODY / Pump Device
5 1
2
4
11
6
2
1
4
5
W8DS-02-03-009
W8R7-E-01(20160803) W2-3-28
BODY / Pump Device
6. Tap and push out journal cross assembly (2), until
needle bearing (4) at the other side can be freed.
At that time, use a soft brass-made round bar that
has a planar section with approximately 0.79 mm
(0.031 in) smaller than the inner diameter of
needle bearing (4). Remove needle bearing (4).
7. Turn over the assembly. Tap and push out the

exposed end of journal cross assembly (2) until
needle bearing (4) at the other side gets freed.
Remove needle bearing (4).
CAUTION: Do not disassemble the needle W8DS-04-51-004

Removal of Needle Bearing
bearing.
8. Tilt journal cross assembly (2) and the flange 2 11

yoke (1) assembly until they are apart from the
shaft assembly (11) yoke. Lift and remove the
journal cross assembly and flange yoke assembly.
Refer to the illustration.
9. Remove journal cross assembly (2) and the

flange yoke (1) assembly from sleeve assembly
(6) by taking the same procedure as above step 3
through 8.
10. Remove journal cross assembly (2) from flange

yoke (1) by taking the same procedure as above W8DS-04-51-005
step 3 through 8. 1
Removal of Journal Cross Assembly
and Flange Yoke Assembly
W8R7-E-01(20160803) W2-3-29
BODY / Pump Device
INSPECTION OF DRIVE SHAFT
2
4
11
8
6
2
W8DS-02-03-009
W8R7-E-01(20160803) W2-3-30
BODY / Pump Device
Inspection of Drive shaft
Sleeve and Shaft Assembly

1. Before disassembling the sleeve and shaft
assembly (6, 11), inspect the drive shaft run out.
Place the drive shaft on two V blocks. Check that
each end of the drive shaft is placed on a flat
surface of the V block.
2. Set a dial gauge to the center of the drive shaft.

Turn the drive shaft on the V block. Run out
reading value must be within 0.050 mm (0.002 in)
on the gauge.
3. If runout exceeds 0.050 mm (0.002 in), inspect

runout of sleeve assembly (6) and shaft assembly
(11) respectively by following steps 1 and 2
described above. Replace all bent parts.
4. Inspect warpage, burr, roundness at ends, and

other defects on the yoke that affects connection
of the flange. Replace damaged or defective
parts.
Slip Joint
1. If the slip joint does not operate freely, inspect the
spline of sleeve assembly (6) and cut, burr, and
sever wear of shaft assembly (11). Use a finishing
grind stone to remove a scratch and burr.
2. Inspect the seal (8) condition.
3. Replace worn parts and damaged parts.
W8R7-E-01(20160803) W2-3-31
BODY / Pump Device
5
2 3
4
11
9 10
8
7
6
3
2
W8DS-02-03-009
W8R7-E-01(20160803) W2-3-32
BODY / Pump Device
Universal Joint
1. Clean all the parts.
2. Inspect all parts for burr, scratch, and sever wear.
3. Apply a film of grease onto journal cross

assembly (2). For recommended grease, refer to
“Operator’s Manual”.
4. Place needle bearing (4) onto journal cross

assembly (2). Inspect the needle bearing for
severe wear while the bearing is rotating.
5. When either one of needle bearing (4) and journal

cross assembly (2) is worn, replace both units. If
either one of above is replaced, a replaced part
gets worn out severely. Always replace both units
together.
W8R7-E-01(20160803) W2-3-33
BODY / Pump Device
ASSEMBLY OF DRIVE SHAFT
5
2
4
11
6
2
1
5
W8DS-02-03-009
W8R7-E-01(20160803) W2-3-34
BODY / Pump Device
Assembly of Drive Shaft
Slip Joint
1. Install seal retainer (10), washer (9), and seal (8)
to shaft assembly (11).
2. Apply sufficient amount of grease onto the spline

of shaft assembly (11). For recommended grease,
refer to “Operator’s Manual”.
Align the Arrows 11
3. Align arrows on shaft assembly (11) and sleeve
assembly (6). If arrows are not provided, use
punched marks made during disassembly
instead.
4. Tighten seal retainer (10). W8DS-02-03-010

6 Setting a Yoke Rag on a Straight Line
NOTE: Refer to the illustration. Exploded view
shows components for explanations and is Assembly of Drive Shaft
for reference. Align parts of the drive shaft
to balance out properly.
Universal Joint
IMPORTANT: Align the position of grease fitting
11
(3) in journal cross assembly (2) to
grease fitting (7) in sleeve assembly
(6).
1. Insert a trunnion at one side of journal cross 2

assembly (2) into a lower bearing hole of the shaft
assembly (11) yoke. While lowering and tilting
journal cross assembly (2), insert a trunnion at the
other side into another bearing hole.
2. Place one needle bearing (4) onto shaft assembly 4

(11). Push needle bearing (4) to a specified
position by using a press. Set the needle bearing W8DS-04-51-007
at the specified position by tapping with the Installation of Cross Assembly
lightweight plastic hammer.
3. Install snap ring (15).
W8R7-E-01(20160803) W2-3-35
BODY / Pump Device
5
2
4
11
6
2
1
5
W8DS-02-03-009
W8R7-E-01(20160803) W2-3-36
BODY / Pump Device
4. Turn shaft assembly (11). Install another needle
bearing (4) by following steps 2 to 3 described
above.
5. If the joint movement is limited, lightly tap needle

bearing (4) in order to release pressure applied
on journal cross assembly (2).
6. Install journal cross assembly (2) to sleeve

assembly (6) by taking the same procedure as
step 1 through 5 described above.
7. Insert two trunnions of journal cross assembly (2)

to flange yoke (1) by taking the same procedure
as above step 1 through 5. Install needle bearing
(4) and snap ring (5).
8. Insert two trunnions of journal cross assembly (2)

to another flange yoke (1) by taking the same
procedure as above step 7. Install needle bearing
(4) and snap ring (5).
W8R7-E-01(20160803) W2-3-37
BODY / Pump Device
MAINTENANCE OF DRIVE SHAFT
The most common cause for drive shaft troubles is

improper lubricating operation.
When the remaining amount of grease is insufficient,
there will be unnecessary abrasion and damage the
drive shaft. For proper lubrication, refer to “Operator’s
Manual”.
For proper lubrication of all needle bearings, inject

grease as much as the grease overflows from all
bearing seals. With this operation, dirt and other
contaminants inside of the needle bearings can be
removed. In addition, needle bearings can be
lubricated sufficiently. Refer to the illustration.
Grease sometimes takes time to come out from

bearing seals. While putting the grease gun against
the grease fitting, apply force to the drive shaft from
other direction. Joints can be bent by grease pressure
from the grease fitting. By taking above procedure,
four needle bearing can be properly lubricated
preliminarily. If lubrication still does not succeed,
W8DS-04-51-008
remove journal cross assembly and needle bearing.
Inspect, repair, and/or replace if necessary.
Always leave the slip joint section in a lubricated

condition. Now, sleeve assembly cavity at the front
section of the shaft can be lubricated. This grease is
distributed at the spline during rotating.
W8R7-E-01(20160803) W2-3-38
BODY / Drive Device
REMOVAL AND INSTALLATION OF DRIVE
DEVICE
1 2 3, 4
W8R7-02-04-072
5 6 7
W8R7-02-04-073
10 9 8
1 - Tire (2 Used) 4 - Washer (46 Used) 7 - Parking Brake Assembly 9 - Drain Plug (2 Used)
2 - Drive Device 5 - Wheel Reduction Device 8 - Lubrication Plug 10 - Level Plug
Assembly
3 - Bolt (46 Used) 6 - Wheel Motor Assembly
W8R7-E-01(20160803) W2-4-1
BODY / Drive Device
13, 14 12 11
15, 16
17, 18
19, 20
W8R7-02-04-074
W8R7-02-04-075
24
22
21
23
W8R7-02-04-076
W8R7-02-04-077
27 25, 26 29, 30 31
29, 30
32
25, 26 28
W8R7-02-04-078
W8R7-02-04-079
11 - Terminal Box 17 - Parking Brake Hose 23 - Air Breather Hose 28 - Brake Cooling Hose
12 - Nut (3 Used) 18 - O-ring 24 - Air Breather Hose 29 - Bolt (8 Used)
13 - Clamp (3 Used) 19 - Rear Brake Hose 25 - Bolt (8 Used) 30 - Split Flange (4 Used)
14 - Bolt (3 Used) 20 - O-ring 26 - Split Flange (4 Used) 31 - Wheel Reduction Device
Cooling Hose
15 - Clamp (3 Used) 21 - Grease Hose 27 - Brake Cooling Hose 32 - Wheel Reduction Device
Cooling Hose
16 - Bolt (3 Used) 22 - Grease Hose
W8R7-E-01(20160803) W2-4-2
BODY / Drive Device
Removal
1. Remove the body. Refer to REMOVAL AND IN-

STALLATION OF BODY.
2. Remove rear tires (1) (2 used) on the drive device

removal side. Refer to REMOVAL AND INSTAL-
LATION OF FRONT TIRE AND RIM.
3. Check that there is no residual voltage on

high-voltage harnesses in terminal box by using a
voltage detecting rod.
12 11
13, 14
4. Loosen nuts (12) (3 used) and remove harnesses
U, V, and W from terminal box on the wheel motor
removal side. Install nuts (12) to the bolts after
removing harnesses.
：19 mm 15, 16
5. Loosen bolts (14) (3 used), (16) (3 used) of

clamps (13) (3 used), (15) (3 used) in terminal box
(11) and the rear axle. Remove harnesses U, V,
and W from clamps (13) (3 used), (15) (3 used).
：17 mm
W8R7-02-04-074
NOTE: Do not remove clamps (13) (3 used), Wheel Motor Side Terminal Box
clamps (15) (3 used), bolts (14) (3 used),
and bolts (16) (3 used).
6. Remove the sensor harnesses of the wheel mo-

tor.
W8R7-E-01(20160803) W2-4-3
BODY / Drive Device
7. Release the residual hydraulic pressure in the
brake system. Refer to REMOVAL AND IN-
STALLATION OF BRAKE VALVE.
8. Disconnect parking brake hose (17) from the

parking brake.
：22 mm
9. Disconnect rear brake hose (19) from the drive

device.
：22 mm
17
19
W8R7-02-04-075
10. Disconnect grease hoses (21, 22) from the wheel

motor.
：17 mm
22
21
W8R7-02-04-076
24
11. Disconnect air breather hoses (23, 24) from the
drive device.
：22 mm
23
W8R7-02-04-077
W8R7-E-01(20160803) W2-4-4
BODY / Drive Device
12. Remove bolts (25) (8 used) and sprit flanges (26)
(4 used) from the drive device. Disconnect brake
cooling hoses (27, 28).
：8 mm
25, 26 28
W8R7-02-04-078
13. Remove bolts (29) (8 used) and sprit flanges (30) 29, 30 31
(4 used) from the drive device. Disconnect wheel
reduction device cooling hoses (31, 32).
：8 mm
NOTE: Fit a plug to the hose that has been dis- 29, 30
connected so that the oil cannot leak out.
32
W8R7-02-04-079
14. Remove drain plugs (9) (2 used) and lubrication

plug (8) and drain the gear oil. After draining the
gear oil, re-fit the drain plugs (9) (2 used) and lu-
brication plug (8).
Gear oil capacity: approximately 140 L
9 W8R7-02-04-080
W8R7-E-01(20160803) W2-4-5
BODY / Drive Device
CAUTION: Drive device weight: 14400 kg (31700 3, 4

lb) 2
15. Using an appropriate hoisting device, hoist and

hold drive device (2) from the body.
Wire ropes Diameter 22 mm (0.9 in.), Length 7 m
(275 in.) (2 used)
Chain blocks (5000 kg) (11000 lb) (2 used)
used). Remove drive device (2) from the body.
：50 mm
W8R7-02-04-088
W8R7-E-01(20160803) W2-4-6
BODY / Drive Device
Installation 3, 4 2
CAUTION: Drive device weight: 14400 kg (31700

lb)
1. Using an appropriate hoisting device, hoist and

hold drive device (2) and align with the body in-
stallation point.
Tools:
Wire ropes Diameter 22 mm (0.9 in.), Length 7 m
(275 in.) (2 used)
Chain blocks (5000 kg) (11000 lb) (2 used)
2. Install drive device (2) to the body with bolts (3)

: 50 mm
W8R7-02-04-088
: 2600 N·m (260 kgf·m, 1920 lbf·ft) 29, 30 31
Tools:
Hydraulic wrench
Socket ( : 50 mm) (2 used)
Impact wrench
29, 30
3. Connect wheel reduction device cooling hoses
(31, 32) with new O-rings to the drive device with
bolts (29) (8 used) and sprit flanges (30) (4 used).
32
：8 mm
：50 N·m (5 kgf·m, 37 lbf·ft)
4. Connect brake cooling hoses (27, 28) with new

O-rings to the drive device with bolts (25) (8 used)
and sprit flanges (26) (4 used).
：8 mm
W8R7-02-04-079
：50 N·m (5 kgf·m, 37 lbf·ft)
27 25, 26
25, 26 28
W8R7-02-04-078
W8R7-E-01(20160803) W2-4-7
BODY / Drive Device
5. Connect air breather hoses (23, 24) to the drive
device.
: 22 mm
: 40 N·m (4.0 kgf·m, 30 lbf·ft)
24
23
W8R7-02-04-077
6. Connect grease hoses (21, 22) to the wheel mo-

tor.
: 17 mm
: 25 N·m (2.5 kgf·m, 18 lbf·ft)
22
21
W8R7-02-04-076
7. Install new O-ring (20) to the drive device. Con-

nect rear brake hoses (19) to the drive device.
：22 mm
：70 N·m (7.0 kgf·m, 52 lbf·ft)
8. Install new O-rings (18) to the tees of parking

brake. Connect rear brake hoses (17) to the tees.
：22 mm
：70 N·m (7.0 kgf·m, 52 lbf·ft)
17, 18
19, 20
W8R7-02-04-075
W8R7-E-01(20160803) W2-4-8
BODY / Drive Device
9. Loosen bolts (14) (3 used), (16) (3 used) of
13, 14 12 11
clamps (13) (3 used), (15) (3 used) in terminal box
(11) and the rear axle. Install harnesses U, V, and
W to clamps (13) (3 used), (15) (3 used).
：17 mm
：20 N·m (2.0 kgf·m, 15 lbf·ft)
15, 16
10. Install the sensor harnesses of the wheel motor.
11. Install harnesses U, V, and W with nuts (12) (3

used) of terminal box (11).
：19 mm
：35 N·m (3.5 kgf·m, 26 lbf·ft)
W8R7-02-04-074
Wheel Motor Side Terminal Box

12. Remove lubrication plug (8) and refill with gear oil.
Refuel capacity: 140 L
13. Install rear tires (1) (2 used) to the drive device.

FRONT TIRE AND RIM.
14. Install the body. Refer to REMOVAL AND IN-

STALLATION OF BODY.
15. Check the level of hydraulic oil. Refill the hydrau-

lic oil if necessary.
8
16. Install the vinyl hose to air bleed plug (33). Attach
the other end of the vinyl hose to oil drain tray.
W8R7-02-04-080
17. Start the engine, and wait until the brake pressure
reaches normal value. Depress the brake pedal,
loosen the air bleed plug, and push out oil until air
bubble does not come out from the hose.
18. Close the air bleed plug and remove the vinyl
hose.
19. Drive the vehicle under a controlled environment

and inspect the brake performance before oper-
ating the vehicle on site.
W8R7-02-04-089
33
W8R7-02-04-090
W8R7-E-01(20160803) W2-4-9
BODY / Drive Device (Wheel Motor Assembly)
REMOVAL AND INSTALLATION OF
WHEEL MOTOR ASSEMBLY
2 3, 4 1
W8R7-02-04-081
1 - Wheel Reduction Device 3 - Bolt (12 Used) 4 - Washer (12 Used) 6- Park Brake Assembly
Assembly
2 - Wheel Motor Assembly
W8R7-E-01(20160803) W2-4-10
Removal
CAUTION: Wheel motor assembly (2) weight:

3360 kg (7410 lb)
1. Attach a nylon sling onto the frame of wheel

motor assembly (2). Hoist and hold the frame.
2. Remove bolts (3) (12 used) and washer (4) (12

used). Pull wheel motor assembly (2) out from
wheel reduction device assembly (1) by ap-
proximately 100 mm (3.9 in.).
: 36 mm
3. Attach the nylon sling onto wheel reduction de-

vice (1) side of the frame. Remove wheel motor
assembly (2). Keep the assembly balanced when
removing.
W8R7-E-01(20160803) W2-4-11
Installation
2 3, 4 1
W8R7-02-04-081
1- Wheel Reduction Device 3- Bolt (12 Used) 4- Washer (12 Used) 6- Parking Brake Assembly
Assembly
2 - Wheel Motor Assembly
W8R7-E-01(20160803) W2-4-12
Installation
CAUTION: Wheel motor assembly (2) weight:

3360 kg (7410 lb)
1. Attach the nylon sling 100 mm (3.9 in.) from the

wheel motor flange surface. Attach the wire rope
onto the parking brake flange (Diameter 12 mm
(0.5 in.), Length 5 m (200 in.)). Hoist the wheel
motor. Keep the wheel motor level when hoisting.
2. Align the shaft of the wheel reduction device and

the wheel motor spline. Insert the wheel motor
into the wheel reduction device. Insert the wheel
motor further once the gear reductor shaft and
the wheel motor spline have engaged.
3. Attach the nylon sling onto the parking brake

frame, and insert the wheel motor further while
holding the parking brake side of the frame.
4. Install wheel motor assembly (2) to wheel reduc-

tion device assembly (1) with bolts (3) (12 used)
and washers (4) (12 used).
: 36 mm
: 950 N·m (95 kgf·m, 700 lb·ft)
W8R7-E-01(20160803) W2-4-13
BODY / Drive device (Parking Brake)
DISASSEMBLY OF PARKING BRAKE
18
17
16
15
14
13
12
11
10
4 11
3 12
9 42 13
8 20 14
7 37 15
20 16
5 17
18
38
39 3
4
5
47 9 T8DS-02-04-216
10
Parking Brake Disassembly Diagram
3- Backup Ring (2 Used) 9- Seal (2 Used) 15 - Spring (12 Used) 37 - Plate

4- Seal (2 Used) 10 - Backup Ring (2 Used) 16 - End Cap (2 Used) 38 - Bolt (4 Used)
5- Piston Housing (2 Used) 11 - Screw (12 Used) 17 - Washer (8 Used) 39 - Washer (4 Used)
6- Bleed Valve (2 Used) 12 - Lining (2 Used) 18 - Bolt (8 Used) 42 - Disc
7- Washer (6 Used) 13 - Piston (2 Used) 20 - Shim (2 Used) 47 - Shim (2 Used)
8- Bolt (6 Used) 14 - Spring (12 Used)
W8R7-E-01(20160803) W2-4-14
40
47
41
34, 35
36
37
42
45 43, 44
T8R7-02-04-084
Detail d
38, 39 View B T8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8
Wheel Motor
30
C
31
T8R7-02-04-082
View C
50
48, 49, 50 49, 51
52
T8DS-02-04-220
5- Piston Housing 34 - Bolt (4 Used) 41 - Hub 47 - Shim
7- Washer (6 Used) 35 - Washer (4 Used) 42 - Disc 48 - Adapter S
8- Bolt (6 Used) 36 - Bracket 43 - Bolt (12 Used) 49 - O-Ring (2 Used)
30 - Parking Brake Head As- 37 - Plate 44 - Washer (12 Used) 50 - Socket S (2 Used)
sembly
31 - Knock Pin (2 Used) 38 - Bolt (5 Used) 45 - Plate 51 - Tee S
32 - Bolt 39 - Washer (5 Used) 46 - Bolt and Washer (4 Used) 52 - Hose
33 - Washer 40 - Key
W8R7-E-01(20160803) W2-4-15
40
47
41
34, 35
36
37
42
45 43, 44
W8R7-02-04-084
Detail d
38, 39 View B W8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8
Wheel Motor
30
C
31
W8R7-02-04-082
50
48, 49, 50 49, 51
52
T8DS-02-04-220
View C
W8R7-E-01(20160803) W2-4-16
Disassembly of Parking Brake
1. Disconnect hose (52) from adapter (48) and tee

S (51). Remove socket S (50) (2 used), adaptor
S (48), tee S (51), and O-rings (49) (2 used) from
parking brake head assembly (30).
: Adapter S 17 mm,
Socket S 24 mm,
Tee S 17 mm,
Hose 19 mm
2. Slowly loosen bolts (8) (6 used) that securing

piston housings (5) (2 used) to plate (37) one
turn at a time. Do not remove bolts (8) (6 used) at
this time. This will cause springs (14, 15) to
weaken and linings (12) (2 used) to separate 7, 8 14 15
from disc (42). 5
: 1-1/8 in
CAUTION: The piston housing (5) assembly

weight: 28 kg (62 lb)
3. Hoist the piston housings (5) (2 used) assembly. 20 42

Hold the piston housings in place. Remove bolts
(8) (6 used), washers (7) (6 used), and shim (20). 37
Slide the piston housing (5) assembly to remove
from disc (42).
T8DS-02-04-226
12
W8R7-E-01(20160803) W2-4-17
40
47
41
34, 35
36
37
42
45 43, 44
W8R7-02-04-084
Detail d
38, 39 View B W8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8
Wheel Motor
30
C
31
W8R7-02-04-082
W8R7-E-01(20160803) W2-4-18
4. Loosen bolts (38) (5 used). Remove plate (37),
shims (47) and bolts (38) (5 used) and washers
(39) (5 used) from bracket (36). Do not remove
knock pin (31) unless necessary.
: 27 mm
CAUTION: Bracket (36) weight: 30 kg (66 lb)
5. Attach nylon sling to bracket (36). Lift and hold

bracket (36).
Loosen bolts (34) (4 used). Remove bracket (36)
along with bolts (34) (4 used) and washers (35)
(4 used) from the wheel motor. Do not remove
knock pin (31) unless necessary.
: 30 mm
CAUTION: Disc (42) weight: 34 kg (75 lb)
6. Attach nylon sling onto disc (42). Lift and hold

disc (42).
Loosen bolts (43) (12 used). Remove disc (42),
bolts (43) (12 used), and washers (44) (12 used)
from hub (41).
: 30 mm
CAUTION: Hub (41) weight: 23 kg (51 lb)
7. Attach nylon sling onto hub (41). Lift and hold

hub (41).
Loosen bolts and washers (46) (4 used) and bolt
(32). Remove plate (45), bolts and washers (46)
(4 used), bolt (32) and washer (33). Remove hub
(41) from the wheel motor shaft. Remove key
(40) from shaft key groove.
Bolt (46)
: 19 mm,
Bolt (32)
: 46 mm
W8R7-E-01(20160803) W2-4-19
18
17
16
15
14
13
12
11
10
4 11
3 12
9 13
14
15
16
5 17
18
3
4
5
9 T8DS-02-04-216
10
W8R7-E-01(20160803) W2-4-20
8. Remove screws (11) (6 used) that holds lining
(12) to piston (13). Epoxy adhesive is used to
hold the screws.
3 4 5 9 10 16 18
IMPORTANT: The temperature must not exceed
176°C (350°F) when loosening the
screw head.
9. Gradually loosen bolts (18) (4 used) one turn at a

time to decrease the load on piston (13) spring.
Remove end cap (16), bolts (18) (4 used), and
washers (17) (4 used) once springs (14, 15) are
fully extended.
: 7/16 in.
10. Remove springs (14, 15) (6 used for each) from

piston interiors.
11. Remove piston (13) from piston housing (5).
12. Remove and discard seals (4, 9) and backup

rings (3, 10) from piston housing (5) interiors and
piston.
NOTE: Make a note of the assembly installation T8DS-02-04-227

13 12 11 Release Area 14 15 18
positions. All components must be reas-
sembled in its correct position.
13. Remove the other piston housing (5) assembly by

following the same procedures.
W8R7-E-01(20160803) W2-4-21
INSPECTION OF PARKING BRAKE
1910 - 2340 N 6230 - 8900 N
195 - 238 kgf 635 - 907 kgf
430 - 525 lbf 1400 - 2000 lbf
3110 - 3600 N 9340 - 12230 N

318 - 367 kgf 80.49 mm 953 - 1247 kgf
700 - 810 lbf (3.17 in.) 2100 - 2750 lbf
75.42 mm
(3.00 in.)
14 15
Piston Housing
Piston
D A
C B
13
Piston Minimum Diameter A 143.81 mm (5.66 in.) W8DS-05-52-001

B 177.57 mm (6.99 in.)
Piston Housing Maximum Diameter C 177.88 mm (7.00 in.)
D 143.05 mm (5.63 in.)
Dimensions of Inspection Points
W8R7-E-01(20160803) W2-4-22
Inspection of Parking Brake
1. Inspect lining (12) for any wear or damage. Re-

place the lining when its thickness is less than
2.54 mm (0.10 in.). The lining should also be re-
placed if any of the maintenance conditions out-
lined in this chapter are met.
2. Inspect piston (13) and piston housing (5) for any

marks or corrosion. If any small marks are found,
use a metallic polishing cloth to remove, or re-
place the component. Refer to the “Dimensions of
Inspection Points” diagram for detail on the wear
level limit.
3. Inspect piston housings (5) for any cracks. In-

spect the piston housing (5) for any stripped
thread.
4. Inspect disc (42) for any wear or cracks. Replace

disc (42) if there are any cracks, wear of up to 16
mm (0.63 in.). The disc should also be replaced if
any of the maintenance conditions are met.
5. Inspect bleed valve (6) screw threads and seat.
6. Inspect springs (14, 15). Replace any springs with

apparent damage. Inspect springs squareness.
Vertically set the spring on a flat surface and
measure the amount of distortion. Permissible
range of spring distortion is 2.54 mm (0.1 in.) or
below.
CAUTION: Failure to replace broken or

damaged springs will result in a loss of
braking ability and may lead to brake failure.
7. Spring (14, 15) load/deflection can be checked

using the values shown on the “Dimensions of
Inspection Points” diagram.
W8R7-E-01(20160803) W2-4-23
ASSEMBLY OF PARKING BRAKE
18
17
16
15
14
13
12
11
10
4 11
3 12
9 42 13
8 20 14
7 37 15
20 16
5 17
18
38
39 3
4
5
47 9 T8DS-02-04-216
10
Parking Brake Assembly Diagram
3- Backup Ring (2 Used) 9- Seal (2 Used) 15 - Spring (12 Used) 37 - Plate

4- Seal (2 Used) 10 - Backup Rings (2 Used) 16 - End Cap (2 Used) 38 - Bolt (4 Used)
5- Piston Housing (2 Used) 11 - Screw (12 Used) 17 - Washer (8 Used) 39 - Washer (4 Used)
6- Bleed Valve (2 Used) 12 - Lining (2 Used) 18 - Bolt (8 Used) 42 - Disc
7- Washer (6 Used) 13 - Piston (2 Used) 20 - Shim (2 Used) 47 - Shim (2 Used)
8- Bolt (6 Used) 14 - Spring (12 Used)
W8R7-E-01(20160803) W2-4-24
40
47
41
34, 35
36
37
42
45 43, 44
W8R7-02-04-084
Detail d
38, 39 View B W8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8
Wheel Motor
30
C
31
W8R7-02-04-082
View C
50
48, 49, 50 49, 51
52
T8DS-02-04-220
5- Piston Housing 34 - Bolt (4 Used) 41 - Hub 47 - Shim
7- Washer (6 Used) 35 - Washer (4 Used) 42 - Disc 48 - Adapter S
8- Bolt (6 Used) 36 - Bracket 43 - Bolt (12 Used) 49 - O-Ring (2 Used)
30 - Parking Brake Head As- 37 - Plate 44 - Washer (12 Used) 50 - Socket S (2 Used)
sembly
31 - Knock Pin (2 Used) 38 - Bolt (5 Used) 45 - Plate 51 - Tee S
32 - Bolt 39 - Washer (5 Used) 46 - Bolt and Washer (4 Used) 52 - Hose
33 - Washer 40 - Key
W8R7-E-01(20160803) W2-4-25
18
17
16
15
14
13
12
11
10
4 11
3 12
9 13
14
15
16
5 17
18
3
4
5
9 T8DS-02-04-216
10
W8R7-E-01(20160803) W2-4-26
Assembly of Parking Brake
CAUTION: Parking brake assembly and oth-

er replacement components are compatible 3 4 5 9 10 16 18, 17
with hydraulic oil. The use of components
that are incompatible with hydraulic oil may
decrease brake performance and could cause
injury.
IMPORTANT: The parking brake will not function

correctly if the backup ring is incor-
rectly installed. Install the backup
ring in the position as indicated on
the diagram.
1. Lubricate new seals (4, 9) and new backup rings

(3, 10) with petroleum jelly and install into piston
housing (5) and piston (13).
2. Before installing new linings (12), clean screws
(11) (6 used) with solvent to remove any dirt or
adhesive. Inspect screw threads and replace if
necessary.
3. Attach new lining (12) to piston (13) using screws
(11) (6 used). Apply LOCTITE #242 or equivalent
to the threads. Release Area
13 12 11 14 15 18, 17
4. Install piston (13) into the piston housing (5), tak-
ing care not to damage seals (4, 9). T8DS-02-04-227
5. Install springs (14, 15) (6 each used) onto the

threaded end of screws (11) (6 used). Embed
spring (14) into spring (15).
6. Install bolts (18) (4 used) and washers (17) (4
used) to end cap (16). Tighten bolts in alternation
to compress springs (14, 15) (6 each used).
: 7/16 in.
: 156 N·m (15.5 kgf·m, 115 lbf·ft)
7. Install the other piston housing (5) assembly us-

ing the same procedures.
W8R7-E-01(20160803) W2-4-27
40
47
41
34, 35
36
37
42
45 43, 44
W8R7-02-04-084
Detail d
38, 39 View B W8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8 Wheel Motor
Wheel Motor
30
C
31
W8R7-02-04-082
T8DS-02-04-220
View C
W8R7-E-01(20160803) W2-4-28
CAUTION: Hub (41) weight: 23 kg (51 lb)
8. Install key (40) into the key groove on the parking

brake installation side of the wheel motor. Hoist
hub (41) with a nylon sling. Install hub (41) to the
shaft. Install plate (45) with bolts and washers
(46) (4 used), bolt (32) and washer (33).
Bolt (46)
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
Bolt (32)
: 46 mm
: 1950 N·m (195 kgf·m, 1440 lbf·ft)
CAUTION: Disc (42) weight: 34 kg (75 lb)
9. Attach nylon sling onto disc (42). Lift and hold disc
(42). Install disc (42) to hub (41) with bolts (43)
: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
CAUTION: Bracket (36) weight: 30 kg (66 lb)
10. Attach nylon sling onto bracket (36). Lift and hold
bracket (36). Align bracket (36) with wheel motor
knock pin (31) installation point. Install bracket.
Install the bracket to wheel motor (36) with bolts
: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
W8R7-E-01(20160803) W2-4-29
40
47
41
34, 35
36
37
42
45 43, 44
W8R7-02-04-084
Detail d
38, 39 View B W8R7-02-04-083
ｄ
43, 44
32, 33
46
7, 8
Wheel Motor
30
C
31
W8R7-02-04-082
50
48, 49, 50 49, 51
52
T8DS-02-04-220
View C
W8R7-E-01(20160803) W2-4-30
11. Apply lubricant oil onto the threaded part of bolts
(38) (5 used). Align plate (37) with bracket (36)
knock pin (31) installation point. Install plate. Us-
ing shims (47) (4 used) (Thickness 0.3 mm (0.012
in.), install plate (37). The offset of the plate (37)
from disc (42) center must be within 0.254 mm
(0.01 in.). Install plate (37) to bracket (36) with
: 27 mm
: 400 N·m (40 kgf·m, 295 lbf·ft)
CAUTION: The piston housing (5) assembly

12. Apply lubricant oil to bolts (8) (6 used).

Attach nylon sling to the piston housing (5) as-
semblies (2 used) of parking brake assembly (30).
Lift and hold piston housing (5).
Install the piston housing (5) assembly (2 used) to
plate (37) with bolts (8) (6 used) and washers (7)
(6 used). At this stage, do not tighten bolts (8) (6
used).
: 1-1/8 in.
13. Install socket S (50) (2 used), adaptor S (48), tee

S (51) and new O-rings (49) (2 used) to parking
brake head assembly (30). Connect hose (52) to
adapter (48) and tee S (51).
: Adaptor S 17 mm,
Socket S 24 mm,
Tee S 17 mm,
Hose 19 mm
W8R7-E-01(20160803) W2-4-31
15
14
13
12
12
42 13
8 20 14
7 37 15
20
5
5
T8DS-02-04-216
Parking Brake Assembly Diagram
W8R7-E-01(20160803) W2-4-32
14. Using a pressurization device, pressurize the in-
side of parking brake head assembly (30) with
hydraulic oil to over 12400 kPa (127 kgf/cm2,
1800 psi).
The above hydraulic pressure must be maintained
within piston housings (5) (2 used) during steps
15 to 19. This pressure will compress springs (14,
15) and releases the parking brake. Check that
piston (13) is fully inserted in piston housing (5).
15. Make a shim pack using shim (20). Install the

shim pack to both sides of plate (37) and loosely
tighten outside bolts (8) (2 used) and washers (7)
(2 used). Do not yet tighten with the specified
torque.
Reference: There are 3 types of shims available –
side thickness of 1.5 mm (3 used), 0.76 mm (1
used), 0.53 mm (2 used).
16. Using the thickness gauge, measure clearance B

between lining (12) and disc (42). 7, 8 14 15 13
17. Use the shim pack to adjust the clearance B be-

tween lining (12) and disc (42) until it is within 5
0.508 to 1.27 mm (0.0209 to 0.0500 in.) on both
sides. Refer to the diagram on the right.
18. Tighten bolts (8) (6 used). 20 42

: 1-1/8 in.
: 520 N·m (52 kgf·m, 384 lbf·ft)
37
19. Re-check clearance B. If necessary, remake the
shim pack using shim (20) and adjust. B
T8DS-02-04-226
12
W8R7-E-01(20160803) W2-4-33
PROCEDURES FOR THE 500-HOUR
MAINTENANCE INSPECTION 7, 8 14 15 13
Rind
5
42
20
37
B
A
12 T8DS-02-04-226
42 T8DS-02-04-228
Parking Brake Clearance
Clearance A Clearance A
Above 1.016 mm (0.04 in.) Below 1.016 mm (0.04 in.)
Disc Thickness Disc Thickness Disc Thickness Disc Thickness

Above 16 mm (0.63 in.) Below 16 mm (0.63 in.) Above 16 mm (0.63 in.) Below 16 mm (0.63 in.)
No Rind Rind Rind No Rind
Lining Thick- Lining Thick- Replace Disc

ness ness and Lining
Below 4.191 Above 4.191
mm (0.165 in.) mm (0.165 in.)
Replace Disc
Replace Lining
Replace Disc
Measure Clearance B
B is over 0.508 mm (0.02 in.) and B is below 0.508 mm (0.02 in.) or

is below 1.651 mm (0.065 in.) is above 1.651 mm (0.065 in.)
Adjust
Service at an authorized
Service Factory
W8DS-05-52-003
Basic Guidelines for Disc and Lining Replacement
NOTE: The rind is the part of the disc (42) with no

wear from the lining.
W8R7-E-01(20160803) W2-4-34
CAUTION: Failure to replace worn discs (41)

will result in loss of braking ability.
Inspect lining (12) and disc (42) every 500 operation

hours using the following procedures. Replace lining
(12) and disc (42) following the specified procedures.
Refer to the diagram on the previous page.
1. Park the machine on a level surface and place 6. When the disc thickness is less than 16 mm (0.63
wheel stops. in.) replace disc (42). When the disc has no outer
diameter rind and when the lining thickness is
2. Engage the parking brake (brake pressure is less than 1.016 mm (0.04 in.), replace the lining.
disengaged) and measure the gap between the Install brake head assembly and proceed to step
outer edge of disc (42) and the lining carrier using 7.
the thickness gauge. Refer to dimension A in the
diagram on the previous page. Take the disc outer 7. Release the parking brake (brake pressure is
diameter rind into consideration when measuring. engaged) and measure lining (12) and disc (42)
Also measure the thickness of the worn surface of clearance B using the thickness gauge. Refer to
the disc. the diagram B on the previous page.
3. When clearance A is over 1.016 mm (0.04 in.) and NOTE: After replacing either the disc or lining, it
the disc thickness is over 16.0 mm (0.63 in.) may be necessary to further adjust the
proceed to step 7. When the disc thickness is less brakes depending on the operating condi-
than 16 mm (0.63 in.) proceed to step 7 after re- tions.
placing disc (42).
8. Adjustment is complete when clearance B is more
4. When clearance A is less than 1.016 mm (0.04 than 0.508 mm (0.02 in.) and less than 1.65 mm
in.), replace either disc (42) or lining (12). Re- (0.065 in.). If it does not fall within this range have
move brake head assembly and measure the the machine inspected at a service center.
thickness of the remaining lining.
9. Brake adjustment is necessary when clearance B
5. When the disc thickness is more than 16 mm is less than 0.508 mm (0.02 in.) and more than
(0.63 in.), follow the procedure below to deter- 1.650 mm (0.065 in.). Using shim (20), obtain an
mine whether to replace disc (42) or lining (12). appropriate clearance. If the machine cannot be
• When the disc has no outer diameter rind, replace adjusted to this range, have the machine in-
the lining. spected at a service center.
• When the disc has no outer diameter rind and
when the lining thickness is less than 4.19 mm
(0.165 in.), replace the lining. After replacing, in- CAUTION: Using the machine with severely
stall brake head assembly and proceed to step 7. worn and unadjusted brakes may cause a
• When the disc has an outer diameter rind and serious accident when the machine is parked
when the lining thickness is more than 4.19 mm on an incline.
(0.165 in.), replace the disc. Install brake head
assembly and proceed to step 7 after replace-
ment.
W8R7-E-01(20160803) W2-4-35
BODY / Drive Device (Wheel Motor)
WHEEL MOTOR ASSEMBLY
1 2 5, 16 7, 17
4
13, 18, 29 19, 20
2, 3 6
ｂ
a
13, 18, 29
8
9
15
10
11
14 12, 13, 29 W8R7-02-04-085
22 23 24
21 25, 26 28
27
Details b W8R7-02-04-087
Details a W8R7-02-04-086
1- Wheel Motor 8- O-Ring 15 - Hose 22 - Retaining Ring

2- Elbow S (2 Used) 9- Adapter S 16 - Bolt (6 Used) 23 - Shaft Coupling
3- Joint 10 - Hose 17 - Bolt (8 Used) 24 - Guide
4- Retainer 11 - Hose 18 - Clip (3 Used) 25 - Bolt (4 Used)
5- Washer (6 Used) 12 - Clip (2 Use) 19 - Bolt 26 - Washer (4 Used)
6- Holder 13 - Washer (5 Used) 20 - Washer 27 - Sleeve
7- Washer (8 Used) 14 - Clip Band (2 Used) 21 - Spacer 28 - Oil Seal
29 - Bolt (5 Used)
W8R7-E-01(20160803) W2-4-36
Removal
1. Remove O-ring (8) from holder (6).
2. Remove clip bands (14) (2 used) from hose (10)

and hose (11).
3. Remove clips (18) (2 used), bolts (29) (2 used),

and washer (13) (2 used) from hose (11).
Remove hose (11) and elbow S (2) from wheel
motor (1).
: Hose 17 mm,
Elbow S 17 mm,
Bolt 17 mm
4. Remove clips (12) (2 used), bolt (16) (2used),

and washer (13) (2 used) from hose (10). Re-
move hose (10) and adapter S (9) from wheel
motor (1).
: Hose 22 mm,
Adapter S 22 mm,
Bolt 17 mm
5. Remove clip (18), bolt (29), and washer (13) from

hose (15). Remove hose (15), elbow S (2), and
joint (3) from wheel motor (1).
: Hose 17 mm, 14mm,
Elbow S 17 mm,
Joint 19 mm,
Bolt 17 mm
W8R7-E-01(20160803) W2-4-37
1 5, 16 7, 17
4
19, 20
6
ｂ
a
W8R7-02-04-085
22 23 24
21 25, 26 28
27
W8R7-E-01(20160803) W2-4-38
CAUTION: Holder (6) weight: 23 kg (51 lb)
6. Loosen bolts (17) (8 used) and washers (7) (8

used). Remove holder (6) from retainer (4).
: 19 mm
CAUTION: The shaft coupling (23) assembly

7. Place a nylon sling onto the shaft coupling (23)

assembly. Lift and hold the shaft coupling (23)
assembly. Remove the shaft coupling (23) as-
sembly from wheel motor (1) by loosening bolt
(19) and washer (20).
: 46 mm
8. Remove guide (24), bolts (25) (4 used) and

washers (26) (4 used) from shaft coupling (23).
: 22 mm
9. Remove spacer (21) and retaining ring (22) from

shaft coupling (23).
10. Remove oil seal (28) from oil seal (28).
CAUTION: Retainer (4) weight: 32 kg (71 lb)
11. Remove retainer (4), bolts (16) (6 used) and

washer (5) (6 used) from the wheel motor (1).
: 19 mm
12. Sleeve (27) is shrink-fitted to the shaft located on

the driveline attachment side of the wheel motor
(1). Do not remove sleeve (27) unless necessary.
W8R7-E-01(20160803) W2-4-39
Installation
1 2 5, 16 7, 17
4
13, 18, 29 19, 20
2, 3 6
ｂ
a
13, 18, 29
8
9
15
10
11
14 12, 13, 29 W8R7-02-04-085
22 23 24
21 25, 26 28
27
1- Wheel Motor 8- O-Ring 15 - Hose 22 - Retaining Ring

2- Elbow S (2 Used) 9- Adapter S 16 - Bolt (6 Used) 23 - Shaft Coupling
3- Joint 10 - Hose 17 - Bolt (8 Used) 24 - Guide
4- Retainer 11 - Hose 18 - Clip (3 Used) 25 - Bolt (4 Used)
5- Washer (6 Used) 12 - Clip (2 Used) 19 - Bolt 26 - Washer (4 Used)
6- Holder 13 - Washer (5 Used) 20 - Washer 27 - Sleeve
7- Washer (8 Used) 14 - Clip Band (2 Used) 21 - Spacer 28 - Oil Seal
29 - Bolt (5 Used)
W8R7-E-01(20160803) W2-4-40
Installation
1. Shrink fit sleeve (27) to the shaft located on the

driveline attachment side of wheel motor (1).
Shrink fit temperature should be set to 200°C
(392°F).
2. Apply THREEBOND #1215 or LOCTITE #5020

onto the attachment surface of retainer (4) and
wheel motor (1). Install eyebolt (M12, Pitch 1.75
mm) to retainer (4). Lift retainer (4), and install
retainer (4) with bolts (16) (6 used) and washers
(5) (6 used).
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
3. Attach oil seal (28) to retainer (4).
CAUTION: The shaft coupling (23) weight: 37

kg (82 lb)
4. Install spacer (21) and retaining ring (22) to shaft

coupling (23).
5. Install guide (24), bolts (25) (4 used) and wash-

ers (26) (4 used) to shaft coupling (23).
: 22 mm
: 180 N·m (18 kgf·m, 133 lbf·ft)
CAUTION: The shaft coupling (23) assembly

6. Place a nylon sling on the shaft coupling (23)

assembly to hoist. Install shaft coupling (23) to
wheel motor (1) with bolt (19) and washer (20).
: 46 mm
: 1950 N·m (195 kgf·m, 1440 lbf·ft)
W8R7-E-01(20160803) W2-4-41
1 2 7, 17
13, 18, 29
2, 3 6
13, 18, 29
8
9
15
10
11
14 12, 13, 29 W8R7-02-04-085
W8R7-E-01(20160803) W2-4-42
CAUTION: Holder (6) weight: 23 kg (51 lb)
7. Hoist holder (6) with a nylon sling. Install holder

(6) to retainer (4) with bolts (17) (8 used) and
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
8. Install hose (15), elbow S (2) and Joint (3) to

wheel motor (1).
Fix hose (15) with clip (18), bolt (29), and washer
(13).
: Hose 17 mm, 14mm,
Elbow S 17 mm,
Joint 19 mm
Bolt 17 mm
9. Install hose (10) and adapter S (9) to wheel mo-

tor (1).
Fix the hose (10) with clip (12) (2 used), bolt (29)
(2 used), and washer (13) (2 used).
: Hose 22 mm, 19mm,
Adapter S 22 mm,
Bolt 17 mm
10. Install hose (11), and elbow S (2) to wheel motor

(1).
Fix hose (17) to wheel motor (1) with clips (18)
(2used), bolts (29) (2 used), and washer (13) (2
used).
: Hose 17 mm, 14mm,
Elbow S 22 mm
Bolt 17 mm
11. Fix hose (11) to hose (10) with clip bands (14)
(2used).
12. Install O-ring (8) to holder (6).
W8R7-E-01(20160803) W2-4-43
DISASSEMBLY OF WHEEL MOTOR
33, 32 35, 34
29 30 31 36 39, 38, 37 40 41 42 43
28
27
26
25
24, 23, 22 44
21 45
46
20
19 47
18
17, 16
1
W8DS-02-04-034
15 14 13 12 11 10 9 8 7 6 5 4 3 2
1- Shaft 13 - Oil Thrower 25 - Speed Sensor 37 - Holding Tool

2- Oil Thrower 14 - Ball Bearing 26 - Bracket 38 - Screw (2 Used)
3- Roller Bearing 15 - Oil Thrower 27 - Socket Bolt (20 Used) 39 - Spring Washer (2 Used)
4- Oil Thrower 16 - Bolt (6 Used) 28 - Connector 40 - Stator Frame
5- Retaining Ring 17 - Lock Washer (3 Used) 29 - Crimp-Type Contact 41 - Lock Pin
(3 Used)
6- Short-Circuit Ring 18 - Gear (For Speed Sensor) 30 - Lead Wire 42 - Stator Core
7- Core Holder 19 - End Cover 31 - Cover 43 - Stator Coil
8- Rotor Core Key 20 - Bolt (6 Used) 32 - Bushing (3 Used) 44 - Socket Bolt (8 Used)
9- Rotor Core 21 - Plug 33 - Band (3 Used) 45 - Roller Bearing Box
10 - Balance Weight 22 - Bolt (2 Used) 34 - Bolt (4 Used) 46 - Bolt (6 Used)
11 - Core Holder 23 - Spring Washer (2 Used) 35 - Spring Washer (4 Used) 47 - End Cover
12 - Retaining Key 24 - Washer (2 Used) 36 - Temperature Sensor
W8R7-E-01(20160803) W2-4-44
BODY / Driveline (Wheel Motor)
Disassembly of Wheel Motor
• Removal of Rotor from the Stator
1. Remove screws (38) (2 used), spring washer

(39), and holding tools (37) (2 used) from stator
frame (40).
2. Remove temperature sensor (36) from stator
frame (40).
Replace insulator cover on the outer perimeter of
temperature sensor (36) if it is ripped or dam-
aged.
3. Remove bolts (22) (2 used), spring washer (23)
(2 used), and washer (24) (2 used).
4. Carefully remove speed sensor (25) from bracket
(26) without damaging the sensor surface. W8DS-02-04-034
: 13 mm
5. Remove socket bolts (44) (8 used) from roller
bearing box (45) on the drive side.
Into the hole exposed (when the socket bolts are
removed), insert 2 long guide bolts (stud bolts)
(for rotor removal) in a 180° symmetrical posi-
tion).
：10 mm Wire Rope Hanger
6. Attach a lifting tool onto the axle ends of the
brake side rotor. Use a special device for lifting.
7. Remove socket bolts (27) (20 used) from bracket Bolt
(26).
Insert removal bolt into the removal hole on 40
bracket (26).
Insert removal bolt into the removal hole located Stud Bolt
on stator frame (40) which holds roller bearing 26
box (45) in place.
Screw the bolts on bracket (26) end and roller Plate
bearing box (45) end in alternation to lift bracket
(26) and roller bearing box (45) off stator frame
(40).
: 17 mm
W8DS-02-04-035
Rotor 45
Example of a Lifting Tool
W8R7-E-01(20160803) W2-4-45
42
26
20
19
18
17, 16 1
W8DS-02-04-034
15 14 9
W8R7-E-01(20160803) W2-4-46
CAUTION: Rotor weight: 1200 kg (2650 lb) Bolt Wire Rope Hanger
8. While laying the wheel motor on its side, lift the

Removing
wheel motor with a lifting tool and support the Direction
motor. Remove the rotor body slowly, using stud
bolts (2 used) as a guide. Remove the rotor from
42 40
the stator slowly without allowing the outer pe-
rimeter of the rotor to come in contact with stator
core (42).
Stud Bolt
9. Carefully place rotor core (9) of the rotor on an
appropriate holder (which has a V-shaped 26
groove) without damaging. Plate
• Removal of Bearing Components
10. Remove bolts (16) (6 used) and lock washers

Rotor 9
(17) (3 used). Remove gear (18) from oil thrower W8DS-02-04-035
(15). Discard lock washers (17) (3 used). Do not Example of a Lifting Tool
reuse lock washers (17). Holding
: 19 mm Nut M16 Plate Stud Bolt Clamp 20 19
26
11. Remove oil thrower (15) from shaft (1), using a
special removal tool.
Center Hole Socket Bolt
12. Remove bolts (20) (6 used) from end cover (19). Cylinder M12
Insert removal bolt into the removal hole, and
remove end cover (19) from bracket (26).
: 19 mm P
CAUTION: The bracket (26) assembly

15
1 W8DS-02-04-037
13. Remove bracket (26) and the ball bearing (14) Example of Oil Thrower (15) Removal Tool
assembly from shaft (1), using a special removal
tool.
Remove ball bearing (14) slowly without damag- Stud
Holding Plate Bolt Clamp 26
ing it. Nut M16
Keep bracket (26) perpendicular to shaft (1) Socket
when removing. Center Hole Bolt
Cylinder
14
1
W8DS-02-04-038
Example of the Bracket (26) Assembly Removal Tool
W8R7-E-01(20160803) W2-4-47
26
45
46
47
W8DS-02-04-034
14 13 3 2
W8R7-E-01(20160803) W2-4-48
14. If ball bearing (14) needs to be replaced, remove Patch
ball bearing (14) from bracket (26), using a spe- 26
cial removal tool. Refer to the bearing inspection
14
section of this chapter. Piston
Discard the removed ball bearing (14). There is
no need to remove the ball bearing (14) from Packing
bracket (26) if the ball bearing is not going to be
replaced. Distant
Piece
P
15. There is no need to remove oil thrower (13) un-
less necessary. If it is required, remove oil Holding
thrower (13) from the shaft (1) using a special Plate
Ram
removal tool. Stand
16. Remove oil thrower (2) from shaft (1), using a

special removal tool.
W8DS-02-04-039
Example of Ball Bearing (14) Removal Tool

CAUTION: The roller bearing box (45) as-
sembly weight: 55 kg (121 lb) Holding Holding
Nut M16 Plate Center Hole Stud Bolt Plate Hook
Cylinder
17. Remove roller bearing box (45), roller bearing (3), 13
and the end cover (47) assembly from shaft (1),
using a special removal tool. P
Remove roller bearing (3) slowly without dam-
aging it.
Keep roller bearing box (45) perpendicular to
shaft (1) when removing. W8DS-02-04-040
Example of Oil Thrower (13) Removal Tool

18. Remove bolts (46) (6 used) from end cover (47).
Stud Bolt Holding Nut M16
Insert removal bolt into the removal hole of end Clamp Socket Bolt M12
Plate
cover (47), and remove end cover (47) from roller Center Hole
bearing box (45). Cylinder
: 19 mm
2 1 W8DS-02-04-041
Example of Oil Thrower (2) Removal Tool

Holding Nut M12
47 46 Stud Bolt Center Hole Plate
Cylinder
45
3 P
1 W8DS-02-04-042
Example of the Roller Bearing Box (45) Assembly

Removal Tool
W8R7-E-01(20160803) W2-4-49
45
W8DS-02-04-034
4 3
W8R7-E-01(20160803) W2-4-50
19. If roller bearing (3) needs to be replaced, remove Claw (same quantity as
anti-friction bearing) Patch
the outer race of roller bearing (3) from roller
bearing box (45) using a special removal tool. 45
Piston
3
Packing
P
Distant
Piece
Holding
Plate
Ram
Stand
W8DS-02-04-043
Example of Roller Bearing (3) Removal Tool
Center Hole Holding

Hook Clamp Stud Bolt Cylinder Plate Nut M16
20. From shaft (1), remove the inner race of roller
bearing (3) along with oil thrower (4), using the
special removal tool. Refer to the bearing in-
spection section of this chapter.
P
Replace the removed roller bearing (3) inner and
outer race.
There is no need to remove the inner race of
roller bearing (3) from shaft (1) if the roller bear-
4 3 1 W8DS-02-04-044
ing is not going to be replaced.
Example of Roller Bearing (3) Removal Tool
W8R7-E-01(20160803) W2-4-51
INSPECTION OF WHEEL MOTOR
Stator
40 43
W8DS-02-04-034
Bearing 9 Rotor Bearing
W8R7-E-01(20160803) W2-4-52
Inspection of Wheel Motor
Rotor Inspection Bearing Inspection

1. Use dry pressurized air to blow away any dirt on 1. After removing the motor from the wheel device,
the rotor surface or the holes on the rotor core. rotate the wheel motor's rotor slowly by hand,
Wipe using a detergent if the dirt is severe. place a stethoscopic bar on the bearing, and
2. Use a varnish to coat the rotor if there is any check that the bearing is in good condition.
peeling on the surface. Dry the rotor in the drying Quiet and clear sound should be heard if the
furnace, or air-dried. bearing is in good condition. Crunching sound is
3. Inspect for any loose rotor bar, or cracks/damage heard if there is any flaking, dent, or crack on the
in shorting ring (6) or retaining ring (5). Replace bearing.
or repair if there are any faults. 2. Replace bearings if it has been removed, or if it is
4. Inspect that all bolts are securely tightened. damaged.
Tighten any loose bolt with a specified torque.
Stator Inspection
1. Use dry pressurized air to blow away any dirt on
the stator inner surface, stator coil end, lead wire
or gap in stator frame. Wipe with a detergent if
the dirt cannot be removed with compressed air.
2. Inspect for damage or cracks on the stator. Re-
place or repair if there are any faults.
3. Inspect stator coil (43) for any short-circuit, or for
any damage on the insulation cover. Replace or
repair if there are any faults.
4. Inspect for any damage on the jumper cable and
lead-wire, and check for any damage on the in-
sulator and its attachments. Replace or repair if
there are any faults.
5. Insulation resistance test – inspect the insulation
resistance between the lead-wire and the con-
nected areas and record the results.
Heat the stator coil (43) surface to 90 to 120°C
(194 to 248°F), dry for 12 hours, and check that
the resistance is over 3M OHM if the insulating
resistance is low due to moisture absorption etc.
Dry the area further if the resistance of over 3M
OHM cannot be obtained.
6. Apply a varnish and dry it at every inspection (or
at every second inspection).
6-1. Pre dry the parts in a 120°C (248°F) furnace
for 3 to 4 hours.
6-2. Cool to 50 to 60°C (122 to 140°F), apply a fin-
ishing varnish onto stator coil (43) and the in-
ner surface of the stator. Air-dry the compo-
nents.
6-3. Dry the parts in a 120°C (248°F) furnace for
over 12 hours.
W8R7-E-01(20160803) W2-4-53
ASSEMBLY OF WHEEL MOTOR
39, 38, 37
33, 32 35, 34
29 30 31 36 40 41 42 43
28
27
26
25 44
24, 23, 22
45
21
20 46
19
47
18
17, 16
1
W8DS-02-04-034
15 14 13 12 11 10 9 8 7 6 5 4 3 2
1 - Shaft 13 - Oil Thrower 25 - Speed Sensor 37 - Holding Tool

2 - Oil Thrower 14 - Ball Bearing 26 - Bracket 38 - Screw (2 Used)
3 - Roller Bearing 15 - Oil Thrower 27 - Socket Bolt (20 Used) 39 - Spring Washer
(2 Used)
4 - Oil Thrower 16 - Bolt (6 Used) 28 - Connector 40 - Stator Frame
5 - Retaining Ring 17 - Lock Washer (3 Used) 29 - Crimp-Type Contact 41 - Lock Pin
(3 Used)
6- Short-Circuit Ring 18 - Gear (For Speed Sensor) 30 - Lead Wire 42 - Stator Core
7- Core Holder 19 - End Cover 31 - Cover 43 - Stator Coil
8- Rotor Core Key 20 - Bolt (6 Used) 32 - Bushing (3 Used) 44 - Socket Bolt (8 Used)
9- Rotor Core 21 - Plug 33 - Band (3 Used) 45 - Roller Bearing Box
10 - Balance Weight 22 - Bolt (2 Used) 34 - Bolt (4 Used) 46 - Bolt (6 Used)
11 - Core Holder 23 - Spring Washer (2 Used) 35 - Spring Washer(4 Used) 47-End Cover
12 - Retaining Key 24 - Washer (2 Used) 36 - Temperature Sensor
W8R7-E-01(20160803) W2-4-54
Assembly of Wheel Motor
45
• Installation of Bearing Components
Use raremax super (Kyodo Yushi) or LGHP2 (SKF) for

lubrication grease. Use it for all lubricant described
below.
1. Heat oil thrower (4) and inner race of roller

bearing (3) with an induction heating to 120°C
(248°F) to shrink-fit to rotator shaft (1). (Use in-
duction heating with demagnetization function.) A
Inner race must be in parallel with shaft (1) when
installing.
W8R7-02-04-092
Apply grease thinly onto the oil sling area located
Grease Injection Diagram
on oil thrower (4) (marked E in the diagram) after
cooling.
Fueling Circuit
3
2. Inject approximately 60 mL (3.7 in ) of grease in-
side the roller bearing (3) (marked B in the dia-
gram). Inject approximately 120 mL (7.3 in3) of
grease inside the roller bearing box (45) (marked Apply grease
A in the diagram). Apply grease thinly onto the 45 thinly.
outer circumference of the roller bearing (3).
3
3. Use a hydraulic press to force fit roller bearing (3) E
outer race onto roller bearing box (45). Set roller
4
bearing (3) horizontally. Do not force-fit the
bearing while it is tilted.
A B W8R7-02-04-091
Patch
(3) Outer Race Piston
45
Ram
Stand
Holding
Plate
W8DS-02-04-048
W8R7-E-01(20160803) W2-4-55
45
46
47
W8DS-02-04-034
4 3 2
W8R7-E-01(20160803) W2-4-56
4. Inject approximately 120 mL (7.3 in3) of grease
inside end cover (47) (marked C in the diagram). 47
Apply grease thinly onto the connecting surface
between end cover (47) and roller bearing box
(45).
5. Install end cover (47) to roller bearing box (45)

with bolts (46) (6 used).
: 19 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
C
CAUTION: The roller bearing box (45) as- W8R7-02-04-093
sembly weight: 55 kg (121 lb) Grease Injection Diagram
6. Install roller bearing box (45), roller bearing (3), Fueling

and end cover (47) to shaft (1). Circuit
Make sure that roller bearing (3) does not get 47
damaged. 45
Keep roller bearing box (45) perpendicular to 46
shaft (1) when installing. Apply grease
Apply grease thinly onto the oil sling area of end 3 thinly.
cover (47) (marked D in the diagram). S
7. Heat oil thrower (2) with an induction heating to 1 2

120°C (248°F) to shrink-fit to rotator shaft (1).
C W8R7-02-04-091
Apply grease Apply grease
thinly. thinly.
W8R7-E-01(20160803) W2-4-57
26
W8DS-02-04-034
14 13
W8R7-E-01(20160803) W2-4-58
8. Heat oil thrower (13) with an induction heating to
26
Apply grease thinly onto the oil sling area of oil
thrower (13) (marked E in the diagram) after
cooling.

inside ball bearing (14) (marked B in the dia-
gram). Inject approximately 450 mL (27.5 in3) of
grease inside bracket (26) (marked A in the dia-
gram). Apply grease thinly onto the outer cir-
cumference of ball bearing (14). A
10. Use a hydraulic press to force-fit ball bearing (14)

W8R7-02-04-095
into bracket (26) while keeping the ball bearing
horizontal. Do not tilt ball bearing (14) when
force-fitting.
Fueling Circuit
Apply grease thinly.

14
26
E
1
13
B A W8DS-02-04-047
Patch
14
Piston
26
Holding Plate
Ram
Stand
W8DS-02-04-049
W8R7-E-01(20160803) W2-4-59
26
20
19
18
16, 17
1
W8DS-02-04-034
15 14
W8R7-E-01(20160803) W2-4-60
CAUTION: The bracket (26) assembly

weight: 165 kg (364 lb) Center Hole
19 26 14
Nut Cylinder
11. Install bracket (26) and ball bearing (14) to shaft Stud Distant
Flat Washer Piece
(1), using a special tool. Bolt

inside end cover (19) (marked C in the diagram).
between end cover (19) and bracket (26).
1
13. Install end cover (19) to bracket (26) with bolts W8DS-02-04-050
Example of the Bracket (26) Assembly Attachment Tool

(20) (6 used).
Apply grease thinly onto the oil sling area of end 19
cover (19) (marked D in the diagram).
: 19 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
14. Heat oil thrower (15) with an induction heating to

15. Install gear (18) to oil thrower (15) with bolts (16)
(6 used) and washers (17) (6 used). C
: 19 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft) W8R7-02-04-094
Fueling Circuit
Apply grease thinly

14
19
20 26
D
18
16, 17 1
15
C W8DS-02-04-047
Apply grease thinly
W8R7-E-01(20160803) W2-4-61
27 40 Stator 42
36
44
45
W8DS-02-04-034
Rotor
W8R7-E-01(20160803) W2-4-62
• Installing Rotor to the Stator
16. Apply grease thinly onto the connecting surface

between bracket (26) and stator frame (40).
between roller bearing box (45) and stator frame
(40).
CAUTION: Rotor weight: 1200kg (2650 lb)

Wire Rope
Hanger
17. Install a lifting tool on axle ends of the brake side Bolt
rotor.
Use a special device tool. 40 Stator
42
18. Have the stator lying flat. Stud Bolt
Use a lifting tool to lift the rotor, and align with the
stator’s installation position. 26
19. Insert two long guide bolts (stud bolts) (for rotor Plate
attachment) into the holes on roller bearing box
(45), in a 180° symmetrical position.
45
20. Install the rotor by using stud bolts (2 used) as a
guide to pull in the rotor towards the stator.
Rotor
Make sure the rotor’s outer perimeter does not W8DS-02-04-035
come in contact with stator’s stator core (42) Example of a Lifting Tool
when installing.
21. Tighten bracket (26) onto stator frame (40) with

socket bolt (27) (20 used) while tightening socket
bolts (44) (8 used) onto roller bearing box (45) in
alternation.
Socket bolt (27)
: 17 mm
: 230 N·m (23 kgf·m, 170 lbf·ft)
Socket bolt (44)
: 10 mm
: 40 N·m (4.0 kgf·m, 30 lbf·ft)
W8R7-E-01(20160803) W2-4-63
39, 38, 37
Fueling Circuit 36 40
26 Fueling Circuit
25
24, 23, 22
W8DS-02-04-034
W8R7-E-01(20160803) W2-4-64
22. Carefully install speed sensor (25) to bracket (26)
without damaging the sensor surface. Install
bolts (22) (2 used), spring washers (23) (2 used),
: 13 mm
: 12 N·m (1.2 kgf·m, 8.8 lbf·ft)
23. Install temperature sensor (36) to stator frame

(40).
Install holding tool (37) to stator frame (40), with
screws (38) (2 used) and spring washers (39) (2
used).
24. Apply grease to two location of the fueling circuit.
W8R7-E-01(20160803) W2-4-65
BODY / Drive Device (Wheel Reduction Device)
DISASSEMBLY OF WHEEL REDUCTION DEVICE
Wheel Reduction
Device Assembly
Spindle Assembly
Wheel Reduction
Device Assembly
W8R7-02-04-100
36 - Stud Bolt (24 Used)
W8R7-E-01(20160803) W2-4-66
W8R7-02-04-101
1- First Stage Carrier Assembly 9- O-Ring 17 - Gear Coupling 28 - Bearing Nut

2- Bolt (8 Used) 10 - Bolt (24 Used) 18 - Retaining Ring 29 - Bearing Washer
3- Washer (8 Used) 11 - Washer (24 Used) 19 - Second Stage Sun Gear 30 - O-Ring (2 Used)
4- Cover 12 - First Stage Ring Gear 20 - Second Stage Ring Gear 31 - O-Ring (2 Used)
5- Shaft 13 - Lock Plate (6 Used) 21 - Second Stage Carrier 32 - Adapter
Assembly
6 - Retaining Ring 14 - Bolt (18 Used) 25 - Sleeve 33 - Bolt (26 Used)
7 - First Stage Sun Gear 15 - Washer (18 Used) 26 - Ball Bearing 34 - Washer (26 Used)
8 - Spacer 16 - Wire (6 Used) 27 - Retaining Ring 35 - Plug (4 Used)
W8R7-E-01(20160803) W2-4-67
W8R7-02-04-103
82 - Wheel 91 - Plug 108 - O-Ring 117 - Bolt (4 Used)

83 - Bearing Retainer 100 - Brake assembly 109 - Bearing Retainer 118 - Washer (4 Used)
84 - Bolt (18 Used) 101 - Spindle 110 - Bolt (36 Used) 119 - Wire
85 - Washer (18 Used) 102 - O-Ring 111 - Washer (36 Used) 120 - Bolt (2 Used)
86 - Shim 103 - O-Ring 112 - O-Ring (2 Used) 121 - Brake Adjusting Pin (4 Used)
87 - Shim 104 - Hose (2 Used) 113 - Pipe 122 - O-Ring (4 Used)
88 - Shim 105 - O-Ring (4 Used) 114 - Roller Bearing (2 Used) 123 - Spacer (4 Used)
89 - Pin (3 Used) 106 - Bolt (32 Used) 115 - Bolt (6 Used) 124 - Nut (4 Used)
90 - Retainer 107 - Washer (32 Used) 116 - Bolt
W8R7-E-01(20160803) W2-4-68
W8R7-02-04-104
92 - O-Ring 95 - Floating Seal 97 - Washer (24 Used) 99 - O-Ring

93 - Coupling 96 - Bolt (24 Used) 98 - Retainer 100 - Brake Assembly
94 - Floating Seal
W8R7-E-01(20160803) W2-4-69
W8R7-02-04-102
42 - Plate 52 - Cover 62 - Bolt (6 Used) 72 - Hose (2 Used)
43 - Bolt (4 Used) 53 - Split Flange (8 Used) 63 - Washer (12 Used) 73 - O-Ring (4 Used)
44 - Washer (4 Used) 54 - Bolt (16 Used) 64 - Nut (6 Used) 74 - Split Flange (4 Used)
45 - O-Ring (2 Used) 55 - Hose 65 - Clip (2 Use) 75 - Plate
46 - Bolt (8 Used) 56 - Bolt (24 Used) 66 - Hose 76 - Bolt (2 Used)
47 - Adapter (4Used) 57 - Washer (24 Used) 67 - Clip (2 Use) 77 - Washer (2 Used)
48 - O-Ring 58 - Bracket 68 - Bracket (4 Used) 78 - Pipe
49 - Plate 59 - Bolt (4 Used) 69 - Bolt (8 Used) 79 - O-Ring
50 - Bolt (8 Used) 60 - Washer (4 Used) 70 - Washer (12 Used) 80 - Bolt (4 Used)
51 - Washer (8 Used) 61 - Plate (2 Used) 71 - Pipe (2 Used) 81 - Spacer (4 Used)
W8R7-E-01(20160803) W2-4-70
DISASSEMBLY OF WHEEL REDUCTION DEVICE
 Removal of hoses, pipes.

used) of clamps (65) (2 used), (67) (2 used)
securing hoses (72) (2 used), hoses (55), (66)
from brackets (68) (4 used).
：19 mm
2. Remove bolts (54) (8 used) and sprit flanges (53)

(4 used) from plate (42). Disconnect hoses (72) (2
Used).
：8 mm
3. Disconnect hoses (55, 66) from adapters (47) (2

Used) of plate (49).
：27 mm

used) from bracket (58). Remove plate (75) from
bracket (58).
：17 mm

used) from cover (52). Remove bracket (58) from
cover (52).
：19 mm
IMPORTANT：Mark the identification numbers to

the hoses (55, 66) for assembling
when removing hoses (55, 66).
6. Remove bolts (56) (24 used) and washers (57)

(24 used) from cover (52). Remove the cover (52)
assembly. Do not remove hoses on cover (52)
unless necessary.
：19 mm
W8R7-E-01(20160803) W2-4-71
101
W8R7-02-04-102
W8R7-E-01(20160803) W2-4-72
7. Remove pipe (78) form spindle (101). O-ring (79)
is installed to pipe (78). Install plug (with O-ring) to
screw hole (G3/8) of spindle (101).
：22 mm

used) from spindle (101). Remove pipe (71),
spacer (81) (4 used) from spindle (101). Cap the
spindle (101) hole with cloth.
：19 mm

used) from plate (49). Remove plates (42) (2
used).
：19 mm
NOTE: THREEBOND #1215 or LOCTITE #5020

has been applied on mounting part of plate
(42).
10. Remove bolts (46) (8 used) from plate (49).

Remove split franges (74) (4 used).
：8 mm
CAUTION: Plate (49) weight: 23 kg (51 lb)

used) from spindle (101). Remove plate (49).
O-rings (45, 48) are installed to plate (49).
：19 mm
NOTE: Threaded area of bolts (50) (8 used) is

applied with LOCTITE #262 or THREE-
BOND #1386B.
12. Cap plate (49) mounting face of spindle (101) with

cardboard or plastic tape.
W8R7-E-01(20160803) W2-4-73
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-74
 Standing the wheel reduction device vertically.
13. Install the special tool holder to wheel reduction Special Flange Special Tool Holder
device with the bolts (12 used) and the washers
(12 used).
14. Install the special flange to wheel reduction device

with the bolts (12 used) and the washers (12
used).
15. Install eyebolts (4 used) and shackles (2 used) to

the special flange.
CAUTION: Wheel reduction device weight:

11000 kg (24300 lb) W8R7-02-04-023
16. Attach a wire rope onto shackles (2 used). Hoist

the wheel reduction device with a crane. Stand the
wheel reduction device vertically.
17. Attach a wire rope onto eyebolts (4 used). Hoist

the wheel reduction device with a crane. Place the
wheel reduction device at the working platform
side.
18. Remove bolts (12 used) and washers (12 used)

from the wheel reduction device. Remove the
special flange from the wheel reduction device.
W8R7-02-04-024
W8R7-02-04-025
W8R7-E-01(20160803) W2-4-75
W8R7-02-04-101
W8R7-E-01(20160803) W2-4-76
 Disassembly of wheel reduction device.

used) from cover (4).
：19 mm
37 4
20. Remove plugs (37) (2 used) from cover (4).
21. Screw removed bolts (2) (2 used) to pulling-out

screw parts. Remove cover (4) from first stage
carrier assembly (1).
：19 mm
NOTE: THREEBOND #1215 or LOCTITE #5020

has been applied on installation surface of
plate (4).
22. Remove retaining ring (6) from shaft (5).
23. Remove first stage sun gear (7) and spacer (8)
from shaft (5).
W8R7-02-04-003
used).
：30 mm
25. Install eyebolts (M20, Pitch 2.5 mm) (3 used) to

first stage carrier assembly (1). Attach the lifting
tool to the eyebolts.
CAUTION: First stage carrier assembly (1) Eyebolt

1
26. Hoist and remove first stage carrier assembly (1)

from the wheel reduction device with a crane.
Remove O-ring (9).
W8R7-02-04-026
W8R7-E-01(20160803) W2-4-77
W8R7-02-04-101
W8R7-E-01(20160803) W2-4-78
(26 used) from adapter (32).
：50 mm

adapter (32). Attach the lifting tool to the eyebolts.
CAUTION: Adapter (32) weight: 306 kg (675

lb)
29. Hoist and remove adapter (32) from the wheel

reduction device with a crane.
Remove O-rings (30, 31)
30. Install eyebolts (M16, Pitch 2 mm) (2 used) to gear

coupling (17) of the first stage ring gear (12)
assembly. Attach the lifting tool to the eyebolts. 33、34
W8R7-02-04-003
CAUTION: First stage ring gear (12)
assembly weight: 365 kg (805 lb)
12 17 19 Eyebolt
31. Hoist and remove the first stage ring gear (12)
assembly from the wheel reduction device with a
crane.
Do not remove gear coupling (17) and second
stage sun gear (19) installed on first stage ring
gear (12) unless necessary.

second stage ring gear (20). Attach the lifting tool
to the eyebolts.
CAUTION: Second stage ring gear (20)

W8R7-02-04-027
20 Eyebolt
33. Hoist second stage ring gear (20) with a crane.
Remove second stage ring gear (20) from the
wheel reduction device.
Remove O-rings (30, 31).
W8R7-02-04-028
W8R7-E-01(20160803) W2-4-79
W8R7-02-04-101
W8R7-E-01(20160803) W2-4-80
34. Install eyebolts (M33, Pitch 3 mm) (4 used) to
second stage carrier assembly (21). Attach the
lifting tool to the eyebolts. 21 5
CAUTION: Second stage carrier assembly

(21) weight: 1700 kg (3750 lb)
35. Hoist and remove second stage carrier assembly

(21) from the wheel reduction device with a crane.

used) from retainer (90). Remove pipe (24) from
retainer (90).
Remove O-ring (112).
：17 mm
W8R7-02-04-029
applied with LOCTITE #262 or THREE- 24, 112 90
22, 23
BOND #1386B.
37. Remove retaining ring (27) from retainer (90). 27
38. Install eyebolt (M12, Pitch 1.75mm) to the tip of

shaft (5). Attach the lifting tool to the eyebolt.
CAUTION: The shaft (5) assembly weight: 82

kg (181 lb)
39. Hoist and remove shaft (5) from the spindle (101)
assembly with a crane.
Do not remove sleeve (25), ball bearing (26), W8R7-02-04-030
bearing nut (28), and bearing washer (29)
installed on shaft (5) unless necessary.
W8R7-E-01(20160803) W2-4-81
W8R7-02-04-103
W8R7-E-01(20160803) W2-4-82
40. Cut locking wire (119). Remove bolts (117) (4
used) and washers (118) (4 used). Remove pipe
(113) from retainer (90). 113 117、118
Remove O-ring (112).
：19 mm
119
90
BOND #1386B. W8R7-02-04-019

(18 used) from spindle (101).
：50 mm

BOND #1386B.

bearing retainer (83). Attach the lifting tool to the
eyebolts.
CAUTION: Bearing Retainer (83) weight: 92

kg (203 lb)
115 120
IMPORTANT：Mark the identification numbers to
shims (86, 87, 88) for assembling as
a shim pack.
43. Hoist and remove bearing retainer (83) from

spindle (101) with a crane.
Remove shims (86, 87, 88).
44. Remove pin (89) from the spindle assembly.
45. Remove bolts (115) (6 used) from retainer (90).

Do not remove mounting bolts (120) (4 used) of
hoses (104) (2 used).
：10 mm

BOND #1386B. W8R7-02-04-016
W8R7-E-01(20160803) W2-4-83
W8R7-02-04-103
W8R7-E-01(20160803) W2-4-84
46. Install eyebolt (M10, Pitch 1.5 mm) and eyebolt
(M12, Pitch 1.75 mm) to retainer (90). Attach the
lifting tool to the eyebolts.
47. Hoist and remove retainer (90) from spindle (101)

with a crane. Do not remove hoses (104) (2 used)
installed on retainer (90) unless necessary.
48. Install eyebolts (M12, Pitch 1.75 mm) (3 used) to 114

the retainer of roller bearings (114). Attach the
NOTE: Roller Bearing (114) Lifting Tool: ST0242
CAUTION: Roller Bearing (114) weight: 203

kg (448 lb)
49. Hoist and remove inner race of roller bearing (114)

from spindle (101) with a crane.

(36 used) from wheel (82).
W8R7-02-04-031
：46 mm Retainer Part

BOND #1386B.

wheel (82). Attach the lifting tool to the eyebolts.
CAUTION: Wheel (82) weight: 2450 kg (5400 36 82

lb)
52. Hoist and remove wheel (82) from coupling (93)

with a crane.
Do not remove stud bolts (36) (24 used), the outer
race of roller bearings (114) (2 used) installed on
wheel (82) unless necessary. W8R7-02-04-004
W8R7-E-01(20160803) W2-4-85
W8R7-02-04-103
W8R7-E-01(20160803) W2-4-86
53. Remove the oil from the coupling (93) part.
Oil
54. Remove O-ring (92) from coupling (93).
55. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to 92

93

kg (448 lb)
56. Hoist and remove inner race of roller bearing (114) W8R7-02-04-032
from spindle (101) with a crane.
57. Remove retaining pins (89) (2 used) of roller

bearing (114) and bearing retainer (109).

bearing retainer (109). Attach the lifting tool to the 101
eyebolts. Inner Race
NOTE: Bearing Retainer (109) Lifting Tool: ST0236
CAUTION: Bearing retainer (109) weight: 106

kg (234 lb)
59. Hoist and remove bearing retainer (109) from

spindle (101) with a crane. Half of floating seal
(94) (Refer to W2-4-88) is attached to bearing
retainer (109).
W8R7-02-04-033
NOTE: Install bearing retainer (109) in a horizontal

position because the clearance between
spindle (101) and bearing retainer (109) is
short.
109
101
W8R7-02-04-034
W8R7-E-01(20160803) W2-4-87
101
108
W8R7-02-04-104
W8R7-E-01(20160803) W2-4-88
coupling (93). Attach the lifting tool to the eyebolts.
CAUTION: Coupling (93) weight: 375 kg (827

lb)
61. Hoist and remove coupling (93) from spindle (101)

with a crane. Half of floating seals (94, 95) are
attached to coupling (93).
62. Remove O-ring (108) from spindle (101).
63. Measure the protrude amount of brake adjusting

pin (121) (Section C) from spindle (101).
A
64. Remove nut (129) and instruction plate (128).
：19 mm
65. Loosen nuts (124) (4 used) of brake adjusting pins

(121) (4 used). Remove brake adjusting pins B W8R7-02-04-002
(121) (4 used), O-rings (122) (4 used), and C

spacers (123) (4 used) from brake assembly (100).
Take care that remaining oil may come out at this
time.
：19 mm
：8 mm

(24 used) from retainer (98).
：24 mm

BOND #1386B.
Section A W8R7-02-04-096
67. Install eyebolts (M20, Pitch 2.5 mm) (4 used) to 121 122 123 124
retainer (98). Attach the lifting tool to the eyebolts.
CAUTION: Retainer (98) weight: 240 kg (529

lb)
68. Hoist and remove retainer (98) from brake Section B W8R7-02-04-021
assembly (100) with a crane. Protrude amount

128 129 121
Half of floating seal (95) is attached to retainer 101
(98).
69. Remove O-ring (99) from brake assembly (100).
Section C
W8R7-02-04-097
W8R7-E-01(20160803) W2-4-89
W8R7-02-04-103
W8R7-E-01(20160803) W2-4-90
(32 used) from spindle (101).
：46 mm

BOND #1386B.

brake assembly (100). Attach the lifting tool to the
eyebolts.
CAUTION: Brake assembly (100) weight:

1020 kg (2250 lb)
72. Hoist and remove brake assembly (100) from

spindle (101) with a crane.
73. Remove O-rings (102, 103) from spindle (101).
W8R7-E-01(20160803) W2-4-91
(Blank)
W8R7-E-01(20160803) W2-4-92
ASSEMBLY OF WHEEL REDUCTION DEVICE
1 2, 3 4 5 6 7 8 10, 11
9
12
13
32
14, 15, 16
17
18
31 19
30 20
21
31
30
22, 23
28, 29
24
27
26
25
W8R7-02-04-001
1- First Stage Carrier Assembly 9 - O-Ring 17 - Gear Coupling 25 - Sleeve

2- Bolt (8 Used) 10 - Bolt (24 Used) 18 - Retaining Ring 26 - Ball Bearing
3- Washer (8 Used) 11 - Washer (24 Used) 19 - Second Stage Sun Gear 27 - Retaining Ring
4- Cover 12 - First Stage Ring Gear 20 - Second Stage Ring Gear 28 - Bearing Nut
5- Shaft 13 - Lock Plate (6 Used) 21 - Second Stage Carrier 29 - Bearing Washer
Assembly
6 - Retaining Ring 14 - Bolt (18 Used) 22 - Bolt (4 Used) 30 - O-Ring (2 Used)
7 - First Stage Sun Gear 15 - Washer (18 Used) 23 - Washer (4 Used) 31 - O-Ring (2 Used)
8 - Spacer 16 - Wire (6 Used) 24 - Pipe 32 - Adapter
W8R7-E-01(20160803) W2-4-93
A
36
33, 34
37
Section A
W8R7-02-04-004
40
41 39
W8R7-02-04-003 W8R7-02-04-005
35
View B
35
39
W8R7-02-04-006
38
View C
B
40
C
W8R7-02-04-007
View D
S
e
c
ti
o
n
C
W8R7-02-04-002
33 - Bolt (26 Used) 36 - Stud Bolt (24 Used) 38 - Cork (For M16) (2 Used) 40 - Cork (For M30) (5 Used)
34 - Washer (26 Used) 37 - Cork (For M12) (2 Used) 39 - Cork (For M20) (11 Used) 41 - Cork (For M33) (2 Used)
35 - Plug (4 Used)
W8R7-E-01(20160803) W2-4-94
43, 44 47
46 47
45
42
W8R7-02-04-009 W8R7-02-04-012
W8R7-02-04-010
49 Section E Section F Section H
Section G W8R7-02-04-011
53, 54 55 56, 57
48 49 50, 51 52
G
F
I
58
59, 60
61
74 73 72 71 62, 63, 64
W8R7-02-04-008
69, 70 68 67 66 65
75 76, 77
78
80, 70
79
81
W8R7-02-04-014
Section I
Section J
W8R7-02-04-013
42 - Plate (2 Used) 52 - Cover 62 - Bolt (6 Used) 72 - Hose (2 Used)

43 - Bolt (4 Used) 53 - Split Flange (8 Used) 63 - Washer (12 Used) 73 - O-Ring (4 Used)
44 - Washer (4 Used) 54 - Bolt (16 Used) 64 - Nut (6 Used) 74 - Split Flange (4 Used)
45 - O-Ring (2 Used) 55 - Hose 65 - Clamp (2 Used) 75 - Plate
46 - Bolt (8 Used) 56 - Bolt (24 Used) 66 - Hose 76 - Bolt (2 Used)
47 - Adapter (4Used) 57 - Washer (24 Used) 67 - Clamp (2 Used) 77 - Washer (2 Used)
48 - O-Ring 58 - Bracket 68 - Bracket (4 Used) 78 - Pipe
49 - Plate 59 - Bolt (4 Used) 69 - Bolt (8 Used) 79 - O-Ring
50 - Bolt (8 Used) 60 - Washer (4 Used) 70 - Washer (12 Used) 80 - Bolt (4 Used)
51 - Washer (8 Used) 61 - Plate (2 Used) 71 - Pipe (2 Used) 81 - Spacer (4 Used)
W8R7-E-01(20160803) W2-4-95
82 83 84, 85 86, 87, 88

89
90
91
92
114
93
113
112 94
95
96, 97
98
110, 111 99
109 100
108
101
106, 107
W8R7-02-04-015
104, 105 103 102
82 - Wheel 91 - Plug 99 - O-Ring 107 - Washer (32 Used)

83 - Bearing Retainer 92 - O-Ring 100 - Brake assembly 108 - O-Ring
84 - Bolt (18 Used) 93 - Coupling 101 - Spindle 109 - Bearing Retainer
85 - Washer (18 Used) 94 - Floating Seal 102 - O-Ring 110 - Bolt (36 Used)
86 - Shim 95 - Floating Seal 103 - O-Ring 111 - Washer (36 Used)
87 - Shim 96 - Bolt (24 Used) 104 - Hose (2 Used) 112 - O-Ring (2 Used)
88 - Shim 97 - Washer (24 Used) 105 - O-Ring (4 Used) 113 - Pipe
89 - Pin (3 Used) 98 - Retainer 106 - Bolt (32 Used) 114 - Roller Bearing (2 Used)
90 - Retainer
W8R7-E-01(20160803) W2-4-96
116
115
O
W8R7-02-04-018
M Section M
117, 118
N
119
Details N W8R7-02-04-019
120
W8R7-02-04-016
View K
W8R7-02-04-020
Section O
P
121 122 123 124
W8R7-02-04-021
Section P
125
126
Q
127
W8R7-02-04-017
View L
W8R7-02-04-022
Section Q
115 - Bolt (6 Used) 119 - Wire 122 - O-Ring (4 Used) 125 - Sleeve (2 Used)
116 - Bolt 120 - Bolt (2 Used) 123 - Spacer (4 Used) 126 - O-Ring (2 Used)
117 - Bolt (4 Used) 121 - Brake Adjusting Pin (4 Used) 124 - Nut (4 Used) 127 - O-Ring (2 Used)
118 - Washer (4 Used)
W8R7-E-01(20160803) W2-4-97
93
94
95
98
109 100
101
106, 107
W8R7-02-04-015
103 102
W8R7-E-01(20160803) W2-4-98
Assembly of Wheel Reduction Device
1. Install the special tool holder to spindle (101). Starting the transmission assembling
Stand spindle (101) vertically. 101
2. Install new O-rings (102, 103) to spindle (101).

brake assembly (100). Attach the lifting tool to the
eyebolts.
CAUTION: Brake assembly (100) weight:

1020 kg (2250 lb)
4. Hoist brake assembly (100) with a crane. Align

sleeve (125) and the drain plug with spindle (101)
and place brake assembly (100).
W8R7-02-04-035
5. Apply LOCTITE #262 or THREEBOND #1386B Special Tool Holder
onto the thread part of bolts (106) (32 used). 101
6. Install brake assembly (100) to spindle (101) with

bolts (106) (32 used) and washers (107) (32 125
used).
：46 mm
：1950 N·m (195 kgf·m, 1440 lbf·ft)
CAUTION: Floating seal (95) weight: 29.2 kg W8R7-02-04-022

(64 lb) 100
IMPORTANT：Refer to the section “Precautions for
Floating Seal Handling".
7. Install new floating seals (95) to retainer (98) and

coupling (93).
NOTE: Floating seal (95) mounting Tool: ST7957
8. Install new floating seals (94) to coupling (93) and

bearing retainer (109).
NOTE: Floating seal (94) mounting tool: ST7958
W8R7-E-01(20160803) W2-4-99
93
Special tools (Height: 201 mm)

94 (3 or more used) are arranged
even intervals in the circle.
95 96, 97
98
99
100
101
W8R7-02-04-015
W8R7-E-01(20160803) W2-4-100
9. Install O-ring (99) to brake assembly (100).

retainer (98). Attach the lifting tool to the eyebolts.

lb)
11. Hoist retainer (98) with a crane. Place retainer

(98) on brake assembly (100).
12. Apply LOCTITE #262 or THREEBOND #1386B

onto the thread part of bolts (96) (24 used).
121 122 100 123 124
13. Install retainer (98) to brake assembly (100) with
：24 mm
：270 N·m (27 kgf·m, 199 lbf·ft)
14. Install O-ring (122) to brake adjusting pin (121).

Install brake adjusting pin (121) to brake assembly
W8R7-02-04-021
(100). Install spacer (123) and nut (124).
：8 mm（121） Inner Gear of Friction Disk
：19 mm（124）
：35 N·m (3.5 kgf·m, 26 lbf·ft)
(Trial Assembly)
15. Apply pressure air (0.4 MPa) on the brake

pressure inlet (G1/2) in order to align the inner
gears of the friction disks (10 used) and to prevent
the gears from displacing while inserting the
coupling spline. At this time, apply pressure for
five minutes and check that there is no pressure
drop occurs. Apply thin coat of soap solution onto
the mating surface of spindle (101) and brake
assembly (100). Check that there is no air leak
occurs.
W8R7-02-04-036
16. Place special tools (height: 201 mm) to support

the coupling (93) on retainer (98).
17. Apply gear oil onto the mating surfaces of floating

seals (94, 95).
Brake Pressure Inlet
W8R7-02-04-013
W8R7-E-01(20160803) W2-4-101
114 89
93
109 100
108
101
W8R7-02-04-015
W8R7-E-01(20160803) W2-4-102
18. Install eyebolts (M30, Pitch 3 mm) (3 used) and
lifting tool to coupling (93).
CAUTION: The Coupling (93) assembly

19. Hoist the coupling (93) assembly with a crane.

Install the outer gear of coupling (93) to the friction
disk inner gear of brake assembly (100).
20. Install greased pins (89) and new O-ring (108) to

spindle (101).

bearing retainer (109). Attach the lifting tool to the 101 109
eyebolts.
CAUTION: Bearing retainer (109) weight: 111

kg (245 lb)
22. Hoist bearing retainer (109) with a crane. Align the

pin (89) position of spindle (101) and install
position because the clearance between
short.
23. Install greased pin (89) to spindle (101).

W8R7-02-04-034
IMPORTANT：Preload adjustment must be carried
out after installing roller bearings
(114) (2 used). Refer to the heading
"Wheel bearing preload operation
management procedures" of this
chapter.

W8R7-E-01(20160803) W2-4-103
82
89
92
114
93
110, 111
101
W8R7-02-04-015
W8R7-E-01(20160803) W2-4-104

kg (448 lb)
25. Hoist roller bearing (114) with a crane. Align the

pin (89) position of spindle (101) and install the
roller bearing (114) inner race.
26. Install the roller bearing (114) outer race (2 used)

to wheel (82).
NOTE: The insertion outer race to wheel (82) has

the following procedures.
• Cool the outer race by placing in dry ice or liquid
nitrogen before inserting. When using liquid
nitrogen do not allow liquid nitrogen to directly
come in contact with the outer race.
• Insert the outer race after washing wheel (82) in
warm water.
Use either one of the two ways. Do not insert the
outer race by force.
Use a clearance gauge to check that there is no gap
between the outer race shoulder and wheel (82)
towards the axial direction after inserting.
27. Install new O-rings (92) to coupling (93).

CAUTION: Wheel (82) weight: 2450 kg (5400

lb)
29. Hoist wheel (82) with a crane. Install wheel (82) to

coupling (93).

W8R7-E-01(20160803) W2-4-105
82 83 86, 87, 88
89
114
93
Special tools (Height: 201 mm)

(3 or more used) are arranged
even intervals in the circle
110, 111
101
W8R7-02-04-015
W8R7-E-01(20160803) W2-4-106
31. Install wheel (82) to coupling (93) with bolts (110)
Remove special tools (height: 201 mm).
：46 mm
：1950 N·m (195 kgf·m, 1440 lbf·ft)

out after installing roller bearings
(114) (2 used). Refer to the heading
"Wheel bearing preload operation
management procedures" of this
chapter for detail. Create a shim
pack of shims (86, 87, 88).


kg (448 lb)

pin (89) position of spindle (101) and install the
roller bearing (114) inner race.
34. Install pin (89) to spindle (101) and roller bearing

(114).
83
35. Install bolt (116) to spindle (101).

：10 mm 116
：90 N·m (9.0 kgf·m, 66 lbf·ft)
36. After preloading roller bearings (114) (2 used),

install a shim pack (comprised of an appropriate
number of three different types of shims (86) (87) 101
W8R7-02-04-018
(88)) to spindle (101).

eyebolts.
W8R7-E-01(20160803) W2-4-107
83 84, 85 112
90
91
114
101
W8R7-02-04-015
104, 105
W8R7-E-01(20160803) W2-4-108

kg (203 lb) 83
38. Hoist bearing retainer (83) with a crane. Align 116

bearing retainer (83) with bolt (116) of spindle
(101) and place bearing retainer (83).

out after installing roller bearings 101
(114) (2 used). Remove remaining W8R7-02-04-018
LOCTITE, accumulated dirt and oil

from bolts (84) and the bolt holes as
axial force of bolts (84) (18 used)
generates pre-compression.

40. Install bearing retainer (83) to spindle (101) with

Tighten bolts (84) (18 used) by using a
cross-wrench (diagonal tightening) method. Check
the torque twice.
：50 mm
：2400 N·m (240 kgf·m, 1770 lbf·ft)
41. Install plug (91) to retainer (90).

：5 mm
：10 N·m (1.0 kgf·m, 7.4 lbf·ft) 120 112
42. Apply LOCTITE #262 or THREEBOND #1386B 90

43. Install new o-rings (105) (2 used) to hoses (104)

(2 used). Install hoses (104) (2 used) to retainer
W8R7-02-04-020
(90) with bolts (120) (4 used). 104 105
：8 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
44. Install new O-rings (112) (2 used) to retainer (90).
45. Install eyebolt (M10, Pitch 1.5 mm) and eyebolt

(M12, Pitch 1.75 mm) to retainer (90). Attach the
W8R7-E-01(20160803) W2-4-109
90
117, 118, 119
28, 29
113
26
25
101
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-110
46. Hoist retainer (90) with a crane. Place retainer 115 90

(90) into spindle (101).

48. Install retainer (90) to spindle (101) with bolts

(115) (6 used).
：10 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)

50. Insert pipe (113) into spindle (101). Install spindle

(101) to retainer (90) with bolts (117) (4 used) and
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft) W8R7-02-04-016
51. Reeve wire (119) into the hole of bolts (117) head
to stop bolts (117) (4 used) from loosening.
113 117、118
52. Warm up sleeve (25). Install sleeve (25) to shaft
(5).
119
53. Warm up ball bearing (26). Install ball bearing (26)
to sleeve (25).
90
W8R7-02-04-019
54. Install bearing nut (28) and bearing washer (29) to
sleeve (25) and tighten by hand. Tighten bearing
nut (28) until the groove of bearing nut (28) fits the
bent portion of bearing washer (29).
55. Bend bearing washer (29) to stop bearing nut (28)

from loosening.
W8R7-E-01(20160803) W2-4-111
21
31
30
22, 23
82
24
90
27
26
101
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-112
56. Install eyebolt (M12, Pitch 1.75mm) to the tip of
shaft (5). Attach the lifting tool to the eyebolts.
CAUTION: The shaft (5) assembly weight: 82

kg (181 lb)
57. Hoist shaft (5) with a crane. Insert ball bearing (26)
of shaft (5) to retainer (90) of spindle (101).
58. Install retaining ring (27) to retainer (90).

60. Install pipe (24) to retainer (90) with bolts (22) (4

used) and washers (23) (4 used).
：17 mm
：65 N·m (6.5 kgf·m, 48 lbf·ft)
101 21 Bearing retainer (83) notch

second stage carrier assembly (21). Attach the Notch of (101)

(21) weight: 1700 kg (3750 lb)
IMPORTANT：Refer to the “Angular Position of the
Second Stage Carrier” diagram for
the angular position of spindle (101)
and second stage carrier assembly
(21).
62. Hoist second stage carrier assembly (21) with a

crane. Install second stage carrier assembly (21)
to spindle assembly (101).
63. Install new O-rings (30, 31) to wheel (82).

W8R7-02-04-037
Angular Position of the Second Stage Carrier
W8R7-E-01(20160803) W2-4-113
12
14
17
18
19
20
82
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-114
second stage ring gear (20). Attach the lifting tool
to the eyebolts.
CAUTION: Second stage ring gear (20)

65. Hoist second stage ring gear (20) with a crane.

Install second stage ring gear (20) to wheel (82).

coupling (17). Attach the lifting tool to the eyebolts.
CAUTION: Gear coupling (17) weight: 154 kg

(340 lb)
67. Hoist gear coupling (17) with a crane. Install the

gear of gear coupling (17) while fitting it with the
gear teeth of second stage sun gear (19).
68. Install gear coupling (17) to second sun gear (19)

with retaining ring (18).

first stage ring gear (12). Attach the lifting tool to
the eyebolts.
CAUTION: First stage ring gear (12) weight :

136 kg (300 lb)
70. Hoist first stage ring gear (12) with a crane. Install
the gear of first stage ring gear (12) while fitting it
with gear teeth of gear coupling (17).

W8R7-E-01(20160803) W2-4-115
12
13
32
14, 15, 16
17
31 19
30
21
20
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-116
72. Install first stage ring gear (12) to gear coupling
(17) with lock plates (13) (6 used), bolts (14) (18 12 14, 15
：24 mm 13
：270 N·m (27 kgf·m, 199 lbf·ft)
73. Reeve wire (16) into a hole on bolts (14) head to

stop bolts (14) (3 used) from loosening. (6 places) 16
W8R7-02-04-038

coupling (17) of the first stage ring gear (12)
assembly. Attach the lifting tool to the eyebolts.
CAUTION: First stage ring gear (12)

75. Hoist the first stage ring gear (12) assembly with a
crane. Insert second stage sun gear (19) to the
planetary gear of second stage carrier assembly
(21). Install the first stage ring gear (12) assembly.
76. Install new O-rings (30, 31) to second stage ring

gear (20).
32 33
adapter (32). Attach the lifting tool to the eyebolts.
Groove
CAUTION: Adapter (32) weight: 306 kg (675
lb)
78. Hoist adapter (32) with a crane. Fit the groove of

second stage ring gear (20) and the groove of
adapter (32). Put adapter (32) onto second stage
ring gear (20).

W8R7-02-04-003
W8R7-E-01(20160803) W2-4-117
1 4 5 6 7 8 10, 11
9
32
20
82
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-118
80. Install adapter (32) and second stage ring gear
(20) to wheel (82) with bolts (33) (26 used) and
：50 mm
：2400 N·m (240 kgf·m, 1770 lbf·ft)
81. Install new O-rings (9) to adapter (32).

1 32 33, 34
first stage carrier assembly (1). Attach the lifting
tool to the eyebolts.
CAUTION: First stage carrier assembly (1)

IMPORTANT：Refer to the “Angular Position of the
First Stage Carrier” diagram for the
angular position of adapter (32) and
first stage carrier assembly (1).
83. Hoist first stage carrier assembly (1) with a crane.

Fit the gear teeth of first stage ring gear (12) and
the planetary gear teeth of first stage carrier
assembly (1). Put carrier assembly (1) onto
adapter (32).
84. Install first stage carrier assembly (1) to adapter

(32) with bolts (10) (24 used) and washers (11) (24
used). W8R7-02-04-003
：30 mm Angular Position of the First Stage Carrier

：550 N·m (55 kgf·m, 406 lbf·ft)
85. Install spacer (8) and first stage sun gear (7) to
shaft (5) with retaining ring (6)..

onto installation surface of cover (4).
W8R7-E-01(20160803) W2-4-119
32 36
A 1 82
35 33, 34
4
37
2, 3 Section A
W8R7-02-04-004
40
W8R7-02-04-005
View B
35 35 41 35 39 W8R7-02-04-003
39
W8R7-02-04-006
38
View C
40
B
W8R7-02-04-007
View D
C
S
e
c
ti
o
n
C
W8R7-02-04-002
W8R7-E-01(20160803) W2-4-120
87. Install cover (4) to first stage carrier assembly (1)
with bolts (2) (8 used) and washers (3) (8 used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
88. Install plugs (with O-ring) (35) (4 used) to first

stage carrier assembly (1) and adapter (32).
：17 mm
：210 N·m (21 kgf·m, 155 lbf·ft)
89. Install corks (37) (2 used), (38) (2 used), (39) (11

used), (40) (5 used), and (41) (2 used) to the
120 mm 32
36
90. Degreasing stud bolts (36) (24 used) and the
82
wheel (82) bolt holes. Apply LOCTITE #262 or
THREEBOND #1386B to the threaded area of
stud bolts (36).
91. Install stud bolts (36) (24 used) to wheel (82) so

that the stud bolts head protrude 120 mm from the
mating surface of adapter (32).
W8R7-02-04-004
W8R7-E-01(20160803) W2-4-121
W8R7-02-04-001
W8R7-E-01(20160803) W2-4-122
 Place the wheel reduction device horizontally.
92. Install the special flange to the wheel reduction Special Flange
device with the bolts (12 used) and the washers
(12 used).
93. Install eyebolts (4 used) and shackles (2 used) to

the special flange.
CAUTION: Wheel reduction device weight:

11000 kg (24300 lb)
94. Attach wire ropes onto eyebolts (4 used). Hoist the

wheel reduction device with a crane. Move the
wheel reduction device from the side of the work
bench.
95. Attach a wire rope onto shackles (2 used). Hoist

the wheel reduction device with a crane. Place the W8R7-02-04-025
wheel reduction device horizontally.
96. Remove bolts (24 used) and washers (24 used)

from the wheel reduction device. Remove the
special tool holder, the special flange from the
W8R7-02-04-024
Special Flange Special Tool Holder
W8R7-02-04-023
W8R7-E-01(20160803) W2-4-123
43、44
46
45
42
W8R7-02-04-012
49 W8R7-02-04-009 W8R7-02-04-010
Section H
Section E Section F Section G W8R7-02-04-011
101
48 49 50, 51
G
F
I
E
104, 105
74 71
W8R7-02-04-008
78
101 80, 70
79
101 81
W8R7-02-04-014
Section I
Section J
W8R7-02-04-013
W8R7-E-01(20160803) W2-4-124
 Installation of Hose and Pipe
98. Install plate (49) with new O-ring (48) to spindle

used)
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
99. Connect hoses (104) (2 used) with new O-rings

(105) (2 used) to plate (49) with split flanges (74)
(4 used) and bolts (46) (8 used).
：8 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
100. Install new O-rings (45) (2 used) to plate (49).

Apply liquid seal onto Do not apply liquid seal onto
the shaded area the O-ring seal surface.
onto the installation surface (shaded area in the
figure) of plates (42) (2 used).
102. Install plates (42) (2 used) to plate (49) with bolts

42
(43) (4 used) and washers (44) (4 used). W8R7-02-04-053
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
103. Install pipes (71) (2 used) to spindle (101) with

bolts (80) (4 used), washers (70) (4 used), and
spacers (81) (4 used).
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
104. Install pipe (78) with new O-ring (79) to spindle

(101).
：22 mm
：70 N·m (7.0 kgf·m, 52 lbf·ft)
W8R7-E-01(20160803) W2-4-125
47
W8R7-02-04-009 W8R7-02-04-012
W8R7-02-04-010
Section F Section H
Section E Section G W8R7-02-04-011
101
55 56, 57
72 53, 54 52
61
73
H
G
F I
61
72 68
62, 63, 64
W8R7-02-04-008
69, 70 67 66 65
W8R7-02-04-014
Section I
Section J
W8R7-02-04-013
W8R7-E-01(20160803) W2-4-126
105. Install plates (61) (2 used) to cover (52) with bolts
(62) (6 used), washers (63) (12 used) and nuts
(64) (6 used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
106. Install the cover (52) assembly to spindle (101)

used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)

(73) (2 used) to plates (61) (2 used) with split
franges (53) (4 used) and bolts (54) (8 used).
：8 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
108. Install adapters (47) (2 used) with new O-ring to

cover (52).
：27 mm
：95 N·m (9.5 kgf·m, 70 lbf·ft)
IMPORTANT：Install hoses (55, 66) to the original

position of cover (52).
109. Connect hoses (55, 66) to adapters (47) (2 Used)

of cover (52).
：27 mm
：95 N·m (9.5 kgf·m, 70 lbf·ft)
110. Install clamps (65) (2 used) and clamps (67) (2

used) to hoses (72) (2 used) and hoses (55, 66)
with brackets (68) (4 used), bolts (69) (4 used) and
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-E-01(20160803) W2-4-127
54 53 47
73 55, 66
42 49
W8R7-02-04-009 W8R7-02-04-012
W8R7-02-04-010
Section H
Section E Section F Section G W8R7-02-04-011
101
53, 54 55
49 72 52
G
F
I
58
59, 60
73 72
W8R7-02-04-008
69, 70 68 66
75 76, 77
78 58
W8R7-02-04-014
Section I
Section J
W8R7-02-04-013
W8R7-E-01(20160803) W2-4-128
111. Install bracket (58) to cover (52) with bolts (59) (4
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
IMPORTANT：Install plate (75) while adjusting its

position with pipe (78) in order not to
apply bending stress to pipe (78).
112. Install plate (75) to bracket (58) with bolts (76) (2

：17 mm
：65 N·m (6.5 kgf·m, 48 lbf·ft)
113. Install adapters (47) (2 used) with new O-ring to

plate (49).
：27 mm
：95 N·m (9.5 kgf·m, 70 lbf·ft)
114. Connect hoses (55, 66) to adapters (47) (2 Used)

of plate (49).
：27 mm
：95 N·m (9.5 kgf·m, 70 lbf·ft)


(73) (2 used) to plates (42) (2 used) with split
flanges (53) (4 used) and bolts (54) (8 used).
：8 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
117. Install brackets (68) (4 used) that secures hoses

(72) (2 used) and hoses (55, 66) to spindle (101)
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-E-01(20160803) W2-4-129
Brake Oil Filler Port
W8R7-02-04-008
W8R7-02-04-096
Section A
128 129 121
W8R7-02-04-097
View B
W8R7-02-04-015
W8R7-E-01(20160803) W2-4-130
118. Remove plug (35). Refill gear oil to the wheel
reduction device through the filler port.
119. Refill brake oil to brake cooling chamber through

35
the brake oil filler port.
120. Adjust the brake clearance by using brake M8R7-07-009
adjusting pin (121).

Refer to the Brake Clearance Adjustment section.
121. After adjusting the brake clearance, install

instruction plate (128) to brake adjusting pin (121)
with nut (129) as illustrated.
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
NOTE: Instruction plate (128) is not delivered with

the wheel reduction device before IMG No.
10-10118. However, it is available at your
authorized dealer.
122. After assembling the wheel reduction device,

perform break-in operation.
Refer to Break-In operation section.
W8R7-E-01(20160803) W2-4-131
DISASSEMBLY OF FIRST STAGE CARRIER ASSEMBLY
W8R7-02-04-106
1- Plate (3 Used) 5- Retaining ring (3 Used) 9- Pin (3 Used) 13 - Wire (3 Used)

2- Bolt (6 Used) 6- Roller Bearing (3 Used) 10 - Plate (3 Used) 14 - Bolt (3 Used)
3- Carrier 7- Plug (3 Used) 11 - Bolt (3 Used) 15 - Washer (3 Used)
4- Planetary Gear (3 Used) 8- Pin (3 Used) 12 - Washer (3 Used) 16 - O-Ring (3 Used)
W8R7-E-01(20160803) W2-4-132
Disassembly of First Stage Carrier Assembly
CAUTION: First stage carrier assembly

1. Cut the looseness prevention wires (13) (3 used) 13, 14, 15

of bolts (14) (3 used).
2. Invert the first stage carrier assembly.

the carrier assembly. Attach the lifting tool to
eyebolts.
4. Hoist the carrier assembly. Put the carrier

assembly onto the special tool. Removing the first stage carrier assembly
W8R7-02-04-026
used) from the first stage carrier assembly.
：36 mm
8
BOND #1386B.

pins (8) (3 used). Attach the lifting tool to the
eyebolts.
7. Hoist and remove pins (8) (3 used) from the first

stage carrier assembly with a crane.
Plug (7), pin (9) and O-ring (16) are removed with
pin (8).
W8R7-02-04-040
W8R7-E-01(20160803) W2-4-133
W8R7-02-04-106
W8R7-E-01(20160803) W2-4-134
8. Install sliding plates (2 used) under planetary gear
(4).
CAUTION: Planetary Gear (4) weight: 90 kg

(198 lb)
9. Install eyebolt (M12, Pitch 1.75 mm) (1 used) to 4 3

Sliding Plate
planetary gear (4). Attach the lifting tool to the
eyebolt.
IMPORTANT：Take care not to damage the sliding

surface of planetary gear (4).
10. Slightly hoist and hold planetary gear (4). Slide

planetary gear (4) on the sliding plate to the Sliding Surface
position where another eye bolt (M12, pitch 1.75
mm) can be installed. Extract planetary gear (4).
11. Install another eyebolt (M12, Pitch 1.75 mm) to

eyebolt. W8R7-02-04-041
12. Slightly hoist and hold planetary gear (4) and

further extract planetary gear (4) from carrier (3).
Remove plate (10) from bottom of planetary gear
(4) and the inner race from the bottom of bearing
(5).
13. Hoist planetary gear (4) with a crane. Remove

planetary gear (4) from carrier (3).
14. Remove other planetary gears (4) (2 used) from

carrier (3) in the same way.
15. Plates (1) (3 used), bolts (2) (6 used), bolts (11) (3

used) and washers (12) (3 used) are attached on
carrier (3). Do not remove them unless necessary.
16. The outer race of roller bearing (6) and retaining

ring (5) are attached on planetary gear (4). Do not
remove them unless necessary.
W8R7-E-01(20160803) W2-4-135
ASSEMBLY OF FIRST STAGE CARRIER ASSEMBLY
3 4 5 6 7 8 9
W8R7-02-04-039
16 14, 15 13 11, 12 10
1- Plate (3 Used) 5- Retaining ring (3 Used) 9- Pin (3 Used) 13 - Wire (3 Used)

2- Bolt (6 Used) 6- Roller Bearing (3 Used) 10 - Plate (3 Used) 14 - Bolt (3 Used)
3- Carrier 7- Plug (3 Used) 11 - Bolt (3 Used) 15 - Washer (3 Used)
4- Planetary Gear (3 Used) 8- Pin (3 Used) 12 - Washer (3 Used) 16 - O-Ring (3 Used)
W8R7-E-01(20160803) W2-4-136
Assembly of First Stage Carrier Assembly
CAUTION: Carrier (3) weight: 360 kg (794 lb)
1. Place carrier (3) onto the special tool. Outer Spacer

Roller Outer Race

(198 lb)
2. Install retaining rings (5) (3 used) to planetary

gears (4) (3 used).

out for roller bearing (6). Refer to the
Operation management chart.
IMPORTANT：One set of roller bearing (6) consists Inner Spacer Inner Race W8R7-02-04-054
of roller bearings, outer spacers and
Roller Bearing (6)
inner spacers (2 used for each). Do
not change the pairing of the
spherical bearing. Refer to the figure
for assembling roller bearing (6) to 4 6
planetary gear (4).
IMPORTANT：Maintain the temperature of planetary
gear (4) and roller bearing (6) for the
ambient temperature +/- 5°C.
IMPORTANT：Maximum pushing force: 140 kN
3. Install the outer race and outer spacer of roller

bearing (6) to planetary gear (4) by using a special
tool and a press. Be sure to check pushing force
beforehand. Check on the operation management
chart. W8R7-02-04-042
IMPORTANT：After assembling the outer race of

roller bearing (6) to planetary gear (4),
be careful not to apply shock while
transporting or assembling the part.
4. Apply gear oil (140W or equivalent) onto the outer

race, inner race and the roller evenly. Check on
the operation management chart.
5. Place planetary gear (4) facing the bolt hole of

lifting device upward. Install inner race (with roller)
of roller bearing (6) on the upper side of planetary
gear (4).
W8R7-E-01(20160803) W2-4-137
6. Install eyebolt (M12, Pitch 1.75 mm) (2 used) to
eyebolt.
7. Hoist planetary gear (4) with a crane. Install the 3

4
inner spacer and inner race (with roller) of roller Sliding Plate
bearing (6) and plate (10) to the bottom side of
planetary gear (4).
8. Place sliding plates (2 used) to the planetary gear

(4) mounting position of carrier (3).
9. Lower planetary gear (4) onto the sliding plate on

carrier (3). At this time, be careful not to separate
the inner race and plate (10). Sliding Surface

10. Slightly hoist planetary gear (4) with a crane. W8R7-02-04-041
Insert planetary gear (4) into carrier (3) until it

contacts with the eye bolts.
4 6 8 7 9 Inner Spacer
11. Remove one eye bolt. Insert planetary gear (4) to
its mounting position. Outer Race
12. Install plug (7), O-ring (16), pin (9) to pin (8).
Check on the operation management chart.
：5 mm
：4 N·m (0.4 kgf·m, 3 lbf·ft)
13. Install pin (8) to carrier (3). At this time, be careful

not to drop O-ring (16).
14. Install washer (15) to bolt (14). Tighten the bolt by

hand until it contacts to carrier (3). This time, do W8R7-02-04-042
not apply LOCTITE #262 or THREEBOND 16 14, 15

3 10
#1386B on the thread of bolt (14). Inner Race
15. In order to facing up the contact surface of the

roller and the outer race/inner race, rotate
planetary gear (4) more than 30 turns. Check on
W8R7-E-01(20160803) W2-4-138
16. Tighten bolt (14) with a torque of 400 N·m while
rotating planetary gear (4). Check on the
operation management chart.
：36 mm
：400 N·m (40 kgf·m, 295 lbf·ft)
17. Rotate planetary gear (4) further 30 rotation or 4 8

more, check that bolt (14) has tightened with a
torque of 400 N·m.
18. If bolt (14) can be tightened further with a torque

of 400 N·m, re-tighten bolt (14) with a torque of
400 N·m while rotating planetary gear (4). Repeat
the procedure until bolt (14) does not rotate with a
torque of 400 N·m.
19. Check that bolt (14) does not rotate with a torque
of 400 N·m, check on the operation management
chart.
W8R7-02-04-042
20. Install eyebolt (M12, Pitch 1.75 mm) to the

3 14, 15
hoisting hole on planetary gear (4).
4
IMPORTANT：Maximum force that required to rotate
planetary gear (4): 60 N
21. Install a digital load meter which has maximum

value holding function to the eye bolt. Measure the
tangential force of the gear. Record the value on
22. If the measured value is out of the specification,

the outer race press fitting process possibly has a
problem. Start from the process of the outer race
press fitting to planetary gear (4) again.
23. When the measured value is in the specification,

remove bolt (14) and washer (15) from pin (8).
Digital Load Meter W8R7-02-04-044
W8R7-E-01(20160803) W2-4-139
onto the thread of bolt (14). Check on the
25. Install washer (15) to bolt (14). Tighten the bolt by 8

4
hand until it contacts to carrier (3).

roller and the outer race / inner race, rotate

rotating planetary gear (4). Check on the
：36 mm
：950 N·m (95 kgf·m, 700 lbf·ft)
W8R7-02-04-042
28. Rotate planetary gear (4) further 30 rotation or

3 14, 15
torque of 950 N·m.
29. If bolt (14) can be tightened further with a torque

of 950 N·m, re-tighten bolt (14) with a torque of
950 N·m while rotating planetary gear (4). Repeat
the procedure until bolt (14) does not rotate with a
torque of 950 N·m.
4
30. Check that the bolt (14) does not rotate with a
torque of 950 N·m, check on the operation
management chart.

IMPORTANT：Maximum force that required to rotate


Digital Load Meter W8R7-02-04-044
W8R7-E-01(20160803) W2-4-140
33. If the measured value is out of the specification, 4
press fitting to planetary gear (4) again. O-ring
(16) is easily damaged while disassembling pin
(8). Replace O-ring (16) with a new one.
34. Install other planetary gears (4) (2 used) to carrier

(3) in the same way.

W8R7-02-04-042
36. Install plates (1) (3 used) to carrier (3) with bolts

3 14 13 11, 12
(2) (6 used).
：19 mm 2 1
：110 N·m (11 kgf·m, 81 lbf·ft)
37. Bend both ends of plates (1) (3 used) to lock bolts

(2) (6 used) from loosening.
CAUTION: First stage carrier assembly

38. Turn over the carrier assembly.

40. Install bolts (11) (3 used) and washers (12) (3

used) to carrier (3).
：24 mm
：270 N·m (27 kgf·m, 199 lbf·ft) W8R7-02-04-044
41. Reeve wires (13) (3 used) into the hole of bolts

(14) (3 used) and bolts (11) (3 used) head to lock Cap
bolts from loosening.
42. Install the cap at the end of the wire, secure it with
a special tool.
W8R7-02-04-043
14 13 11, 12
W8R7-E-01(20160803) W2-4-141
Roller Bearing Installation: Operation Management Chart
Equipment manufacture number:
First stage carrier assembly
Date of operation: Operator:
1. Installation of the outer race and the outer spacer of the roller bearing into the planetary gear
(1) (2) (3)
• Press fitting by using a special tool and a press Check mark
2. Temporary installation of the planetary gear and the roller bearing to the carrier (3 used)
• Apply gear oil (140W or equivalent) to the bearing. Check mark
• Install O-ring to the pin Check mark
• Rotate the planetary gear 30 turns or more Check mark
• Tighten the bolt with a torque of 400 N·m while rotating the planetary gear Check mark
• Check the bolt tightening torque : 400 N·m Check mark
• Measured value of the digital load meter
(screw hole position) (1) (N) (N) (N)
(Three time for each gear) (2) (N) (N) (N)
Allowable load: 60 N or less : (3) (N) (N) (N)
3. Installation of the planetary gear and the roller bearing to the carrier (3 used)
• Apply LOCTITE on the thread of bolts. Check mark
• Measured value of the digital load meter
W8R7-E-01(20160803) W2-4-142
(Blank)
W8R7-E-01(20160803) W2-4-143
DISASSEMBLY OF SECOND STAGE CARRIER ASSEMBLY
W8R7-02-04-107
1- Carrier 6- Roller Bearing (4 Used) 11 - Oil Guide 16 - Lock Washer (8 Used)

2- Planetary Gear (4 Used) 7- Plate (4 Used) 12 - Lock Washer (4 Used) 17 - Bolt (16 Used)
3- Pin (4 Used) 8- Bolt (4 Used) 13 - Bolt (8 Used) 18 - Oil Guide
4- Pin (4 Used) 9- Washer (4 Used) 14 - Oil Guide 19 - Baffle
5- Retaining ring (4 Used) 10 - Wire (4 Used) 15 - Oil Guide 20 - Baffle
W8R7-E-01(20160803) W2-4-144
Disassembly of Second Stage Carrier Assembly

1. Cut the looseness prevention wires (10) (4 used)

of bolts (8) (4 used).

used) from the second stage carrier assembly.
：41 mm
NOTE: Threaded area of bolt (8) is applied with

LOCTITE #262 or THREEBOND #1386B.
3. Install eyebolts (M10, Pitch 1.5 mm) (4 used) to Pedestal of Special

pins (4) (4 used). Attach the lifting tool to the Tool (Round) W8R7-02-04-046
eyebolts. Disassembling Position of Second Stage Carrier Assembly
CAUTION: Pin (4) weight: 34 kg (75 lb)

Eyebolt
4. Hoist and remove pins (4) (4 used) from the Sliding Surface
1
second stage carrier assembly with a crane.
2
Pin (4) is removed with pin (3) together.

(220 lb)
5. Install eyebolt (M12, Pitch 1mm) (1 used) to

eyebolt.

6. Slightly hoist and pull planetary gear (2) from W8R7-02-04-047
carrier (1) until another eye bolt can be installed

on planetary gear (2).
W8R7-E-01(20160803) W2-4-145
W8R7-02-04-107
W8R7-E-01(20160803) W2-4-146
eyebolt.
IMPORTANT：Take care not to damage the sliding Sliding Surface Eyebolt

2 1
8. Hoist and pull planetary gear (2). Remove plate

(7), the inner race and inner spacer of roller
bearing from bottom of planetary gear (2).
NOTE: Carefully hold the bottom center of

planetary gear (2) in order not to drop plate
(7), the inner race and inner spacer of roller
bearing (6).
9. Remove planetary gear (2) from carrier (1).
10. Remove other planetary gears (3) (3 used) from W8R7-02-04-048
carrier (3) in the same way.
11. Oil guides (11, 14, 15 and 18), lock washers (12)
(4 used), bolts (13) (4 used), baffles (19, 20), lock
washers (12) (8 used) and bolts (13) (8 used) are
attached on carrier (1). Do not remove them
unless necessary.
12. The outer race and outer spacer of roller bearing

(6) and retaining ring (5) are attached on planetary
gear (2). Do not remove them unless necessary.
W8R7-E-01(20160803) W2-4-147
ASSEMBLY OF SECOND STAGE CARRIER ASSEMBLY
1 2 3 4
16, 17 6
8, 9, 10
20
19
11
18
12
13
17
16
14
15
W8R7-02-04-045
1- Carrier 6- Roller Bearing (4 Used) 11 - Oil Guide 16 - Lock Washer (8 Used)

2- Planetary Gear (4 Used) 7- Plate (4 Used) 12 - Lock Washer (4 Used) 17 - Bolt (16 Used)
3- Pin (4 Used) 8- Bolt (4 Used) 13 - Bolt (8 Used) 18 - Oil Guide
4- Pin (4 Used) 9- Washer (4 Used) 14 - Oil Guide 19 - Baffle
5- Retaining ring (4 Used) 10 - Wire (4 Used) 15 - Oil Guide 20 - Baffle
W8R7-E-01(20160803) W2-4-148
Assembly of Second Stage Carrier Assembly
1. Place carrier (1) facing the spline part upward.

3. Install oil guide (11, 14, 15 and 18) to carrier (1)

used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
4. Bend both ends of lock washers (12) (4 used) to

lock bolts (13) (8 used) from loosening.

6. Install baffle (19) to carrier (1) with bolts (17) (8

used) and lock washers (16) (4 used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)

CAUTION: Carrier (1) weight: 1,000 kg (2200

lb)
8. Turn over carrier (1). Lower carrier (1) onto the

round shape pedestal of special tool.
Pedestal of Special
Tool (Round)
W8R7-02-04-046
Assembly Position of Second Stage Carrier Assembly
W8R7-E-01(20160803) W2-4-149
1 16, 17 2
20
W8R7-02-04-045
W8R7-E-01(20160803) W2-4-150
onto the thread part of bolts (17) (8 used). 20 17 16
10. Install baffle (20) to carrier (1) with bolts (17) (8

used) and lock washers (16) (4 used).
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)


(218 lb)
12. Install retaining rings (5) (4 used) to planetary W8R7-02-04-049

gears (2) (4 used). Outer Spacer
Roller Outer Race

out for roller bearing (6). Refer to the
Preload Operation Management
Chart.
IMPORTANT：One set of roller bearing (6) consists
of roller bearings, outer spacers and
inner spacers (2 used for each). Do
not change the pairing of the
spherical bearing. Refer to the figure
for assembling roller bearing (6) to
planetary gear (2). Inner Spacer Inner Race
W8R7-02-04-054
IMPORTANT：Maintain the temperature of planetary
gear (2) and roller bearing (6) for the Roller Bearing (6)
ambient temperature +/- 5°C.
IMPORTANT：Maximum pushing force: 140 kN 2 6
13. Install the outer race and outer spacer of roller

bearing (6) to planetary gear (2) by using a special
tool and a press. Be sure to check pushing force
beforehand. Check on the operation management
chart.
IMPORTANT：After assembling the outer race of

roller bearing (6) to planetary gear (2),
be careful not to apply shock while
transporting or assembling the part.
14. Apply gear oil (140W or equivalent) onto the outer

W8R7-02-04-050
race, inner race and the roller evenly.Check on the
W8R7-E-01(20160803) W2-4-151
15. Place planetary gear (2) facing the bolt hole of
lifting device upward. Install inner race (with roller) Eyebolt
Sliding Surface
of roller bearing (6) (1 used) on the upper side of 1
planetary gear (2). 2

eyebolt.
17. Hoist planetary gear (2). Install the inner spacer,

inner race (with roller) and plate (7) of roller
bearing (6) to the bottom side of planetary gear
(4).

18. Insert planetary gear (2) into carrier (1) until it W8R7-02-04-047
contacts with the eye bolt.At this time, be careful

not to separate the inner race and plate (7).
Inner Spacer Inner Race
19. Remove one eye bolt. Insert planetary gear (2) to 1 3 4 2
its mounting position.
20. Install eyebolt (M10, Pitch 1.5 mm) to pin (4).

Attach the lifting tool to the eyebolt.
CAUTION: Pin (4) weight: 34 kg (75 lb)
21. Hoist pin (4) with a crane. Install retaining pin (3)
to pin (4). Install pin (4) to carrier (1).
7
22. Install washer (9) to bolt (8). Manually tighten the
bolt until it contacts to carrier (1). This time, do not
apply LOCTITE #262 or THREEBOND #1386B on
the thread of bolt (8). W8R7-02-04-050
8, 9 Inner Race
roller and the outer race/inner race, rotate
W8R7-E-01(20160803) W2-4-152
rotating planetary gear (2). Check on the operation
management chart.
：41 mm
：400 N·m (40 kgf·m, 295 lbf·ft)

more, check that bolt (8) has tightened with a 1 4 2
torque of 400 N·m.
26. If bolt (8) can be tightened further with a torque of

400 N·m, re-tighten bolt (8) with a torque of 400
N·m while rotating planetary gear (2). Repeat the
procedure until bolt (8) does not rotate with a
torque of 400 N·m.
management chart.

W8R7-02-04-050
IMPORTANT：Maximum force that required to rotate 8, 9

2

W8R7-02-04-098
31. When the measured value is in the specification, Digital Load Meter
remove bolt (8) and washer (9) from pin (4).

onto the thread of bolt (8). Check on the operation
management chart.
33. Install washer (9) to bolt (8). Tighten the bolt by

hand until it contacts to carrier (1).
W8R7-E-01(20160803) W2-4-153
roller and the outer race / inner race, rotate 1 2

rotating planetary gear (2). Check on the operation
management chart.
：41 mm
：1050 N·m (105 kgf·m, 774 lbf·ft)

torque of 1050 N·m.
W8R7-02-04-050
37. If bolt (8) can be tightened further with a torque of
1050 N·m, re-tighten bolt (8) with a torque of 950 8
N·m while rotating planetary gear (2). Repeat the
procedure until bolt (8) does not rotate with a
2
torque of 950 N·m.
management chart.

IMPORTANT：Maximum force that required to rotate W8R7-02-04-098

Digital Load Meter
tangential force of the gear. Record the value on Hole

problem. Start from the process of the outer race 11, 14
W8R7-02-04-051
8 10
42. Install other planetary gears (2) (2 used) to carrier
(3) in the same way.
Hole
43. Reeve wires (10) (4 used) into the hole of bolts (8)
(4 used) head and the oil guides (11, 14, 15 and
15, 18
18) to lock bolts (8) (4 used) from loosening. W8R7-02-04-052
W8R7-E-01(20160803) W2-4-154
Roller Bearing Installation: Operation Management Chart
Second stage carrier assembly
1. Installation of the outer race and the outer spacer of the roller bearing into the planetary gear (4 used)
(1) (2) (3) (4)
• Press fitting by using a special tool and a press Check mark
2. Temporary installation of the planetary gear and the roller bearing to the carrier (4 used)
• Apply gear oil (140W or equivalent) to the bearing. Check mark
• Check the bolt tightening torque : 400 Nm Check mark
• Measured value of the digital load meter (1) (N) (N) (N)
3. Installation of the planetary gear and the roller bearing to the carrier (4 used)
• Apply LOCTITE on the thread of bolts. Check mark
• Measured value of the digital load meter (1) (N) (N) (N)
W8R7-E-01(20160803) W2-4-155
DISASSEMBLY OF BRAKE ASSEMBLY
W8R7-02-04-105
1- Housing 7- Washer (12 Used) 13 - Split Pin (11 Used) 18 - O-Ring (2 Used)
2- Plate 8- Spacer (12 Used) 14 - Nut (11 Used) 19 - Sleeve (2 Used)
3- Damper Plate (2 Used) 9- Seal Ring(12 Used) 15 - Washer (11 Used) 20 - O-Ring (2 Used)
4- Reaction Plate (9 Used) 10 - Wear Ring (12 Used) 16 - Spring (11 Used) 21 - *U-ring (12 Used)
5- Friction Disc (10 Used) 11 - Piston (12 Used) 17 - Bolt (11 Used) 22 - *Backup Ring (12 Used)
6- Bolt (12 Used) 12 - Plug
As for the item with mark *, refer to W2-4-160.
W8R7-E-01(20160803) W2-4-156
Disassembly of Brake Assembly
Special Tool Pedestal (ST5118)
CAUTION: The brake assembly weight: 1020
kg (2250 lb)
1. Place the brake assembly onto the special tool

pedestal (ST5118).
2. Remove dumper plates (3) (2 used), reaction

plates (4) (9 used) and friction disks (5) (10 used)
from the brake assembly.
W8R7-02-04-059
Screw hole (M33, Pitch 3 mm)
used to push up bolt (17)
2
3. Insert a pin into stopper part of piston (11) on plate
(2). Remove bolts (6) (12 used), washers (7) (12
used) and spacers (8) (12 used) from piston (11).
：19 mm

6
BOND #1386B.
W8R7-02-04-060
Retaining Pin
2
11
Stopper Part
6
1
W8R7-02-04-056
W8R7-E-01(20160803) W2-4-157
W8R7-02-04-105
W8R7-E-01(20160803) W2-4-158
4. Insert the special tool (bolt) into the screw hole of
the special tool pedestal to push up bolts (17) (11
used). Remove split pins (13) (11 used). Remove
nuts (14) (11 used) and washers (15) (11used)
from bolts (17) (11 used).
：22 mm 14
5. Remove the special tool (bolt) that push up bolts

(17) (11 used) from below. Remove bolts (17) (11
used) and springs (16) (11 used).

plate (2). Attach the lifting tool to the eyebolts. W8R7-02-04-061
13 14 15 16
17
7. Hoist plate (2) with a crane. Remove plate (2)
from housing (1).
8. Remove pistons (11) (12 used), seal rings (9) (12

used), wear rings (10) (12 used), U-rings (21) (12
used) and backup rings (22) (12 used) from
housing (1).
NOTE: U-rings (21) (12used) and backup rings W8R7-02-04-057

(22) (12 used) are not delivered together
with the reduction gear before MFG No.
10-10113. 9 21, 22 10
9. Do not remove plug (12) (with O-ring) (1 used), 11

sleeves (19) (2 used) and O-rings (18, 20) (2 used
for each) from housing (1) unless necessary.
W8R7-02-04-056
12
W8R7-E-01(20160803) W2-4-159
ASSEMBLY OF BRAKE ASSEMBLY
1 2 8 9 21, 22 10
7
11
6
3
4
5
W8R7-02-04-056
12
13 14 15 16
17
W8R7-02-04-057
18
19
20 W8R7-02-04-058
W8R7-02-04-055
1- Housing 7- Washer (12 Used) 13 - Split Pin (11 Used) 18 - O-Ring (2 Used)
2- Plate 8- Spacer (12 Used) 14 - Nut (11 Used) 19 - Sleeve (2 Used)
3- Damper Plate (2 Used) 9- Seal Ring(12 Used) 15 - Washer (11 Used) 20 - O-Ring (2 Used)
4- Reaction Plate (9 Used) 10 - Wear Ring (12 Used) 16 - Spring (11 Used) 21 - U-ring (12 Used)
5- Friction Disc (10 Used) 11 - Piston (12 Used) 17 - Bolt (11 Used) 22 - Backup Ring (12 Used)
6- Bolt (12 Used) 12 - Plug
W8R7-E-01(20160803) W2-4-160
Installation of Brake Assembly
1. Install plug (12) (with O-ring) to housing (1) .

：17 mm
：210 N·m (21 kgf·m, 155 lbf·ft)
2. Install O-rings (18) (2 used) to housing (1).
3. Install O-rings (20) (2 used) to the inner surface of

sleeves (19) (2 used). Install sleeves (19) (2 used)
to housing (1) by tapping with a wooden hammer.
CAUTION: Housing (1) weight: 520 kg (258

lb)
4. Place housing (1) onto the special tool pedestal Special Tool Pedestal (ST5118)
(ST5118).
5. Install seal rings (9) (12 used), wear rings (10) (12
used), U-rings (21) (12 used) and backup rings
(22) (12 used) to housing (1). Fill grease in the
groove of U-ring (21). Install U-ring (21) as
illustrated direction.
NOTE: U-rings (21) (12used) and backup rings

(22) (12 used) are not delivered together
with the reduction gear before MFG No.
10-10113. W8R7-02-04-059
Screw hole (M33, Pitch 3 mm)
used to push up bolt (17)
6. Apply brake oil onto the seals installed on housing
(1). Install pistons (11) (12 used).

plate (2). Attach the lifting tool to the eyebolts.
W8R7-E-01(20160803) W2-4-161
1 2 8
7
11
6
W8R7-02-04-056
13 14 15 16
17
W8R7-02-04-057
W8R7-02-04-058
W8R7-02-04-055
W8R7-E-01(20160803) W2-4-162
IMPORTANT：Take care not to lap over the notches
(2 places) of plate (2) outer edge and
the brake adjustment pin holes (4
places).
8. Hoist plate (2) with a crane. Install plate (2) to

housing (1).
9. Install springs (16) (11 used) and bolts (17) (11

used) to housing (1). Install special tool (bolt) to 14
the special tool pedestal in order to push up bolts
(17) (11 used) from below.
10. Push up bolts (17) (11 used) from below by using

the special tool (bolt). Install washers (15) (11
used) and nuts (14) (11 used) to bolts (17) (11
W8R7-02-04-061
used).
：22 mm Installation of Split Pin (13)
：35 N·m (3.5 kgf·m, 26 lbf·ft)
2
11. Loosen nuts (14) (11 used) to fit the holes of bolts
(17) (11 used) and the grooves of nuts (14) (11
used).
12. Install split pins (13) (11 used) to bolts (17) (11
used) and nuts (14) (11 used).
6

14. Insert a pin into stopper part of piston (11) on plate

(2). Install bolts (6) (12 used), washers (7) (12 W8R7-02-04-060
used) and spacers (8) (12 used) to piston (11).

Retaining Pin
：19 mm
：110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-E-01(20160803) W2-4-163
1 2
3
4
5
W8R7-02-04-056
W8R7-02-04-057
W8R7-02-04-058
W8R7-02-04-055
W8R7-E-01(20160803) W2-4-164
15. Apply hydraulic oil on both side of dumper plates
(3) (2 used), reaction plates (4) (9 used) and
friction discs (5) (10 used).
16. Place dumper plate (3) facing cork side downward.

Install dumper plate (3) (1 used) into housing (1).
17. Install friction disc (5) and reaction plate (4) in this
order to install friction discs (5) (10 used) and
reaction plates (4) (9 used) to housing (1)
alternately.
18. Finally, place dumper plate (3) facing cork side

upward. Install dumper plate (3) (1 used) into
housing (1).
W8R7-E-01(20160803) W2-4-165
WHEEL BEARING PRELOAD OPERATION MANAGEMENT PROCEDURES
82 83 84, 85 86, 87, 88
89
114
89
101
109
W8R7-02-04-062
82 - Wheel 85 - Washer (18 Used) 88 - Shim (4 Used) 109 - Bearing Retainer

83 - Bearing Retainer 86 - Shim (8 Used) 89 - Pin (3 Used) 114 - Roller Bearing (2Used)
84 - Bolt (18Used) 87 - Shim (4 Used) 101 - Spindle
W8R7-E-01(20160803)
Wheel Bearing Preload Operation Management
Procedures
Gauge Hole
The purpose of wheel bearing preload operation
83
management procedures are to insert the inner and
the outer race of roller bearing (114) to its specified
position, closely fit the outer race to wheel (82), and
to make sure that inner race moves smoothly on
spindle (101). Install bearing retainer (109), roller
bearings (114) (2 used), wheel (82), and bearing
retainer (83) to spindle (101) to create a shim pack.
IMPORTANT： When new roller bearing (114) or

bearing retainers (83, 109) is used,
create a new shim pack following
this procedures.
• Measuring the Bearing Retainer Board Thickness

W8R7-02-04-064
1. Use a micrometer to measure the thickness of Bearing Retainer (83)

Thickness
bearing retainer (83) circumference in four places
(near the gauge hole, 10.3 diameter hole) to
obtain an average value. The measured average
value is the Y dimension. Record the
measurement result in the precharge operation W8R7-02-04-065
management chart.
NOTE: Do not measure using a slide caliper.

101
• Bearing insertion operation
2. Install the special tool holder to spindle (101).

Secure the special tool holder vertically.
3. Install greased pins (89) (2 used) to spindle (101).

eyebolts.
W8R7-02-04-035
Special Tool
Holder
W8R7-E-01(20160803)
kg (245 lb)
5. Hoist bearing retainer (109) with a crane. Align
the pin (89) position of spindle (101) and install
position because the clearance between 82
short.
6. Install the roller bearing (114) outer race (2 used)

to wheel (82).
NOTE: The insertion outer race to wheel (82) has
the following procedures. 114
• Cool the outer race by placing in dry ice or liquid 89
nitrogen before inserting. When using liquid
nitrogen do not allow liquid nitrogen to directly
come in contact with the outer race.
• Insert the outer race after washing wheel (82) in 109
warm water. 101
Use either one of the two ways. Do not insert the
outer race by force.
Use a clearance gauge to check that there is no gap
between the outer race shoulder and wheel (82)
towards the axial direction after inserting.
7. Apply gear oil (equivalent 140W) to the inner

races and the rollers of roller bearings (114) (2
used).
W8R7-02-04-063
8. Install eyebolts (M12, Pitch 1.75 mm) (4 used)

to the retainer of roller bearings (114). Attach the

kg (448 lb)

pin (89) position of roller bearing (114) and
spindle (101) and install the roller bearing (114)
inner race to spindle (101).

W8R7-E-01(20160803)
CAUTION: Wheel (82) weight: 2450 kg (5400
lb)
82 83 84, 85 86, 87, 88
11. Hoist wheel (82) with a crane. Install wheel (82) to
89
spindle (101).

114

kg (448 lb)
13. Hoist roller bearing (114) with a crane. Align the 101
pin (89) position of roller bearing (114) and spindle
(101) and install the roller bearing (114) inner
race.
14. Install pin (89) to spindle (101) and roller bearing

(114).

bearing retainer (83). Attach the lifting tool to the W8R7-02-04-063
eyebolts.

kg (203 lb)
114
16. Hoist bearing retainer (83) with a crane. Align
bearing retainer (83) with the bolt position of
spindle (101) and place bearing retainer (83). 82
17. Tighten bolts (84) (18 used) and washers (85) (18
used) by hand. Do not install shims (86, 87, 88).
Check on the preload operation management
chart 1.
18. Rotate wheel (82) 10 turns to have roller bearing

Rotate with 101
(114) anti-friction sitting on the inner race flange. winch.
chart 1.
T8DS-02-04-298
W8R7-E-01(20160803)
19. Tighten bolts (84) (18 used) by using a
cross-wrench (diagonal tightening) method with a 82 83 84
torque of 40 N·m.
：50 mm
20. Rotate wheel (82) once using a winch.
21. Check that all socket bolts (84) (18 used) are
tightened with a torque of 40 N·m by using the
following method.
(1). Rotate wheel (82) once.
(2). Check that the tightening torque is 40 N·m
for all 18 bolts.
(3). If bolt (84) turns then retighten to 40 N·m.
(4). Repeat steps (1) to (3) until bolts (84) are at
40 N·m and do not loosen. 101
chart 1.
22. Measure each gauge hole to an accuracy of 0.001

mm by using a depth gauge. Ensure that the
measured values are within a variation of less
than 0.30 mm and record the results on the
preload operation management chart 1.
W8R7-02-04-063
23. Repeat the tightening torque steps 19 to 21 in the

following order of increasing torque 80, 120, 180, Gauge Hole
240 N·m. Check on the preload operation
management chart 1. 83
24. Check that all socket bolts (84) (18 used) are
tightened with a torque of 240 N·m by using the
following method.
(1). Rotate wheel (82) once.
(2). Check that the tightening torque is 240 N·m
for all 18 bolts.
(3). If bolt (84) turns then retighten to 240 N·m.
(4). Repeat steps (1) to (3) until bolts (84) are at
240 N·m and do not loosen.
chart 1.
W8R7-02-04-064
Bolt (84) Hole
W8R7-E-01(20160803)
25. Loosen bolts (84) (4 used) one turn located in the
Gauge Hole
vicinity of the gauge hole. (Bearing retainer (83)
fly-out prevention) Check on the preload
operation management chart 1. 83
26. Remove remaining bolts (84) (14 used). Rotate

wheel (82). At this time, the sound of roller
bearing (114) pushing back wheel (82) can be
heard, or a kickback can be observed. If neither is
observed, rotate wheel (82) further, or tap the
wheel with a hammer or a bar to make sure that
the preload has been fully released.
chart 1.
27. After checking that the preload has been fully

released, remove loosened bolts (84) (4 used). Bolt (84) Hole
W8R7-02-04-064
• Measuring the Clearance

114
Measure the clearance GA at the specified torque TA.
28. Arrange bolts (84) (9 used) on bearing retainer

(83) with even intervals. Tighten bolts (84) (9 82
used) by using a cross-wrench (diagonal
tightening) method with a torque of 40 N·m.
chart 1.
：50 mm
29. Rotate wheel (82) once. Rotate with

winch. 101
30. Check that the tightening torque is at 40 N·m. If Fix to keep the spindle
from rotating.
the bolt turns at 40 N·m, retighten with a torque of T8DS-02-04-298
40 N·m and rotate wheel (82) once.
Z or X dimension
31. Repeat steps (30) until bolts (84) (9 used) are at 84
Y dimension
40 N·m and do not loosen. Check on the preload 83 Gap GA
operation management chart 1.
114
32. Measure each gauge hole to an accuracy of 0.001
mm. Record the values in the preload operation
management chart 1. Work out the average value
82
to obtain the Z dimension.
101
W8R7-02-04-066
W8R7-E-01(20160803)
33. If each gauge measurement value is not within a
variation of less than 0.30 mm, there is a
possibility that roller bearing (114) has been
installed on an angle. Start from step 28 to correct
Actual Gap
any abnormalities. Record the values onto the
preload operation management chart 1. TA
Bolt Torque
34. Repeat the tightening torque steps 28 to 31 in the
following order of increasing torque 60, 90, 120,
150, 180 N·m.
chart 1. GA GB
Gap
35. After tightening bolt (84) with the specified torque GD GC
TA (180 N·m), measure each gauge hole to an
accuracy of 0.001 mm. Record the values in the T8DS-02-04-300
preload operation management chart 1. Work out TA: Specified torque

the average value to obtain the X dimension. GA: Clearance when at the specified torque
GB: Gap between the gap of specified torque TA and
36. If each gauge measurement value is not within a theoretical preload zero = uniform
variation of less than 0.30 mm, there is a GC: Amount of insertion when at a random precharge.
possibility that roller bearing (114) has been Preload amount.
installed on an angle. Start from step 28 to correct GD: Specified constant. The preload amount GC is
any abnormalities. Record the values onto the determined by this number.
37. Check that amount of insertion (the value when

the X dimension is subtracted from the Z
dimension) is more than 0.40 mm. Check on the
If amount of insertion is less than 0.40 mm,
consult the Hitachi Construction Service Center.
• Calculating the shim pack thickness
38. The clearance at the specified torque TA can be

obtained by subtracting the bearing retainer
thickness Y from the X dimension. Record the
clearance GA value in the preload operation
management chart 2.
39. Calculating the shim pack thickness required.

The target shim pack thickness value is the sum
of specified constant GD and clearance GA
Specified constant GD is 1.013 mm. Record the
target shim pack thickness value in the preload
operation management chart 2.
W8R7-E-01(20160803)
• Creating a Shim Pack
86、87、88
40. Create a shim pack of the required thickness
using shims (87, 88) (4 used for each) and shim
(86) (8 used). The tolerance of the shim pack
thickness (against the target thickness) must be
within -0.00 to +0.05 mm.
oil. Use a micrometer to measure the thickness.
Check that the total measurement value is within
the tolerance value described above. Record the
values in the preload operation management
chart 2.
41. Lay the shims. Measure the shim pack thickness

to ensure that it is within the tolerance value
described above. Shim (86) 0.05 mm and shim
(87) 0.3 mm must be stacked in between shims
(88) 0.8 mm. Record the shim pack thickness in
the preload operation management chart 2.
W8R7-02-04-063
W8R7-E-01(20160803)
Preload operation management chart 1

1. Bearing retainer board thickness

(1) mm
(2) mm
(3) mm
(4) mm
Average value of (1) to (4) mm • Dimension Y (55 mm on the drawing)
2. Bearing insertion operation

• Bolts: Manually tighten bolt (M33) (18 used) Check mark
• Rotate wheel 10 times or more Check mark
• Check the tightening torque: 40 N·m Check mark
• Depth measurement value at 40 N·m torque
(1) mm
(2) mm
(3) mm
(4) mm
Variation of (1) to (4) mm • Difference of maximum and minimum value is 0.30 mm or less
• Tightening torque: 80, 120, 180, 240 N·m Check mark
• Load removal operation: Loosen bolts (4 places) at the side of the gauge hole one turn Check mark
• Remove other bolts (14 places). Turn the wheel one time to release preload. Check mark
3. Measuring the Clearance

• Bolts: Bolts (M33) (9 used) (Evenly arranged on the circumference) Check mark
(1) mm
(2) mm
(3) mm
(4) mm
Average value of (1) to (4) mm ← Dimension Z
• Tightening torque: 60, 90, 120, 150, 180 N·m Check mark
(1) mm
(2) mm
(3) mm
(4) mm
Average value of (1) to (4) mm • Dimension X
• Push in amount: mm • (Dimension Z – Dimension X) is 0.40 mm or larger
Check mark
W8R7-E-01(20160803)
Preload operation management chart 2

4. Calculating the shim pack thickness

• Clearance (GA) when at the specified torque (TA) :
Dimension X – Dimension Y = mm • Clearance (GA)
• Target shim pack thickness
Clearance GA + Specified constant GD (1.013 mm) = mm • Target shim pack thickness
5. Creating a Shim Pack

• Thickness of each shim
(1) mm
(2) mm
(3) mm
(4) mm
(5) mm
(6) mm
(7) mm
(8) mm
(9) mm
Total value of (1) to (9) mm • Tolerance of the target shim pack thickness must be
within -0.00 to +0.05 mm.
• Measure the shim pack thickness (Lay the shims) : mm
W8R7-E-01(20160803)
Precaution for Floating Seal Handling
(Wheel Reduction Device)
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings (A) together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces. W105-03-05-019
B
(2) Check the slide surface (C) on seal ring (A) for
scuffing, scoring, corrosion, deformation or
uneven wear. Correct
(3) Check O-ring (B) for tears, breaks, deformation

or hardening.
Further, when re-applying, the contact state of O-ring Twist
the sealing face changes, and there is a Incorrect
possibilty that hydraulic leakage is woken an O-ring Bend
early stage.
W8DS-02-04-068
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.

bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch. W8DS-02-04-069
(3) Check that the O-ring (B) is not twisted, and S

Correct Incorrect
that it is installed correctly on the seal ring (A). a a
C
(4) When including seal ring assembly in a
housing, be sure to use special tool. An
example of special tool construction is shown
on the right tigure. B
(5) After installing the floating seal, check that seal

ring surface (C) is parallel with seal mating
face (D) by measuring the distances (C) and
(D) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b a` b W110-03-05-004
W8R7-E-01(20160803)
(Blank)
W8R7-E-01(20160803)
BRAKE CLEARANCE ADJUSTMENT
PROCEDURE
1
B
C
Brake Adjusting
Pin (6) (4 Places) W8R7-02-04-017
Section A
2 3 4 5 6
W8R7-02-04-002
W8R7-02-04-068
Section B
Protrude amount
7 8 6
5
Section C W8R7-02-04-097
1 - Wheel Reduction Device 3 - Plate 5 - Nut (4 Used) 7 - Instruction Plate

2 - Housing 4 - Spacer (4 Used) 6 - Brake Adjusting Pin (4 Used) 8 - Nut
W8R7-E-01(20160803)
Brake Clearance Adjustment Procedure
1. Apply pressure oil (16 MPa) through the brake

port (ORS11/16-16UN-2A).
• In case all friction discs are replaced.

2. Loosen nuts (5) (4 used).
：19 mm
3. Tighten brake adjusting pins (6) (4 used) until

brake adjusting pins (6) meet plate (3).
：8 mm
Brake Port
4. Loosen brake adjusting pins (6) (4 used) 3 turns W8R7-02-04-067
while brake adjusting pins (6) are meeting with
plate (3).
5. Tighten nuts (5) (4 used).

：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
6. Release the pressure oil of the brake port. Brake Activation

Pressure
• In case all friction discs are not replaced.

2. Adjust the protrude amount of brake adjusting pin W8R7-02-04-069
(6) (Section C) to measure the dimension before 3 6 5

disassembly.
：8 mm
3. Tighten nuts (5) of brake adjusting pin (5) (Section

C).
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
4. Adjust the brake clearance of other brake

adjusting pin (5) (3 used) for upper brake
clearance adjustment procedure. W8R7-02-04-070
(3.75 mm)
3 6 5
W8R7-02-04-071
W8R7-E-01(20160803)
FRICTION DISC WEAR MEASUREMENT
PROCEDURE
1 Brake Adjusting Pin

(5) (4 places)
A
2
3
4
W8R7-02-04-017
7 5 6
W8R7-02-04-071
Section A
W8R7-02-04-055
1 - Brake Assembly 3 - Reaction Plate (9 Used) 5 - Brake Adjusting Pin (4 Used) 7 - Plate
2 - Damper Plate (2 Used) 4 - Friction Disc (10 Used) 6 - Nut (4 Used)
W8R7-E-01(20160803)
Friction Disc Wear Measurement Procedure
• In case the brake assembly is disassembled

Measure the depth of friction metal grooves on both
sides of friction discs (4) (10 used). If 0.25 mm or
less groove depth is found, replace all friction discs
(4) (10 used).
• In case the brake assembly is not disassembled

1. Apply pressure oil (16 MPa) through the brake
port (ORS11/16-16UN-2A).
2. Tighten brake adjusting pins (5) (4 used) until they
hit plate (7) according to the brake clearance
adjustment procedure. When tightening brake
adjusting pins (5) (4 used), record the number of
each pin rotation. Record the number up to the
first decimal place.
･ When measuring the wear for the first time after

the factory shipment or friction disk replacement. Brake Port
3. Calculate the average value by subtracting 3 W8R7-02-04-067
rotations from the rotation numbers of brake
adjusting pins (5) (4 used).
Brake Adjusting Pin (5)
･ Brake clearance was adjusted before Brake Adjusting Pin (5)
(Random Distribution
(Not Random Distribution Position)
3. Calculate the value by subtracting 3 rotations from Position 3 places)
the rotation numbers of brake adjusting pin (5)
(Not random distribution position).
4. Calculate the value by multiplying 1.25 mm of

screw pitches of brake adjusting pin (5) to the
calculated rotation numbers. This value is
increase amount of the brake clearance.
5. If this value exceeds 3.6 mm (The limit of total
wear of friction disk is 3 mm and the shrinkage of
the damper plate is 0.6 mm.), replace all friction
discs (4) (10 used).
6. If this value is less than 3.6 mm, return the brake
adjusting pin (5) (Not random distribution position)
to the position before the measurement work of
procedure 2.
7. Loosen brake adjusting pins (5) (3 used) W8R7-02-04-017
(Random distribution position) 3 turns and tighten

nuts (6) (3 used).
8. Release the pressure oil of the brake port.
W8R7-E-01(20160803)
BREAK-IN OPERATION OF WHEEL
REDUCTION DEVICE
After disassembling and assembling the wheel

reduction device, perform break-in operation by
3
following the table below. The break-in operation is
carried out for facing-up the floating seal and for 1 2
flushing the wheel reduction device. The break-in
operation should be performed on a bench which is
able to circulate and filtering gear oil.
1. Ensure that appropriate amount of gear oil and

brake oil is filled in the wheel reduction device.
2. Install the wheel reduction device on the break-in
bench. Connect reduction gear cooling hose (1) to
the wheel reduction device. 1
3. Unplug the above mentioned brake cooling hose
(1) and breather hose (3). W8R7-02-04-067
4. Perform break-in operation by following the table
below.
Order Input Rotation speed Rotating Time Set Number of
(rpm) Direction (min) Numbers Rotations
1 500 Forward 10 1 5000
2 500 Reverse 10 1 5000
3 500 Forward 30 1 15000
4 1000 Forward 30 1 30000
5 500 Reverse 30 1 15000
6 1000 Reverse 30 1 30000
7 500 Forward 60 1 30000
8 1000 Forward 90 1 90000
9 500 Reverse 60 1 30000
10 1000 Reverse 90 1 90000
11 500 Forward 10 1 5000
Total 450 345000
5. Measure the temperature at three locations of flat

part vicinity to first stage carrier bolt (4) by using a 4
contact type temperature gauge within 3 minutes
after finishing the operation. Ensure that all
measured temperature is 100°C or under and
variation of three results is less than 10°C.
6. If the results is out of above temperature range,
consult your nearest Hitachi dealer.
M8R7-07-009
W8R7-E-01(20160803)
BODY / Front Axle
FRONT AXLE
3 4
8 7 6 5 T8DS-06-10-001
1 - Trailing Arm: R 3 - Suspension Cylinder 5 - Front Wheel 7 - Trailing Arm: L

2 - Spindle: R 4 - Tie Rod 6 - Spindle: L 8 - Suspension Tube
W8R7-E-01(20160803) W2-5-1
BODY / Front Axle
2 11
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 15, 16, 17 14 13
29
34
34 35, 36
30
35, 36
F
31
32
33 48
37
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004
E View D View E
Section A
41 42, 43 44 45
40 47
39
38
46
40
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-2
BODY / Front Axle
24 25 25 3, 4, 5, 6, 49
G
7, 8, 9, 10
28 27
26 26
W8R7-02-05-007
Section C Section G
View H 23 21
22
50
27, 28
19, 20 Section I
I
W8R7-02-05-008 W8R7-02-05-009
1- Spindle: L 14 - Tie Rod 27 - Clamp 39 - Retaining Ring (2 Used)

2- Trailing Arm: L 15 - Bolt (4 Used) 28 - Clamp 40 - Spacer (4 Used)
3- Shim (2 Used) 16 - Nut (4 Used) 29 - Bushing (4 Used) 41 - Pin (2 Used)
4- Shim (2 Used) 17 - Washer (4 Used) 30 - Bushing (4 Used) 42 - Washer (2 Used)
5- Shim (2 Used) 18 - Rod End: L 31 - King Pin (2 Used) 43 - Plane Washer (2 Used)
6- Shim (2 Used) 19 - Bolt (8 Used) 32 - Thrust Bearing (2 Used) 44 - Bolt (2 Used)
7- Plate (4 Used) 20 - Washer (8 Used) 33 - Thrust Plate (2 Used) 45 - Spacer (2 Used)
8- Bolts And Washer (4 Used) 21 - Bolt (2 Used) 34 - Cover (4 Used) 46 - Nut (4 Used)
9- Washer (4 Used) 22 - Angle (2 Used) 35 - Bolt (24 Used) 47 - Bolt (2 Used)
10 - Nut (4 Used) 23 - Nut (2 Used) 36 - Washer (24 Used) 48 - Bracket (2 Used)
11 - Trailing Arm: R 24 - Suspension Tube 37 - Bracket (2 Used) 49 - Shim (2 Used)
12 - Spindle: R 25 - Dust Seal (4 Used) 38 - Spherical Bearing (2 Used) 50 - Lock Pin (2 Used)
13 - Rod End: R 26 - Bushing (4 Used)
W8R7-E-01(20160803) W2-5-3
BODY / Front Axle
INSPECTING FRONT AXLE ASSEMBLY
PLAY
2 11
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 14 13
29
30
F
31
32
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004

E View D View E
Section A
38
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-4
BODY / Front Axle
Inspecting Front Axle Assembly Play
Check for play in the steering linkage. Locate the

point of play by the method outlined below.
Point of play can be detected using a suitable tire
handler.
1. Unload the machine. Engage the parking brake

and set wheel stops on the rear wheels. Use a
hoisting device such as a jack to lift the front of
the machine until front wheels are off the ground.
2. Check the play of the king pin (31) bushing (29,

30) while an assistant pulls and pushes the bot-
tom of the tire. Place a finger in the area where
thrust bearing (32) and trailing arms (2, 11) meet.
This part will move if any wear exist on the king
pin (31) or its bushings (29, 30).
3. Check for play where tie rod (14), rod end (13, 18),
and the spindle (1, 12) assembly arm meet while
an assistant pulls and pushes at the front of the
tire. This part will move if spherical bearing (38) is
worn.
W8R7-E-01(20160803) W2-5-5
BODY / Front Axle
REMOVAL AND INSTALLATION OF SPIN-
DLE ASSEMBLY
Rc 1/8 Hole 2 11
32
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 15, 16, 17 14 13
34
34
Rc 1/8 Hole Rc 1/8 Hole
32
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004

E View D View E
Section A
41 42, 43 44 45
40
40
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-6
BODY / Front Axle
Removal
1. Engage the parking brake and set wheel stops on

CAUTION: The tie rod (14) assembly weight:
the rear tires. Raise the front end of the machine
until both front tires are clear of the ground. Use 149 kg (328 lb)
an appropriate block that will support the front half The tie rod (14) weight: 111 kg (245 lb)
of the machine frame.
8. Slide to remove the tie rod (14) assembly and
2. Remove the front tire and rim. Refer to REMOVAL spacers (40) (2 used) from the spindle: L (1) as-
AND INSTALLATION OF FRONT TIRE AND RIM. sembly. Remove bolts (15) (2 used), nuts (16) (2
used), washers (17) (2 used) to remove rod end
3. Remove the front brake. Refer to REMOVAL AND (13) from tie rod (14) as required. Similarly, re-
INSTALLATION OF FRONT BRAKE. move spindle: R (12).
: 24 mm
4. Remove the front wheels. Refer to REMOVAL
AND INSTALLATION OF FRONT WHEEL.
5. Remove the steering cylinder. Refer to REMOVAL

AND INSTALLATION OF STEERING CYLINDER.
6. Remove the lubrication tubes from covers (34) (4

places) of spindle (1, 12) assembly and thrust
bearing (32) (2 used). Remove the lubrication
tube from pins (41) (2 places) of the tie rod (14)
assembly.
7. Remove bolt (44), pin (41), spacer (45), plane

washer (43) and washer (42) from rod end: L (18).
Similarly, remove bolt (44), pin (41), spacer (45),
plane washer (43) and washer (42) from rod end:
R (13).
: 19 mm
W8R7-E-01(20160803) W2-5-7
BODY / Front Axle
2 11
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
29
34
34 35, 36
35, 36
F
31
32
33 48
37
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004
E View D View E
Section A
47
39
38
46
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-8
BODY / Front Axle
CAUTION: The spindle: L (1) assembly

9. Hoist the spindle: L (1) assembly. Remove bolts
(35) (12 used), washers (36) (12 used), covers
(34) (2 used) and brackets (37, 48) from top and
bottom of the spindle: L (1) assembly.
: 30 mm
10. Remove bolt (47) and nuts (46) (2 used) from

trailing arm: L (2).
: 30 mm
CAUTION: King pin (31) weight: 201 kg (443

lb)
11. Remove king pin (31) from the spindle: L (1) as-
sembly.
CAUTION: thrust bearing (32) weight: 41 kg

(90 lb)
12. Slide to remove the spindle: L (1) assembly from
trailing arm: L (2). Remove thrust bearing (32) and
thrust plate (33).
13. Tap or push out bushings (29) (2 used) from

spindle: L (1) assembly using a removal tool that
is 0.8 mm (1/32 in) smaller than the outer diame-
ter of bushing (29). Removed bushing (29) and
thrust bearing (32) are not reusable. Replace new
bushing (29) and thrust bearing (32) when as-
sembling.
NOTE: Bushing (29) outer diameter : 230 mm
(9.06 in)
14. Remove retaining ring (39). Remove spherical

bearing (38) from spindle: L (1) assembly.
CAUTION: The spindle: R (12) assembly

Weight: 1340 kg (2950 lb)
13. Remove spindle: R (12) in the same way as
shown in steps 9 to 14.
W8R7-E-01(20160803) W2-5-9
BODY / Front Axle
2 11
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 15, 16, 17 14 13
29
34
34 35, 36
30
35, 36
F
31
32
33 48
37
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004
E View D View E
Section A
41 42, 43 44 45
40 47
39
38
46
40
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-10
BODY / Front Axle
Inspection
1. Clean all parts thoroughly. Ensure that all bushing

holes and lubrication tubes are free of any dirt.
2. Check all screw heads and pins for wear or

damage. Repair or replace parts as required.
3. Replace any components which are damaged or

worn.
W8R7-E-01(20160803) W2-5-11
BODY / Front Axle
Installation
Rc 1/8 Hole 2 11
32
View J
1 J
12
W8R7-02-05-001
29
F
31
32
33
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004

E View D View E
Section A
Locking hole Locking hole
31
39
38
2
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-12
BODY / Front Axle
Installation
1. Install a new spherical bearing (38) onto spindle: L 1

(1). Secure it with retaining ring (39).
2. Install new bushings (29) (2 used) to the spindle: L Outer Ring

Split Surface
(1) assembly.
CAUTION: The spindle: L (1) assembly

Thrust bearing (32) weight：41 kg (90 lb)
38
W8R7-02-05-012
3. Hoist and place the spindle: L (1) assembly to

trailing arm: L (2). Install thrust plate (33) and new Spherical Bearing (38) installing direction
thrust bearing (32) between lower the spindle: L
(1) assembly arm and trailing arm (2). Align thrust
bearing (32) with lubrication tube port Rc l/8 as
indicated by arrow J.
CAUTION: King pin (31) weight: 201 kg (443

lb)
IMPORTANT: Using a special installation tool, in-
stall king pin (31) in order to avoid
damage.
4. Hoist to align locking holes of king pin (31) and
trailing arm: L (2).
Drive king pin (31) through spindle arm: L (1) into
trailing arm: L (2) until locking holes of king pin
(31) and trailing arm: L (2) are aligned.
W8R7-E-01(20160803) W2-5-13
BODY / Front Axle
2 11
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 15, 16, 17 14 13
34
34 35, 36
35, 36
F
31
48
37
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004
E View D View E
Section A
41 42, 43 44 45
40 47
46
40
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-14
BODY / Front Axle
5. Secure king pin (31) onto trailing arm: L (2) using
bolt (47) and nuts (46) (2 used).
: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
6. Install covers (34) (2 used) and bracket (37, 48) to

the top and bottom of spindle: L (1) arm using bolt
(35) (12 used) and washers (36) (12 used). Align
and install cover (34) as indicated by arrows D, E
with lubrication tube holes Rc l/8.
: 30 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
CAUTION: Spindle: R (12) weight: 1340 kg

(2950 lb)
7. Install spindle: R (12) by following steps 1 to 7.
CAUTION: The tie rod (14) assembly weight:

149 kg (328 lb)
The tie rod (14) weight: 111 kg (245 lb)
8. Install rod ends (13, 18) to tie rod (14) with bolt
(15) (4 used), nuts (16) (4 used) and washers (17)
(4 used). Align the tie rod (14) assembly,and
spacers (40) (4 used) with installation positions of
spindle (1, 12) assembly.
: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft)
9. Install pin (41), spacer (45), plane washer (43),

and washer (42) to rod end: L (18) with bolt (44).
Similarly, install pin (41), spacer (45), plane
washer (43) and washer (42) to rod end: R (13)
with bolt (44).
: 19 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-E-01(20160803) W2-5-15
BODY / Front Axle
Rc 1/8 Hole 2 11
32
View J
Steering Cylinder
1 J
12
W8R7-02-05-001
18 15, 16, 17 14 13
29
34
34 35, 36
30
35, 36
F
31
32
33 48
37
W8R7-02-05-002 W8R7-02-05-003 W8R7-02-05-004
E View D View E
Section A
41 42, 43 44 45
40 47
39
38
46
40
Section F
Section B W8R7-02-05-006 W8R7-02-05-005
W8R7-E-01(20160803) W2-5-16
BODY / Front Axle
10. Install lubrication tube to the spindle (1, 12) as-
sembly cover (34) (2 places) and thrust bearing
(32) (2 places). Install lubrication tube to the tie
rod (14) assembly pin (41) (2 places).
11. Install steering cylinder. Refer to REMOVAL AND

INSTALLATION OF STEERING CYLINDER.
12. Install the front wheels. Refer to REMOVAL AND

INSTALLATION OF FRONT WHEELS.
13. Install the front brake. Refer to REMOVAL AND

INSTALLATION OF FRONT BRAKE.
14. Install the front tires and rims. Refer to REMOVAL

AND INSTALLATION OF TIRE AND RIM.
15. Set a jack underneath the front of the machine

frame and lower to the machine after removing
the block.
16. Adjust the toe-in. Refer to FRONT WHEEL AD-

JUSTMENT.
17. Bleed any air from the brake system.

Refer to AIR BLEEDING OF FRONT BRAKE
W8R7-E-01(20160803) W2-5-17
BODY / Front Axle
TRAILING ARM
2 11
View J Steering Cylinder
1
J 12
W8R7-02-05-001
14
24 25 25 3, 4, 5, 6, 49
G
7, 8, 9, 10
28 27
26 26
W8R7-02-05-007
Section G
Section C
View H 23 21
22
50
27, 28
19, 20 Section I
I
W8R7-02-05-008 W8R7-02-05-009
W8R7-E-01(20160803) W2-5-18
BODY / Front Axle
Removal

until both front tires are clear of the ground. Use
an appropriate block that will support the front half
of the machine frame.
2. Remove the front tire and rim. Refer to REMOVAL

AND INSTALLATION OF FRONT TIRE AND RIM.
3. Remove the front brake. Refer to REMOVAL AND

4. Remove the front wheels. Refer to REMOVAL

AND INSTALLATION OF FRONT WHEEL.
5. Remove the steering cylinder. Refer to REMOVAL

6. Remove the lubrication tube from trailing arm: L

(2) and trailing arm: R (11).
7. Remove the front axle spindle: L (1) assembly, the

spindle: R (12) assembly and the tie rod (14) as-
sembly.
SPINDLE ASSEMBLY.
8. Place a trolley under trailing arm: L (2), trailing

arm: R (11) and suspension tube (24). Use a
block to secure the above components on the
trolley as required.
9. Remove front suspension cylinder. Refer to RE-

MOVAL AND INSTALLATION OF FRONT SUS-
PENSIO CYLINDER.
W8R7-E-01(20160803) W2-5-19
BODY / Front Axle
2 11
View J
1
J 12
W8R7-02-05-001
24 25 25 3, 4, 5, 6, 49
G
7, 8, 9, 10
28 27
26 26
W8R7-02-05-007
Section G
Section C
矢視 H 23 21
22
50
27, 28
19, 20 Section I
I
W8R7-02-05-008 W8R7-02-05-009
W8R7-E-01(20160803) W2-5-20
BODY / Front Axle
CAUTION: Trailing arm: L (2) + Trailing arm:

R (11) + The suspension tube (24) assembly
weight: 5790 kg (12800 lb)
Clamp (28, 27) weight: 93.6 kg (206 lb)
10. Loosen nut (23) (2 used), and remove bolt (21) (2

used) and washer (22) (2 used) from clamp (28,
27). Remove bolts (19) (8 used) and washers (20)
(8 used). Remove clamps (28, 27). Lower sus-
pension tube (24), trailing arm: L (2) and the trail-
ing arm: R (11) assembly. Remove these com-
ponents from the underside of the machine frame.
：19 mm, 60 mm
11. Loosen nuts (10) (4 used) to remove bolts and

washers (8) (4 used), washers (9) (4 used), and
plates (7) (4 used). Remove the shim (3, 4, 5, 6,
and 49) assembly.
: 17 mm
CAUTION: Trailing arm: L (2), R (11) weight:

2560 kg (5640 lb)
12. Remove trailing arm: L (2) and trailing arm: R (11)

from suspension tube (24).
13. Remove dust seals (25) (2 used) from trailing

arm: L (2). Use a bearing puller to remove bush-
ings (26) (2 used) from trailing arm: L (2).
Similarly, remove bushings (26) (2 used) from
trailing arm: R (11) by using a bearing puller after
removing dust seals (25) (2 used) from trailing
arm: R (11).
W8R7-E-01(20160803) W2-5-21
BODY / Front Axle
14. Remove bushings (30) (2 used) from trailing arm:
L (2) by using a bearing puller. Similarly, remove
bushings (30) (2 used) from trailing arm: R (11) by
using a bearing puller.
30
W8R7-02-05-002
W8R7-E-01(20160803) W2-5-22
BODY / Front Axle
Inspection
1. Clean all parts thoroughly.
2. Ensure that all bushing holes and lubrication tube

parts are free of any adhering dirt.
3. Check for any excessive damage or wear in all

parts.
W8R7-E-01(20160803) W2-5-23
BODY / Front Axle
Installation
2 11
View J
1
J 12
W8R7-02-05-001
24 25 25
G
28 27
26 26
W8R7-02-05-007
Section G
Section C
矢視 H 23 21
22
50
27, 28
19, 20 Section I
I
W8R7-02-05-008 W8R7-02-05-009
W8R7-E-01(20160803) W2-5-24
BODY / Front Axle
Installation
1. Install bushings (30) (2 used) to trailing arm: L (2). 2, 11
Similarly, install bushings (30) (2 used) to trailing
arm: R (11).
2. Install bushings (26) (2 used) to trailing arm: L (2).
Install dust seals (25) (2 used) to trailing arm: L
(2) as shown in the diagram. Similarly, install
bushings (26) (2 used) to trailing arm: R (11). In- 30
stall dust seals (25) (2 used) to trailing arm: R (11)
as shown in the diagram.
CAUTION: Trailing arm: L (2), R (11) weight:
2560 kg (5640 lb)
3. Install trailing arm: L (2) and trailing arm: R (11) to
suspension tube (24).
W8R7-02-05-002
CAUTION: Trailing arm: L (2) + Trailing arm:

R (11) + The suspension tube (24) assembly 25 26 2, 11 26 25
weight: 5790 kg (12800 lb)
Clamp (28, 27) weight: 93.6 kg (206 lb)
4. Place suspension tube (24), trailing arms: L (2)
and trailing arms: R (11) assemblies on a wheeled
platform. Align all components to their installation
position on the underside of the machine frame.
Align lock pin (50) holes of suspension tube (24)
and clamp (28, 27) by adjusting suspension tube
(24).
Attach components to the underside of the frame W8DS-02-05-010
with clamps (28, 27), bolts (19) (8 used) and
Install lock pin (50) with bolt (21), nut (23), and
angle (22) to baffle suspension tube (24).
: 60 mm
: 3700 N·m (370 kgf·m, 2730 lbf·ft)
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
25
26
W8DS-02-05-009
2
W8R7-E-01(20160803) W2-5-25
BODY / Front Axle
2 11
View J
1 J 12
W8R7-02-05-001
14
24 3, 4, 5, 6, 49
G
7, 8, 9, 10
28 27
W8R7-02-05-007
Section C Section G
View H
27, 28
I Section I
W8R7-02-05-008 W8R7-02-05-009
W8R7-E-01(20160803) W2-5-26
BODY / Front Axle
5. Widen the gap between trailing arm: L (2) and
trailing arm: R (11) and contact them to clamp (28,
27) by using an appropriate tool. The size of the
gap between trailing arm: L (2) and trailing arm: R
(11) must be less than 3.2 mm (0.126 in). Install or
remove away shims (3, 4, 5, 6, 49) as necessary
to maintain the appropriate gap.
Secure the assembled shim pack with plates (7)
(4 used), bolts and washers (8) (4 used), washers
(9) (4 used) and nuts (10) (4 used).
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
NOTE: Shim (3, 4, 5, 6, 49) dimension

Shim (3): 4.5 mm (0.177 in)
Shim (4): 6 mm (0.236 in)
Shim (5): 9 mm (0.354 in)
Shim (6): 12 mm (0.472 in)
Shim (49): 3.2 mm (0.126 in)
No shims are necessary when the gap
between trailing arm: L (2) and R (11) is
less than the size of the smallest shim.
6. Install the suspension cylinder. Refer to RE-

MOVAL AND INSTALLATION OF FRONT SUS-
PENSIO CYLINDER.
7. Install the spindle: L (1) assembly, the spindle: R

(12) assembly and the tie rod (14) assembly. Re-
fer to REMOVAL AND INSTALLATION OF
SPINDLE ASSEMBLY.
8. Install the lubrication tube to trailing arm: L (2) and

trailing arm: R (11).
W8R7-E-01(20160803) W2-5-27
BODY / Front Axle
2 11
View J Steering Cylinder
1
J 12
W8R7-02-05-001
14
24 25 25 3, 4, 5, 6, 49
G
7, 8, 9, 10
28 27
26 26
W8R7-02-05-007
Section G
Section C
View H 23 21
22
50
27, 28
19, 20 Section I
I
W8R7-02-05-008 W8R7-02-05-009
W8R7-E-01(20160803) W2-5-28
BODY / Front Axle
9. Install the steering cylinders. Refer to REMOVAL
10. Install the front wheels. Refer to REMOVAL AND

INSTALLATION OF FRONT WHEEL.
11. Install the front brake. Refer to REMOVAL AND

12. Install the front tires and rims.

TIRE AND RIM.

the block.
14. Adjust the toe-in. Refer to FRONT WHEEL AD-

JUSTMENT.
15. Bleed any air from within the brake system.

Refer to AIR BLEEDING OF FRONT BRAKE.
W8R7-E-01(20160803) W2-5-29
BODY / Front Axle
FRONT WHEEL ADJUSTMENT
• Lubrication
Adhere to the instructions shown in sections Ma-
chine Specifications and “Regular Inspection and
Maintenance” chart.
• Alignment
Correct front wheel alignment is determined by three Caster Camber
fundamental factors which configure the geometry of
the steering system - the angles of caster, camber
and toe-in. The relationship among the three is very
critical; a change in any one directly affects the other
two, and also affects the steering of the machine.
Caster and camber angles are determined at the
time of assembly and are not adjustable, but the
toe-in is adjustable. Frequency of adjustment is
largely dependent upon road conditions, the rougher
the terrain, the greater the necessity for toe-in ad-
justments. The caster angle is the forward or rear- Front
ward tilt of the king pin in the axle assembly. (refer to
the diagram). When the top of the king pin is tilted
forward, the caster angle is “negative”. When the top
of the king pin is tilted rearward, caster is “positive”.
The caster angle changes as the suspension cylin-
der is compressed or extended.
Machine with “positive” caster angle have the ten-

dency to bring the wheels back to the straight-ahead Toe-in
(Front of Wheels)
position at the completion of a turn. This keeps the
wheels straight. Machine with “zero” or “negative” T704-06-00-020
caster angle have the tendency to wobble, and have Alignment

no tendency to return to the straight-ahead position.
Therefore, wheels will remain in a turning-in position
after the completion of a turn.
W8R7-E-01(20160803) W2-5-30
BODY / Front Axle
The camber is set so that the upper front wheel is an-
gled towards the outside. (Refer to the diagram). The Caster Camber
front wheels of this machine are pre-set to a camber
angle of 1°. This angle cannot be adjusted. The ex-
tended lines that pass through each tire center and
king pin axis center will have two points of intersection
with the road when the camber angle is set. By setting
the distance between the intersecting points, the im-
pact from the road on the steering devices will be re-
duced.
If there is too higher camber angle the steering will be
heavy and cause extra wear on the outer edge of the
tire. Conversely, if there is too lower camber angle the Front
steering will be heavy and cause extra wear on the
inner edge of the tire. If the camber angle is not set
equally on both sides, the steering will become unsta-
ble and the impact from the road surface on the
steering will be considerable. This can cause abnor-
mal vibration to the wheel (shimmy) or considerable
wear on the tires.
Toe-in
(Front of Wheels)
T704-06-00-020
W8R7-E-01(20160803) W2-5-31
BODY / Front Axle
View J
W8R7-02-05-001
15, 16 14
W8R7-E-01(20160803) W2-5-32
BODY / Front Axle
Toe-in is the measurement between the left and right
wheel center taken at the axle height. The length be-
tween the front side are shorter than the length be-
tween the rear side (refer to the diagram). Toe-out A
length between the front side are longer than the
length between the rear side. Toe-in is effective for
reducing the adverse effect of camber on tire wear.
However, the main purpose of the toe-in is to prevent
wobbling. Outside tread could suffer from scuffing, or
the tire may wear rapidly if the toe-in level is set too
high. Insufficient toe-in will cause the same effect on
the inside tread. Either conditions can cause “bias”
and “wobbling” in the steering system.
Toe-in is the measurement at the tire bulge on the
horizontal center line of the left and right wheel. Use a
B
slide bar with an edge that has been appropriately
bent (refer to the diagram). To adjust the toe-in, loosen Bias Tire:
the tie rod (14) assembly clamping bolt (15). Next, use (A-B)=19.0 to 25.4 mm (0.75 to 1.00 in)
a pipe wrench to turn tie rod (14) until the correct toe-in Radial Tire:
(A-B)=0.0 to 3.0 mm (0.00 to 0.12 in)
value (indicated in the diagram) is obtained. Lastly,
tighten bolts (15) (4 used) and nuts (16) (4 used).
: 24 mm
Horizontal Center Line
: 270 N·m (27 kgf·m, 199 lbf·ft)
Front View
-
T704-06-00-021
Toe-In Measurement
W8R7-E-01(20160803) W2-5-33
BODY / Front Axle
REMOVAL AND INSTALLATION OF FRONT WHEEL
16
26
17
Detail a
19 28
18
11, 12, A
13, 14
27
21
20
a 29
10
30
6, 7
5
A
15
31
8, 9
33, 34
32
15 W8R7-02-05-010
Section A
Left Side of the Front Wheel
5- Cover 12 - Shim t=0.05 mm (4 Used) 19 - Wheel 29 - Roller Bearing

6- Bolt (8 Used) 13 - Shim t=0.3 mm (4 Used) 20 - Pin 30 - Spindle
7- Washer (8 Used) 14 - Shim t=0.8 mm (4 Used) 21 - Pin 31 - Floating Seal
8- Bolt (8 Used) 15 - Plug (2 Used) 26 - Retainer 32 - Brake Disc
9- Washer (8 Used) 16 - Plate 27 - O-ring 33 - Bolt (26 Used)
10 - Plug 17 - O-ring 28 - Knock Pin 34 - Washer (26 Used)
11 - Retainer Plate 18 - Roller Bearing
NOTE: The number of shims (12 to 14) vary de-

pending on the machine.
W8R7-E-01(20160803) W2-5-34
BODY / Front Axle
Removal
1. Engage the parking brake and set wheel stops on 7. Remove plate (16) and O-ring (17) from spindle
the rear tires. Raise the front end of the machine (30). Discard O-ring.
until both tires are clear off the ground. Use an
appropriate block that will support the front half of
CAUTION: The wheel (19) assembly weight:
the machine frame.
Approx. 1400 kg (3090 lb)
2. Remove front tire and rim. Refer to REMOVAL
AND INSTALLATION OF THE FRONT TIRE AND 8. Install a lifting device onto the wheel (19) assem-
RIM. bly and vertically hoist it.
3. Remove the front brake. Refer to REMOVAL AND CAUTION: Roller Bearing (18) weight: 33.5 kg
INSTALLATION OF FRONT BRAKE. (73.9 lb)
4. Turn the wheel (19) so that plugs (15) (2 used) are 9. Hoist the wheel (19) assembly slightly, and re-
at the 6 and 12 o'clock positions. Set plug (10) at move it from the end of spindle (30) by sliding
the 6 o'clock position. Remove plug (15) (2 used) sideways. Do not rest the wheel (19) assembly on
and drain gear oil. After draining the gear oil re-fit top of spindle (30) while doing this operation.
plug (15) (2 used). Remove the inner race and pin (20) from roller
Gear oil capacity: approximately 17.5 L bearing (18). Remove the wheel (19) assembly
：8 mm from the machine.
5. Remove bolts (6) (8 used) and washers (7) (8 10. Remove floating seal (31) from retainer (26). Dis-
used) that are securing the cover to wheel (19). card the floating seal.
Remove cover (5).
: 19 mm
NOTE: Installation surface of cover (5) is applied

with THREEBOND #1215 or LOCTITE
#5020.

used) that are securing retainer plate (11) and
shims (12 to 14) to spindle (30). Remove retainer
plate (11) and shim (12 to 14). Keep shims (12 to
14) together to use as a reference during assem-
bly. The numbers of shims (12 to 14) vary de-
：19 mm
W8R7-E-01(20160803) W2-5-35
BODY / Front Axle
26
Detail a
19 28
18
A
27
21
a 29
30
31
33, 34
32
W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-36
BODY / Front Axle
CAUTION: Roller Bearing (29) weight: 45.2 kg

(100 lb)
11. Remove the inner race and pin (21) of roller

bearing (29) from spindle (30).

lb)
12. Remove retainer (26), O-ring (27) and knock pin

(28) from spindle (30) as required.

lb)
13. Brake disc (32) must be replaced if there are any

warps, cracks, or gouges. The disc must also be
replaced if frictional wear reduces the disk thick-
ness below 18 mm (0.7 in).
14. Hoist and hold brake disc (32). Remove bolts (33)
(26 used) and washers (34) (26 used). Remove
brake disc (32) from wheel (19).
: 50 mm
15. Remove floating seal (31) from wheel (19). Dis-

card the floating seal.
16. Removal of the roller bearing (18, 29) outer race

from wheel (19) is required only when replacing
the roller bearing. Use a drift or a chisel made
from soft material when removing the roller bear-
ing (18, 29) outer race.
NOTE: Replace retainer (26) if there is any pitching

or frictional wear on the outer side of re-
tainer (26).
W8R7-E-01(20160803) W2-5-37
BODY / Front Axle
Inspection of Front Wheel
16
26
17
Detail a
19 28
18
11, 12, A
13, 14
27
21
20
a 29
10
30
6, 7
5
A
15
31
8, 9
33, 34
32
15 W8R7-02-05-010
Section A


W8R7-E-01(20160803) W2-5-38
BODY / Front Axle
Inspection of Front Wheel
1. Apart from the roller bearing inner race and outer

race, thoroughly wash all other metal parts with a
solvent. To ease the assembly procedures, apply
low viscosity oil to all the following components
after drying with compressed air.
2. Wash the roller bearing (18, 29) inner race and the
outer race with a volatile petroleum based alcohol
and wipe down with a lint-free cloth. After applying
low viscosity oil, turn the wheels to check that
there is no catching due to wear or faults. If there
is any severe wear to either the inner or outer race
of roller bearing (18, 29), or if the wheel does not
turn smoothly, or if there are any abnormal noises
made while the wheel is turning, replace both the
inner and outer race.
3. Inspect cover (5) to check that the seal of the oil is

sufficient.
W8R7-E-01(20160803) W2-5-39
BODY / Front Axle
Installation
16
26
17
Detail a
19 28
18
11, 12, A
13, 14
27
21
20
a 29
10
30
6, 7
5
A
15
31
8, 9
33, 34
32
15 W8R7-02-05-010
Section A


W8R7-E-01(20160803) W2-5-40
BODY / Front Axle
Installation

lb)
1. Install retainer (26), O-ring (27), and knock pin

(28) to spindle (30), if these were removed in the
removal process. Apply oil to O-ring. Install O-ring
to groove of retainer (26). Insert retainer (26)
through spindle (30). Do not damage floating seal
(31) installation positions such as O-ring (27) and
retainer (26).
2. Install one side of new floating seal (31) to retainer

(26).
3. If outer race of roller bearings (18, 29) were re-

moved, cool the outer race of new roller bearings
(18, 29) 50°C cooler than the wheel (19) tem-
perature. Install outer race of roller bearings (18,
29) to wheel.
CAUTION: Roller bearing (29) weight: 45.2 kg

(100 lb)
4. Apply oil to the inner roller bearing (29) inner race.

Install the inner race of roller bearing (29) and pin
(21) to spindle (30).
5. Install remaining side of new floating seal (31) to

wheel (19).
W8R7-E-01(20160803) W2-5-41
BODY / Front Axle
16
17
Detail a
19
18
A
20
a 29
30
33, 34
32
W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-42
BODY / Front Axle
CAUTION: Brake Disc (32) weight: 137 kg

(302 lb)
6. If brake disc (32) is removed from the wheel (19)

assembly, install brake disc to wheel (19) with
bolts (33) (26 used)
: 50 mm
: 2600 N·m (260 kgf·m, 5730 lbf·ft)
7. Install O-ring (17) to plate (16). Install the plate

(16) assembly to spindle (30).
CAUTION: The wheel (19) assembly weight:

Approx. 1400 kg (3090 lb)
8. Use a lifting device to install the wheel (19) as-

sembly in order to hoist the wheel (19) assembly
vertically.
9. Apply gear oil or hydraulic oil to the roller bearing

(29) outer race. Hoist the wheel (19) assembly
slightly. Install the wheel (19) assembly to the end
of spindle (30) by sliding sideways from the edge.
10. Apply gear oil or hydraulic oil to the roller bearing

(18) outer and inner race. Install inner race into
the wheel (19) assembly outer race.
11. Install pin (20) to the inner race of roller bearing

(18) and spindle (30).
W8R7-E-01(20160803) W2-5-43
BODY / Front Axle
Detail a
19
11, 12, A
13, 14
8, 9
W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-44
BODY / Front Axle
12. Use a micrometer to measure the thickness of
retainer plate (11) in two places and obtain an av-
11 8
erage value. This value is required in step 28.
Record the value into “Retainer Plate Thickness
Y” column. Refer to “Standard data table” in this
section.
b h
13. Install retainer plate (11) to spindle (30) with bolts
(8) (8 used) and washers (9) (8 used) without in-
f d
stalling shims (12 to 14). Tighten lubricated bolts
(8) (7 used) with a torque of 55 N·m (5.5 kgf·m, 41
lbf·ft) in diagonal order (in the order “a, b, c” shown
c e
in the diagram).
Measurement g a
：19 mm Hole
14. Rotate wheel (19) by 180° to inspect the tightening

torque. Retighten the bolt (8) with a torque of 55 W8R7-02-05-011
N·m (5.5kgf·m, 41 lbf·ft). Repeat this process until

the bolts are securely tightened.
15. Tighten bolts (8) (8 used) with increased torque of

110 N·m (11 kgf·m, 81 lbf·ft). Repeat the proce-
dures outlined in step 14.
16. Repeat steps 15 until the tightening torque has

reached 220 N·m (22.4 kgf·m, 162 lbf·ft).
17. Check that all bolts (8) (8 used) are tightened with
a torque of 220 N·m (22 kgf·m, 162 lbf·ft).
· Rotate wheel (19) by 180°.
· Check the tightening torque.
· Retighten the bolt (8) with a torque of 220 N·m
(22 kgf·m, 162 lbf·ft) if bolt (8) turns.
18. Repeat steps 17 until bolts do not turn at the

tightening torque of 220 N·m (22 kgf·m, 162 lbf·ft).
19. Remove all bolts (8) (8 used) except for the two
bolts as shown (marked as ‘a’ and ‘b’) in the dia-
gram. Loosen the remaining bolts by approxi-
mately 3 mm (0.12 in).
W8R7-E-01(20160803) W2-5-45
BODY / Front Axle
Detail a
19
18
11 A
a 29
8, 9
W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-46
BODY / Front Axle
20. After removing bolts (8) as instructed in step 19,
the sound of roller bearing (18, 29) pushing back
wheel (19) can be heard, or a kickback can be
observed. If none of the above can be observed,
rotate wheel (19) or tap with a hammer to check
that retainer plate (11) has returned to position
where remaining bolts (8) are located. Check that
wheel (19) rotates smoothly. If wheel does not
rotate smoothly, check for any abnormalities on
roller of roller bearing, or any damage to spindle
(45) surface. Repeat from procedure 9.
11 8
21. Remove all bolts (8). Install bolts (8) (2 used) on
retainer plate (11) to positions shown as ‘a’ and ‘b’
in diagram. Retighten bolts.
The tightening torque for bolt (8) is 35 N·m (3.5
kgf·m, 26 lbf·ft). b h
：19 mm
f d
22. Rotate wheel (19) by 180° to inspect the tighten-
ing torque. Retighten the bolt (8) with a torque of
35 N·m (3.5 kgf·m, 26 lbf·ft) if bolt (8) turns. Re-
c e
peat this process until the bolts are securely in
Measurement g a
place. Hole
23. Tighten bolts (8) (2 used) with increased torque of

70 N·m (7.0 kgf·m, 52 lbf·ft). Repeat the proce- W8R7-02-05-011
dures outlined in step 22.
24. Repeat steps 23 until the tightening torque has

reached 245 N·m (24.5 kgf·m, 181 lbf·ft).
W8R7-E-01(20160803) W2-5-47
BODY / Front Axle
Detail a
11, 12, A
13, 14
a 30
W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-48
BODY / Front Axle
Left Wheel Right Wheel

Depth No.1
Depth No.2
Subtotal
Average depth (divide the subtotal by 2) X
Retainer plate thickness Y
Average gap Ga
Added constant Gb 0.12 mm (0.0047 in) 0.12 mm (0.0047 in)
Amount of insertion at the specified precharge Gc 0.07 mm (0.0028 in) 0.07 mm (0.0028 in)
Total shim pack thickness Ga+Gb-Gc
Thickness of actual shim pack used
Standard Data Table
25. Measure the depth (in unit of 1/1000 mm) from 30. If the actual shim pack thickness to be used is
retainer plate (11) edge to spindle (30) edge by different from the values recorded in the “Total
inserting depth micrometer into the two meas- Shim Pack Thickness”, record the actual thick-
urement holes located on retainer plate (11). ness in the “Thickness of Actual Shim Pack Used"
Round the values to 1/1000 mm. Record meas- column.
urements in the “Depth No.1, Depth No.2” column
in the reference data table. IMPORTANT: The thickness of actual shim pack
must be within 0.03 mm (0.0012 in)
26. Add “Depth No.1” and “Depth No.2” to obtain the of the “Total Shim Pack Thickness”.
"Subtotal".
NOTE: Shims (12 to 14) of different thickness (0.05
27. Divide the “Subtotal” by 2, to obtain the average mm, 0.3 mm, 0.8 mm (0.0002 in, 0.012 in,
value. Record this value in the “Average Depth X” 0.03 in) are available. For information re-
column. garding the shim parts number, refer to the
“Parts Catalogue”.
28. Subtract “Retainer Plate Thickness Y” (refer to
step 12) from “Average Thickness X”. Record the 31. Assemble Shim Pack according to the aforemen-
value in the “Average Gap Ga” column. tioned dimension.
29. Add the specified “Added Constant Gb” of 0.12 oil. Use a micrometer to measure the thickness.
mm (0.0047 in) to the “Average Gap”. Then sub- Check that the total measurement value is within
tract the "Amount of Insertion at the Specified the tolerance value described above.
Precharge" of 0.07 mm (0.0028 in) to obtain the
required "Total Shim Pack Thickness”. Record
this value in the “Total Shim Pack Thickness”
column.
W8R7-E-01(20160803) W2-5-49
BODY / Front Axle
Detail a
19
18
11, 12, A
13, 14
a 29
30
6, 7
5
A
15
8, 9
15 W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-50
BODY / Front Axle
32. Stuck shims (12, 13, 14). Measure the shim pack
thickness with a micrometer to ensure that the
“Thickness of Actual Shim Pack Used” is within
the tolerance value shown in the “Total Shim Pack
Thickness”.
33. Remove bolts (8) (2 used) from retainer plate (11).

：19 mm
34. Insert the assembled shim pack in between re-

11 8
tainer plate (11) and spindle (30). Install bolts (8)
(8 used) and washers (9) (8 used). Refer to the
tightening order shown by the alphabetical order
in the diagram. Check the torque twice.
：19 mm b h
: 1400 N·m (140 kgf·m, 1030 lbf·ft)
f d
IMPORTANT: Rotate wheel (19) to check the ro-
tating status of the inner race roller
located on outer roller bearing (18)
c e
before installing cover (5). All rollers
must rotate continuously when g a
wheel (19) is turned. The rollers ro-
tate in the following way if preload is
present in roller bearing (18). Read- W8R7-02-05-011
just acroset bearing (steps 4 to 25) if

any of the rollers are not rotating.
IMPORTANT: Do not allow dirt to adhere to roller

bearing (18, 29) outer race and inner
race. Inner race rollers cannot rotate
smoothly if any dirt is adhered to it.

onto the installation surface of wheel (19) cover
(5). Align the notch on cover (5) plug (15) with the
two holes on wheel (19) plug (15). Install cover to
the wheel. Install cover (5) with bolts (6) (8 used)
: 19 mm
: 110 N·m (11 kgf·m, 81 lbf·ft)
W8R7-E-01(20160803) W2-5-51
BODY / Front Axle
Detail a
19
18
A
a 29
10
30
15
8, 9
32
15 W8R7-02-05-010
Section A
W8R7-E-01(20160803) W2-5-52
BODY / Front Axle
36. Turn the wheel so that plugs (15) are at the 6 and
12 o'clock positions. Have plug (10) at the 6
o'clock position. Remove plug (15) at the 12
o'clock position and plug (10). Pour gear oil into
plug (15) hole. Fill until the gear oil flows out from
plug (10) hole. Reinstall plugs (15, 10).
Gear oil capacity: approximately 17.5 L (2.25 US
gal).
：8 mm
37. Rotate wheel (19) in forward and backward direc-

tion for 10 times to allow gear to be distributed
throughout bearings (18, 29).
38. Install the front brake.

FRONT BRAKE.
39. Install the front tire and rim.

TIRE/RIM.

the block.
41. Bleed any air from the brake system.

Refer to AIR BLEEDING OF FRONT BRAKE
W8R7-E-01(20160803) W2-5-53
BODY / Front Axle
(Blank)
W8R7-E-01(20160803) W2-5-54
BODY / Tire and Rim
TIRE / RIM / AIR PRESSURE
6 7
5
9
4
3 4
2 1 12 11 10 T704-07-00-047
Cross-Section of a Typical Tubeless Tire and Rim Assembly
1- Bead Seat Band 4- Side Flange 7- Tread 10 - Bead

2- O-Ring 5- Sidewall 8- Breaker 11 - Rim Base
3- Lock Ring 6- Carcass 9- Plies 12 - Inner Liner
CAUTION: Always inspect the lock rings and

rims located on the wheel or the brake device
before carrying out maintenance on tires or
rims. Deflate the tire before removing the tire
and the rim.
IMPORTANT: To remove the tire and rim to carry

out maintenance on wheel, deflate
the tire to a pressure of 138 to 172
kPa (1.4 to 1.76 kgf/cm², 20 to 25 psi).
Do not allow the tire beeds to drop
out. Pull out the valve cap and core,
and fully deflate the tire to remove
the tire from the rim once it is re-
moved from the machine.
W8R7-E-01(20160803)
W8R7-EN-01(20160330) W2-6-1
BODY / Tire and Rim
REMOVAL AND INSTALLATION OF FRONT
TIRE AND RIM
9 10
11
6、7、12
a
4
3
Detail a
W8R7-02-06-001
Front Tire and Rim
1 - Stud Bolt (39 Used) 4 - Rim Clamp (39 Used) 7 - Bolt 10 - Rim
2 - Nut (39 Used) 5 - Wheel 8 - Valve 11 - Tire
3 - Washer (39 Used) 6 - Bracket 9 - Adaptor 12 - Washer
W8R7-E-01(20160803) W2-6-2
BODY / Tire and Rim
Removal
CAUTION: Park the machine on a level sur-

face with the service position. Refer to the
Operator’s Manual.
1. Place wheel stops on all wheels except for the

wheels that are to be raised. Use wooden blocks
of size 100 x 100 mm (4 x 4 in) for wheel stops.
CAUTION: Do not remove mounting nut (2)
when deflating. The tire may deflate rapidly
and could cause rim component to blow off.
This may result in injuries.
2. Loosen nuts (2) (39 used) just enough to facilitate

their removal after the machine is jacked up and
the tires are completely deflated.
：36 mm
3. Lift the machine only as high as necessary to

remove rim (10), and then place a block under the
front of the machine frame for support.
4. Remove valve’s (8) valve core from the valve

stem and completely deflate the tire.
5. Remove the outer nut securing valve (8) to

bracket (6). Install the outer nut to valve (8) after
removing bracket (6).
6. Remove bolt (7) and washer (12). Remove

bracket (6) from wheel (5).
：19 mm
CAUTION: Tire and rim assembly weight:

5250 kg (11600 lb)
5. Hoist tire (11) and rim (10) assembly. Remove
nuts (2) (39 used), washer (3) (39 used) and rim
clamps (4) (39 used) from wheel (5) to remove the
tire (11) and rim (10) assembly. Adapter (9) and
valve (8) are installed to rim (10).
：36 mm
W8R7-E-01(20160803) W2-6-3
BODY / Tire and Rim
Installation
9 10
11
6、7、12
a
4
3
Detail a
W8R7-02-06-001
Front Tire and Rim
1 - Stud Bolt (39 Used) 4 - Rim Clamp (39 Used) 7 - Bolt 10 - Rim
2 - Nut (39 Used) 5 - Wheel 8 - Valve 11 - Tire
3 - Washer (39 Used) 6 - Bracket 9 - Adaptor 12 - Washer
W8R7-E-01(20160803) W2-6-4
BODY / Tire and Rim
Installation
Refer to the tire manufacturer’s maintenance manual 4. Install rim clamps (4) (39 used) to wheel (5). Apply
for procedures with regards to installing and removing lubricant oil onto nuts (2) (39 used). Install nuts
the tire from the rim. An authorized tire repair servic- (2) (39 used) and washers (3) (39 used) to stud
ing is recommended when removing or installing tires bolts (1) (39 used). Tighten nuts (2) (39 used) in a
from/to the rim. pattern that will reduce distortion, such as a star
or triangular pattern, to half of its specified torque.
1. Remove stud bolts (1) (39 used), and clean each Following the same pattern, tighten nuts (2) (39
stud bolt (1) and hole threads in order to remove used) with the specified torque.
all dirt and grease. ：36 mm
：950 N·m (95 kgf·m, 700 lbf·ft)
2. Apply LOCTITE #262 or THREEBOND #1386B to
the threaded area of stud bolts (1) (39 used). In- 5. Install bracket (6) to wheel (5) with bolt (7) and
stall stud bolts (1) (39) to wheel (5). washer (12). Install valve (8) to bracket (6) with
the outer nut of valve (8).
NOTE: The LOCTITE or THREEBOND thread ：19 mm
locking compound should be fully cured ：90 N·m (9.0 kgf·m, 66 lbf·ft)
before tightening the nut with its specified
torque. The thread locking compound can 6. Inflate the tires with air. Refer to the Operator’s
be fully cured in 1 to 2 hours at room tem- Manual.
perature, and 10 minutes at a temperature
of 121 to 149°C (250 to 300°F). If required, 7. Set a jack underneath the front of the machine
the nut can be tightened with its specified frame and lower the machine onto the ground af-
torque 10 minutes after it is cured. However, ter removing the block.
the torque must be re-inspected after driv-
ing the machine for 2 hours. Refer to the
compound manufacturer's manual for cur-
ing condition requirements if using a lock-
ing compound other than LOCTITE #262 or
THREEBOND #1386B.

5250 kg (11600 lb)
3. Hoist and install the tire (11) and rim (10) assem-
bly to wheel (5). Before operation, Install adapter
(9) and valve (8) to rim (10).
W8R7-E-01(20160803) W2-6-5
BODY / Tire and Rim
REMOVAL AND INSTALLATION OF REAR
TIRE AND RIM
9 10、11
6 8 2 7 8
Detail a
1 1
12
5
4
3 13
Detail b
W8R7-02-06-002
Rear Tire and Rim
1- Rim (2 Used) 5 - Washer (24 Used) 8 - Adapter (2 Used) 11 - Washer

2- Spacer 6 - Valve (Outside) 9 - Bracket 12 - Stud Bolt (24 Used)
3- Rim Clamp (12 Used) 7 - Valve (Inside) 10 - Bolt 13 - Tire
4- Nut (24 Used)
W8R7-E-01(20160803) W2-6-6
BODY / Tire and Rim
Removal
CAUTION: Park the machine on a level sur- CAUTION: Tire and rim assembly weight:
face in the service position. Refer to the Op- 5250 kg (11600 lb)
erator’s Manual.
7. Attach a chain or a rope band with sufficient
1. Remove the body. Refer to REMOVAL AND IN- strength onto an appropriate lifting device to hoist
STALLATION OF BODY. the outer tire (13) and rim (1).
2. Place wheel stops on all wheels except for the

CAUTION: When removing nut (4) without
wheels that are to be raised. Use wooden blocks
of size 100 x 100 mm (4 x 4 in) or larger for wheel releasing tension of rim clamp (3), its tension
stops. is released rapidly and the rim component
flies out. This may result in injuries.
CAUTION: Do not remove mounting nut (4) 8. Release tension of rim clamps (3) (12 used).
when deflating. The tire may deflate rapidly Remove nuts (4) (24 used), washer (5) (24 used),
and could cause rim component to blow off. and rim clamps (3) (12 used) from stud bolts (12)
This may result in injuries. (24 used). Hoist and remove the tire (13) and rim
(1) assembly. Adapter (8) and valve (6) are in-
3. Loosen nuts (4) (24 used) just enough to facilitate stalled to rim (1).
their removal after the machine is jacked up and ：50 mm
the tires are completely deflated.
：50 mm
CAUTION: Spacer weight: 205 kg (452 lb)
4. Lift the machine only as high as necessary to re-
9. Insect the state of rim (1) when removing inner tire
move the tire (13) and rim (1) assembly, and then
(13) and rim (1) assembly. Remove valve’s (7)
place a block under the rear axle for support.
valve core from the valve stem and completely
deflate the tire if a fault is felt on the rim. Remove
5. Inspect all rim components. Remove valve’s (6)
spacer (2). Attach the hoisting device onto the tire
valve core from the valve stem and completely
(13) and rim (1) assembly to remove the tire (13)
deflate the tire if a fault is felt on rim (1) (2 used).
and rim (1) assembly from the machine. Adapter
(8) and valve (7) are installed to rim (1).
6. Remove the nut which hold valves (6, 7) onto
bracket (9), and remove valves (6, 7) from bracket
(9). Remove bolts (10), washers (11), and bracket
(9).
：30 mm
W8R7-E-01(20160803) W2-6-7
BODY / Tire and Rim
Installation
9 10、11
6 8 2 7 8
Detail a
1 1
12
5
4
3 13
Detail b
W8R7-02-06-002
Rear Tire and Rim
1- Rim (2 Used) 5 - Washer (24 Used) 8 - Adapter (2 Used) 11 - Washer

2- Spacer 6 - Valve (Outside) 9 - Bracket 12 - Stud Bolt (24 Used)
3- Rim Clamp (12 Used) 7 - Valve (Inside) 10 - Bolt 13 - Tire
4- Nut (24 Used)
W8R7-E-01(20160803) W2-6-8
BODY / Tire and Rim
Installation
Refer to the tire manufacturer’s maintenance manual

for procedures with regards to installing and removing
5250 kg (11600 lb)
the tire from the rim. An authorized tire repair servic-
ing is recommended when removing or installing tires
3. Hoist and install the inner tires (13) and the rim (1)
from/to the rim.
assembly to the wheel reduction device. Before
operation, install adapter (8) and valve (7) to rim
1. Remove the stud bolts (12) (24 used), and clean
(1).
each stud bolts (12) and hole threads in order to
remove all dirt and grease.
CAUTION: Spacer weight: 205 kg (452 lb)
2. Apply LOCTITE #262 or THREEBOND #1386B to
the threaded area of stud bolts (12) (24 used). In- 4. Install spacer (2). Hoist and install the outer tires
stall stud bolts (12) (24 used) to wheel reduction (13) and the rim (1) assembly to the wheel reduc-
device with the specified dimension. tion device. Before operation, install adapter (8)
and valve (6).
120 mm
12
W8R7-02-04-004
NOTE: The LOCTITE or THREEBOND thread

locking compound should be fully cured
before tightening the nut with its specified
torque. The thread locking compound can
be fully cured in 1 to 2 hours at room tem-
perature, and 10 minutes at a temperature
of 121 to 149°C (250 to 300°F). If required,
the nut can be tightened with its specified
torque 10 minutes after it is cured. However,
the torque must be re-inspected after driv-
ing the vehicle for 2 hours. Refer to the
compound manufacturer's manual for cur-
ing condition requirements if using a locking
compound other than LOCTITE #262 or
THREEBOND #1386B.
W8R7-E-01(20160803) W2-6-9
BODY / Tire and Rim
9 10、11
6 7
Detail a
12
5
4
Detail b
W8R7-02-06-002
Rear Tire and Rim
W8R7-E-01(20160803) W2-6-10
BODY / Tire and Rim
IMPORTANT: Do not apply lubricant except the
thread part.
5. Install rim clamps (3) (12 used) to the wheel re-

duction device as shown in the detail b diagram.
Apply lubricant oil onto nuts (4) (24 used). Install
nuts (4) (24 used) and washers (5) (24 used) to
stud bolts (12). Tighten nuts (4) (24 used) in a
pattern that will reduce distortion, such as a star or
triangular pattern, to half of its specified torque.
Following the same pattern, tighten nuts (4) (24
used) with the specified torque.
: 50 mm
：1950 N·m (195 kgf·m, 1440 lbf·ft)
6. The nuts on the rim clamp should be checked for

its tightening torque after one set of operation, or
after 1 hour of operation.
7. Install bracket (9) to the wheel reduction device

with bolt (10) and washer (11). Secure valves (6,
7) to bracket (9) with the outer nuts of valves (6,
7).
：30 mm
：550 N·m (55 kgf·m, 406 lbf·ft)
8. Inflate the tires with air. Refer to the Operator’s

Manual.
9. Set a jack underneath the rear axcel and lower to

the machine onto the ground after removing the
block.
10. Install the body. Refer to REMOVAL AND IN-

STALLATION OF BODY.
W8R7-E-01(20160803) W2-6-11
BODY / Tire and Rim
TIRE CARE
Follow the below cautionary points to prolong the

lifespan of the off-highway tires.
1. Maintain correct tire pressure.
2. Use vehicle on good road surfaces.
3. Do not overload the vehicle.
4. Do not allow petroleum products to come in con-
tact with the tire.
TIRE AIR PRESSURE INSPECTION
Description
The tire pressure varies depending on the machine

loading air weight and traveling speed. These tires
are designed and built to deform at a specific range,
depending on the type of usage.
Over-inflated tires put stress on the cord, which re-

duces resistance to blowouts from impacts, raises the
risk of punctures.
The amount of deflection will increase and the de-

formation will become excessive if the tire pressure is
low. If the machine is operated under too low tire
pressure, various troubles such as uneven wear of
tread pattern, radiating cracks on the side wall, de-
lamination of ply inside the tire, loosen or break the
code may occur.
Refer to the recommended pressure value by the

manufacturer for more information. The tire pressure
depends on tire structure, size, and ply performance.
Ask the tire dealer for the correct tire pressure.
W8R7-E-01(20160803) W2-6-12
BODY / Front Brake
REMOVAL AND INSTALLATION OF FRONT
BRAKE
Removal
CAUTION: Brake accumulator supplies the

pressure oil to the brake valves when the en-
gine stops. Before removing brake compo-
nents, release the hydraulic pressure in the
brake accumulator. Refer to REMOVAL AND
INSTALLATION OF BRAKE VALVE.
IMPORTANT: Only hydraulic oil can be used for

the brake head assembly of this
brake system. The use of incompati-
ble brake fluids such as those made
from plants may cause brake failure.
2 3 4 5 6, 7
NOTE: This section outlines the procedures for the
left front brake. Follow the same proce-
dures for the right front brake.
NOTE: When only lining (4) replacement is re-
quired, the brake head (3) assembly is not 8, 9
needed to be removed from spindle as-
sembly (10). Refer to REMOVAL AND IN-
STALLATION OF LINING.
1
10
the machine frame.
T8DS-05-11-001
2. Remove front tire and rim (2). Refer to REMOVAL

AND INSTALLATION OF FRONT TIRE AND RIM. 14 11 12 14
3. Place a clean tray underneath the connecting 6, 7

parts of brake hoses (11, 12, 13). Disconnect
brake hoses (11, 12, 13) from the brake head (3) 3
assembly. 13
: 19 mm, 22 mm
14
6, 7
W8DS-02-07-001
W8R7-E-01(20160803) W2-7-1
BODY / Front Brake
CAUTION: The brake head (3) assembly

1 3 4 5 8, 9 6, 7
4. Mark identification codes on brake heads (3) (3

used) and spindle (10) for assembling. 10
5. Loosen bolts (6) (8 used) that hold the brake head 15

(3) assembly to spindle (10).
: 1-7/8 in
IMPORTANT: The shim (8, 9) assembly is installed Brake Head, Brake Disc Installation Cross-Section Diagram
between brake head (3) and spindle W8DS-05-11-003
(10). Mark same identification code

as brake head (3) on the shim (8, 9)
assembly for assembling. 14 11 12 14 12
6, 7
6. Hoist the brake head (3) assembly and hold it in
place. Remove bolts (6) (8 used), washers (7) (8
used), the shim (8, 9) assembly, and the brake 3 13
head (3) assembly from spindle (10).
14
Remove two other brake head (3) assemblies in
the same way.
: 1-7/8 in
CAUTION: Brake disc (5) weight: 137 kg

(302 lb) 5
7. Brake disc (5) must be replaced if there are any

warps, cracks, or gouges. The disc must also be
W8DS-02-07-001
replaced if frictional wear reduces the disk thick-
ness below 18 mm (0.7 in).
8. Remove brake disc (5) to remove front wheel (1).

FRONT WHEEL.
W8R7-E-01(20160803) W2-7-2
BODY / Front Brake
Installation
1 3 13 5 8, 9 6, 7
CAUTION: Brake disc (5) weight: 113 kg (249

lb)
1. When brake disc (5) is removed from wheel (1),

install brake disc (5) to wheel (1). Refer to RE- 15
MOVAL AND INSTALLATION OF FRONT
WHEEL.
2. Apply LOCTITE #242 onto the thread part of bolts Brake Head, Brake Disc Installation Cross-Section Diagram
(6) (8 used). W8DS-05-11-003
CAUTION: Brake head (3) assembly weight:

11 12 14 12
120 kg (265 lb) 14
6, 7
3. Hoist and hold the brake head (3) assembly at the
locations according to the identification codes. In- 3 13
stall the shim (8, 9) assembly between the brake
head (3) assembly and spindle (10) according to 14
the identification codes.
4. Install the brake head (3) assembly to spindle (10)

Install two other the brake head (3) assemblies in
the same way. 5
: 1-7/8 in
: 1950 N·m (195 kgf·m, 1440 lbf·ft)
W8DS-02-07-001
5. Check that bleed valves (14) (3 used) are in the
correct positions. Refer to the diagram in the right.
6. Connect brake hoses (11, 12, 13) to the brake

head (3) assembly.
: 19 mm, 22 mm 3 4 5 8, 9 6, 7
: 100 N·m (10 kgf·m, 74 lbf·ft)
10
T8DS-05-11-001
W8R7-E-01(20160803) W2-7-3
BODY / Front Brake
7. Install front tire and rim. Refer to REMOVAL AND
INSTALLATION OF FRONT TIRE AND RIM.

frame and lower to the machine onto the ground
after removing the block.
9. Check the level of hydraulic oil. Refill the hydraulic

oil if necessary.
10. Bleed air from the brake system. Refer to AIR

BREEDING OF FRONT BRAKE.
11. Drive the machine under a controlled environment

ating the machine on site.
W8R7-E-01(20160803) W2-7-4
BODY / Front Brake
(Blank)
W8R7-E-01(20160803) W2-7-5
BODY / Front Brake
DISASSEMBLY OF BRAKE HEAD
1 2 3
4
5
6
14
7
13
8
12 9
11 10
W8DS-02-07-002
1- Brake Head 5- Piston (6 Used) 9 - Washer (12 Used) 12 - Washer (8 Used)

2- Lining (2 Used) 6- Piston Seal (6 Used) 10 - Bolt (12 Used) 13 - Block (4 Used)
3- Piston Boot (6 Used) 7- Lid Seal (3 Used) 11 - Bolt (8 Used) 14 - Bleed Valve
4- Boot Ring (6 Used) 8- Lid (3 Used)
W8R7-E-01(20160803) W2-7-6
BODY / Front Brake
Disassembly of Brake Head
1. Mark identification codes onto blocks (13) (4

used) and the brake head (1) for assembly.

used). Remove blocks (13) (4 used) from brake
head (1).
: 1-1/2 in
3. Remove linings (2) (2 used) by sliding them to

brake head (1) edges.
4. Remove bleed valve (14), bolts (10) (12 used),

washers (9) (12 used), lids (8) (3 used), and lid
seals (7) (3 used) from brake head (1).
Bleed Valve (14)
: 7/16 in
Bolt (10)
: 13/16 in
5. Remove lid seals (7) (3 used) from lids (8) (3

used).
6. Remove pistons (5) (6 used) with the piston boots

(3) (6 used) from brake head (1) by using special
tool.
7. Remove piston boots (3) (6 used) from pistons (5)

(6 used).
8. Remove boot rings (4) (6 used) and piston seals

(6) (6 used) from brake head (1).
W8R7-E-01(20160803) W2-7-7
BODY / Front Brake
INSPECTION OF BRAKE HEAD AND
BRAKE DISC
1 2 3
5
6
7
13
W8DS-02-07-002
W8R7-E-01(20160803) W2-7-8
BODY / Front Brake
Inspection of Brake Head and Brake Disc
1. Clean all components and dry with pressurized

air.
2. Replace piston boots (3) (6 used), piston seals (6)

(6 used), lid seals (7) (3 used) with new ones.
3. Check for any frictional wear on piston (5). And

check for any pitching, slide marks, frictional wear
on the piston hole on brake head (1) and groove
hole on block (13). Small scratches may be cor-
rected with a metallic polishing cloth. Replace the
component if damages cannot be corrected.
Replace with new components if piston (5)
chrome plating is worn off.
4. Inspect lining (2).

Refer to Inspection of Lining.
5. Check for any damages on the screw compo-

nents.
W8R7-E-01(20160803) W2-7-9
BODY / Front Brake
ASSEMBLY OF BRAKE HEAD
1 2 3
4
5
6
14
7
13
8
12 9
11 10
W8DS-02-07-002
1- Brake Head 5- Piston (6 Used) 9 - Washer (12 Used) 12 - Washer (8 Used)

2- Lining (2 Used) 6- Piston Seal (6 Used) 10 - Bolt (12 Used) 13 - Block (4 Used)
3- Piston Boot (6 Used) 7- Lid Seal (3 Used) 11 - Bolt (8 Used) 14 - Bleed Valve
4- Boot Ring (6 Used) 8- Lid (3 Used)
W8R7-E-01(20160803) W2-7-10
BODY / Front Brake
Assembly of Brake Head
1. Apply hydraulic oil on piston seal (6). Install piston

seal (6) to grooves on the brake head (1) piston
hole.
2. Install boot ring (4) to the groove of brake head

(1).
3. Inject and apply grease (Molytone Grease No.2)

onto the interiors of piston boots (3) and the pis-
ton boot groove. Install piston boots (3) onto the
piston boot groove on piston (5).
4. Apply hydraulic oil onto piston (5) and align it to

the center of the piston seal (6). Insert piston (5)
into the piston hole on brake head (1) while ro-
tating piston (5).
Repeat the process for remaining pistons (5) (5
used) to attach.
5. Apply hydraulic oil to lid seal (7).

Install lid seal (7) onto the groove of lid (8).
6. Apply lubricant to bolts (10) (4 used).

Install lid (8) to brake head (1) with bolts (10) (4
Install other lids (8) (2 used) in the same way.
: 13/16 in
: 150 N·m (15 kgf·m, 110 lbf·ft)
W8R7-E-01(20160803) W2-7-11
BODY / Front Brake
1 2 Tab
14
13
12
11
W8DS-02-07-002
W8R7-E-01(20160803) W2-7-12
BODY / Front Brake
7. Install bleed valve (14) to brake head (1).
The attachment position of bleed valve (14) is
shown in the right diagram.
: 7/16 in 14 14
: 9.5 N·m (0.95 kgf·m, 7.0 lbf·ft) 1
1
8. Install linings (2) (2 used) onto brake head (1) with
the metallic surface facing outside.
9. Install blocks (13) (4 used) onto brake head (1) by 14

following the identification code marked at the
time of disassembly. Fit the tabs of linings (2) (2
used) to grooves on blocks (13) (4 locations).
10. Apply lubricant oil onto the thread part of bolts (11)
(8 used). Install blocks (13) (4 used) to brake 1
head (1) with bolts (11) (8 used) and washers (12)
(8 used).
: 1-1/2 in
: 1000 N·m (100 kgf·m, 738 lbf·ft) W8DS-02-07-001
W8R7-E-01(20160803) W2-7-13
BODY / Front Brake
REMOVAL AND INSTALLATION OF LINING
1 2
14
13
12
11
W8DS-02-07-002
W8R7-E-01(20160803) W2-7-14
BODY / Front Brake
Removal
CAUTION: Brake accumulator supplies the

pressure oil to the brake valves when the
engine stops. Before removing brake com-
ponents, release the hydraulic pressure in
the brake accumulator. Refer to REMOVAL
AND INSTALLATION OF BRAKE VALVE.
IMPORTANT: Only hydraulic oil can be used for

the brake head assembly of this
brake system. The use of incom-
patible brake fluids such as those
made from plants may cause brake
failure.

the rear tires. Raise the front end of the machine 1 2 Rim
the machine frame.
2. Remove the front tire and rim.

FRONT TIRE AND RIM.
3. Mark identification codes to blocks (13) (4 used)

and the brake head (1) for assembly.
Remove bolts (11) (4 used) on the removed side
of linings (2) (2 used) and washers (12) (4 used).
Remove blocks (13) (2 used) from brake head (1).
Cross-Section Diagram of Front Brake/Mount
: 1-1/2 in
T8DS-05-11-001
4. Remove linings (2) (2 used) from brake head (1) 14

14
by sliding the linings towards the edge of brake
head (1).
1
5. Remove linings (2) (4 used) from two other brake
heads (1) in the same way.
14
13
11, 12
W8DS-02-07-001
W8R7-E-01(20160803) W2-7-15
BODY / Front Brake
1 2 5
14
13
12
11
W8DS-02-07-002
W8R7-E-01(20160803) W2-7-16
BODY / Front Brake
Inspection
CAUTION: Do not continue to use linings if

its thickness is below 8 mm (0.31 in). The
braking performance may be significantly 1 2 Rim 5
reduced on worn linings.
1. Inspect lining (2) for any wear or damage. Re-

place lining (2) if its thickness (the thickness of the
non-metallic parts) is below 8 mm (0.31 in).
The lining is reusable if the thickness is greater
than the usage limit. Continuing to use worn lining
will lead to poor brake performance and could
cause damage to the disc.
IMPORTANT: Do not mix old and new components

when replacing the brake lining of
the brake head assembly. When re-
Cross-Section Diagram of Front Brake/Mount
using a used component with a
thickness greater than the usage T8DS-05-11-001
limit, check the thickness of both

lining materials. The thickness def-
ference between both linings must
be within 3 mm (1/8 in). 14
14
2. Open bleed valves (14) (3 use) to release any
pressure. 1
: 7/16 in
3. Contract piston (5) fully by using the special tool.

14
The disc will be worn if the brake lining is worn.
Inspect the minimum thickness of the disc.
FRONT BRAKE.
13
11, 12
W8DS-02-07-001
W8R7-E-01(20160803) W2-7-17
BODY / Front Brake
Installation
1 2 5
14
13
12
11
W8DS-02-07-002
W8R7-E-01(20160803) W2-7-18
BODY / Front Brake
Installation
14 14
1. Tighten bleed valves (14) (3 used).
: 7/16 in
: 9.5 N·m (0.95 kgf·m, 7.0 lbf·ft) 1
2. Install linings (2) (2 used) onto brake head (1) with

the metallic surface facing outside. Install blocks
(13) (2 used) onto brake head (1), following the
marked identification codes. Fit the tabs of linings
(2) (2 used) to two grooves on block (13).
Apply lubricant oil onto the thread part of bolts
(11) (4 used). Install blocks (13) (2 used) to brake
head (1) with bolts (11) (4 used) and washers (12)
(4 used). 13
Install linings (2) (2 used for each) to other brake
heads (1) in the same way. 11, 12
: 1-1/2 in
: 1000 N·m (100 kgf·m, 738 lbf·ft) W8DS-02-07-001
3. Install front tire and rim. 1 2 Rim

FRONT TIRE AND RIM.

frame and lower to the machine onto the ground
after removing the block.
5. Start the engine, and run the engine until the

brake pressure reaches normal value. Drive the
vehicle under a controlled environment and in-
spect the brake performance before operating the
vehicle on site.
Front Brake / Section of Mount

T8DS-05-11-001
W8R7-E-01(20160803) W2-7-19
BODY / Front Brake
AIR BLEEDING OF FRONT BRAKE
1. Connect air bleed hose to the bleed valve located

at the highest position. Attach the other end of the
hose to oil drain tray. Shut all other bleed valves.
2. Check the oil level in the hydraulic tank and refill if

necessary.
3. Start the engine, and run the engine until the

brake pressure is normal.
4. Open the bleed valve with the hose attached

while another operator depresses the brake pedal.
Push out oil until air bubble does not come out
from the hose. Close the bleed valve and remove
the hose. Carry out the same operation for each
brake head, and remove the air inside the system
completely.
5. Inspect the oil level in the hydraulic tank and refill

if necessary.

to inspect the brake performance before operat-
ing the machine on site.
W8R7-E-01(20160803) W2-7-20
BODY / Brake Valve
BRAKE VALVE
Removal

vice position.
2. Remove the front access cover on the cab. 1
CAUTION： Brake accumulator supplies the 25

pressure oil to the brake valves when the en- FRONT
gine stops. Before removing brake compo-
nents, release the hydraulic pressure in the
brake accumulator. REAR
22 20
3. Connect the hydraulic hoses (2 used) to each test
ports (22, 25) on brake valve (1). Attach the other
end of the hoses to oil drain tray. W8DS-02-08-003
Tray capacity: 5 L or more
4. Depresses service brake pedal (20) slowly and

drain the oil in the brake accumulator to release
the oil pressure from the service brake circuit.
5. Mark identification codes on all pipes (10, 11, 12, 5, 8 1 2, 3 4, 5

13, 14, 15) before removal for assembly.
6
6. Disconnect pipes (10, 11, 12, 13, 14, 15) from 15
brake valve (1). 5, 7
Cap each pipe in order to prevent contamination
from entering the system and to prevent hydraulic
oil leaking out of the pipe. 14
: 24 mm, 36 mm
5, 9
7. Remove adapter S (4), elbow S (6), adaptor S (9) 13
10
(2 used), and O-rings (5) (3 used) as required. 12
Do not remove adaptor S (7), elbow S (8), and
11
O-ring (5) (2 used).
: 24 mm, 32 mm
W8R7-02-08-001
W8R7-E-01(20160803) W2-8-1
BODY / Brake Valve
8. Disconnect connector of brake switch (16) from
brake valve (1). 2, 3
1
16
9. Remove brake valve (1) from the plate at the front
of the cab by loosening bolts (2) (6 used) and
: 17 mm
NOTE: Brake switch (16) is installed to brake valve

(1).
W8R7-02-08-002
W8R7-E-01(20160803) W2-8-2
BODY / Brake Valve
Installation
1. Align brake valve (1) to the opening of the plate at

5, 8 1 2, 3 4, 5
the front of the cab. Install brake valve (1) with
: 17 mm 6
15
: 65 N·m (6.5 kgf·m, 48 lbf·ft) 5, 7
2. Install adapter S (4), elbow S (6), adaptor S (9) (2

used), and O-rings (5) (3 used). Adaptor S (7),
14
elbow S (8), and O-ring (5) (2 used) were already
installed when the brake valve was assembled. 5, 9
: 24 mm 13
: 110 N·m (11 kgf·m, 81 lbf·ft) 10
12
: 32 mm
: 240 N·m (24 kgf·m, 177 lbf·ft) 11
3. Remove caps from each pipe (10, 11, 12, 13, 14,
15). W8R7-02-08-001
Connect pipes (10, 11, 12, 13, 14, 15) to brake
valve (1) by following identification marks.
: 24 mm
: 110 N·m (11 kgf·m, 81 lbf·ft) 2, 3
1
: 36 mm 16
: 300 N·m (30 kgf·m, 221 lbf·ft)
4. Connect connector of brake switch (16) to brake

valve (1).
5. Adjust brake switch (16) on brake valve (1).
W8R7-02-08-002
W8R7-E-01(20160803) W2-8-3
BODY / Brake Valve
6. Check the oil level in the hydraulic oil tank and re-
fill if necessary. Refer to the Operator’s Manual for 27, 28
26
details. Start the engine and check that the system
is functioning properly.
Warm the hydraulic oil to its operating tempera- 25
ture and check all parts for any leakage. FRONT
24
7. Install the calibrated hydraulic pressure gauge REAR
onto applicable test port (22, 24, 25) on brake 23
valve (1). Measure the maximum brake pressure. 20
Maximum brake operation pressure is 20690±173 22
2
kPa (211±1.76 kgf·cm , 3000±25 psi) for the front
16 W8DS-02-08-003
brake and 15860±173 kPa (162±1.76 kgf·cm2, View A
2300±25 psi) for the rear brake.
Refer to Hydraulic Equipment Performance
Measurement section for details.
8. If maximum brake operation pressure is out of the 1 17

specified value, adjust the brake pressure with A
plunger collars (21) (2 used) located at brake car- 18, 19
tridges (23, 26). 23, 26
When plunger collar (21) is rotated to counter-
clockwise, hydraulic pressure increases. When 20
plunger collar (21) is rotated to clockwise, hydrau-
lic pressure decreases.
9. Adjust brake valve (1) full stroke position with nut

(19) and set screw (18). Adjust set screw (18) in
21
order to achieve maximum brake operating pres- W8DS-02-08-001
sure on both front and rear brakes when the brake

pedal is depressed fully.
After adjustment is complete, tighten jam nut (19).
: 9/16 in
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
W8R7-E-01(20160803) W2-8-4
BODY / Brake Valve
10. Adjust the brake pedal (20) returning position of
brake valve (1) with jam nuts (28) (2 used) and set 27, 28
screw (27).
Adjust the set screw (27) in order to attain a mini-
mum clearance of 0.76 mm (0.03 in) between
plunger (17) and set screw (18) points of connec- FRONT
tion.
After adjustment is complete, tighten jam nuts (28) REAR
(2 used).
: 9/16 in 20
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
W8DS-02-08-003
11. Install front access cover onto the cab. View A
12. Start the engine, and check for any oil leaks.
1 17
13. Bleed any air from within the brake system. A
Refer to AIR BLEEDING OF FRONT BRAKE 18, 19
20
W8DS-02-08-001
W8R7-E-01(20160803) W2-8-5
BODY / Brake Valve
DISASSEMBLY OF BRAKE VALVE
74
75
17
13 11 73
9 37
36
1
10
35 10
34
9
5 3 11
24 8
35
30, 31 34
12
2 4
14
27, 28
23, 25 26, 29
33 18, 19
22
32
6 20, 21
15
7
16
W8R7-02-08-003
Brake Valve
1 - Manifold 11 - O-Ring (2 Used) 21 - Jam Nut (2 Used) 31 - Jam Nut

2 - *Front Brake Cartridge 12 - *Low Pressure Sensor (LPS) 22 - Spring 32 - Bolt (Longer than Bolt 33)
Valve (4 Used)
3- *Rear Brake Cartridge 13 - *Solenoid Valve 23 - Shaft 33 - Bolt (4 Used)
4- Shuttle Ball Valve 14 - Orifice Plug 24 - Nylon Washer (4 Used) 34 - O-Ring (2 Used)
5- Brake Mounting Plate 15 - Bracket 25 - E-Ring (2 Used) 35 - Backup Ring (2 Used)
6- Brake Pedal 16 - Bolt (2 Used) 26 - Plug 36 - O-Ring
7- Pedal Cover 17 - Adaptor S 27 - Shaft 37 - O-Ring
8- Elbow S 18 - Set Screw 28 - E-Ring (2 Used) 73 - Plate
9- Spring (2 Used) 19 - Jam Nut (2 Used) 29 - O-Ring 74 - Bolt (4 Used)
10 - Check Valve (2 Used) 20 - Eye Screw 30 - Set Screw 75 - Elbow S
NOTE: * Refer to the detailed cross-section diagram of the brake valve.
W8R7-E-01(20160803) W2-8-6
BODY / Brake Valve
From Low Pressure

Spool Pilot Part
40 41 42 43 44 Sensor Valve 45 46
38 39
60 59 58 57 56
To Tank 55 54 53 52 51 50 49 48 47
From Supply To Delivery Port
Port P Port (BF, BR)
Front / Rear Brake Cartridge
61 66
62 72
63
62 67 71
64
68 69
65
67 70
64
Solenoid Valve 69
T8DS-05-25-002
Low Pressure Sensor (LPS) Valve
Detailed Cross-Section Diagram of the Brake Valve
38 - Cap (2 Used) 47 - Plunger Collar (2 Used) 56 - Backup Ring (2 Used) 65 - O-Ring

39 - Spool (2 Used) 48 - Plunger (2 Used) 57 - O-Ring (2 Used) 66 - O-Ring
40 - Ball Bearing (2 Used) 49 - Plunger Guide (2 Used) 58 - Backup Ring (2 Used) 67 - Backup Ring (2 Used)
41 - Retainer (2 Used) 50 - O-Ring (2 Used) 59 - O-Ring (2 Used) 68 - O-Ring
42 - Cartridge Body (2 Used) 51 - O-Ring (2 Used) 60 - Spring (2 Used) 69 - Backup Ring (2 Used)
43 - Spring Guide (2 Used) 52 - Spacer (2 Used) 61 - O-Ring 70 - O-Ring
44 - Seal (2 Used) 53 - Spring (2 Used) 62 - Backup Ring (2 Used) 71 - O-Ring
45 - T-Seal (2 Used) 54 - Spring (2 Used) 63 - O-Ring 72 - Backup Ring
46 - Rod Wiper (2 Used) 55 - Spring (2 Used) 64 - Backup Ring (2 Used)
W8R7-E-01(20160803) W2-8-7
BODY / Brake Valve
35
34
5 3
24
35
30, 31 34
2
27, 28
23, 25
33 18, 19
22
32
6 20, 21
15
7
16
W8R7-02-08-003
Brake Valve
W8R7-E-01(20160803) W2-8-8
BODY / Brake Valve
Disassembly of Brake Valve
1. Remove E-rings (28) (2 used) from shaft (27).

Push out shaft (27) and drop spring (22).
2. Remove E-rings (25) (2 used) from shaft (23).

Push out shaft (23). Remove nylon washers (24) Brake Switch
(4 used), brake pedal (6), and related parts at-
tached to the brake pedal.
3. Remove bolts (32, 33) (4 used for each) that se-

curing brake mounting plate (5) to manifold (1).
Remove mounting plate (5), together with bracket
(15), eye screw (20), the brake switch, and its re-
lated parts.
: 9/16 in
4. Carefully pulling out front brake cartridge (2) and

rear brake cartridge (3) in a straight line from
manifold (1). The cartridge is fixed to brake
mounting plate (5). W8R7-02-08-004
5. Remove and discard O-ring (34) and backup ring

(35) from manifold (1).
48
6. Remove and discard O-rings (59, 57, 50) and

backup rings (58, 56) from front brake cartridge
(2) and rear brake cartridge (3). (Refer to diagram
at right.)
NOTE: Do not disassemble any parts from front T8DS-05-00-020

59 58 57 56 50
brake cartridge (2) and rear brake cartridge
(3) except for outer seal and plunger (48) Front/Rear Brake Cartridge
seal. Refer to Cartridge Seal Replacement
section for replacing parts.
W8R7-E-01(20160803) W2-8-9
BODY / Brake Valve
74
75
17
13 11 73
9 37
36
1
10
10
9
11
8
12
4
14
26, 29
W8R7-02-08-003
Brake Valve
W8R7-E-01(20160803) W2-8-10
BODY / Brake Valve
7. Remove low pressure sensor (LPS) valve (12)
from manifold (1).
: 1 in
8. Remove and discard O-rings (66, 68, 70, 71) and

back up rings (67, 69, 72) from low pressure
sensor (LPS) valve (12). (Refer to cross-section
diagram in the right.)
NOTE: Do not disassemble low pressure sensor

(LPS) valve (12) other than the seal.
9. Remove plug (26) and O-ring (29) from manifold

(1). Remove orifice plug (14) and shuttle ball
66 72
valve (4).
: 1-1/4 in 71
67
10. Remove elbow S (8), adaptor S (17), and O-rings 68 69
(11) (2 used) from manifold (1). Remove springs 67
(9) (2 used), and check valves (10) (2 used). 70
Remove and discard O-rings (11) (2 used). 69
: 24 mm W8DS-02-08-006

11. Remove solenoid valve (13) from manifold (1).
: 1-1/8 in
12. Remove and discard rings (61, 63, 65) and

backup rings (62, 64) (2 each used) from solenoid
valve (13). (Refer to the cross-section diagram in
the right.)
NOTE: Do not disassemble the solenoid valve

other than the seal.
61
NOTE: Do not remove plate (73), bolts (74) (4
used), O-rings (36, 37), and elbow (75) 62
unless necessary. 63
62
64
65
64
W8DS-02-08-005
Solenoid Valve
W8R7-E-01(20160803) W2-8-11
BODY / Brake Valve
INSPECTION OF BRAKE VALVE
13
30, 31
12
2
W8R7-02-08-003
Brake Valve
W8R7-E-01(20160803) W2-8-12
BODY / Brake Valve
Inspection of Brake Valve
1. Inspect front brake cartridge (2), rear brake
cartridge (3), low pressure sensor (LPS) valve
(12), solenoid valve (13) and any holes on these
parts for scratches, grooves or excessive wear.
Replace with new parts if any of the above are
found.
2. Inspect the machine finished surface of all valve

housing for any dents or burrs that could lead to
leakage.
3. Discard all used seals, O-rings, and backup rings.

New seals, O-rings, and backup rings must be
used in assembly.
4. Clean all parts before assembly.
W8R7-E-01(20160803) W2-8-13
BODY / Brake Valve
ASSEMBLY OF BRAKE VALVE
26, 29 14
22 15, 16 17 12
B-B
20, 21
74 11
27, 28
4
73, 36, 37 9
23, 24, 25
10
30, 31
A A
6 10
7
9
13
11 8, 36
13
Section A-A
1 2 12 5 34, 35 18, 19
16 23, 24, 25
27, 28
22
FRONT
REAR
24
15
32 33
3 20, 21 13 C-C
View C-C W8R7-02-08-005
View B-B
Brake Valve
1 - Manifold 11 - O-Ring (2 Used) 21 - Jam Nut (2 Used) 31 - Jam Nut

2 - *Front Brake Cartridge 12 - *Low Pressure Sensor (LPS) 22 - Spring 32 - Bolt (Longer than Bolt 33)
Valve (4 Used)
3- *Rear Brake Cartridge 13 - * Solenoid Valve 23 - Shaft 33 - Bolts (4 Used)
4- Shuttle Ball Valve 14 - Orifice Plug 24 - Nylon Washer (4 Used) 34 - O-Ring
5- Brake Mounting Plate 15 - Bracket 25 - E-Ring (2 Used) 35 - Backup Ring (2 Used)
6- Brake Pedal 16 - Bolt (2 Used) 26 - Plug 36 - O-Ring
7- Pedal Cover 17 - Adaptor S 27 - Shaft 37 - O-Ring
8- Elbow S 18 - Set Screw 28 - E-Ring (2 Used) 73 - Plate
9- Spring (2 Used) 19 - Jam Nut (2 Used) 29 - O-Ring 74 - Bolts (4 Used)
10 - Check Valve (2 Used) 20 - Eye Screw 30 - Set Screw
NOTE: * Refer to the detailed cross-section diagram of the brake valve.
W8R7-E-01(20160803) W2-8-14
BODY / Brake Valve
From Low Pressure

Sensor Valve
Spool Pilot Part
40 41 42 43 44 45 46
38 39
60 59 58 57 56
To Tank 55 54 53 52 51 50 49 48 47
From Supply To Delivery Port
Port P Port (BF, BR)
Front / Rear Brake Cartridge
61 66
62 72
63
62 67 71
64
68 69
65
67 70
64
Solenoid Valve 69
T8DS-05-25-002
Detailed Cross-Section Diagram of the Brake Valve
38 - Cap (2 Used) 47 - Plunger Collar (2 Used) 56 - Backup Ring (2 Used) 65 - O-Ring

39 - Spool (2 Used) 48 - Plunger (2 Used) 57 - O-Ring (2 Used) 66 - O-Ring
40 - Ball Bearing (2 Used) 49 - Plunger Guide (2 Used) 58 - Backup Ring (2 Used) 67 - Backup Ring (2 Used)
41 - Retainer (2 Used) 50 - O-Ring (2 Used) 59 - O-Ring (2 Used) 68 - O-Ring
42 - Cartridge Body (2 Used) 51 - O-Ring (2 Used) 60 - Spring (2 Used) 69 - Backup Ring (2 Used)
43 - Spring Guide (2 Used) 52 - Spacer (2 Used) 61 - O-Ring 70 - O-Ring
44 - Seal (2 Used) 53 - Spring (2 Used) 62 - Backup Ring (2 Used) 71 - O-Ring
45 - T-Seal (2 Used) 54 - Spring (2 Used) 63 - O-Ring 72 - Backup Ring
46 - Rod Wiper (2 Used) 55 - Spring (2 Used) 64 - Backup Ring (2 Used)
W8R7-E-01(20160803) W2-8-15
BODY / Brake Valve
26, 29 14
17
B-B
11
9 4
10
A A
10
13 9
11
8 13
Section A-A
FRONT
REAR
W8R7-02-08-005
13 C-C View C-C
View B-B
Brake Valve
W8R7-E-01(20160803) W2-8-16
BODY / Brake Valve
Assembly of Brake Valve BR
AR
1. Install check valves (10) (2 used) and spring (9) (2
used) into the holes of port AF and port AR on
manifold (1)
Rear
NOTE: Face the arrows on check valves (10) (2 P
used) to the outside of manifold (1). (Refer
to Section A-A on Brake Valve diagram.)
Brake Valve
Front
2. Insert elbow S (8) (2 used) with O-ring (11) and
adaptor S (17) into manifold (1) and tighten them.
: 24 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft)
AF BF
3. Insert shuttle ball valve (4) into manifold (1). T8DS-05-25-004
Install orifice plug (14) and plug (26) with O-ring Brake Valve Port and Identification Code
(29) to manifold (1).
: 1-1/4 in
: 36 N·m (3.6kgf·m, 27 lbf·ft)
4. Install new O-rings (61, 63, 65) and new backup

rings (62, 64) (2 each used) to solenoid valve (13).
Check that the seal contacts to the groove and
the installation position / direction are correct. 61
Refer to diagram in the right for correct installation
of the seal. 62
63
62
64
65
64
W8DS-02-08-005
5. Insert solenoid valve (13) into manifold (1) and Solenoid Valve
tighten.
: 1-1/8 in
: 25 N·m (2.5 kgf·m, 18 lbf·ft) Install the O-ring in between the Backup Rings
O-Ring
Backup
Ring
W8DS-02-08-007
W8R7-E-01(20160803) W2-8-17
BODY / Brake Valve
B-B 22 12
27, 28
23, 24, 25
A A
6
7
View A-A
1 2 12 5 34, 35
23, 24, 25
27, 28
22
FRONT
REAR
24
32 33
W8R7-02-08-005
3 C-C View C-C
View B-B
Brake Valve
W8R7-E-01(20160803) W2-8-18
BODY / Brake Valve
6. Insert new backup rings (35) (2 used) and new
O-rings (34) (2 used) into manifold (1).
7. Install new O-ring (50) to front brake cartridge (2)
and rear brake cartridge (3). Install O-rings (57,
59) and backup rings (56, 58) to the front and the
rear brake cartridges. Check that the installation
position and direction of the backup ring and
O-ring are correct. (Refer to the cross-section
diagram in the right.) 59 58 57 56 50 T8DS-05-00-020
8. Carefully insert front brake cartridge (2) and rear Front / Rear Brake Cartridge
brake cartridge (3) into manifold (1). The words
“front” and “rear” are engraved on the front brake
and rear brake cartridge housings respectively.
Install each cartridge to its corresponding valve
port.
9. Attach new O-rings (66, 68, 70, 71) and new
backup rings (67, 69) (2 each used), and (72) to
the low pressure sensor (LPS) valve (12). Check
that the installation position and direction of the
backup ring and O-ring are correct. (Refer to the
cross-section diagram at right.)
10. Carefully screw in low pressure sensor (LPS)
66
valve (12) to manifold (1).
: 1 in
: 31 N·m (3.1 kgf·m, 23 lbf·ft)
11. Install brake mounting plate (5) to manifold (1) 72
with bolts (32, 33) (4 each used). Use the long 67 71
bolts (32) for the 4 upper holes. 68
: 9/16 in 67 69
: 37 N·m (3.7 kgf·m, 27 lbf·ft) 70
12. Install shaft (27) and E-rings (28) (2 used) to the 69
brake pedal (6). Low Pressure Sensor (LPS) Valve W8DS-02-08-006
13. Install the brake pedal (6) assembly onto the
brake mounting plate (5) assembly with shaft (23),
nylon washers (24) (4 used), and E-rings (25) (2
used). Install the O-ring in Between the Backup Rings
14. Install spring (22) onto shaft (27) of brake pedal
(6).
68, 70 67, 69
W8DS-02-08-007
Install the O-ring Facing Base of the Ports
71 72
W8DS-02-08-008
Attachment Position and Direction of O-ring and

Back-Up Ring
W8R7-E-01(20160803) W2-8-19
BODY / Brake Valve
REPLACEMENT OF BRAKE CARTRIDGE
SEAL
38 39 40 41 42 43 44 45 46
60 59 58 57 56 55 54 53 52 51 50 49 48 47
T8DS-05-00-020
Front/Rear Brake Cartridge
38 - Cap 44 - Seal 50 - O-Ring 56 - Backup Ring

39 - Spool 45 - T-Seal 51 - O-Ring 57 - O-Ring
40 - Ball Bearing 46 - Rod Wiper 52 - Spacer 58 - Backup Ring
41 - Retainer 47 - Plunger Collar 53 - Spring 59 - O-Ring
42 - Cartridge Body 48 - Plunger 54 - Spring 60 - Spring
43 - Spring Guide 49 - Plunger Guide 55 - Spring
W8R7-E-01(20160803) W2-8-20
BODY / Brake Valve
Replacement of Brake Cartridge Seal
Do not disassemble components from the brake 7. Apply lubricant (such as grease) onto new O-ring
cartridge unless required for plunger (48) seal (51), seal (44), T-seal (45), and rod wiper (46).
replacement. Install O-ring (51) and seal (44) onto plunger (48).
Install T-seal (45) and rod wiper (46) onto plunger
NOTE: The brake cartridge components must guide (49).
withstand a severe usage environment.
Service these components in a clean 8. Apply film of locktight onto the screw part of
environment. Use residual free liquids and plunger guide (49). Insert plunger (48) into
cloths with no nap. plunger guide (49) carefully.
Tag cartridge components with cartridge Do not apply oil to plunger (48) for at least 24
part number (stamped on plunger guide 49) hours.
and cartridge serial number (etched on
cartridge body) for assembly identification. 9. Screw plunger collar (47) into plunger (48). Install
springs (53, 54, 55) and screw plunger guide (49)
1. Remove the brake cartridge from manifold (1) into cartridge body (42).
following the procedures shown in the previously Plunger guide (49):
stated disassembly. : 25 ± 2 N·m (2.5±0.2 kgf·m, 18±1.5 bf·ft)
2. Remove plunger guide (49) from cartridge body 10. Install the brake cartridge to manifold (1),
(42). following the procedures discussed in the
previous section “Assembly”.
3. Remove springs (53, 54, 55) and inspect.
11. Adjust the hydraulic pressure with plunger collar
4. Check for free spool (39) movement by pushing (47), following the procedures discussed in the
left on spring guide (43). If spring or spool previous section.
damage is suspected replace cartridge assembly.
5. Loosen the bolt holding plunger collar (47).

Remove plunger collar (47) from plunger (48).
6. Push plunger (48) through plunger guide (49).

Remove and discard rod wiper (46), T-seal (45),
seal (44) and O-ring (51) taking note of their
proper orientation.
W8R7-E-01(20160803) W2-8-21
BODY / Brake Valve
(Blank)
W8R7-E-01(20160803) W2-8-22
BODY / Brake Accumulator
REMOVAL AND INSTALLATION OF REAR
BRAKE ACCUMULATOR
Removal
1. Park the machine on a level surface with the ser- 4, 5, 6

vice position.
CAUTION: Release the oil pressure from the 1
brake system before removal of brake accu-
mulator.
Main Accumulator A
7
2. Release the oil from the rear brake valve.
BRAKE VALVE.
3. Disconnect hose (8) from elbow S (9) which is 12

attached to end cover (12) at the bottom of rear
brake accumulator (1). Cap hose (8) to prevent 9, 10, 11
debris from entering.
Remove reducer (11) and O-rings (10). 8
: 19 mm, 22 mm, 27 mm
CAUTION: Rear brake accumulator (1)

4. Hoist and support rear brake accumulator (1).

and plates (6) (4 used) that hold bracket (7) onto
rear brake accumulator (1).
W8R7-02-09-002
: 17 mm
Accumulator Attachment Point
6. Remove rear brake accumulator (1) from bracket

(7).
4, 5 6 W8DS-02-09-002
Section A Detail
W8R7-E-01(20160803) W2-9-1
Installation
CAUTION: Rear brake accumulator (1)

4, 5, 6
2
1. Hoist rear brake accumulator (1) with top cover 1
(2) facing upwards.
2. Install rear brake accumulator (1) to bracket (7) Main Accumulator A

7
with plates (6) (4 used), bolts (4) (4 used), and
: 17 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
12
3. Install reducer (11), new O-ring (10), and elbow S
(9) to end cover (12) of rear brake accumulator 9, 10, 11
(1).
: 22 mm, 27 mm 8
: 95 N·m, (9.5 kgf·m, 70 lbf·ft)
4. Connect hose (8) to elbow S (9).

: 19 mm, 22 mm
: 70 N·m (7.0 kgf·m, 52 lbf·ft)
6. Bleed air from the rear brake system.

DRIVELINE. W8R7-02-09-002
Accumulator Attachment Point

IMPORTANT: For the first week after the brake

accumulator is reinstalled, check the
nitrogen gas pressure to make sure
there are no leaks. Thereafter, the
gas pressure should be checked
W8DS-02-09-002
every month. 5, 6 7
Section A Detail
W8R7-E-01(20160803) W2-9-2
FRONT BRAKE ACCUMULATOR
Removal

vice position.
1
CAUTION: Release the oil pressure from the
4, 5, 6
brake system before removal of brake ac- Main Accumulator
cumulator.
7
A
2. Release the oil from the front brake valve.
BRAKE VALVE.
8, 9
3. Disconnect hose (10) from elbow S (8) attached
to end cover (7) at the bottom of front brake ac- 11
cumulator (1). Cap hose (10) to prevent debris
from entering.
: 19 mm, 22 mm, 27 mm
CAUTION: Front brake accumulator (1)

4. Hoist and hold front brake accumulator (1).

and plates (6) (4 used) that secure bracket (11)
W8R7-02-09-002
onto front brake accumulator (1).
: 17 mm Accumulator Attachment Point
6. Remove front brake accumulator (1) from bracket

(11).
4, 5 6 W8DS-02-09-002
Section A Detail
W8R7-E-01(20160803) W2-9-3
Installation
CAUTION: Front brake accumulator (1)

1 2
1. Hoist front brake accumulator (1) with top cover
(2) facing upwards. 4, 5, 6
Main Accumulator
2. Install front brake accumulator (1) to bracket (11)
with plates (6) (4 used), bolts (4) (4 used), and 7
A
: 17 mm 10
: 50 N·m (5 kgf·m, 37 lbf·ft)
8, 9
3. Install new O-ring (9) and elbow S (8) to end
cover (7) of front brake accumulator (1). 11
: 22 mm, 27 mm
: 95 N·m (9.5 kgf·m, 70 lbf·ft)
4. Install hose (8) to elbow S (9).

: 19 mm, 22 mm
: 70 N·m (7.0 kgf·m, 52 lbf·ft)
6. Bleed air from the front brake system.

Refer to AIR BLEEDING OF FRONT BRAKE.
7. Drive the machine under a controlled environment W8R7-02-09-002
and inspect the brake performance before oper- Accumulator Attachment Point
IMPORTANT: For the first week after the brake

accumulator is reattached, check the
nitrogen gas pressure to make sure
there are no leaks. Thereafter, the
gas pressure should be checked
every month.
W8DS-02-09-002
4, 5 6
Section A Detail
W8R7-E-01(20160803) W2-9-4
(Blank)
W8R7-E-01(20160803) W2-9-5
DISASSEMBLY OF BRAKE ACCUMULA-
TOR
6, 7 6 7 5 2 3, 4 1 8 3, 4 9
C B
A
P
13, 14 12 10 11 12
E
5
Detail P
13 14
Detail S
View E
T8DS-05-27-005
Brake Accumulator
1- Cylinder 6- Plug 11 - Piston Ring A - Port A

2- Top Cover 7- O-Ring 12 - O-Ring (2 Used) B - Hydraulic Oil
3- O-Ring (2 Used) 8- Piston 13 - Plug C - Dry Nitrogen Gas
4- Backup Ring (2 Used) 9- End Cover 14 - O-Ring
5- Inflation Valve 10 - Ring Seal
W8R7-E-01(20160803) W2-9-6
Disassembly of Brake Accumulator Inspection
1. Inspect all the screws for damage. Replace any

CAUTION: Brake accumulator weight
damaged parts.
Rear: 26 kg (57 lb)
Front: 20 kg (44 lb)
2. Inspect the cylinder (1) interiors and piston outer
circumference for any scratches. Correct any
1. Place the brake accumulator on a clean platform,
protrusion or dent with a sand cloth. Replace any
and hold with blocks to prevent it from moving. Do
parts that cannot be corrected.
not hold the accumulator with a vice.
CAUTION: Release the gas pressure from

the brake accumulator before disassembly of
brake accumulator.
2. Slightly open plug (13) and fully discharge the ni-

trogen gas. Remove plug (13) and O-ring (14).
Dispose of O-ring (14).
: 22 mm
3. Remove plug (6) and O-ring (7) from top cover

(2).
: 41 mm
4. Remove inflation valve (5) from the top cover (2).

: 14 mm
5. Attach a spanner onto the holes on top cover (2).

Remove the top cover (2) from cylinder (1).
6. Remove and discard backup ring (4) and O-rings

(3, 12) from the top cover (2).
7. Attach a spanner onto the holes on end cover (9).

Remove end cover (9) from cylinder (1).
8. Remove and discard backup ring (4) and O-rings

(3, 12) from end cover (9).
9. Insert a rod. Gently tap the end of the rod with a

hammer to remove piston (8).
10. Remove and discard ring seal (10) and piston ring
(11) from piston (8).
W8R7-E-01(20160803) W2-9-7
ASSEMBLY OF BRAKE ACCUMULATOR
6, 7 6 7 5 2 3, 4 1 8 3, 4 9
C B A
P
13, 14 12 11 12
10 E
5
Detail P
13 14
Detail S
View E
T8DS-05-27-005
Brake Accumulator
6- Cylinder 6- Plug 11 - Piston Ring A - Port A

7- Top Cover 7- O-Ring 12 - O-Ring (2 Used) B - Hydraulic Oil
8- O-Ring (2 Used) 9- Piston 13 - Plug C - Dry Nitrogen Gas
9- Backup Ring (2 Used) 9- End Cover 14 - O-Ring
10 - Inflation Valve 10 - Ring Seal
W8R7-E-01(20160803) W2-9-8
Assembly of Brake Accumulator
1. Install ring seal (10) to the wider groove side on

piston (8).
10 8 11
2. Install piston ring (11) to the narrow groove side
on piston (8). Piston ring (11) have an orientation.
Install piston ring (11) in the correct direction, as
shown on the right diagram.
3. Apply film of oil onto the inner wall of cylinder (1).
IMPORTANT: Do not damage ring seal (10) or

piston ring (11) with the screw part
of cylinder (1) when inserting piston W8DS-02-09-003
(8) into cylinder (1).
4. Face ring seal (10) side of piston (8) towards the

accumulator inflation valve (5) and insert piston
(8) into the cylinder (1).
5. Apply film of clean hydraulic oil onto O-rings (3) (2

used), O-rings (12) (2 used), and back up rings
(4) (2 used).
6. Install O-ring (3) and backup ring (4) in this order

from the unthreaded side of end cover (9).
Install backup ring (4) facing the concave side
facing O-ring (3).
Install O-ring (12) to end cover (9).
7. Install end cover (9) to the lower part of cylinder

(1). Slowly rotate the end cover (9) clockwise until
the screw meets the end. Do not over-tighten the
screw.
: 300±30 N·m (30±3.0 kgf·m, 221±22 lbf·ft)
W8R7-E-01(20160803) W2-9-9
6, 7 6 7 5 2 3, 4 1 8 3, 4 9
C A
P
13, 14 12 10 11 12
E
5
Detail P
13 14
Detail S
View E
T8DS-05-27-005
Brake Accumulator
W8R7-E-01(20160803) W2-9-10
8. Install O-ring (3) and backup ring (4) in this order
from the unthreaded side of top cover (2).
Install backup ring (4) facing the concave side
facing O-ring (3).
Install O-ring (12) to top cover (2).
9. Install top cover (2) to the upper part of cylinder

(1). Slowly rotate top cover (2) clockwise until the
screw meets the end. Do not over-tighten the
screw.
: 300±30 N·m (30±3.0 kgf·m, 221±22 lbf·ft)
10. Apply clean hydraulic oil onto O-ring (14).

Install O-ring (14) to plug (13).
Install plug (13) onto top cover (2).
: 22 mm
: 20 to 45 N·m (2.0 to 4.5 kgf·m, 15 to 33
lbf·ft)
11. Install inflation valve (5) onto top cover (2).

: 14 mm
: 10 to 13 N·m (1.0 to 1.3 kgf·m, 7.3 to 9.6
lbf·ft)
12. Prepare dry nitrogen gas required for pressurizing

brake accumulator.
13. Connect an appropriate adapter to inflation valve

(5) and charge the required amount of nitrogen
gas into the brake accumulator. Refer to
CHARGING NITROGEN GAS.
Gas pressure: 8.3±0.25 MPa (85±2.5 kfg/cm²,
1200±36 psi)
Nitrogen gas capacity
Rear brake accumulator: 5.0 L (1.32 US gal)
Front brake accumulator: 2.8 L (0.73 US gal)
14. Apply clean hydraulic oil onto O-ring (7).

Install O-ring (7) to plug (6).
Install the plug (6) onto top cover (2).
: 41 mm
: 75 to 100 N·m (7.5 to 10 kgf·m, 55 to 74
lbf·ft)
W8R7-E-01(20160803) W2-9-11
CHARGING NITROGEN GAS
2 1 3
7
5
6
N2 Cylinder
W8DS-02-10-025
1 - Charging Valve Assembly 3 - Handle (for Adjust Screw) 5 - Charging Valve Body 7- Hose Assembly
2 - Pressure Gauge 4 - Handle (for Bleed Plug) 6 - Inflation Valve
W8R7-E-01(20160803) W2-9-12
Charging Nitrogen Gas
1. Check that any hydraulic pressure is fully re- 9. Return the inflation valve (6) piston to its original
leased before charging the nitrogen gas. The gas position by rotating handle (3) anticlockwise.
cannot be filled unless the hydraulic pressure is at Open handle (4) by turning anticlockwise, and
zero. release any residual gas that is in charging valve
assembly (1) and hose assembly (7).
2. Turn charging valve assembly (1) handle (3) fully
to the left. 10. Remove charging valve assembly (1) from the
accumulator.
3. Rotate bleed plug handle (4) to the left and open
the plug. 11. Apply soapy water or water on inflation valve (6)
to check for any gas leak. Attach the plug to com-
4. Remove the plug on inflation valve (6). Connect plete the process.
charging valve assembly (1).
5. Open the nitrogen cylinder valve slightly to pre- Maintenance

vent gas from being released suddenly. The gas
will exit from handle (4) area when the gas is re- For the first week after the brake accumulator is re-
leased at 0.2 to 0.3 MPa (2 to 3 kfg/m², 28 to 43 attached, check the nitrogen gas pressure to make
psi). Turn handle (4) clockwise to prevent the gas sure there are no leaks. Thereafter, the gas pressure
from escaping. should be inspected every month. For detailed in-
formation, refer to the maintenance period shown in
6. Rotate handle (3) clockwise slowly with pushing the “Operator’s Manual”.
the inflation valve (6) piston.
7. Slowly open the nitrogen cylinder valve to gently

charge the nitrogen gas into the accumulator.
Close the nitrogen cylinder valve occasionally to
read the indicated pressure on pressure gauge
(2) of the charging valve assembly (1) once the
reading has stabilized.
8. Securely close the nitrogen cylinder valve once

the gas is charged to the specified pressure. Ro-
tate handle (4) to the left to release some gas if
the pressure is higher than the set pressure.
The relation between the temperature (when
charged gas) and the gas pressure is as follows:
Px = Ps (MPa) × [273+t (°C)] / [273+20 (°C)]
Px : Inserted Gas Pressure (MPa)
t : Gas temperature when inserted
(≒ OUTER temperature)
Ps : Specified gas pressure (MPa)
W8R7-E-01(20160803) W2-9-13
(Blank)
W8R7-E-01(20160803) W2-9-14
BODY / Steering System
STEERING COLUMN ASSEMBLY
1
Park the machine on a level surface with the service
position. Dashboard
CAUTION: Bleed air from the hydraulic oil

tank and Release oil pressure from hydraulic 2, 3
circuit before doing any work.
Removal 4, 5,
6, 17
1. Remove bolt (4), nut (5), washer (6) and washer
(17).
: 17 mm 7
2. Remove the steering column (1) assembly wire

harness. 10, 11,
12
3. Hold steering column (1) and remove bolts (2) (4 36
used) and washers (3) (4 used). Remove steer-
ing column (3) from the dashboard.
: 17 mm
4. Slowly pull and remove the steering column (1)

assembly from driveshaft (7) to avoid damaging
the spline.
5. Remove bolts (11) (4 used) and washers (12) (4 W8R7-02-10-001
used) from the cab floor. Remove the half-round

plates (10) (2 used) and spacer (36) (4 used).
: 6 mm
6. Remove bolts (38) (4 used), washers (39) (4 38, 39

used). Remove under cover (37) from the cab.
: 17 mm 37
W8R7-02-10-016
W8R7-E-01(20160803) W2-10-1
7. Remove bolt (13), nut (14), washers (15) and
washers (18).
: 13 mm
9 7 8
CAUTION: Driveshaft (7) weight: 32 kg (71 lb)
8. Slowly pull and remove the driveshaft (7) from the

shaft (16) to avoid damaging the spline on the
driveshaft (7) spline yoke.
16
9. Remove boot (9) and cover (8) from driveshaft as
required.
10. Clean the port area of steering valve (21) before

disconnecting hoses (31) (2 used), (32) (2 used), 13, 14,
15, 18
and (33) that are connected to steering valve (21).
Remove hoses (31) (2 used), (32) (2 used), and 22
(33). Attach identification tags to each hose for 19, 20
assembly. As there may be residual hydraulic oil in 21
the pipes, drain any residual oil in an appropriate
container when disconnecting the hose.
: 27 mm
11. Hold steering valve (21) and the shaft (16). W8R7-02-10-002
Remove bolts (19) (4 used) and washers (20) (4

used). Remove steering valve (21) and the shaft
(16) from bracket (22).
: 17 mm 31
33
32
NOTE: Steering valve (21) can be removed without
removing the steering column (1) and
driveshaft (7).
21 W8R7-02-10-003
W8R7-E-01(20160803) W2-10-2
12. Remove adapters S (28) (2 used), adapters S (29)
(2 used), and O-rings (30) (4 used) from steering
valve (21).
: 24 mm, 27 mm 29, 30
13. Remove elbow S (35) from orifice (34). Remove 28, 30

orifice (34) from steering valve (21).
: 22 mm
14. Remove bracket (22), bolts (23) (4 used), washers

(24) (8 used), washers (26) (4 used), mounts (25)
(4 used), and nuts (27) (4 used). 21
Inspect mounts (25) (4 used) and other assembly
parts. Replace any damaged parts with new ones. 34 35
W8R7-02-10-003
: 17 mm
23, 24,
25, 26,
22 27
W8R7-02-10-002
W8R7-E-01(20160803) W2-10-3
Installation
1. Install bracket (22) to the cab frame with bolts (23)

(4 used), washers (24) (8 used), washers (26) (4
used), mounts (25) (4 used), and nuts (27) (4
used).
: 17 mm 16
: 40 N·m (4 kgf·m, 30 lbf·ft)
19, 20
2. Install adapters S (28) (2 used), adapters S (29) (2
used), and O-rings (30) (4 used) to steering valve
(21).
: 24 mm, 27 mm
: 175 N·m (17.5 kgf·m, 129 lbf·ft) 23, 24,
25, 26,
3. Connect orifice (34) to steering valve (21). Con- 22 27
nect elbow S (35) to orifice (34)
Orifice (34)
: 22 mm
: 20 N·m (2.0 kgf·m, 15 lbf·ft) 21
Elbow S (35)
: 22 mm
: 70 N·m (7.0 kgf·m, 52 lbf·ft) W8R7-02-10-002
4. Hold steering valve (21) and shaft (16).

Install steering valve (21) and shaft (16) to bracket 27
(22) with bolts (19) (4 used) and washers (20) (4 24
26
used).
: 17 mm 25
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
23 W8DS-02-10-008
Mount (25) Installation Point
28, 30 29, 30
21
34 35
W8R7-02-10-003
W8R7-E-01(20160803) W2-10-4
5. Connect hose to steering valve (21).
Connect hoses following the identification tags
attached to each port at disassembly. Connect
31
hoses (31) (2 used), (32) (2 used), and (33) to the 33
steering valve (21) ports. 32
: 27 mm
: 95 N·m (9.5 kgf·m, 70 lbf·ft)
6. Install boot (9) and cover (8) to driveshaft (7).

21
CAUTION: Driveshaft (7) weight: 32 kg (71 lb)
W8R7-02-10-003
7. Hoist and hold driveshaft (7).

7
8. Slowly install driveshaft (7) into shaft (16) to avoid 9 8
damaging the spline on driveshaft (7) spline yoke.
9. Secure driveshaft (7) to shaft (16) spline with bolt

(13), nut (14), washers (15), and washers (18).
: 13 mm
: 20 N·m (2.0 kgf·m, 15 lbf·ft) 16
10. Install under cover (37) to the cab with bolts (38)
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft) 13, 14,
15, 18
21
W8R7-02-10-002
38, 39
37
W8R7-02-10-016
W8R7-E-01(20160803) W2-10-5
11. Slowly install the steering column (1) assembly
into the driveshaft (7) to prevent damaging the
spline. 1
12. Hold the steering column (1) assembly.

Dashboard
Install steering column (1) to the dashboard with
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft) 2, 3
13. Connect wire harness to the steering column (1)

assembly. 4, 5,
6, 17
14. Secure driveshaft (7) to the steering column (1) 8
spline with bolt (4), nut (5), washer (6) and washer
9 7
(17).
: 17 mm
: 50 N·m (5.0 kgf·m, 37 lbf·ft) A
10, 11,
12
15. Rotate boot (9) in the cab floor so that the angle of
boot (9) and the steering column assembly are 36
aligned on a straight line.
Install the boot (9) to the cab floor with half around
plates (10) (2 used), bolts (11), washers (12) (4
used), and spacers (36) (4 used). Install cover (8)
onto boot (9).
W8R7-02-10-001
9
Front Side
W8R7-02-10-004
Section A
W8R7-E-01(20160803) W2-10-6
DISASSEMBLY AND ASSEMBLY OF
DRIVESHAFT
15
14
13
10 12
11
9
8
7
4
3
2
1
6
5
T8DS-04-51-001
Exploded View of the Steering Driveshaft
1 - Yoke (Engaged to the 5 - Grease Fitting 9 - Dust Cap 13 - Cross Assembly

Steering Column)
2 - Cross Assembly 6 - Grease Fitting 10 - Shaft Assembly 14 - Grease Fitting
3 - Bearing Cap Assembly 7 - Sleeve Assembly 11 - Snap Ring (4 Used) 15 - Yoke (Engaged to the
(4 Used) Steering Valve)
4 - Snap Ring (4 Used) 8 - Washer 12 - Bearing Cap Assembly
(4 Used)

STEERING COLUMN
Do not disassemble the steering column.
W8R7-E-01(20160803) W2-10-7
DISASSEMBLY, ASSEMBLY, AND
INSPECTION OF STEERING VALVE
1 2
5
6
7
8
9
10
3 13
14 4 11
15
12
16
17
18
19 22
18
20 24
21
23 W8R7-02-10-005
Steering Valve Assembly Diagram
1- Dust Seal 7- Needle Thrust Bearing 11 - Pin 16 - Stator

2- Housing 8- Bearing Race 12 - Driveshaft 17 - End Cap
3- Ball 9- Ring 13 - O-Ring 18 - Washer (7 Used)
4- Thread Bushing 10 - Spool 14 - Plate 19 - Cap Screw (6 Used)
5- Seal 11 - Sleeve 15 - Rotor 20 - Special Screw
6- Bearing Race 12 - Center Spring 16 - O-ring (2 Used) 21 - Name Plate
W8R7-E-01(20160803) W2-10-8
Inspection of Steering Valve
1. Clean all components with clean solvent and dry

with air. Do not wipe with cloths or paper towel.
Fiber dust and foreign objects may enter the hy-
draulic system and could damage the compo-
nents.
2. Inspect for any severe damage or frictional wear

in the holes and or on the edge of housing (2).
3. Inspect for any severe damage or frictional wear

in the control edge and inner/outer surface of the
spline of spool (10).
4. Check for any damage in the inner/outer surfaces

and edges of the sleeve (11).
5. Check the needle thrust bearing (7) and bearing

race (6, 8) for any frictional wear or damage.
6. Check driveshaft (14) tooth and rotor (17) spline

for any severe damages or frictional wear.
7. Check rotor (17) robe and inner surface of stator

(19) for any severe damage or frictional wear.
8. Replace the O-rings (15, 18) and seal (1, 5) be-

fore assembly.
IMPORTANT: The entire steering valve must be

replaced if a spool (10), sleeve (11),
or housing (2) requires replacement.
Also, the stator (19) and rotor (17)
must be replaced in one pair (in as-
sembly) if either the stator or the
rotor needs to be replaced.
W8R7-E-01(20160803) W2-10-9
REMOVAL AND INSTALLATION OF FLOW
AMPLIFIER

position.
CAUTION: Always bleed the air from the hy-

draulic tank and release oil pressure from
hydraulic circuit before carrying out the op-
eration.
Removal
IMPORTANT：As there may be residual hydraulic

oil in the pipes, collect any residual
oil in an appropriate container when
disconnecting the hose. Place a cap
onto the hose to prevent debris from
entering. Attach identification tags
to each hose for assembly.
3
1. Loosen socket bolts (4) (4 used) on block (2) lo-
cated on flow amplifier (1). Remove split flanges 4, 5, 6
(5) (2 used). 1
Remove hose (3) and O-ring (6) from flow ampli-
fier (1). Discard O-ring (6).
：10 mm 2 W8R7-02-09-002
2. Loosen socket bolts (8) (4 used) on block (2) lo- 2

cated on flow amplifier (1). Remove split flanges
1
(9) (2 used).
Remove hose (7) and O-ring (10) from flow am-
plifier (1). Discard O-ring (10). 8, 9, 10
：8 mm
3. Remove hose (12) and O-ring (40) from elbow S 7

(11) on block (2) located on flow amplifier (1).
Discard O-ring (40).
：22 mm
W8R7-02-10-007
12, 40
11
2 1
W8R7-02-10-008
W8R7-E-01(20160803) W2-10-10
4. Remove hoses (13, 14, 15, 16), and O-rings (38)
(3 used) from flow amplifier (1). Discard O-rings
(38) (3 used).
：27 mm
5. Loosen socket bolts (20) (12 used) and remove

split flanges (21) (6 used) from flow amplifier (1).
Remove hoses (17, 18) and pipe (19) from flow
amplifier (1).
：8 mm
B 1
6. Remove and discard O-rings (22) (3 used) from
hoses (17, 18) and pipe (19).
CAUTION: Flow amplifier (1) assembly


used). Remove flow amplifier (1) from the frame.
：19 mm A
8. Remove bolts (26) (2 used), bolt (27), and wash-

ers (28) (3 used). Remove plate (23) from flow
amplifier (1). T8R7-01-02-007
：5/8 in
1 13, 38 14, 38
20, 21
17, 22
19, 22
T 18, 22
L 15, 38
16
View A W8R7-02-10-009
24, 25 23
26, 28
27, 28
26, 28
View B W8R7-02-10-010
W8R7-E-01(20160803) W2-10-11
used). Remove block (2) from flow amplifier (1).
29, 30 1
Remove elbow S (11) and O-ring (31) from block
(2). Discard O-ring (31). 2, 31
：5/8 in
：22 mm
10. Loosen socket bolts (33) (4 used) and remove 11

split flanges (34) (2 used) from flow amplifier (1).
Remove cover (32) and O-ring (35) from flow 33, 34
amplifier (1). Discard O-ring (35).
：10 mm
32, 35
11. Remove plug (36) from flow amplifier (1).
：17 mm 36 W8R7-02-10-010
12. Remove adapter S (37) (3 used) and adapter S

37 37
(39) from flow amplifier (1).
：27 mm, 22 mm
1
37
T
39 W8R7-02-10-009
W8R7-E-01(20160803) W2-10-12
Installation
1. Install adapter S (37) (3 used) and adapter S (39)

to flow amplifier (1).
：27、22 mm
：95 N·m (9.5 kgf·m, 70 lbf·ft)
2. Install plug (36) to flow amplifier (1).

：17 mm
：30 N·m (3.0 kgf·m, 22 lbf·ft) B 1
3. Install split flanges (34) (2 used), cover (32), and

O-ring (35) to flow amplifier (1) with socket bolts
(33) (4 used).
：10 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
4. Install block (2) and O-ring (31) to flow amplifier

used). Install elbow S (11) to block (2). A
：5/8 in
：90 N·m (9.0 kgf·m, 66 lbf·ft)
：22 mm
：70 N·m (7.0 kgf·m, 52 lbf·ft) T8R7-01-02-007
5. Install plate (23) to flow amplifier (1) with bolts 37 37

(26) (2 used), bolt (27), and washers (28) (3
used). 1
：5/8 in
：90 N·m (9.0 kgf·m, 66 lbf·ft)
CAUTION: Flow amplifier (1) assembly

weight: 38 kg (84 lb) 37
T
6. Install flow amplifier (1) assembly to the frame L
used). 39 W8R7-02-10-009
View A
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
24, 25 23 29, 30
2, 31
26, 28
27, 28 11
33, 34
26, 28 32, 35
1
36 W8R7-02-10-010
View B
W8R7-E-01(20160803) W2-10-13
7. Install split franges (21) (6 used), hoses (17 , 18),
pipe (19), and O-ring (22) (3 used) to flow ampli- 1 13, 38 14, 38
fier (1) with socket bolts (20) (12 used).
：8 mm
：34 N·m (3.4 kgf·m) 20, 21
17, 22
8. Install hoses (13, 14, 15, 16), and O-ring (38) (3
used) to flow amplifier (1).
：27 mm 19, 22
：95 N·m (9.5 kgf·m, 70 lbf·ft) 18, 22
T
9. Install hose (12) and O-ring (40) to elbow S (11) L 15, 38

16
on block (2) located on flow amplifier (1).
：22 mm W8R7-02-10-009
：70 N·m (7.0 kgf·m, 52 lbf·ft) 12, 40
10. Install split flanges (9) (2 used), hose (7), and 11

O-ring (10) to block (2) on flow amplifier (1) with
socket bolts (8) (4 used).
：8 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
2 1
11. Install split franges (5) (2 used), hose (3), and
O-ring (6) to block (2) on flow amplifier (1) with
socket bolts (4) (4 used). W8R7-02-10-008
：10 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft) 2
8, 9, 10
W8R7-02-10-007
4, 5, 6
W8R7-02-10-011
W8R7-E-01(20160803) W2-10-14
DISASSEMBLY AND ASSEMBLY OF FLOW
AMPLIFIER
17
6
15
10 3, 4
14
1
13 2
7
9
16
10
5
2
1
12
11
9
3
7
W8R7-02-10-012
4 8
1 - Bolt (16 Used) 6 - O-ring (4 Used) 10 - Relief Valve (2 Used) 14 - Back Pressure Valve
(for Crossover Relief)
2 - Washer (16 Used) 7 - O-ring (4 Used) 11 - Direction Control Spool 15 - Relief Valve (Unused)
3 - Bolt (2 Used) 8 - O-ring (2 Used) 12 - Check Valve 16 - Amplifier spool assembly
(for Amplifier Spool)
4 - Washer (2 Used) 9 - Spring Assembly(2 Used) 13 - Housing 17 - End Cover
(for Direction Control
Spool)
5 - End Cover
W8R7-E-01(20160803) W2-10-15
STEERING CYLINDER
Removal
The structures of both the left and right side of the

steering cylinder attachment areas are similar. This 2
section contains information on the left steering cyl-
inder. 1

position.
3, 4
CAUTION: Steering cylinder (9) weight: 110

kg (243 lb) 5
1. Support steering cylinder (9). 6, 7, 8

9
7, 8, 10
2. Remove lubrication hose (3) from pin (5).
4, 12
Remove lubrication hose (12) from pin (11).
W8R7-02-10-013
: 17 mm, 14 mm, 19 mm 11
3. Remove bolt (14), washer (15), plane washer (16),

and spacer (17) from wheel spindle (1). Remove 11
pin (11) and spacers (13) (2 used) from wheel
13
spindle (1). 14
: 19 mm 15
4. Start the engine and retract the piston rod on 16

steering cylinder (9). 17 9
CAUTION: Always bleed the air from the hy-

draulic tank and release oil pressure from
hydraulic circuit before carrying out the op- 1 W8DS-02-10-010
eration. Pin (11) Installation Point
5. Disconnect hoses (6, 10) from steering cylinder

(9).
Cap hoses (6, 10) to prevent debris from entering
the pipe and prevent hydraulic oil from leaking out.
: 36 mm
W8R7-E-01(20160803) W2-10-16
6. Remove bolt (14), washer (15), plane washer (16),
and spacer (19) from steering cylinder (9). Elbow (5) Installation
Point
5
Remove pin (5) and spacers (18) (2 used) from 14 18
steering cylinder (9).
: 19 mm 15
16
7. Remove steering cylinder (9) from trailing arm (2).
19
8. Remove elbow S (4) (2 used) from pins (5, 11) if 2
required.
: 16 to 17 mm
9. Remove elbow S (7) (2 used) and O-rings (8) (2

used) from steering cylinder (9) if required. 9
: 32 mm W8DS-02-10-011
Pin (5) Installation Point
W8R7-02-10-013
11
W8R7-E-01(20160803) W2-10-17
Installation
1. Install elbow S (7) (2 used) and O-rings (8) (2

used) to steering cylinder (9). 2
: 32 mm 1
: 140 N·m (14 kgf·m, 103 lbf·ft)
2. Attach elbow S (4) (2 used) to pins (5, 11).

: 16 to 17 mm
4
CAUTION: Steering cylinder (9) weight: 110

kg (243 lb) 5
3. Hold steering cylinder (9). 4 6, 7, 8

9
7, 8, 10
4. Align steering cylinder (9) to trailing arm (2) in-
stallation position.
W8R7-02-10-013
11
5. Install steering cylinder (9) to trailing arm (2) with
pin (5) and spacers (18) (2 used).
Elbow (4) Installation
Install pin (5) to trailing arm (2) with bolt (14), 14 Point 5 18
washer (15), plane washer (16), and spacer (19).
: 19 mm 15
: 90 N·m (9.0kgf·m, 66 lbf·ft)
16
6. Connect hoses (6, 10) into steering cylinder (9). 19
: 36 mm
: 180 N·m (18 kgf·m, 133 lbf·ft) 2
7. Start the engine. Extend the steering cylinder (9)

piston rod and align wheel spindle (1) installation
hole.
9
W8DS-02-10-011
W8R7-E-01(20160803) W2-10-18
8. Install pin (11) and spacers (13) (2 used) onto
wheel spindle (1).
Install pin (11) to wheel spindle (1) with bolt (14),
washer (15), plane washer (16), and spacer (17).
: 19 mm
: 90 N·m (9.2 kgf·m, 66 lbf·ft) 1
9. Install lubrication hose (3) to elbow S (4) of pin (5).

Install lubrication hose (12) to elbow S (4) of pin
(11). 3, 4
: 17 mm, 14 mm, 19 mm
: 45 N·m (4.5 kgf·m, 33 lbf·ft)
5
10. Charge grease onto the lubricating part of pins (5, 6
11). 9
10
11. Inspect the hydraulic tank oil level and refill if 4, 12
necessary. To ensure proper function of the W8R7-02-10-013
11
steering system, start the engine and turn the
steering wheel fully to both left and right to bleed
the air from the steering cylinder. Check the con- 11
nection point of steering cylinder (9) hoses (6, 10) 14 13
and piston rod area for any oil leaks.
15
12. Re-check the hydraulic oil tank level. 16
Check the oil level when the engine is running and
17 9
when the engine is stopped.
W8DS-02-10-010
W8R7-E-01(20160803) W2-10-19
DISASSEMBLY OF STEERING CYLINDER
(Serial No.: 010001 to 010016, 010018,
010019)
Elbow S Installation Elbow S Installation

Position Position
3 4
1 2
8 9
6, 7 A B W8DS-02-10-012
5
10 2 11 12 13 14, 15 16 17 18, 19 4 20 21
W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
1- Piston Rod 7- Washer (12 Used) 12 - Rod Packing 17 - Snap Ring

2- Cylinder Head 8- Spherical Bearing 13 - Rubber Ring 18 - O-Ring
3- Cylinder Tube 9- Retaining Ring (2 Used) 14 - Backup Ring 19 - Backup Ring (2 Used)
4- Piston 10 - Snap Ring 15 - O-Ring 20 - Piston Ring
5- Set Screw 11 - Dust Seal 16 - Bush 21 - Wear Ring
6- Bolt (12 Used)
W8R7-E-01(20160803) W2-10-20
Disassembly of Steering Cylinder
NOTE: The structure of the left and right steering 6. Remove the cylinder head (2) assembly from
cylinders are identical. piston rod (1).
1. Remove hose assembly elbow S from bottom

side port and rod side port of cylinder tube (3).
Discard elbow S O-ring.
CAUTION: The piston rod (1) assembly


used) from cylinder head (2). Disconnect cylinder
head (2) from cylinder tube (3). Remove piston (4),
cylinder head (2), and the piston rod (1) assembly
from cylinder tube (3).
3. Remove the piston rod (1) assembly. Secure the

piston rod (1) assembly in a vice. Hold the piston
rod (1) assembly by using non-metallic tool.
4. Remove set screw (5) from piston (4).
5. Remove the piston (4) assembly from piston rod

(1). Remove O-ring (18), backup rings (19) (2
used), piston ring (20), and wear ring (21) from
piston (1).
Discard O-ring (18), backup rings (19) (2 used),
and wear ring (21).
Ф10 Hole
W8DS-02-10-021
W8R7-E-01(20160803) W2-10-21
Elbow S Installation Position Elbow S Installation Position
3 4
1 2
8 9
6, 7 A B W8DS-02-10-012
5
10 2 11 12 13 14, 15 16 17 18, 19 4 20 21
W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
W8R7-E-01(20160803) W2-10-22
7. Remove the cylinder head (2) assembly from
piston rod (1) by sliding. Remove O-ring (15) and
backup ring (14) on cylinder head (2) outer cir-
cumference.
Remove snap ring (10), dust seal (11), rod pack-
ing (12), rubber ring (13), bushing (16), and snap
ring (17) from the inner circumference of cylinder
head (2).
8. Discard all seals, O-rings, backup rings, and wear

rings.
9. Remove retaining rings (9) (2 used) from the edge

of spherical bearing (8), and carefully remove
spherical bearing (8) from piston rod (1) hole.
W8R7-E-01(20160803) W2-10-23
INSPECTION OF STEERING CYLINDER
(Serial No.: 010001 to 010016, 010018,
010019)
3 4
1 2
8
A 5 B W8DS-02-10-012
2 4
5 W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
W8R7-E-01(20160803) W2-10-24
Inspection of Steering Cylinder
1. Use an appropriate solvent to clean all parts.
2. Inspect piston rod (1) for any cracks, wear,

crushed screw thread, and flaking of plate-coating.
Also make sure that the piston rod is not bent.
Replace the piston rod if abnormal.
3. Inspect the bore of cylinder tube (3) for any

damage or cracks. Also check for any grooves or
damage formed in piston (4). Use metal polishing
cloths or oil stone to clean any minor damage.
4. Inspect coating surface of cylinder head (2) for

any burr. Use metal polishing cloths to rectify any
burring. Place cylinder head (2) and piston rod (1)
together to check for any distortion.
5. Inspect spherical bearing (8) and steering cylinder

installation pins (2 used) for any wear, and re-
place as required.
W8R7-E-01(20160803) W2-10-25
ASSEMBLY OF STEERING CYLINDER
(Serial No.: 010001 to 010016, 010018,
010019)
Elbow S Installation Elbow S Installation

Position Position
3 4
1 2
8 9
6, 7 A B W8DS-02-10-012
5
10 2 11 12 13 14, 15 16 17 18, 19 4 20 21
W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
1- Piston Rod 7- Washer (12 Used) 12 - Rod Packing 17 - Snap Ring

2- Cylinder Head 8- Spherical Bearing 13 - Rubber Ring 18 - O-Ring
3- Cylinder Tube 9- Retaining Ring (2 Used) 14 - Backup Ring 19 - Backup Ring (2 Used)
4- Piston 10 - Snap Ring 15 - O-Ring 20 - Piston Ring
5- Set Screw 11 - Dust Seal 16 - Bush 21 - Wear Ring
6- Bolt (12 Used)
W8R7-E-01(20160803) W2-10-26
Assembly of Steering Cylinder
IMPORTANT: Apply clean hydraulic oil onto the

contact surfaces. This prevents
damage to the components, and
helps the assembly process.
CAUTION: Piston rod weight: 39 kg (86 lb)
1. Secure pin mounting part in a vice by using soft

material that prevents damage for piston rod (1).
2. Apply Idemitsu Ebonex Grease SR No.2 (or

equivalent) onto grooves on inner dust seal and Special Tool Special Tool
rubber ring of cylinder head (2).
Install bush (16) into cylinder head (2) by using
special tool. 16 11
Install snap ring (17).
Install rubber ring (13) and rod packing (12).
Install dust seal (11) and secure with a snap ring
(10) by using a special tool.
3. Install new backup ring (14) and O-ring (15) to the

outer bore of cylinder head (2). W8DS-02-10-022
Install the cylinder head (2) assembly to piston

rod (1). 17
14, 15
16
IMPORTANT: Seals and rings must always be in-
stalled in the correct positions.
4. Install piston ring (20) to the outer bore of piston

(4). Install wear ring (21) to the outer bore of pis- 13
ton (4). Install O-ring (18) and backup rings (19) 11
(2 used) to the bore of piston (4). 12
10 W8DS-02-10-023
W8R7-E-01(20160803) W2-10-27
3 4
1 2
8 9
6, 7 A B W8DS-02-10-012
5
2 4 20 21
5 W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
W8R7-E-01(20160803) W2-10-28
5. Install piston (4) and piston rod (1) so that the
screw hole of the set screw aligns by using spe-
cial tool. Apply LOCTITE #262 onto set screw (5)
4
thread. Secure the piston onto the piston rod with
a set screw. Use a punching device to caulk four
positions after installation.
Piston (4) tightening torque:
: 300 N·m (30 kgf·m, 221 lbf·ft)
Ф10 Hole
Set screw (5) tightening torque: W8DS-02-10-021
: 67.5±7.5 N·m (6.75±0.75 kgf·m, 49.8±5.5

lbf·ft)
CAUTION: The piston rod (1) assembly

6. Apply hydraulic oil to the outer circumference of

piston (4) and the ring that is installed on the pis-
ton. Use an appropriate device to insert the piston
rod (1) assembly into cylinder tube (3). Do not
damage piston ring (20) and wear ring (21) when
inserting.
7. Install the cylinder head (2) assembly to cylinder

tube (3) with a pre-assembled seal, ring, and
packing.
Align the directions of cylinder tube (3) and the
cylinder head (2) assembly.
Install cylinder head (2) to cylinder tube (3) with
: 165±15 N·m (16.5±1.5 kgf·m, 122±11 lbf·ft)
W8R7-E-01(20160803) W2-10-29
3 4
1
8 9
A B W8DS-02-10-012
Port at Rod Side
Port at Bottom Side
5 W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
W8R7-E-01(20160803) W2-10-30
8. Install spherical bearing (8) and retaining rings (9)
(2 used) onto the piston rod (1) assembly pin in-
stallation points. Split Surface
IMPORTANT: Split face of spherical bearing (8) Load Direction

must be perpendicular to the load
direction. Refer to the diagram.
9. Install O-ring and elbow S to the cylinder ports 90°

located on the bottom and the rod end of tube (3).
Load Direction
W8DS-06-45-004
Installation Diagram for Spherical Bearing (8)
W8R7-E-01(20160803) W2-10-31
TEST OF STEERING CYLINDER (Serial
No.: 010001 to 010016, 010018, 010019)
3 4
1 2
A B W8DS-02-10-012
Maximum Extension 1946.5 mm (76.6 in)

Minimum Extension 1216.5 mm (47.9 in)
2 4
W8DS-02-10-014
W8DS-02-10-013
Detail A Detail B
W8R7-E-01(20160803) W2-10-32
Test of Steering Cylinder
1. Place the steering cylinder on an appropriate test 7. Measure the length of the fully retracted steering
stand and connect the pressurized oil supply hose cylinder. The correct length is 1216.5 mm (47.9
to the port located at the bottom of the cylinder. in).
Connect the oil discharge hose to the port on the Check for any debris between piston (4) and cyl-
rod side of the cylinder. inder tube (3), or between piston (4) and cylinder
head (2) if the length is below the above specifi-
2. Set the temperature of the pressurized oil to ap- cation. Check that the cylinder head is correctly
proximately 71°C (160°F). installed on the cylinder tube assembly.
3. Pressurize the steering cylinder and maintain the 8. Disassemble the steering cylinder and re-inspect
2
system pressure at 20.6 MPa (210 kgf/cm , 2990 the inner components if correct values cannot be
psi). Check for any oil leaks from the welded parts obtained.
of the casting. Measure the amount of oil dis-
charged from the hose while maintaining the
pressure. Check for any oil leaks between cylin-
der head (2), piston rod (1), and cylinder tube (3).
Replace if an oil leak is detected.
4. Repeat step 3 with system pressure of 1.72 MPa

2
(17.5 kgf/cm , 250 psi) to check sealing at low
pressure to make sure it is equivalent to the
sealing at high pressure.
5. Measure the length of the fully extended steering

cylinder by measuring the distance between the
two pin hole centers. The correct length is 1946.5
mm (76.6 in). Check for any debris between pis-
ton (4) and cylinder head (2) if the length is below
the above specification. Check that the piston or
the cylinder head is installed correctly if the length
is longer than the above specification.
6. Release pressure from the port at the bottom end.

Reverse hose connections. Repeat steps 2 and 3
and test the system while having the steering
cylinder fully retracted.
W8R7-E-01(20160803) W2-10-33
REMOVAL AND INSTALLATION OF MAIN
ACCUMULATOR
Removal
15, 16 1
vice position.
CAUTION: Release oil pressure from main

accumulator (1) before removing main ac-
cumulator (1). Wait until main accumulator
will bleed down (Bleed down time will be 40
second after engine stop). Stop the engine, 17
and turn the steering wheel for several times
to remove any residual hydraulic pressure in
the circuit.
20, 21, 22, 23
18
2. Disconnect hoses (15, 16, 18, 19) from pipe (17)
(2 used). 19
: 36 mm, 41 mm
3. Remove U-bolts (20) (2 used), washers (21) (4

used), and nuts (22) (8 used) from main accumu-
lator (1). Remove pipes (17) (2 used) and brack-
ets (23) (2 used) together.
: 24 mm
WQFB-02-10-001
W8R7-E-01(20160803) W2-10-34
4. Loosen socket bolts (4) (4 used) located at the
bottom of main accumulator (1). Remove split
flanges (5) (2 used).
Remove hose (3) from main accumulator (1).
: 8 mm
5. Remove and discard O-ring (6) from hose (3). Cap

hose (3) to prevent debris from entering. 1
4, 5, 6
W8R7-02-09-002
Main Accumulator (1) Installation Point
W8R7-E-01(20160803) W2-10-35
CAUTION: Main accumulator (1) weight: 420

kg (926 lb)
6. Hold main accumulator (1) and remove nuts (9) (8

used) and washers (10) (4 used) of U-bolt (8) (2
used). 1
: 24 mm
7. Remove bolts (12) (2 used), nuts (13) (2 used), 7

and washers (14) (2 used) that holds main accu-
mulator (1) onto cross member (11).
: 36 mm
8, 9, 10
8. Hoist main accumulator (1). Place main accumu-
lator (1) onto a work bench.
11
12, 13, 14
W8R7-02-09-002
9, 10 7
W8DS-02-10-017
Bracket (7) Installation Point
13
14
11
12
W8DS-02-10-018
Cross Member (11) Installation Point
W8R7-E-01(20160803) W2-10-36
Installation

kg (926 lb)
1. Align and hold main accumulator (1) to cross 1

member (11) installation position.
2. Install main accumulator (1) to cross member (11) 7

with bolts (12) (2 used), nuts (13) (2 used), and
: 36 mm
: 950 N·m (95kgf·m, 700 lbf·ft) 8, 9, 10
3. Install main accumulator (1) to bracket (7) with

U-bolts (8) (2 used), nuts (9) (8 used), and wash- 11
ers (10) (4 used).
: 24 mm
: 270 N·m (27 kgf·m, 200 lbf·ft) 12, 13, 14
W8R7-02-09-002
13
14
11
12
W8DS-02-10-018
Cross Member (11) Installation Point
9, 10 7
W8DS-02-10-017
Bracket (7) Installation Point
W8R7-E-01(20160803) W2-10-37
4. Remove caps attached on hose (3). Install new
O-ring (6) on hose (3).
5. Install hose (3) to the bottom of main accumulator

(1) with split flanges (5) (2 used) and socket bolts 1
(4) (4 used).
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
4, 5, 6
W8R7-02-09-002
W8R7-E-01(20160803) W2-10-38
6. Install brackets (23) (2 used) and pipes (17) (2
used) together to main accumulator (1) with
U-bolts (20) (2 used), washers (21) (4 used), and
nuts (22) (8 used).
: 24 mm 15, 16 1
: 270 N·m (27 kgf·m, 200 lbf·ft)
7. Connect hoses (15, 16, 18, 19) to pipes (17) (2
used).
: 36 mm, 41 mm
: 210 N·m (21 kgf·m, 155 lbf·ft)
8. Start the engine. Check for any oil leaks.
17
20, 21, 22, 23

18
19
WQFB-02-10-001
W8R7-E-01(20160803) W2-10-39
DISASSEMBLY AND ASSEMBLY OF MAIN ACCUMULATOR
14 16 15 4 2 3 1 9 3 13 4
D
C B
A
12 10, 11 12
7 8 5 6
View D
Main Accumulator
WQHA-02-10-005
1- Cylinder 7- Cap 13 - End Cover A - Port A

2- Top Cover 8- O-Ring 14 - Bracket B - Hydraulic Oil
3- O-Ring (2 Used) 9- Piston 15 - Band C - Nitrogen Gas
4- Pin (2 Used) 10 - Ring Seal 16 - Bolt (4 Used)
5- Locking Screw 11 - O-Ring
6- Seal Ring 12 - Guide Ring (2 Used)
W8R7-E-01(20160803) W2-10-40
Disassembly of Main Accumulator Inspection
Inspect cylinder (1), piston (9), top cover (2), and end
cover (13) for any cracks in the welding or any deep
kg (926 lb)
grooves. Illuminate the inside of cylinder (1) with a
light and check for any extrusions, dents, or abra-
1. Secure the main accumulator in a vice if possible.
sions. Use a fine grindstone to correct any extrusion,
If a vice cannot be used, place the main accu-
dents, or abrasions before cleaning. Replace all
mulator on a clean work bench and keep it from
components with new parts if the damages cannot be
moving.
corrected.
CAUTION: Release the gas pressure from

the main accumulator before disassembly of
main accumulator.
2. Remove cap (7) and O-ring (8) from top cover (2).
Discard O-ring (8).
: 32 mm
3. Slightly rotate locking screw (5) counterclockwise

to fully discharge the nitrogen gas. Remove lock-
ing screw (5) and seal ring (6). Discard seal ring
(6).
: 6 mm
4. Insert the screw driver to space between top

cover (2) and cylinder (1). Push out and remove
pin (4). Discard pin (4).
5. Attach a hook wrench onto the holes on top cover

(2). Remove top cover (2) from cylinder (1).
6. Remove and discard O-ring (3) from top cover (2).
7. Insert the screw driver to space between end

cover (13) and cylinder (1). Push out and remove
pin (4). Dispose pin (4).
8. Attach a hook wrench onto the holes on end cover

(13). Remove end cover (13) from cylinder (1).
9. Remove and discard O-ring (3) from end cover

(13).
10. Remove piston (9) from cylinder (1).
11. Remove and discard ring seal (10), O-ring (11),

and guide rings (12) (2 used) from piston (9).
W8R7-E-01(20160803) W2-10-41
ASSEMBLY OF MAIN ACCUMULATOR
14 16 15 4 2 3 1 9 3 13 4
D
C B
A
12 10, 11 12
7 8 5 6
View D
Main Accumulator
WQHA-02-10-005
1- Cylinder 7- Cap 13 - End Cover A - Port A

2- Top Cover 8- O-Ring 14 - Bracket B - Hydraulic Oil
3- O-Ring (2 Used) 9- Piston 15 - Band C - Nitrogen Gas
4- Pin (2 Used) 10 - Ring Seal 16 - Bolt (4 Used)
5- Locking Screw 11 - O-Ring
6- Seal Ring 12 - Guide Ring (2 Used)
W8R7-E-01(20160803) W2-10-42
Assembly of Main Accumulator
1. Install new ring seal (10) and O-ring (11) to piston

(9).
2. Install new guide rings (12) (2 used) to piston (9).

12 9 11 10 12
3. Apply a film of hydraulic oil onto the inside of cyl-

inder (1).
IMPORTANT: Do not damage parts such as guide

ring (12) and ring seal (10) with
threads of cylinder (1) when in-
stalling piston (9) to cylinder (1).
WQHA-02-10-006
4. Insert the piston (9) assembly into the upper part

of cylinder (1) with ring seal (10) facing to end
cover (13) side.
5. Apply a film of clean hydraulic oil onto new

O-rings (3) (2 used).
6. Install O-ring (3) to end cover (13) from un-

threaded side.
7. Install end cover (13) to the lower part of cylinder

(1). Slowly rotate end cover (13) clockwise until
the screw meets the end. Do not over-tighten the
screw.
8. Install new pin (4) to the lower part of cylinder (1).
9. Install O-ring (3) to top cover (2) from unthreaded

side.
W8R7-E-01(20160803) W2-10-43
10. Install top cover (2) to the upper part of cylinder
(1). Slowly rotate top cover (2) clockwise until the
screw meets the end. Do not over tighten the
screw.
11. Install new pin (4) to the upper part of cylinder (1).
12. Install locking screw (5) and new seal ring (6) to
top cover (2).
13. Prepare dry nitrogen gas with capacity sufficient

to charge main accumulator.
14. Connect an appropriate adapter to inflation valve

and charge the required amount of nitrogen gas
into the main accumulator. Refer to Charging Ni-
trogen Gas.
2
Gas pressure: 9.0 MPa (9 kfg/cm , 1310 psi)
Nitrogen gas capacity: 85 L (22.5 US gal)
15. Tighten locking screw (5).

: 6 mm
: 20 N·m (2 kgf·m, 15 lbf·ft)
16. Install new O-ring (8) to cap (7).

Install cap (7) to top cover (2).
: 32 mm
W8R7-E-01(20160803) W2-10-44
CHARGING NITROGEN GAS
Charging nitrogen gas of the accumulator the gas

charging kit body valve (ST 7556) and the hose (ST
7557) with G1 adapter attached.
1 2 3
Gas Charging Kit Body Valve (ST 7556)

WQHA-02-10-007
5 6
Hose (ST 7557) with G1 Adapter

WQEB-02-10-007
1 - Spindle 3 - Pressure Relief Valve 5 - G1 Adapter

2 - Pressure Gauge 4 - Check Valve 6 - Cap Nut
W8R7-E-01(20160803) W2-10-45
Charging Nitrogen Gas
1. Check that any hydraulic pressure is fully released

before charging the nitrogen gas. The gas cannot 7
be filled unless the hydraulic pressure is at zero.
8
2. Remove cap (7) and O-ring (8) from accumulator
(12). 9
：32 mm
3. Slightly rotate locking screw (10) of accumulator

(12) counterclockwise (about 1/2 rotation) by
using wrench (9) and loosen locking screw (10).
：6 mm 10
4. Install the gas charging kit body valve (ST 7556)

to cap mounting part (11) of accumulator (12).
5. Close pressure relief valve (3) of the gas charging

kit body valve (ST 7556). 11
WQHA-02-10-008
12
10
WQEB-02-10-009
ST 7556
12
3 WQEB-02-10-011
W8R7-E-01(20160803) W2-10-46
5 6
NOTE: The kind of the additional adapter varies
depending on the manufacturing maker of
the nitrogen gas cylinder and the country.
(Refer to page W2-10-52.) In case the
nitrogen gas cylinder equivalent to G1 ST 7557 WQEB-02-10-008
adapter is used, the additional adapter is

not required.
NOTE: The additional adapter is bought from local
HYDAC.
6. Connect G1 adapter (5) of the hose (ST 7557)

with G1 adapter attached to nitrogen gas cylinder
(13). Install the additional adapter to G1 adapter
(5) if necessary.
7. Connect cap nut (6) of the hose (ST 7557) with G1

adapter attached to check valve (4) of the gas
charging kit body valve (ST 7556).
8. Rotate spindle (1) of the gas charging kit body 6 4 WQEB-02-10-013

valve (ST 7556) counterclockwise (two rotations)
and loosen locking screw (10).
9. Open the nitrogen cylinder (13) valve slightly to

prevent gas from being released suddenly. The
2
gas is released at 0.2 to 0.3 MPa (2 to 3 kgf/m ,
28 to 43 psi).
10. Slowly open the nitrogen cylinder (13) valve and 13

gradually insert the nitrogen gas into the
accumulator. Close the nitrogen cylinder (13)
valve occasionally to read the indicated pressure
on pressure gauge (2) of the gas charging kit body
valve (ST 7556) once the reading has stabilized.
WQEB-02-10-012
1 2
ST 7556
WQEB-02-10-010
W8R7-E-01(20160803) W2-10-47
11. Securely close the nitrogen gas cylinder valve
once the gas is inserted to the specified pressure.
Rotate pressure relief valve (3) counterclockwise 1
and release some gas if the pressure is higher
than the set pressure.
The relation between the temperature (when
charging gas) and the gas pressure is as follows:
Px = Ps (MPa) × [273+t (°C)] / [273+20 (°C)] ST 7556
Px: Inserted gas pressure (MPa)
t : Gas temperature when inserted
(≒ OUTER temperature)
Ps : Specified gas pressure (MPa)
12
12. Rotate spindle (1) of the gas charging kit body
valve (ST 7556) clockwise and tighten locking
screw (10). 3 WQEB-02-10-011
13. Open pressure relief valve (3) by rotating 12

counterclockwise and release any residual gas
that is in the gas charging kit body valve (ST
7556) and the hose (ST 7557) with G1 adapter
attached. 10
14. Disconnect the hose (ST 7557) with G1 adapter

attached.
15. Remove the gas charging kit body valve (ST 9

7556) from accumulator (12).
16. Tighten locking screw (10) of accumulator (12) by

using wrench (9).
WQEB-02-10-009
：6 mm
：20 N·m (2 kgf·m)
17. Apply soap solution or water on locking screw (10)

and check for any gas leak. Install cap (7) and
7
O-ring (8) to complete the process.
：32 mm
8
10
11
WQHA-02-10-008
W8R7-E-01(20160803) W2-10-48
Measurement of Inserted Gas Pressure
1. Check that any hydraulic pressure is fully released

before charging the nitrogen gas. The gas cannot 7
be filled unless the hydraulic pressure is at zero.
8
2. Remove cap (7) and O-ring (8) from accumulator
(12). 9
：32 mm
3. Slightly rotate locking screw (10) of accumulator

(12) counterclockwise (about 1/2 rotation) by
using wrench (9) and loosen locking screw (10).
：6 mm 10
4. Install the gas charging kit body valve (ST 7556)

to cap mounting part (11) of accumulator (12).
5. Close pressure relief valve (3) of the gas charging

kit body valve (ST 7556). 11
6. Rotate spindle (1) of the gas charging kit body WQHA-02-10-008

valve (ST 7556) counterclockwise (two rotations)
and loosen locking screw (10).
12
7. Read the indicated pressure on pressure gauge

(2) of the gas charging kit body valve (ST 7556).
10
WQEB-02-10-009
1 ST 7556 2
12
3 WQEB-02-10-011
W8R7-E-01(20160803) W2-10-49
8. Rotate spindle (1) of the gas charging kit body
valve (ST 7556) clockwise and tighten locking
screw (10). 1
9. Open pressure relief valve (3) by rotating

counterclockwise and release any residual gas
that is in the gas charging kit body valve (ST
7556). ST 7556
10. Remove the gas charging kit body valve (ST

7556) from accumulator (12).
11. Tighten locking screw (10) of accumulator (12) by 12

using wrench (9).
：6 mm
：20 N·m (2 kgf·m)
3 WQEB-02-10-011
12. Apply soap solution or water on locking screw

12
(10) and check for any gas leak. Install cap (7)
and O-ring (8) to complete the process.
：32 mm
10
WQEB-02-10-009
10
11
WQHA-02-10-008
W8R7-E-01(20160803) W2-10-50
Maintenance
For the first week after the main accumulator is

reattached, inspect the nitrogen gas pressure to
make sure there are no leaks. Thereafter, the gas
pressure should be inspected every month. For
detailed information, refer to the maintenance period
shown in the Operator’s Manual.
W8R7-E-01(20160803) W2-10-51
List of Special Tool
Gas Charging Kit of Accumulator made by HYDAC

Special Tool No. Part Name HYDAC Part No.
ST 7555 Gas Charging Kit Case PN2110457
Accumulator Charging Kit
ST 7556 FPU-1-250
Body Valve
ST 7557 Hose with G1 Adapter 273405
- Additional Adapter Refer to the table below.
Additional Adapter
Kind of Adapter HYDAC Part No.
G1 -
G2 236376
G3 2103421
G4 236374
G5 236373
G6 2103423
G7 236377
G8 2103425
G9 241168
G10 2103427
G11 3018678
G12 3195556
W8R7-E-01(20160803) W2-10-52
Adapter for Nitrogen Gas Cylinder - Table according to Country and City
Name of Country Kind of Adapter
and City G1(1) G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12
Ireland ●
United States of
●
America
UAE ●
Algeria ●
Argentina ●
Albania ●
England ●
Israel ●
Italy ●
Iraq ●
Iran ●
India ●
Indonesia ●
Uruguay ●
Ecuador ●
Egypt ●
Ethiopia ●
Australia ●
Austria ●
Oman ●
Holland ●
Ghana ●
Guyana ●
Qatar ●
Canada ●
Gabon ●
Gambia ●
Guinea ●
Cyprus ●
Greece ●
Guatemala ●
Kuwait ●
Kenya ●
Cote d'Ivoire ●
Costa Rica ●
Colombia ●
Saudi Arabia ●
Zambia ●
●Recommended
(1) with ST 7557 attached
W8R7-E-01(20160803) W2-10-53
Name of Country and Kind of Adapter
City G1(1) G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12
Djibouti ●
Jamaica ●
Syria ●
Singapore ●
Switzerland ●
Sweden ●
Sudan ●
Spain ● ●
Suriname ●
Sri Lanka ●
Swaziland ●
Thailand ●
Tanzania ●
Czechoslovakia ●
Tunisia ●
Chile ●
Denmark ●
Germany ●
Trinidad and Tobago ●
Dominican Republic ●
Turkey ●
Nigeria ●
New Zealand ●
Norway ●
Bahrain ●
Pakistan ●
Commonwealth of
Bahamas ●
Paraguay ●
Barbados ●
Hungary ●
Bangladesh ●
Myanmar ●
Fiji ●
Philippines ●
Finland ●
Puerto Rico ●
Brazil ●
France ●
●Recommended
W8R7-E-01(20160803) W2-10-54
Name of Country and Kind of Adapter
City G1(1) G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12
Bulgaria ●
Vietnam ●
Venezuela ●
Peru ●
Belgium ●
Poland ●
Botswana ●
Bolivia ●
Portugal ●
Honduras ●
Malawi ●
Malta ●
Malaysia ●
Mexico ●
Mauritius ●
Mozambique ●
Morocco ●
Jordan ●
Libya ●
Romania ●
Lebanon ●
Russia ●
China ●
South Africa ●
Taiwan ●
Japan ● ●
former Yugoslavia ●
Korea ●
Hong Kong ●
●Recommended
(2) Bosnia and Herzegovina, Croatia, Macedonia, Slovenia
W8R7-E-01(20160803) W2-10-55
(Blank)
W8R7-E-01(20160803) W2-10-56
SECTION 2 BODY
Disassembly and Assembly of Steering

Cylinder (Serial No.: 010017, Up to 010020)
2 1
3 4
11, 12 9, 10 8 15 13, 14 6, 7 5 16 17 18 20, 21 22 23
24 Elbow S Installation Position Elbow S Installation Position TQHA-03-07-001
1- Cylinder Tube 7- Retaining Ring 13- O-Ring 20- O-Ring

2- Piston Rod 8- Seal 14- Backup Ring 21- Backup Ring (2 Used)
3- Spherical Bearing 9- U-Ring 15- O-Ring 22- Nut
4- Retaining Ring 10- Backup Ring 16- Piston 23- Set Screw (2 Used)
5- Cylinder Head 11- Dust Seal 17- Seal 24- Bolt (14 Used)
6- Bushing 12- Retaining Ring 18- Wear Ring
W8R7-E-01(20160803) W2-10-57
SECTION 2 BODY
Disassembly of Steering Cylinder
fNOTE: The structure of the left and right steering

cylinders are identical.
dCAUTION: The piston rod (1) assembly weight:

46 kg (101 lb)
1. Remove bolts (24) (14 used) from cylinder head (5).
Separate cylinder head (5) from cylinder tube (1).
l : 12 mm
2. Remove the piston rod (2) assembly. Secure the
piston rod (2) assembly in a vice by using non- 2
metallic material.
3. Remove set screws (23) (2 used) from nut (22).
l : 4 mm
ST 3407
4. Remove nut (22) from piston rod (2) by using special
tool (ST 3407).
5. Remove the piston (16) assembly from piston rod WQEB-02-10-003
(2) by using special tool (ST 3408). 22
6. Remove O-ring (20) and backup rings (21) (2 used)
from the inner circumference of piston (16). ST 3408
Remove seal (17) and wear ring (18) on piston (1)
outer circumference.
Discard O-ring (20), backup rings (21) (2 used), and
2
wear ring (18).
18
WQEB-02-10-004
W8R7-E-01(20160803) W2-10-58
SECTION 2 BODY
7. Remove the cylinder head (5) assembly from piston

rod (2) by sliding.
8. Remove O-rings (13, 15) and backup ring (14) from
cylinder head (5) outer circumference.
Remove retaining ring (12), dust seal (11), U-ring (9),
backup ring (10), seal (8), bushing (6), and retaining
ring (7) from the inner circumference of cylinder
head (5).
9. Discard all seals, O-rings, backup rings, and wear
rings.
10. Remove retaining ring (4) from the edge of spherical
bearing (3), and carefully remove spherical bearing
(3) from the piston rod (2) hole.
W8R7-E-01(20160803) W2-10-59
SECTION 2 BODY
Inspection of Steering Cylinder

1. Use an appropriate solvent and clean all parts.
2. Inspect piston rod (2) for any cracks, wear, crushed
screw thread, and flaking of plate-coating.
Also make sure that the piston rod is not bent.
Replace the piston rod if abnormal.
3. Inspect the bore of cylinder tube (1) for any damage
or cracks. Also check for any grooves or damage
formed in piston (16). Use metal polishing cloths or
oil stone to clean any minor damage.
4. Inspect coating surface of cylinder head (5) for
any burr. Use metal polishing cloths to rectify any
burring. Place cylinder head (5) and piston rod (2)
together to check for any distortion.
5. Inspect spherical bearing (3) and steering cylinder
installation pins (2 used) for any wear, and replace
as required.
W8R7-E-01(20160803) W2-10-60
SECTION 2 BODY
2 1
3 4
11, 12 9, 10 8 15 13, 14 6, 7 5 16 17 18 20, 21 22 23
24 Elbow S Installation Position Elbow S Installation Position TQHA-03-07-001
1- Cylinder Tube 7- Retaining Ring 13- O-Ring 20- O-Ring

2- Piston Rod 8- Seal 14- Backup Ring 21- Backup Ring (2 Used)
3- Spherical Bearing 9- U-Ring 15- O-Ring 22- Nut
4- Retaining Ring 10- Backup Ring 16- Piston 23- Set Screw (2 Used)
5- Cylinder Head 11- Dust Seal 17- Seal 24- Bolt (14 Used)
6- Bushing 12- Retaining Ring 18- Wear Ring
W8R7-E-01(20160803) W2-10-61
SECTION 2 BODY

IMPORTANT: Apply clean hydraulic oil onto the
contact surfaces. This prevents damage to the
components, and helps the assembly process.
dCAUTION: Piston rod (2) weight: 41 kg (90 lb)

1. Secure pin mounting part in a vice by using soft
material that prevents damage for piston rod (2). ST 7758 ST 7559
dCAUTION: Seal (8) is too hot. Be careful of burns. 6 11

dCAUTION: Heat hydraulic oil by using an electric
heater. Heating by fire may cause a fire.
2. Apply Idemitsu Ebonex Grease SR No.2 (or
equivalent) onto grooves on inner dust seal and seal
of cylinder head (2).
Install bush (6) into cylinder head (5) by using
special tool (ST 7558). W8DS-02-10-022
Install retaining ring (7).
Dip seal (8) for approximately five minutes in
hydraulic oil which is heated at 150 to 180 °C (302 to 13, 14 7
356 °F) by using an electric heater in order to make
seal (8) soft. 15 6
Install seal (8), U-ring (9), and backup ring (10).

Install dust seal (11) and secure with retaining ring 8
(12) by using special tool (ST 7559).
9
3. Install new O-ring (15), backup ring (14), and O-ring 11
10
(13) to the outer bore of cylinder head (5). 12 W8DS-02-10-023
4. Install the cylinder head (5) assembly to piston rod
(2).
dCAUTION:
burns.
Seal (17) is too hot. Be careful of
dCAUTION: Heat hydraulic oil by using an electric

heater. Heating by fire may cause a fire.
IMPORTANT: Seals (17) and wear rings (18) must
always be installed in the correct positions.
5. Dip seal (17) for approximately five minutes in
hydraulic oil which is heated at 150 to 180 °C (302
to 356 °F) in order to make seal (17) soft. Install seal
(17) and wear ring (18) to the outer bore of piston
(16). Install O-ring (20) and backup ring (21) to the
inner bore of piston (16).
W8R7-E-01(20160803) W2-10-62
SECTION 2 BODY
6. Install the piston (16) assembly to piston rod (2) by

ST 3408
using special tool (ST 3408).
m : 981±98 N∙m (100±10 kgf∙m, 723±72 lbf∙ft)

7. Install nut (22) to piston rod (2) by using special tool
2
(ST 3407) so that the screw hole of the set screw
aligns. Apply LOCTITE #242 onto set screw (23)
thread. Secure the piston onto the piston rod with
set screws (23) (2 used). Use a punching device to 16
crimp four positions after installation. WQEB-02-10-004
Nut (22)
m : 1860±186 N∙m (190±19 kgf∙m, 1370±137 2

lbf∙ft)
Set screw (23)
l : 4 mm
m : 15 N∙m (1.5 kgf∙m, 11 lbf∙ft)
dCAUTION: The piston rod (1) assembly weight:

46 kg (101 lb) WQEB-02-10-003
8. Apply hydraulic oil to the outer circumference of ST 3407 22
piston (16), seal (17), and wear ring (18). Use an
appropriate device to insert the piston rod (2)
assembly into cylinder tube (1). Do not damage seal
(17) and wear ring (18) when inserting.
9. Align the screw holes of cylinder tube (1) and the
cylinder head (5) assembly.
10. Apply LOCTITE #242 onto bolts (24) (14 used)
thread. Install cylinder head (5) to cylinder tube (1)
with bolts (24) (14 used).
l : 12 mm
m : 226 to 235 N∙m (23 to 24 kgf∙m, 167 to 173

lbf∙ft)
W8R7-E-01(20160803) W2-10-63
SECTION 2 BODY
IMPORTANT: Split face of spherical bearing (3) must

be perpendicular to the load direction. Refer to
the diagram. Split Surface
11. Install spherical bearing (3) and retaining ring (4)

onto the piston rod (2) assembly pin installation
Load Direction
points by using special tool (ST 7549).
90°
Load Direction
WQEB-02-10-006
Installation Diagram for Spherical Bearing (3)
ST 7549
WQEB-02-10-005
W8R7-E-01(20160803) W2-10-64
SECTION 2 BODY
2 1
Maximum Extension 1946.5 mm (46.4 in)

Minimum Extension 1216.5 mm (11.9 in)
5 16
TQHA-03-07-001
W8R7-E-01(20160803) W2-10-65
SECTION 2 BODY

1. Place the steering cylinder on an appropriate test 7. Measure the length of the fully retracted steering
stand and connect the pressurized oil supply hose cylinder. The correct length is 1216.5 mm (11.9 in).
to the port located at the bottom of the cylinder.
Check for any debris between piston (16) and
Connect the oil discharge hose to the port on the
cylinder tube (1), or between piston (16) and
rod side of the cylinder.
cylinder head (5) if the length is above the above
2. Set the temperature of the pressurized oil to specification. Check that the cylinder head is
approximately 70°C (158°F). correctly installed on the cylinder tube assembly.
3. Pressurize the steering cylinder and maintain the 8. Disassemble the steering cylinder and re-inspect
system pressure at 20.6 MPa (210 kgf/cm2, 2990 psi). the inner components if correct values cannot be
Check for any oil leaks from the welded parts of the obtained.
casting. Measure the amount of oil discharged from
the hose while maintaining the pressure. Check for
any oil leaks between cylinder head (5), piston rod
(2), and cylinder tube (1). Replace if an oil leak is
detected.
4. Repeat step 3 with system pressure of 1.7 MPa (18
kgf/cm2, 250 psi) to check sealing at low pressure
to make sure it is equivalent to the sealing at high
pressure.
5. Measure the length of the fully extended steering
cylinder by measuring the distance between the
two pin hole centers. The correct length is 1946.5
mm (46.4 in). Check for any debris between piston
(16) and cylinder head (5) if the length is below the
above specification. Check that the piston or the
cylinder head is installed correctly if the length is
longer than the above specification.
6. Release pressure from the port at the bottom end.
Reverse hose connections. Repeat steps 3 and 4 and
test the system while having the steering cylinder
fully retracted.
W8R7-E-01(20160803) W2-10-66
SECTION 2 BODY
Removal and Installation of Front Suspension

Cylinder
Removal
1. Park the machine on a level surface with the service
position.
dCAUTION: Use appropriate sized hoisting

devices, jacks, and wheel stops when lifting the
machine or components to prevent injuries and
accidents.
dCAUTION:
lbf)
Front axle weight: 77000 kgf (170000 2
2. Engage the parking brake and set wheel stops

on the rear wheels. Raise the front of machine
frame until suspension cylinders (2) (2 used) are
T8DS-06-10-001
fully extended. Use an appropriate block that will
support the front of the machine frame. 5 3, 4
3. Remove the front tire and rim. 6
1
Refer to REMOVAL AND INSTALLATION OF FRONT
TIRE AND RIM. 8 A
7
4. Remove the pressure sensor (8) wiring and the Section A
grease lubrication hose from suspension cylinder
(2).
2
j : 19 mm, 17 mm
5. Remove bolts (3) (2 used), washers (4) (2 used), and
guard (5) from suspension cylinder (2).
j : 17 mm
6. Remove cap (23) of inflation valve (6) from
suspension cylinder (2).
Slightly turn outer lock nut (22) on inflation valve (6)
counterclockwise to release any helium gas. Tighten W8R7-02-11-001
outer lock nut (22) and install cap (23) back to its
original position once helium gas is fully released
from suspension cylinder (2).
j : 3/4 in
m : 46 N·m (4.6 kgf·m, 34 lbf·ft)

23
22
Inflation Valve (6)
T704-07-00-014
W8R7-E-01(20160803) W2-11-1
SECTION 2 BODY
7. Remove valve (7).
j : 27 mm 1
A
dCAUTION: Suspension cylinder (2) is
disconnected from frame (1) when pin (9) is
7
Section A
removed. If suspension cylinder (2) is not securely
held in place, the cylinder may suddenly collapse
and injure workers or damage other devices. Keep 2
workers or other devices away from suspension
cylinder (2) when removing it.
dCAUTION:
kg (1100 lb)
Suspension cylinder (2) weight: 500
8. Attach a wire rope on to the cylinder tube on

suspension cylinder (2). Hold suspension cylinder
(2).
9. Remove plate (11), bolts (14) (3 used), washers (13)
(3 used), spacer (26), and bolt (27) that secure pin W8R7-02-11-001
(9). 10 1
11
j : 19 mm, 24 mm
9
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection, 13, 14
26
such as goggles, helmets, etc in order to prevent
personal injury. 27
10. Remove pin (9) and spacers (10) (2 used) by using a

hammer and a bar.
11. Retract suspension cylinder (2). Reinstall valve (7).
j : 27 mm
2
m : 20 N·m (2.0 kgf·m, 15 lbf·in)
Upper Installation Position of Suspension Cylinder (2).
W8R7-02-11-002
W8R7-E-01(20160803) W2-11-2
SECTION 2 BODY
12. Slightly lift and hold suspension cylinder (2).

Remove plate (12), bolts (14) (3 used), washer (13)
(3 used), spacer (26), and bolt (27) that secures pin
(24).
2
j : 19 mm, 24 mm

a hammer is used. Wear necessary protection,
26
such as goggles, helmets, etc in order to prevent 27

personal injury. 12
13. Remove pin (24) and spacer (25) by using a hammer

and a bar. 24
13, 14
Remove elbow S (2 used) for lubrication hose from 25
pins (9, 24) if necessary.
15
j : 16 to 17 mm
14. Lower suspension cylinder (2) onto the ground. Lower Installation Position of Suspension Cylinder (2)
15. Remove retaining rings (17) (2 used), spherical W8R7-02-11-003
bearing (16), and bush (18) from frame (1) if
1
necessary.
Remove retaining rings (19) (2 used), spherical
bearing (20), and bush (21) from trailing arm (15).
16. Repeat procedures 4 to 15 to remove suspension
cylinder (2) on the opposite side. 16
17 18
W8R7-02-11-004
19
20
15 21
W8R7-02-11-005
W8R7-E-01(20160803) W2-11-3
SECTION 2 BODY
Installation 1
1. Install bush (18), spherical bearing (16), and

retaining rings (17) (2 used) to frame (1).
Split face of outer ring must be perpendicular to
the load direction when installing spherical bearing
16
(16).
retaining rings (19) (2 used) to trailing arm (15). 17 18
Split face of outer ring must be perpendicular to W8R7-02-11-004
(20). 19
dCAUTION:
kg (1100 lb)
Suspension cylinder (2) weight: 500 20
3. Lift suspension cylinder (2) upright with the rod

facing down. Move suspension cylinder (2) to the
frame (1) installation position and align the pin hole. 15 21
Install suspension cylinder (2) with pin (9) and

spacers (10) (2 used) to frame (2).
4. Install plate (11), bolts (14) (3 used), washers (13) (3
used), spacer (26), and bolt (27) to pin (9).
W8R7-02-11-005
j : 19 mm
m : 110 N·m (11 kgf·m, 81 lbf·ft) Loading Direction
j : 24 mm 90°
m : 270 N·m (27 kgf·m, 199 lbf·ft)
Splitting
Surface
Outer
Splitting
Surface
Spherical Bearing (16, 20) Installation Position

W8DS-07-25-002
10 1
11
13, 14
26
27
Upper Installation Position of Suspension Cylinder (2).

W8R7-02-11-002
W8R7-E-01(20160803) W2-11-4
SECTION 2 BODY
5. Align the hole position of suspension cylinder (2)

and trailing arm (15) by adjusting height of frame
(1). 2

spacers (25) (2 used) to the trailing arm (15). 26
6. Install plate (12), bolts (14) (3 used), washers (13) (3 27
used), spacer (26), and bolt (27) to pin (24). 12
j : 19 mm
24
m : 110 N·m (11 kgf·m, 81 lbf·ft) 13, 14
25
j : 24 mm
15
m : 270 N·m (27 kgf·m, 199 lbf·ft)
7. Install lubrication hose elbow S (2 used) to pins (9, Lower Installation Position of Suspension Cylinder (2)
24). W8R7-02-11-003
j : 16 to 17 mm 5 3, 4
8. Install a wiring of pressure sensor (8) and lubrication 6 9
hose to suspension cylinder (2). 1
8 A
j : 19 mm, 17 mm
7
m : 45 N·m (4.5 kgf·m, 33 lbf·ft) Section A
9. Install guard (5) with bolts (3) (2 used) and washers

(4) (2 used) to suspension cylinder (2). 2
j : 17 mm
m : 50 N·m (5.0 kgf·m, 37 lbf·ft)

10. Repeat procedures 1 to 9 if suspension cylinder (2) 24
is removed on the opposite side.
11. Charge the helium gas to suspension cylinder (2)
from inflation valve (6).
Refer to CHARGING HELIUM GAS. W8R7-02-11-001
frame and lower to the machine after removing the
block.
W8R7-E-01(20160803) W2-11-5
SECTION 2 BODY
Disassembly of Front Suspension Cylinder
22 24, 25
3 A
View A
4, 5
6
2
11 3 6 2
12
13
14
7
8, 9 15
1
16
17
10
18
1
16
14
7
19
8
20
9
Suspension Cylinder Cross Section Diagram

W8DS-07-25-004
1- Piston Rod 7- Cylinder Head 13- Backup Ring 19- Soft Wiper
2- Cylinder Tube Assembly 8- Washer (18 Used) 14- Wear Ring (4 Used) 20- Dust Seal
3- Piston 9- Socket Bolt (18 Used) 15- Buffer Ring 22- Inflation Valve
4- Socket Bolt (12 Used) 10- Cushion Plate 16- Backup Ring (2 Used) 24- Valve
5- Washer (12 Used) 11- Steel Ball (4 Used) 17- Rod Seal 25- Pressure Sensor
6- Wear Ring (2 Used) 12- O-Ring 18- Backup Ring
W8R7-E-01(20160803) W2-11-6
SECTION 2 BODY
Disassembly of Front Suspension Cylinder

1. Remove the cap of inflation valve (22). Slowly
loosen outer lock nut on inflation valve (22)
counterclockwise. Check that any helium gas is fully
released from the suspension cylinder. Tighten the
outer lock nut on inflation valve (22) by turning it
clockwise after checking. Install the cap.
j : 3/4 in
dCAUTION:
(1100 lb)
Suspension cylinder weight: 500 kg
2. Stand the suspension cylinder upright, with the

piston rod facing upwards.
3. Remove inflation valve (22). Drain the liquid
(neocon oil) inside the suspension cylinder into an
appropriate tray. Take care not to spill the liquid
onto the ground.

4. Remove socket bolts (9) (18 used) from cylinder
head (7). Remove piston rod (1) from cylinder tube
assembly (2).
l : 17 mm
5. Place piston rod (1) in a horizontal position. Remove
wear rings (6) (2 used) from piston (3).
dCAUTION: Piston (3) weight: 15.5 kg (34 lb)

6. Remove socket bolts (4) (12 used) and washers (5)
(12 used) from piston (3). Remove piston (3) from
piston rod (1). Check that steel balls (11) (4 used) are
not lost when piston (2) is removed.
l : 14 mm
dCAUTION:
lb)
Cylinder head (7) weight: 22 kg (48.5
7. Pull out cylinder head (7) from piston rod (1).

Remove O-ring (12), buffer ring (15), backup ring
(13), wear rings (14) (4 used), backup ring (16) (2
used), rod seal (17), backup ring (18), soft wiper (19),
and dust seal (20).
W8R7-E-01(20160803) W2-11-7
SECTION 2 BODY
Inspection of Front Suspension Cylinder
22 24, 25
3 A
View A
4, 5
6
2
11 3 6 2
12
13
14
7
8, 9 15
1
16
17
10
18
1
16
14
7
19
8
20
9

W8DS-07-25-004
W8R7-E-01(20160803) W2-11-8
SECTION 2 BODY
Inspection of Front Suspension Cylinder

1. Clean all components with an appropriate solvent
and dry with compressed air. Check that piston (3)
and cylinder head (7) have been cleaned.
2. Check all screw heads for any damage. Check
cylinder tube (2), wear ring (8), and buffering (15)
for any scouring, pitching, or excessive wear.
IMPORTANT: If dust seal (20) performance degrades,
dirt may enter and damage soft wiper (19), rod
seal (17), and buffer ring (15). Entering of dirt can
also cause excessive wear on the wear ring (14),
and deformation of soft wiper (19), rod seal (17),
and buffer ring (15). Replace any damaged or
worn components.
3. Consider replacing the piston rod if excessive wear
is detected on the outer diameter of the piston rod
(1).
4. Check cylinder tube assembly (2), piston rod (1), and
cylinder head (7) for any cracks or distortion. Repair
or replace components if necessary.
W8R7-E-01(20160803) W2-11-9
SECTION 2 BODY
Assembly of Front Suspension Cylinder
22 24, 25
3 A
View A
4, 5
6
2
11 3 6 2
12
13
14
7
8, 9 15
1
16
17
10
18
1
16
14
7
19
8
20
9

W8DS-07-25-004
W8R7-E-01(20160803) W2-11-10
SECTION 2 BODY
Assembly of Front Suspension Cylinder

IMPORTANT: Replace all seals when the suspension
cylinder is disassembled. Apply a film of
suspension cylinder fluid onto new seals before
installing.
1. Clean all screw heads and remove all grease before
assembling.
2. Install new backup rings (16) (2 used) to cylinder
head (7) with the chamfering surface of backup
rings (16) (2 used) facing towards rod seal (17) and
dust seal (20) of the cylinder head (7).
3. Install O-ring (12), backup ring (13), dust seal (20),
soft seal (19), wear rings (14) (4 used), backup ring
(18), rod seal (17), and buffer ring (15) to cylinder
head (7).

4. Stand and hold piston rod (1) vertically. Fit cushion
plate (10) to the piston rod.
dCAUTION:
lb)
Cylinder head (7) weight: 22 kg (48.5
5. Insert cylinder head (7) to piston rod (1), taking

caution not to damage dust seal (20).
6. Install steel balls (11) (4 used) to piston rod (1).
dCAUTION: Piston (3) weight: 16 kg (34 lb)

7. Check that steel balls (11) are properly setting in the
seat. Place piston (3) on top of piston rod (1).
W8R7-E-01(20160803) W2-11-11
SECTION 2 BODY
22 24, 25
3 A
View A
4, 5
6
2
3 6 2
12
13
7
8, 9
1
7
8
9

W8DS-07-25-004
W8R7-E-01(20160803) W2-11-12
SECTION 2 BODY
8. Apply LOCTITE #242 or equivalent adhesive to 13. Install inflation valve (22), valve (24), and pressure
socket bolt (4) (12 used). Install socket bolts (4) (12 sensor (25).
Inflation valve (22)
l : 14 mm
j : 3/4 in
m : 270 N·m (27 kgf·m, 199 lbf·ft)
m : 46 N·m (4.6 kgf·m, 34 lbf·ft)
fNOTE: The recommended standing time for the Valves (24)
LOCTITE #242 is 24 hours in room temperature.
9. Install wear ring (6) (2 used) to piston (3). Make j : 27 mm
sure that the sharp edge of wear ring (6) does not
m : 20 N·m (2.0 kgf·m, 15 lbf·ft)
contact with other components.
Pressure sensor (25)
10. Apply a film of neocon oil to the interior of cylinder
tube assembly (2) and all its seals before final j : 27 mm
assembly.
m : 100 N·m (10 kgf·m, 74 lbf·ft)
d CAUTION: Cylinder tube assembly (2) weight:
315 kg (694 lb) 14. Charge neocon oil to the suspension cylinder.
11. Hold cylinder tube assembly (2) vertically. Slowly Refer to CHARGING NEOCON OIL.
insert piston rod (1) to cylinder tube assembly (2).
Make sure that the wear ring (6), O-ring (12), and
backup ring (13) will not be damaged during this
process.
12. Align the socket bolts (9) (18 used) holes on cylinder
tube assembly (2) and cylinder head (7).
Secure cylinder tube assembly (2) and cylinder head
(7) with socket bolts (9) (18 used) and washers (9)
(18 used).
l : 17 mm
m : 550 N·m (55 kgf·m, 406 lbf·ft)
W8R7-E-01(20160803) W2-11-13
SECTION 2 BODY
Charging Neocon Oil
Hose No.4
[305 mm (12 in)]
Tee
Port A Port B Port B Port A

Charging Neocon Oil
Hose No.4 Port A – Inflation Valve
[406 mm Port B – No.5 SAE Straight Thread Fitting
(16 in)] Items marked with ** is not included in the charging kit
Note: Figures in brackets are the hose lengths
** Bleed Valve ** Liquid Pump
Tray
Hose No.4
[660 mm (26 in)]
Gauge
Hose No.4 0 to 10340 kPa
[406 mm Gas (0 to 105 kgf/cm2,
(16 in)] Bleed 0 to 1500 psi)
Valve
Right Ball Valve Left Ball Valve
Charging Helium Gas Hose No.4

Port A – Inflation Valve Manifold [305 mm (12 in)]
Port B – No.5 SAE Straight Thread Fitting
Note: Figures in brackets are the hose lengths Regulator Valve
0 to13790 kPa
(0 to 141 kgf/cm2,
Helium Supply Tank 0 to 2000 psi)
Helium Gas / Neocon Oil Charging Procedural Diagram

T704-07-00-021
 Front Suspension Cylinder Charge Data

X-1 Rod dimension Suspension cylinder when fully extended 350 mm (13.78 in)
X-2 Rod dimension When empty (After 48-hour operation) 171 mm (6.73 in)
X-4 Rod dimension Immediately after charging neocon oil only 0 mm (0 in)
P-1 Charging pressure Neocon oil/helium gas immediately after 7.92 MPa (80.8 kgf/cm2, 1150 psi)
charging
P-1A Charging pressure After 48-hour operation (When fully 7.35 MPa (74.9 kgf/cm2, 1070 psi)
extended)
Neocon oil charge capacity 36.5 Liters (9.64 US gal)
W8R7-E-01(20160803) W2-11-14
SECTION 2 BODY
Charging Neocon Oil
dCAUTION:
kg (1100 lb)
1. Lift and hold the suspension cylinder (1) upright

with the piston rod facing down.
2. Remove valve (7) and fully extend suspension
cylinder (1). The maximum rod dimension is as
shown in (X-1) of the suspension cylinder (1) charge 1
data.
3. Connect the neocon oil charging kit. Refer to
the helium gas / neocon oil charging procedural
diagram.
An example of a charge kit is shown in the diagram.
4. Connect the neocon oil charge line to the valve (7)
port. Loosen inflation valve (6) outer locknut (5) by X-1
turning it counterclockwise. X X-2
X-4
5. Charge suspension cylinders (1) with neocon
oil. Charge until the bubbles stop forming from
inflation valve (6).
6. Close inflation valve (6) outer locknut (5). Retract
suspension cylinder (1). Place a tray by the edge
of the neocon oil charge line. Adjust suspension Suspension Cylinder (1) Rod Dimension
cylinder (1) to specified rod dimension (X-4) by T8DS-04-05-008
pouring out the neocon oil from the valve (7) port
to a tray.
7. Remove the neocon oil charge line. Connect valve
(7). Do not spill charged neocon oil.
j : 27 mm
4
m : 20 N·m (2.0 kgf·m, 15 lbf·ft)
8. When neocon oil is filled into suspension cylinder
(1) and the outer lock nuts on inflation valve (6) and 5
valve (7) are shut, do not extend the suspension
Inflation Valve (6)
cylinder (1) until suspension cylinder (1) is charged T704-07-00-014
with helium gas. Air will enter through the seal if the
suspension cylinder (1) is extended. 1
W8DS-02-11-006
W8R7-E-01(20160803) W2-11-15
SECTION 2 BODY
Charging Helium Gas
Hose No.4
[305 mm (12 in)]
Tee

Charging Neocon Oil
Hose No.4 Port A – Inflation Valve
(16 in)] Items marked with ** is not included in the charging kit
Note: Figures in brackets are the hose lengths
Tray
Hose No.4
[660 mm (26 in)]
Gauge
No.4 Hose 0 to10340 kPa
[406 mm Gas (0 to105 kgf/cm2,
Valve
Charging Helium Gas No.4 Hose

Note: Figures in brackets are the hose lengths Regulator Valve
0 to 13790 kPa
(0 to 141 kgf/cm2,
Helium Gas / Neocon Oil Charging Procedural Diagram

T704-07-00-021
 Front Suspension Cylinder Charge Data

X-1 Rod dimension Suspension cylinder fully extended 350 mm (13.78 in)
X-2 Rod dimension When empty (After 48-hour operation) 171 mm (6.73 in)
X-4 Rod dimension Immediately after charging neocon oil only 0 mm (0 in)
P-1 Charging pressure Immediately after charging neocon oil/helium 7.92 MPa (80.8 kgf/cm2, 1150 psi)
gas (When fully extended)
extended)
Neocon charge capacity 36.5 Liters (9.65 US gal)
W8R7-E-01(20160803) W2-11-16
SECTION 2 BODY
Charging Helium Gas

IMPORTANT: Use a charge kit to charge helium gas
to both front suspension cylinders (1) at the same
time.
dCAUTION: Only charge helium gas into

suspension cylinders (1). Do not charge using any
other gas.
1. Connect helium gas charge kit adapter to port
A inflation valve (6) located on both suspension 9
cylinders (1). Open inflation valve (6) by turning
outer locknut (5) by turning counterclockwise. 6
dCAUTION:
(170000 lbf)
Machine front axle weight: 77000 kgf A
2. Prepare to lift the front of machine frame (9) when

Section A
charging suspension cylinder (1).
3. Set the regulator valve to minimum pressure of 690 1
kPa (7 kgf/cm2, 100 psi).
4. Open the ball valves on the left and the right
manifolds. Simultaneously, lift the front of the
machine as high as possible and charge helium gas
to suspension cylinders (1). Air entering through
the seal can be avoided by charging suspension
cylinder (1) with regulator valve pressure of over
690 kPa (7 kgf/cm2, 100 psi) while extending.
W8R7-02-11-001
5
Inflation Valve (6)
T704-07-00-014
W8R7-E-01(20160803) W2-11-17
SECTION 2 BODY
5. Check that the machine is stable, and charge

helium gas to suspension cylinder (1) until it is fully
extended. If suspension cylinder (1) fails to extend
fully with helium gas pressure, apply external force P-1
and extend gradually. The length of the rod should P-1A
be at a dimension stated on the charge data (X-1).
Check the length of both suspension cylinders (1).
1
6. Adjust the pressure of regulator valve to suspension
cylinder (1) initial settings pressure (P-1), and open
both ball valves for 2 minutes in order to adjust
balance of both suspension cylinders (1).
Set the helium gas charging pressure to 7.92 MPa
when the suspension cylinder (1) is fully extended.
fNOTE: The helium gas (charging) pressure when X-1

fully extended will become 7.35 MPa after 48 hours of X X-2
operation. X-4
7. Turn inflation valve (6) outer locknut (5) clockwise
to close inflation valve (6) (port A) on suspension
cylinder (1).
8. Close the valve of helium supply tank. Release the
pressure in the line by open the gas bleed valve
on the manifold. Remove the helium gas charge Suspension Cylinder (1) Rod Dimension
kit assembly from inflation valve (6) and place T8DS-04-05-008
protective cap (4).
5
Inflation Valve (6)
T704-07-00-014
W8R7-E-01(20160803) W2-11-18
SECTION 2 BODY
Servicing Procedure of Front Suspension

Cylinder (1)
For the first 48 hours of operation after charging,
the helium gas and neocon oil mixes and dissolute
inside suspension cylinders (1). Suspension cylinder
(1) dimension may become shorter when dissolution P-1
occurs. Regularly inspect suspension cylinder (1) after P-1A
operating the machine for 48 hours. Measure the distance
between cylinder head (2) and piston rod (3) head (X-2) to
determine the state of suspension cylinder (1). Measure 1
the length on a flat ground with no load on the machine.
Operate the machine for at least 1 hour before measuring.
(Do not apply excessive braking.) Correct measurement
cannot be taken if the above conditions are not met.
2
Check the following points if the piston rod dimension
(X-2) of the suspension cylinder (1) is out of its permissible
range.
X-1
1. Neocon oil, helium gas leak X X-2
X-4
2. Measure the suspension cylinder (1) pressure when
the cylinder is fully extended (P-1A). Solve any
issues found, and follow the charging procedures 3
and recharge the oil/gas.
Suspension Cylinder (1) Rod Dimension

Suspension Cylinder (1) Storage T8DS-04-05-008
Inject specified amount of oil, and plug all ports when

storing the suspension cylinder (1). Store in a way that the
finishing does not corrode, and chrome plated area of the
piston rod (3) does not become damaged. If the neocon
oil had to be left charged in the cylinder (1) when storing,
have the suspension cylinder (1) upright with piston rod
(3) facing down.
W8R7-E-01(20160803) W2-11-19
SECTION 2 BODY
Removal and Installation of Rear Suspension

Cylinder
Removal
1. Park the machine on a level surface with the service 2
position.
dCAUTION: Use appropriate sized hoisting

devices, jacks, and wheel stops when lifting the
machine or components to prevent injuries and
accidents.
dCAUTION:
(187000 lbf)
Machine rear axle weight: 85000 kgf
2. Engage the parking brake and set wheel stops

on each tire. Raise the rear section of machine
frame (1) until suspension cylinders (2) (2 used) are
fully extended. Use an appropriate block that will W8DS-02-11-007
support the rear section of machine frame (1).
1
3. Remove the pressure sensor (8) wiring and the
grease lubrication hose from suspension cylinder
(2). A
j : 19 mm, 17 mm
2
4. Remove bolts (3) (2 used), washers (4) (2 used), and
9, 10
guard (5) from suspension cylinder (2).
j : 17 mm 11
5. Remove cap (23) of inflation valve (6) from
7 3, 4
suspension cylinder (2).
Slightly turn outer lock nut (22) on inflation valve (6) 8
5
counterclockwise to release any helium gas. Tighten 6
outer lock nut (22) and install cap (23) back to its W8DS-02-11-009 W8DS-02-11-008
original position once helium gas is fully released
from suspension cylinder (2).
j : 3/4 in
m : 46 N·m (4.6 kgf·m, 34 lbf·ft)

6. Remove valve (7).
23
j : 27 mm
7. Remove rubber (11), bolts (9) (5 used), and washers
(10) (5 used) from suspension cylinder (2). 22
Inflation Valve (6)
j : 19 mm T704-07-00-014
W8R7-E-01(20160803) W2-11-20
SECTION 2 BODY
1
dCAUTION: Suspension cylinder (2) is
disconnected from frame (1) when pin (13) is
B
removed. If suspension cylinder (2) is not securely

held in place, the cylinder may suddenly collapse
and injure workers or damage other devices. Keep 2
workers or other devices away from suspension 12
13
cylinder (2) when removing it. 17, 18 14
d CAUTION: Suspension cylinder (2) weight: 700
kg (1540 lb)
19 16
8. Attach a wire rope on to the cylinder tube on
suspension cylinder (2). Hold the suspension
cylinder.
Section B
9. Remove bolt (16), spacer (14), bolt (17) (3 used),
washers (18) (3 used), and plate (19) from pin (13). W8DS-02-11-010 W8DS-02-11-008
j : 19 mm

A

2
personal injury.
10. Remove pin (13) and spacers (12) (2 used) by using a
hammer and bar.
11. Retract suspension cylinder (2). Reinstall valve (7).
j : 27 mm 7
8
m : 20 N·m (2.0 kgf·m, 15 lbf·in)
Section A
12. Slightly lift and hold suspension cylinder (2).
W8DS-02-11-009 W8DS-02-11-008
Remove bolt (16), spacer (14), bolt (17) (3 used),
washers (18) (3 used), and plate (19) from pin (13).
j : 19 mm
14
19 16
13 C
17, 18
12
20
Section C
W8DS-02-11-016 W8DS-02-11-008
W8R7-E-01(20160803) W2-11-21
SECTION 2 BODY

personal injury.
13. Remove pin (13) and spacer (12) by using a hammer
and bar.
Remove elbow S (2 used) for lubrication hose from
pins (13) (2 used) if necessary.
j : 16 to 17 mm
14. Lower suspension cylinder (2) onto the ground.
15. Remove retaining rings (22) (2 used), spherical
13 C
bearing (21), and bush (23) from frame (1) if
necessary. 12
Section C 20
Remove retaining rings (25) (2 used), spherical
bearing (24), and bush (26) from rear axle housing W8DS-02-11-016 W8DS-02-11-008
(20).
16. Repeat steps 3 to 15 to remove suspension cylinder 23
1
(2) on the other side.
21
D
22
Section D
W8DS-02-11-011 W8DS-02-11-012
26
24
E
25
20
Section E
W8DS-02-11-013 W8DS-02-11-014
W8R7-E-01(20160803) W2-11-22
SECTION 2 BODY
Installation
23
1. Install bush (23), spherical bearing (21), and 1
retaining rings (22) (2 used) to frame (1).
21
22
(21).
D
retaining ring (25) (2 used) to the rear axle housing Section D
(20).
W8DS-02-11-011 W8DS-02-11-012
26
(24).
dCAUTION:
(1540 lb)
24
3. Lift the suspension cylinder (2) upright with the rod
facing down. Move suspension cylinder (2) to the
frame (1) installation position and align the pin hole. 25 E

spacers (12) (2 used) to frame (2).
4. Secure pin (13) to suspension cylinder (2) with bolt
(16), spacer (14), bolts (17) (3 used), washers (18) (3 Section E 20
used), and plate (19).
W8DS-02-11-013 W8DS-02-11-014
j : 19 mm
Loading Direction
m : 110 N·m (11 kgf·m, 81 lbf·ft)
90°
j : 24 mm
m : 270 N·m (27 kgf·m, 199 lbf·ft)

Splitting
Surface
Outer Splitting
Surface
Spherical Bearing (21, 24) Installation Position

W8DS-07-25-002
2
12
13
14
17, 18
19 16
Section B
W8DS-02-11-010 W8DS-02-11-008
W8R7-E-01(20160803) W2-11-23
SECTION 2 BODY
5. Adjust the height of frame (1) and align the pin hole
position of suspension cylinder (2) and rear axle 1
housing (20).
2
spacers (12) (2 used) to rear axle housing (20).
6. Secure pin (13) to suspension cylinder (2) with bolt
(16), spacer (14), bolts (17) (3 used), washers (18) (3
used), and plate (19).
14
j : 19 mm
17, 18 16
m : 110 N·m (11 kgf·m, 81 lbf·ft)
13 20
j : 24 mm 19
12 C
m : 270 N·m (27 kgf·m, 199 lbf·ft) Section C
7. Install lubrication hose elbow S (2 used) to pin (13) W8DS-02-11-016 W8DS-02-11-008

(2 used).
j : 16 to 17 mm
8. Install guard (5) to suspension cylinder (2) with bolts
A
m : 17 mm
j : 50 N·m (5.0 kgf·m, 37 lbf·ft) 2
9. Install a wiring of pressure sensor (8) and lubrication 9, 10

hose to suspension cylinder (2).
11
j : 19 mm, 17 mm
m : 45 N·m (4.5kgf·m, 33 lbf·ft) 3, 4
10. Install rubber (11), bolts (9) (5 used), and washers 8

5
(10) (5 used) to suspension cylinder (2). 6
W8DS-02-11-009 W8DS-02-11-008
j : 19 mm
m : 35 N·m (3.5kgf·m, 26 lbf·ft)

11. Repeat procedures 1 to 10 if suspension cylinder (2)
is removed on the opposite side.
12. Charge the helium gas to suspension cylinder (2)
from inflation valve (6).
Refer to CHARGING HELIUM GAS.
13. Lower the machine.
W8R7-E-01(20160803) W2-11-24
SECTION 2 BODY
(Blank)
W8R7-E-01(20160803) W2-11-25
SECTION 2 BODY
Disassembly of Rear Suspension Cylinder
22
25, 26
A View A
3 4, 5
6
2 11 3 6 2
12
7
13
14
8, 9
15
10
16
1
17
1 14
18
16
19 7
20
8, 9
W8DS-07-26-002
W8R7-E-01(20160803) W2-11-26
SECTION 2 BODY
Disassembly of Rear Suspension Cylinder

1. Remove the cap of inflation valve (22). Slowly
loosen outer lock nut on inflation valve (22)
counterclockwise. Check that any helium gas is fully
released from the suspension cylinder. Tighten the
outer lock nut on inflation valve (22) by turning it
counterclockwise after checking. In-stall the cap.
l : 3/4 in
dCAUTION:
(1540 lb)
2. Stand the suspension cylinder upright, with the

piston rod facing upwards.
3. Remove inflation valve (22). Drain the liquid
(neocon oil) inside the suspension cylinder into an
appropriate tray. Take care not to spill the liquid
onto the ground.

4. Remove socket bolts (9) (18 used) from cylinder
head (7). Remove the piston rod (1) assembly from
cylinder tube (2).
l : 17 mm
5. Place piston rod (1) in a horizontal position. Re-
move wear rings (6) (2 used) from piston (3).

(12 used) from piston (3). Remove piston (3) from
piston rod (1). Check that steel balls (11) (4 used) are
not lost when piston (2) is removed.
l : 14 mm
dCAUTION: Cylinder head (7) weight: 42 kg (92 lb)

7. Pull out cylinder head (7) from piston rod (1).
Remove O-ring (12), backup ring (13), wear rings
(14) (4 used), buffer ring (15), backup ring (16) (2
used), rod seal (17), backup ring (18), soft wiper (19),
and dust seal (20).
W8R7-E-01(20160803) W2-11-27
SECTION 2 BODY
Inspection of Rear Suspension Cylinder
22
25, 26
A View A
3 4, 5
6
2 11 3 6 2
12
7
13
14
8, 9
15
10
16
1
17
1 14
18
16
19 7
20
8, 9
W8DS-07-26-002
W8R7-E-01(20160803) W2-11-28
SECTION 2 BODY
Inspection of Rear Suspension Cylinder

1. Clean all components with an appropriate solvent
and dry with compressed air. Check that piston (3)
and cylinder head (7) have been cleaned.
2. Check all screw heads for any damage. Check
cylinder tube (2), wear ring (8), and buffering (15)
for any scouring, pitching, or excessive wear.
IMPORTANT: If dust seal (20) performance degrades,
the dirt may enter and damage the soft wiper
(19), rod seal (17), and buffer ring (15). Entering
of dirt can also cause excessive wear on wear ring
(14), and deformation of soft wiper (19), rod seal
(17), and buffer ring (15). Replace any damaged or
worn components.
3. Consider replacement of the piston rod if excessive
wear is detected on the outer diameter of piston
rod (1).
4. Check cylinder tube assembly (2), piston rod (1), and
cylinder head (7) for any cracks or distortion. Repair
or replace the components if necessary.
W8R7-E-01(20160803) W2-11-29
SECTION 2 BODY
Assembly of Rear Suspension Cylinder
22
25, 26
A View A
3 4, 5
6
2 11 3 6 2
12
7
13
14
8, 9
15
10
16
1
17
1 14
18
16
19 7
20
8, 9
W8DS-07-26-002
W8R7-E-01(20160803) W2-11-30
SECTION 2 BODY
Assembly of Rear Suspension Cylinder

IMPORTANT: Replace all seals when the suspension
cylinder is disassembled. Apply a film of
suspension cylinder fluid onto new seals before
installing.
1. Clean all screw heads and remove all grease before
assembling.
2. Install new backup rings (16) (2 used) to cylinder
head (7) with the chamfering surface of backup
rings (16) (2 used) facing towards rod seal (17) and
dust seal (20) of the cylinder head (7).
3. Install O-ring (12), backup ring (13), dust seal (20),
soft seal (19), wear rings (14) (4 used), backup ring
(18), rod seal (17), and buffer ring (15) to cylinder
head (7).

4. Stand and hold piston rod (1) vertically. Fit cushion
plate (10) to piston rod (1).
dCAUTION: Cylinder head (7) weight: 42 kg (91 lb)

5. Insert cylinder head (7) to piston rod (1), taking
caution not to damage dust seal (20).
6. Install steel balls (11) (4 used) to piston rod (1).

7. Check that steel balls (11) are properly setting in the
seat. Place piston (3) on top of piston rod (1).
W8R7-E-01(20160803) W2-11-31
SECTION 2 BODY
22
25, 26
A View A
3 4, 5
6
2 11 3 6 2
8, 9
8, 9
W8DS-07-26-002
W8R7-E-01(20160803) W2-11-32
SECTION 2 BODY
8. Apply LOCTITE #242 or equivalent adhesive to 13. Install inflation valve (22), valve (24), and pres-sure
socket bolt (4) (12 used). Install socket bolts (4) (12 sensor (25).
Inflation valve (22)
l : 14 mm
j : 3/4 in
m : 270 N·m (27 kgf·m, 199 lbf·ft)
m : 46 N·m (4.6 kgf·m, 34 lbf·ft)
fNOTE: The recommended standing time for the Valve (24)
LOCTITE #242 is 24 hours in room temperature.
9. Install wear ring (6) (2 used) to piston (3). Make j : 27 mm
sure that the sharp edge of wear ring (6) does not
m : 20 N·m (2.0 kgf·m, 15 lbf·in)
contact with other components.
Pressure sensor (25)
10. Apply a film of neocon oil to the interior of cylinder
tube assembly (2) and all seals before the final j : 27 mm
assembly.
m : 100 N·m (10 kgf·m, 74 lbf·ft)
d CAUTION: The cylinder tube (2) assembly
weight: 225 kg (496 lb) 14. Charge neocon oil to the suspension cylinder.
11. Hold cylinder tube assembly (2) vertically. Slowly Refer to CHARGING NEOCON OIL.
insert piston rod (1) to cylinder tube assembly
(2). Make sure that wear ring (6), O-ring (12), and
backup ring (13) will not be damaged during this
process.
12. Align socket bolt (9) (18 used) holes on cylinder
tube assembly (2) and cylinder head (7).
Secure cylinder tube assembly (2) and cylinder head
(7) with socket bolts (9) (18 use) and washers (9) (18
used).
l : 17 mm
m : 550 N·m (55 kgf·m, 406 lbf·ft)
W8R7-E-01(20160803) W2-11-33
SECTION 2 BODY
Charging Neocon Oil
No.4 Hose
[305 mm (12 in)]
Tee

Charging Neocon Oil
No.4 Hose Port A – Inflation Valve
(16 in)] Items marked ** not included in the charging kit
Note: Figures in brackets are hose lengths
Tray
No.4 Hose
[660 mm (26 in)]
Gauge
No.4 Hose 0 to 10340 kPa
Valve

Note: Figures in brackets are hose lengths Regulator Valve
0 to 13790 kPa
(0 to 141 kgf/cm2,
Helium Gas/Neocon Oil Charging Procedural Diagram

T704-07-00-021
 Rear Suspension Cylinder Charge Data

X-2 Rod dimension When empty (After 48-hour operation) 79.0 mm (3.11 in)
X-4 Rod dimension After charging neocon oil only 37.0 mm (1.46 in)
charging
extended)
Neocon oil charge capacity 36.4 Liters (9.62 US gal)
W8R7-E-01(20160803) W2-11-34
SECTION 2 BODY
Charging Neocon Oil
dCAUTION:
kg (1540 lb)
1. Lift and hold the suspension cylinder (1) upright

with the piston rod facing down.
2. Remove valve (7) and fully extend suspension
cylinder (1). The maximum rod dimension is as
shown in (X-1) of the suspension cylinder (1) charge
data.
1
3. Connect the neocon oil charge kit. Refer to the
helium gas / neocon oil charging procedural
diagram.
An example of a charge kit is shown in the diagram.
4. Connect the neocon oil charge line to the valve (7)
port. Loosen inflation valve (6) outer lock nut (5) by
turning it counterclockwise. X-1
X X-2
5. Charge suspension cylinders (1) with neocon X-4
oil. Charge until the bubbles stop forming from
inflation valve (6).
6. Close inflation valve (6) outer locknut (5). Retract
suspension cylinder (1). Place a tray by the edge of
the neocon charge line. Adjust suspension cylinder
(1) to specified rod dimension (X-4) by pouring out Suspension Cylinder (1) Rod Dimension
the neocon oil from the valve (7) port to a tray. T8DS-04-05-008
7. Remove the neocon oil charge line. Connect valve
(7). Do not spill the charged neocon oil.
j : 27 mm
m : 20 N·m (2.0 kgf·m, 15 lbf·ft)

8. When neocon oil is filled into suspension cylinder
(1) and the outer lock nuts on inflation valve (6) and
valve (7) are shut, do not extend the suspension 4
cylinder (1) until suspension cylinder (1) is charged
with helium gas. Air will enter through the seal if the
suspension cylinder (1) is extended. 5
Inflation Valve (6)
T704-07-00-014
W8DS-02-11-006
W8R7-E-01(20160803) W2-11-35
SECTION 2 BODY
Charging Helium Gas
No.4 Hose
[305 mm (12 in)]
Tee

Charging Neocon Oil
No.4 Hose Port A – Inflation Valve
(16 in)] Items marked ** not included in the charging kit
Note: Figures in brackets are hose lengths
Tray
No.4 Hose
[660 mm (26 in)]
Gauge
No.4 Hose 0 to 10340 kPa
Valve

Note: Figures in brackets are hose lengths Regulator Valve
0 to 13790 kPa
(0 to 141 kgf/cm2,
Helium Gas/Neocon Oil Charging Procedural Diagram

T704-07-00-021
 Rear Suspension Cylinder Charge Data

X-2 Rod dimension When empty (After 48-hour operation) 79.0 mm (3.11 in)
X-4 Rod dimension Immediately after charging neocon oil only 37.0 mm (1.46 in)
charging
P-1A Charging pressure After 48-hour operation (When fully 1.30 MPa (13.3 kgf/cm2,189 psi)
extended)
Neocon oil charging capacity 36.4 Liters (9.62 US gal)
W8R7-E-01(20160803) W2-11-36
SECTION 2 BODY
Charging Helium Gas

IMPORTANT: Use a charge kit to charge helium gas
to both rear suspension cylinders (1) at the same
time.
dCAUTION: Only charge helium gas into

suspension cylinder (1). Do not charge using any
other gas.
1. Connect helium gas charge kit adapter to port
A inflation valve (6) located on both suspension
cylinders (1). Open inflation valve (6) by turning
outer locknut (5) by turning counterclockwise.
A
d CAUTION: Machine rear axle weight: 85000 kgf
(187000 lbf)
1
2. Prepare to lift the rear of the machine frame when
charging the suspension cylinder (1).
3. Set the regulator valve to minimum pressure of 690
kPa (7 kgf/cm2, 100 psi).
4. Open the ball valves on the left and the right
manifolds. Simultaneously, lift the rear part of the
machine as high as possible and charge helium gas 7 6
to the suspension cylinders (1). Air entering through Section A
the seal can be avoided by charging suspension W8DS-02-11-009 W8DS-02-11-008
cylinder (1) with regulator valve pressure of over
690 kPa (7 kgf/cm2, 100 psi) while extending.
5
Inflation Valve (6)
T704-07-00-014
W8R7-E-01(20160803) W2-11-37
SECTION 2 BODY
5. Check that the machine is stable, and charge

helium gas to suspension cylinder (1) until it is fully
extended. If suspension cylinder (1) fails to extend
fully with helium gas pressure, apply external force P-1
and extend gradually. The length of the rod should P-1A
be at a dimension stated on the charge data (X-1).
Check the length of both suspension cylinders (1).
6. Adjust the pressure of regulator valve to suspension 1
cylinder (1) initial settings pressure (P-1), and open
both ball valves for 2 minutes in order to adjust
balance of both suspension cylinders (1).
Set the helium gas charging pressure to 1.99 MPa
when the suspension cylinder (1) is fully extended.
fNOTE: The helium gas (charging) pressure when

X-1
fully extended will become 1.30 MPa after 48 hours of X-2
X
operation. X-4
7. Turn inflation valve (6) outer locknut (5) clockwise
to close inflation valve (6) (port A) on suspension
cylinder (1).
8. Close the valve of helium supply tank. Release the
pressure in the line by open the gas bleed valve
on the manifold. Remove the helium gas charge Suspension Cylinder (1) Rod Dimension
kit assembly from inflation valve (6) and place T8DS-04-05-008
protective cap (4).
5
Inflation Valve (6)
T704-07-00-014
W8R7-E-01(20160803) W2-11-38
SECTION 2 BODY
Servicing Procedure of Rear Suspension

Cylinder (1)
For the first 48 hours of operation after charging,
the helium gas and neocon oil mixes and dissolute
inside suspension cylinders (1). Suspension cylinder P-1
P-1A
(1) dimension may become shorter when dissolution
occurs. Regularly inspect suspension cylinder (1) after
operating the machine for 48 hours. Measure the distance
between cylinder head (2) and piston rod (3) head (X-2) to 1
determine the state of suspension cylinder (1). Measure
the length on a flat ground with no load on the machine.
Operate the machine for at least 1 hour before measuring.
(Do not apply excessive braking.) Correct measurement 2
cannot be taken if the above conditions are not met.
Check the following points if the piston rod dimension
(X-2) of the suspension cylinder (1) is out of its permissible
range. X-1
X X-2
X-4
1. Neocon oil, helium gas leak
2. Measure the suspension cylinder (1) pressure when
the cylinder is fully extended (P-1A). Solve any 3
issues found, and follow the charging procedures
and recharge the oil/gas.
Suspension Cylinder (1) Rod Dimension
T8DS-04-05-008
Suspension Cylinder (1) Storage
Inject specified amount of oil, and plug all ports when
storing the suspension cylinder (1). Store in a way that the
finishing does not corrode, and chrome plated area of the
piston rod (3) does not become damaged. If the oil had
to be left charged in the cylinder when storing, have the
suspension cylinder (1) upright with piston rod (3) facing
down.
W8R7-E-01(20160803) W2-11-39
SECTION 2 BODY
(Blank)
W8R7-E-01(20160803) W2-11-40
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
SECTION 3
HOIST DEVICE
CONTENTS
Group 1 Hoist Control Valve
Hoist Control Valve .............................. W3-1-1
Structure of Hoist Control
Valve Assembly .................................. W3-1-6
Disassembly of Hoist Control Valve ..... W3-1-8
Assembly of Hoist Control Valve ........ W3-1-12
Overload Relief Valve ........................ W3-1-16
Structure of Make-Up Valve ............... W3-1-18
Group 2 4-Unit Proportional Control So-

lenoid Valve
Removal and Installation of 4-Unit
Proportional Control Solenoid Valve .... W3-2-1
Structure of 4-Unit Proportional
Control Solenoid Valve Assembly ........ W3-2-3
Disassembly of Proportional
Control Solenoid Valve ........................ W3-2-4
Assembly of Proportional
Control Solenoid Valve ........................ W3-2-6
Group 3 Hoist Cylinder

Hoist Cylinder ...................................... W3-3-1
Disassembly of Hoist Cylinder ................. W3-3-6
Inspection of Hoist Cylinder ................... W3-3-10
Assembly of Hoist Cylinder .................. W3-3-12
Group 4 Dump Body

Dump Body .......................................... W3-4-1
W8R7-E-01(20160803) 8R7W-3-1
(Blank)
W8R7-E-01(20160803) 8R7W-3-2
HOIST DEVICE / Hoist Control Valve
REMOVAL AND INSTALLATION OF HOIST
CONTROL VALVE
Removal
1. Park the machine in the service position on a level 1 2 5, 6 3

surface.
CAUTION: Release oil pressure from hy-

draulic circuit before doing any work.
2. Remove split flanges (5) (4 used), socket bolts (6)

(8 used), split flanges (7) (2 used), and socket
bolts (8) (4 used) from hoist control valve (1).
Remove hoses (2, 3, 4).
：10 mm
NOTE: Attach identification tags to the removed

hoses for reassembling.Cap the removed 5, 6
hoses.
9 7, 8 4 10 W8R7-03-01-001
3. Remove hoses (9, 10, 11, 12, 13, 14, 15) from 11 1 12
hoist control valve (1).
Wrench Size (mm)

: 17, 19 Hose (10)
: 19, 22 Hose (9)
: 36, 32 Hoses (11, 15)
: 41 Hose (14)
: 50, 46 Hoses (12, 13)
W8R7-03-01-002
13 14 15
W8R7-E-01(20160803) W3-1-1
4. Remove hoses (16, 17, 18, 19, 20) from hoist
control valve (1). 21, 22 22, 23
Wrench Size (mm)

: 17, 19 Hoses (18, 19, 20)
: 19, 22 Hoses (16, 17)
1
CAUTION: Hoist control valve (1) assembly
16
24
5. Hold hoist control valve (1).

used), and nuts (23) (4 used). Remove hoist con- 18
trol valve (1) from bracket (24).
：24 mm
17 W8R7-03-01-003
19 20
1 W8R7-03-01-004
W8R7-E-01(20160803) W3-1-2
Installation
CAUTION: Hoist control valve (3) assembly

weight: 266 kg (586 lb) 21, 22 22, 23
1. Hold hoist control valve (3) at the installation po-
sition of bracket (24).
2. Install hoist control valve (1) to bracket (24) with

bolts (21) (4 used) washers (22) (8 used), and
nuts (23) (4 used). 1
: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft) 16
24
3. Install disconnected hoses (16, 17, 18, 19, 20) to
hoist control valve (1).
Wrench Size Tightening Remark 18

(mm) Torque
N·m (kgf·m)
: 17, 19 30 (3.0) Hoses (18, 19,
20) 17 W8R7-03-01-003
: 19, 22 40 (4.0) Hoses (16, 17)

19 20
1 W8R7-03-01-004
W8R7-E-01(20160803) W3-1-3
4. Install O-ring to O-ring seal. Install disconnected
hoses (9, 10, 11, 12, 13, 14, 15) to hoist control 11 1 12
valve (1).
Wrench Size Tightening Remark

(mm) Torque
N·m (kgf·m)
: 17, 19 30 (3.0) Hose (10)
: 19, 22 40 (4.0) Hose (9)
: 36, 32 180 (18) Hoses (11, 15)
: 41 200 (20) Hose (14)
: 50, 46 350 (35) Hoses (12, 13)
5. Install the O-ring to hoses (2, 3, 4). Install hoses

(2, 3, 4) to hoist control valve (1) with split flanges
(5) (4 used), socketa bolts (6) (8 used), split
flanges (7) (2 used), and socket bolts (8) (4 used). W8R7-03-01-002
13 14 15
：10 mm
：110 N·m (11 kgf·m)
1 2 5, 6 3
6. When completing the work, check the hydraulic oil

level and any oil leaks.
5, 6
9 7, 8 4 10 W8R7-03-01-001
W8R7-E-01(20160803) W3-1-4
(Blank)
W8R7-E-01(20160803) W3-1-5
STRUTURE OF HOIST CONTROL VALVE
ASSEMBLY
Hoist Control Valve
W8R7-03-01-005
W8R7-E-01(20160803) W3-1-6
Structure of Hoist Control Valve Assembly
Before starting disassembly/assembly of the hoist
control valve, installation/removal of the piping mani-
fold and elbow are required. Conduct the work by
referring to wrench sizes and tightening torques pro-
vided in the following table.
CAUTION: Hoist control valve assembly

No. Part Name Q’ty Wrench Size Tightening Torque Remark
(mm) N·m (kgf·m)
Hoist control valve 1 Weight: 186 kg (410 lb)
1 Manifold 1
2 Manifold 1
3 Manifold 1
4 Manifold 1
5 O-ring 7
6 Bolt 8 : 24 210 (21) M16
7 Washer 36
8 Bolt 8 : 24 210 (21) M16
9 Bolt 8 : 24 210 (21) M16
10 Nut 8 : 24 210 (21)
13 Manifold 1
14 Bolt 4 : 24 210 (21) M16
15 Manifold 1
16 O-ring 1
17 Socket bolt 1 : 10 90 (9.0) M12
18 Washer 4
19 Plug 1 : 27 95 (9.5) G1/2
20 Elbow S 1 : 22 70 (7.0) G3/8
21 Elbow S 4 : 22 70 (7.0) G3/8
22 Tee S 1 : 22 70 (7.0) G3/8
23 Elbow S 1 : 19 30 (3.0) G1/4
24 Elbow S 2 : 32 140 (14) G3/4
25 Elbow S 2 : 50 340 (34) G1-1/4
27 Adapter S 1 : 41 210 (21) G1
NOTE: 1 N·m = 0.7376 lbf·ft
W8R7-E-01(20160803) W3-1-7
DISASSEMBLY OF HOIST CONTROL
VALVE
10
9
8
7 11
2 6 12
5
3 4
15 13
22 14
16
1 17
20 18
19
22
21
22
27 30
24
28
29 31
22 23 32
25
33
40
39 26 34
38
35 23
W8DS-03-01-002
36
37
Exploded View of Hoist Control Valve
1 - Outlet Section 11 - Plug (2 Used) 21 - O-Ring (3 Used) 31 - Flange

2 - Nut (4 Used) 12 - O-Ring (2 Used) 22 - Make-Up Valve (4 Used) 32 - O-Ring
3 - Tie Rod (4 Used) 13 - Spring Seat (2 Used) 23 - Overload Relief Valve 33 - Inlet Section
(2 Used)
4- Spring (2 Used) 14 - Spool (2 Used) 24 - Housing 34 - Nut (4 Used)
5- Spring (2 Used) 15 - Socket Bolt (8 Used) 25 - Housing 35 - O-Ring (2 Used)
6- Spring Seat (2 Used) 16 - Plate (2 Used) 26 - Main Relief Valve 36 - Spacer (2 Used)
7- Spool End (2 Used) 17 - O-Ring (2 Used) 27 - Socket Bolt (4 Used) 37 - Cap (2 Used)
8- O-Ring (2 Used) 18 - Spring (2 Used) 28 - Flange 38 - Socket Bolt (4 Used)
9- Cap (2 Used) 19 - Poppet (2 Used) 29 - O-Ring 39 - O-Ring (2 Used)
10 - Socket Bolt (4 Used) 20 - O-Ring (6 Used) 30 - Socket Bolt (4 Used) 40 - Plug (2 Used)
W8R7-E-01(20160803) W3-1-8
Disassembly of Hoist Control Valve
• Before disassembling the hoist control valve, read

CAUTION: Inlet section (33) weight: 62 kg
Precautions on Disassembly and Assembly on
W1-1-1. (137 lb)
Outlet section (1) weight: 23 kg (51 lb)
IMPORTANT: Many components of the hoist con- Housings (24, 25) Weight: 30 kg (66 lb)
trol valve have a similar shape and a 3. Loosen socket bolts (15) (8 used). Remove plates
particular installing direction. (16) (2 used) and O-rings (17) (2 used) from
Therefore, while disassembling the housings (24, 25).
: 10 mm
valve, put identification marks on
components for assembly.
4. Remove springs (18) (2 used) and poppets (19)
(2 used) from housings (24, 25).
CAUTION: Hoist control valve weight: 186 kg
(410 lb) 5. Remove socket bolts (27) (4 used) and socket
1. Place the hoist control valve on a clean work- bolts (30) (4 used). Remove flange (28), flange
bench. (31), O-rings (29, 32) from inlet section (33).
: 10 mm, 14 mm
IMPORTANT: Do not disassemble overload relief
valve (23). A special tester is re- 6. Loosen nuts (2) (4 used) and remove tie rods (3)
quired for adjustment of the over- (4 used) by pulling.
load relief valve after re-assembly. : 30 mm
Put the spanner at the body side
when removing overload relief valve IMPORTANT: When hoisting each section of the
(23) or main relief valve (26). hoist control valve or housing, in-
2. Remove overload relief valves (23) (2 used) and stall eyebolt (M16, Pitch 2.0 mm) into
makeup valves (22) (4 used) from housings (24, the bolt holes for pipe. At this time,
25). do not fall off O-ring.
Remove main relief valve (26) from inlet section 7. Separate inlet section (33), housings (25, 24) and
(33). outlet section (1) individually.
: 38 mm
W8R7-E-01(20160803) W3-1-9
10
9
8
7 11
6 12
5
4
14
21
20
24
25
33
40
39
38
35
W8DS-03-01-002
36
37
W8R7-E-01(20160803) W3-1-10
8. Remove O-rings (20) (6 used) and O-rings (21) (3
used) from inlet section (33) and housings (25,
24).
IMPORTANT: LOCTITE is applied on plug (11). Do

not remove the plug unless neces-
sary.
9. Loosen socket bolts (10) (4 used). Remove caps
(9) (2 used) and O-rings (8) (2 used) from hous-
ings (24, 25).
: 10 mm
IMPORTANT: Rotate and remove spool (14) slowly.

10. Remove spools (14) (2 used) from housings (24,
25).
IMPORTANT: LOCTITE is applied on plug (40). Do

not remove the plug unless neces-
sary.
11. Loosen socket bolts (38) (4 used). Remove caps
(37) (2 used) and O-rings (35) (2 used) from
housings (24, 25). Remove spacers (36) (2 used)
from caps (37) (2 used).
: 10 mm
12. Clamp spool (14) in a vise by using wooden

pieces. Heat the outer diameter of spool end (7) of
spool (14) to 200 to 250 °C (392 to 482 °F). Turn
and remove spool end (7) by using a spanner
from spool (14). (2 places)
: 30 mm
13. Remove spring seats (6, 13) and springs (4, 5)

from spool end (7). (2 places)
W8R7-E-01(20160803) W3-1-11
ASSEMBLY OF HOIST CONTROL VALVE
1 2 21 3 20
22
38
24
37
9
11, 12
39, 40
10
A
25
26 33
W8DS-03-01-003
27 28, 29 34 31, 32 30
Section A
17 15 16 18 19
8 6 7
39, 40 36 35
13
Install Position
9
11, 12
37
4 5
W18C-02-05-009
23 14
Install Position
Assembly Diagram of Hoist Control Valve
1 - Outlet Section 12 - O-Ring (2 Used) 23 - Overload Relief Valve 34 - Nut (4 Used)

(2 Used)
2- Nut (4 Used) 13 - Spring Seat (2 Used) 24 - Housing 35 - O-Ring (2 Used)
3- Tie Rod (4 Used) 14 - Spool (2 Used) 25 - Housing 36 - Spacer (2 Used)
4- Spring (2 Used) 15 - Socket Bolt (8 Used) 26 - Main Relief Valve 37 - Cap (2 Used)
5- Spring (2 Used) 16 - Plate (2 Used) 27 - Socket Bolt (4 Used) 38 - Socket Bolt (4 Used)
6- Spring Seat (2 Used) 17 - O-Ring (2 Used) 28 - Flange 39 - O-Ring (2 Used)
7- Spool End (2 Used) 18 - Spring (2 Used) 29 - O-Ring 40 - Plug (2 Used)
8- O-Ring (2 Used) 19 - Poppet (2 Used) 30 - Socket Bolt (4 Used)
9- Cap (2 Used) 20 - O-Ring (6 Used) 31 - Flange
10 - Socket Bolt (4 Used) 21 - O-Ring (3 Used) 32 - O-Ring
11 - Plug (2 Used) 22 - Make-Up Valve (4 Used) 33 - Inlet Section
W8R7-E-01(20160803) W3-1-12
Assembly of Hoist Control Valve
IMPORTANT: Assemble the valve by following 4. When spool end (7) is removed, assemble spool
matching marks put during disas- end (7) in following procedure.
sembly. • Clamp spool (14) in a vise by using wooden
pieces.
IMPORTANT: Before assembling, apply hydraulic • Apply LOCTITE #271 onto the thread part on
oil onto parts in order to prevent spool end (7).
them from seizing. • Install spring seat (6, 13) and spring (4, 5) to spool
end (7).
IMPORTANT: Apply grease onto O-rings (20, 21) • Install spool end (7) onto spool (14).
for preventing O-rings from falling : 30 mm
off. : 27±1.5 N·m (2.7±0.15 kgf·m, 20±1.1 lbf·ft)
1. Install O-rings (20) (6 used) and O-rings (21) (3
used) to housings (24, 25) and inlet section (33). 5. Install spacers (36) (2 used) to caps (37) (2 used).
Install O-rings (35) (2 used) and caps (37) (2
used) to housings (24, 25) with socket bolts (38)
CAUTION: Inlet section (33) weight: 62 kg
(4 used).
(137 lb) : 10 mm
Outlet section (1) weight: 23 kg (51 lb) : 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
Housing (24, 25) weight: 30 kg (66 lb)
IMPORTANT: Check and arrange the housings and IMPORTANT: Slowly rotate and insert spool (14) to
sections in the right order and di- each housing.
rection. 6. Install the spool (14) assemblies (2 used) to
IMPORTANT: During the operation, check that housings (24, 25).
O-ring is not falling off or extruded.
2. Hoist each section and housing with a crane and
place them in order.
NOTE: When hoisting each section and housing,
install eyebolt (M16, Pitch 2.0 mm) into the
holes for pipe.
3. Pass tie rods (3) (4 used) through each section

and housing and tighten with nuts (2) (4 used)
and nuts (34) (4 used).
: 30 mm
: 415±21 N·m (41.5±2.1 kgf·m, 306±19 lbf·ft)
W8R7-E-01(20160803) W3-1-13
22
38
24
37
9
10
22 A
25
26 33
W8DS-03-01-003
27 28, 29 31, 32 30
Section A
17 15 16 18 19 25
8 7
36 35
W18C-02-05-009
23 23
Install Position Install Position
W8R7-E-01(20160803) W3-1-14
7. Install O-rings (8) (2 used) and caps (9) (2 used)
to housing (24, 25) with socket bolts (10) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
8. Install poppets (19) (2 used) and springs (18) (2

used) to housings (24, 25). Install O-rings (17) (2
used) and plates (16) (2 used) to housings (24,
25) with socket bolts (15) (8 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
9. Install O-rings (29, 32) and flanges (28, 31) to

inlet section (33) with socket bolts (27) (4 used)
and socket bolts (30) (4 used).
: 10 mm
: 110 N⋅m (11 kgf⋅m, 81 lbf⋅ft)
: 14 mm
: 270 N⋅m (27 kgf⋅m, 199 lbf⋅ft)
10. Install overload relief valves (23) (2 used) to

housing (25). Install main relief valve (26) onto
inlet section (33).
: 38 mm
: 95 to 110 N⋅m (9.5 to 11 kgf⋅m, 70 to 81
lbf⋅ft)
11. Install make-up valves (22) (4 used) into housings

(24, 25).
: 38 mm
: 150 to 170 N⋅m (15 to 17 kgf⋅m, 110 to
125 lbf⋅ft)
W8R7-E-01(20160803) W3-1-15
OVERLOAD RELIEF VALVE
3 4 7 11 12 5 1 11 2
14
13
15
17
W18B-02-04-009
16
9 10 6 8
1- Cap 6- Pilot Poppet 11 - O-Ring 16 - O-Ring

2- Plug 7- Spring 12 - Name Plate 17 - Backup Ring
3- Sleeve 8- Pilot Spring 13 - Lock Nut
4- Main Poppet 9- O-Ring 14 - O-Ring
5- Pilot Seat 10 - Backup Ring 15 - Adjusting Screw
W8R7-E-01(20160803) W3-1-16
Disassembly and Assembly of Overload Relief Assembly
Valve
IMPORTANT: Before assembling, apply hydraulic
IMPORTANT: Overload relief valve requires per- oil onto parts in order to prevent
formance test and adjustment solely. them from seizing.
Do not disassemble the valve unless
necessary. 1. Install O-ring (16) and backup ring (17) onto main
poppet (4).
Disassembly
2. Install main poppet (4) into sleeve (3).
1. Put the matching marks onto plug (2) and adjust-
ing screw (15). 3. Install O-ring (9) and backup ring (10) onto pilot
seat (5).
2. Put a spanner on plug (2). Loosen lock nut (13)
and remove adjusting screw (15). Do not fall off 4. Install sleeve (3) and spring (7) into cap (1).
pilot spring (8) and pilot poppet (6).
: 17 mm, 38 mm 5. Install plug (2) to cap (1).
: 6 mm NOTE: When assembling plug (2) to cap (1), as-
semble with cap (1) at a vertical condition.
IMPORTANT: As pilot seat (5) is secured onto plug
(2), pilot seat (5) cannot be disas- IMPORTANT: When assembling pilot poppet (6),
sembled. check that pilot poppet (6) is in-
3. Clamp cap (1) into a vise. Loosen and remove stalled into pilot seat (5) securely.
plug (2) from cap (1). Pilot seat (5) is removed 6. Assemble pilot poppet (6) and pilot spring (8) to
with plug (2) together. plug (2). Align the matching marks made when
: 38 mm disassembling and install adjusting screw (15) to
plug (2). Lock with lock nut (13).
4. Remove spring (7) and sleeve (3) from cap (1). : 17 mm
: 50 N⋅m (5.0 kgf⋅m, 37 lbf⋅ft)
5. Remove O-ring (9) and backup ring (10) from pilot : 6 mm
seat (5). : 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
6. Remove main poppet (4) from sleeve (3). 7. Install O-ring (11) to plug (2) and install to cap (1).
: 38 mm
7. Remove O-ring (16) and backup ring (17) from : 150 N⋅m (15 kgf⋅m, 111 lbf⋅ft)
main poppet (4).
IMPORTANT: After the assembly, always check
that main poppet (4) moves.
W8R7-E-01(20160803) W3-1-17
STRUCTURE OF MAKE-UP VALVE
3 7 8 2 6 9 1
W18B-02-04-008
4 5
Torque
Part Name Q’ty Remark
N⋅m (kgf⋅m)
1- Plug 1 98 (10) : 38 mm
2- Sleeve 1
3- Poppet 1
4- Washer 1
5- Lock Nut 1
6- Spring 1
7- O-Ring 1
8- Backup Ring 1
9- O-Ring 1
NOTE: 1 N⋅m = 0.7376 lbf⋅ft
W8R7-E-01(20160803) W3-1-18
HOIST DEVICE / 4-Unit Proportional Control Solenoid Valve
REMOVAL AND INSTALLATION OF 4-UNIT
PROPORTIONAL CONTROL SOLENOID 2
VALVE
Removal

surface.
CAUTION: Release oil pressure from hy-

draulic circuit before doing any work. 4
2. Disconnect each harness (4) of 4-unit proportional

control solenoid valves (2) from the connector.
Attach identification tags to the removed har-
nesses for reassembling.
3. Disconnect all hoses (5, 6, 7, 8, 9, 10, and, 11)

from 4-unit proportional control solenoid valve (2). W8R7-03-02-001
Attach identification tags to the removed hoses for

reassembling. 6 7 3 2 8
Cap the removed hoses.
Wrench Size (mm) Remark

: 14, 17 Hose (5) 5
: 17, 19 Hoses (6, 7, 8)
: 19, 22 Hoses (9, 10, 11)
3. Remove socket bolts (3) (2 used). Remove 4-unit

proportional control solenoid valve (2) from
bracket (1).
：8 mm
1
W8R7-03-02-002
9 10 11
W8R7-E-01(20160803) W3-2-1
Installation
6 7 3 2 8
1. Install 4-unit proportional control solenoid valve
(2) to bracket (1) with socket bolts (3) (2 used).
：8 mm
5
：65 N·m (6.5 kgf·m, 48 lbf·ft)
2. Connect all disconnected hoses (5, 6, 7, 8, 9, 10,

and 11) to 4-unit proportional control solenoid
valve (2).
Tightening
Wrench Size
Torque Remark
(mm)
N·m kgf·m
1
: 14, 17 25 (2.5) Hose (5)
: 17, 19 30 (3.0) Hoses (6, 7, 8) W8R7-03-02-002
: 19, 22 40 (4.0) Hoses (9, 10, 11) 9 10 11
NOTE: 1N·m = 0.7376 lbf·ft 2
3. Connect each harness (4) of 4-unit proportional

control solenoid valves (2) to the connector.
4. When completing the work, check the hydraulic oil

level and check for any oil leaks.
W8R7-03-02-001
W8R7-E-01(20160803) W3-2-2
STRUCTURE OF 4-UNIT PROPORTIONAL
CONTROL SOLENOID VALVE ASSEMBLY
Adopters, elbows, tees, and plugs are equipped with

4-unit proportional control solenoid valve assembly for
piping. If installation/removal is required, conduct the
work by referring to wrench sizes and tightening
torques provided in the following table.
4-unit Proportional Control Solenoid Valve
W8R7-03-02-003
No. Part Name Q’ty Wrench Size Tightening Torque Remark

(mm) N·m (kgf·m)
4-unit Proportional 1
Control Solenoid Valve
1 Adapter S 2 : 24 30 (3.0) G1/4
2 Adapter S 1 : 24 30 (3.0) G1/4
3 Tee S 1 : 24 30 (3.0) G1/4
4 Elbow S 2 : 22 70 (7.0) G3/8
5 Plug 1 : 22 70 (7.0) G3/8
6 Plug 6 : 19 30 (3.0) G1/4
NOTE: 1 N·m = 0.7376 lbf·ft
W8R7-E-01(20160803) W3-2-3
DISASSEMBLY OF PROPORTIONAL
CONTROL SOLENOID VALVE
2
3
4
5
7
8
9
10
13
11
12 14
15
16
17
18
W157-02-11-016
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W8R7-E-01(20160803) W3-2-4
Disassembly of Proportional Control Solenoid
Valve

solenoid (6).
: 3 mm
IMPORTANT: Do not lose spring (7) in the solenoid

hole when removing solenoid (6).
Do not disassemble lock nut (2) and
adjusting screw (4).
2. Pull out spool (10) and remove diaphragm (9),
washer (11), and spring (12).
3. Remove sleeve (16), O-rings (13, 14, 15), plate

(17), and washer (18) in this order.
W8R7-E-01(20160803) W3-2-5
ASSEMBLY OF PROPORTIONAL CON-
TROL SOLENOID VALVE
4 2 6 1 8 16 13 14 10 15 18
3, 5
9 7 11 12 17
W157-02-11-001
1- Socket Bolt (2 Used) 6- Solenoid 11 - Washer 15 - O-Ring

2- Lock Nut 7- Spring 12 - Spring 16 - Sleeve
3- O-Ring 8- O-Ring 13 - O-Ring 17 - Plate
4- Adjusting Screw 9- Diaphragm 14 - O-Ring 18 - Washer
5- Spring 10 - Spool
W8R7-E-01(20160803) W3-2-6
Assembly of Proportional Control Solenoid Valve
IMPORTANT: Apply grease on O-rings (13, 14, 15) IMPORTANT: When installing spool (10) into
and apply hydraulic oil on sleeve sleeve (16), do not damage the edge
(16). inside sleeve (16).
During assembly of the sleeve, align After installing the spool, slide the
the sleeve hole and the housing hole. spool for 3 to 5 mm (0.11 to 0.20 in)
In addition, install the sleeve so that with your finger.
the end faces of sleeve and body Apply hydraulic oil onto the spool.
can be aligned. 2. Install diaphragm (9), washer (11), and spring (12)
1. Install washer (18) and plate (17) into the housing. to spool (10) and install it into sleeve (16).
Install O-rings (13, 14, 15) on sleeve (16). Insert
into the housing.
10
16
15
14
13
9
16
Housing
12
W157-02-11-005
11 Housing
W157-02-11-009
IMPORTANT: As lock nut (2), adjusting screw (4),

spring (5), and O-ring (3) are not
separated, reassembly of these parts
is unnecessary.
When installing solenoid (6), do not
drop spring (7).
3. Install solenoid (6) with socket bolts (1) (2 used).
: 3 mm
: 3 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft)
1
W157-02-11-011
W8R7-E-01(20160803) W3-2-7
(Blank)
W8R7-E-01(20160803) W3-2-8
HOIST DEVICE / Hoist Cylinder
REMOVAL AND INSTALLATION OF HOIST
CYLINDER
Removal

vice position. Set wheel stops on the rear tires.
2. Set the hoist lever to the hold position.

2
3. Remove lubrication hose (4) on pin (2) from elbow
S (3).
: 17 mm, 19 mm 1
4. Remove lubrication hose (5) at the rod side of

hoist cylinder (1) from elbow S (3).
: 17 mm, 19 mm
5. Remove elbow S (3) on pin (2) from adaptor (9).

: 16 to 17 mm
CAUTION: Hoist cylinder (1) weight (which

includes the hydraulic oil): 520 kg (1150 lb)
6. Hold hoist cylinder (1). Remove plate (10), bolt

(11) (3 used), washer (12) (3 used), and bolt (8) 3, 5 T8R7-03-09-001
from pin (2).

Remove pin (2) and spacers (6) (2 used) from 10
6
hoist cylinder (1).
If necessary, remove spacer (7). 3, 4
: 19 mm, 24 mm 2
11
7. Set the hoist lever to a float position. Retract hoist 7
cylinder (1). 12
8
8. Secure the cylinder tube, so the piston rod does
not extend.
This procedure is necessary as the piston rod may
extend and cause damage when removing hoist
cylinder (1) from the machine. T8R7-03-09-002
W8R7-E-01(20160803) W3-3-1
9. Remove socket bolts (14, 17) (4 used for each)
and split flanges (13, 16) (2 used for each) from
hoist cylinder (1). Disconnect hydraulic hoses (15,
1
18) from hoist cylinder (1).
Drain remaining hydraulic oil in hydraulic hoses
(15, 18) and hoist cylinder (1) to a proper con-
tainer.
Cap hydraulic hoses (15, 18). Install a plug to the
hoist cylinder (1) port.
: 8 mm
: 12 mm
CAUTION: Hoist cylinder weight: 465 kg

(1030 lb) 13, 14
15
10. Set hoist cylinder (1) vertically. Hoist a little and
release weight applied at the bottom section.
16, 17
Remove bolts (22) (4 used), washers (23) (4 used),
and plate (21) from frame (19). 18
: 24 mm 3, 5 T8R7-03-09-001
11. Remove hoist cylinder (1) from mounting section

of frame (19).
1
12. Remove spacer (20) from frame (19).
If necessary, remove bushing (24) from hoist cyl-
inder (1).
21 20 19
13. If necessary, remove elbows S (3) (2 used) of lu- 22
brication hoses (4, 5) from pin (2) and hoist cylin-
der (1).
: 16 to 17 mm, 19 mm
14. Repeat steps 3 through 13 when removing hoist

23
cylinder (1) on the other side.
24 W8DS-03-03-003
3, 4 2
T8R7-03-09-002
W8R7-E-01(20160803) W3-3-2
Installation
Grease Inlet
1. Install bushing (24) to piston rod of hoist cylinder
(1).
As for installing direction of bushing (24), refer to
the illustration on the right.
2. Install elbows S (3) of lubrication hoses (5) to hoist

cylinder (1).
: 16 to 17 mm
: 30 N·m (3 kgf·m, 22 lbf·ft)
24
W8R7-03-03-002
3. Secure the piston rod with a cylinder tube. Installation Position of the Cylinder Bushing
Refer to “Removal” section for more detailed
procedure.
1
(1030 lb)
4. Install spacer (20) to frame (19). Install the piston

rod of hoist cylinder (1) to frame (19). Install plate
(21), washers (23) (4 used), and bolts (22) (4
used) to frame (19).
: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft)
3, 5 T8R7-03-09-001
21 20 19
22
23
24 W8DS-03-03-003
W8R7-E-01(20160803) W3-3-3
5. Install adaptor (9) to pin (2).
: 19 mm
: 35 N·m (3.5 kgf·m, 26 lbf·ft) 10
6
9
6. Insert the bottom side of hoist cylinder (1) to the
3, 4
installation position of dump body. Insert spacers 2
(6) (2 used) in the installation position. Insert pin 11
(2) and spacer (7) to the installation position of 7
hoist cylinder (1).
12
Install bolts (8) to hoist cylinder (1). 8
Install plate (10), washers (12) (3 used), and bolts
(11) (3 used) to hoist cylinder (1).
: 24 mm
: 270 N·m (27 kgf·m, 199 lbf·ft)
: 19 mm T8R7-03-09-002
: 110 N·m (11 kgf·m, 81 lbf·ft)
7. Install O-rings (25, 26) to hydraulic hoses (15, 18).

1
8. Install hydraulic hoses (15, 18) to hoist cylinder (1)
with split flanges (13, 16) (2 used each) and
socket bolts (14, 17) (4 used for each).
: 8 mm
: 50 N·m (5 kgf·m, 37 lbf·ft)
: 12 mm
: 140 N·m (14 kgf·m, 103 lbf·ft)
9. Remove the fixture securing the piston rod and

the cylinder tube.
13, 14
10. Install elbow S (3) of lubrication hose (4) to adap- 15, 25
tor (2) of pin (2).
: 16 to 17 mm 16, 17
: 30 N·m (3.0 kgf·m, 22 lbf·ft)
18, 26
3, 5
11. Install lubrication hoses (4, 5) to elbows S (3) (2 T8R7-03-09-001
used).
: 17 mm
: 30 N·m (3.0kgf·m, 22 lbf·ft)
W8R7-E-01(20160803) W3-3-4
12. Install hoist cylinder (1) on the other side by taking
steps 1 through 11.
27
13. Check oil level of the hydraulic oil tank. If the oil 1
level is low, refill the oil.
14. Set hoist lever to the float position. Start the en-
gine and keep to idling condition. Due to this, hy-
draulic oil circulates by going through the hoist
system. Loosen plugs (27) on both hoist cylinders
(1). Bleed air until clean hydraulic oil without
mixed air flows out from the cylinder.
: 19 mm
: 40 N·m (4 kgf·m, 30 lbf·ft)
15. Check that no leakage exists at hoist cylinder (1)

and each piping.
16. If there is any leak from hoist cylinder (1), disas-

semble and check that the seal, O-ring, and dust T8R7-03-09-001
seal is not damaged. Then, repeat the above
steps.
17. Re-check oil level of the hydraulic oil tank. Refill oil
if necessary.
W8R7-E-01(20160803) W3-3-5
DISASSEMBLY OF HOIST CYLINDER
16 17 18 19 20 21 29, 30 31 32 33 34
35
36
28
27
37
15
42
41
40 39 38
2 3 4 5
Port at B Rod
12, 13 14
9, 10 7, 8 6 Trans Tube
Port at A Bottom
Sectional View of Hoist Cylinder
View A W8R7-03-03-003
1- Cylinder Tube 12 - Bolt (16 Used) 27 - Stopper Ring 37 - Wiper Seal

2- Piston Rod 13 - Washer (16 Used) 28 - Stopper Ring 38 - U-Cup Rod Seal
3- Cylinder Rod 14 - Bushing 29 - O-Ring 39 - Rod Seal
4- Cylinder Rod 15 - Wear Ring (2 Used) 30 - Backup Ring 40 - Rod Seal
5- Cylinder Head 16 - Wear Ring (2 Used) 31 - Wear Ring 41 - Wear Ring
6- Pistons 17 - Wear Ring (2 Used) 32 - Rod Seal 42 - Wear Ring
7- Socket Bolt (7 Used) 18 - Piston Ring 33 - U-Cup Rod Seal
8- Washer (7 Used) 19 - Piston Ring 34 - Wiper Seal
9- Plug 20 - Piston Ring 35 - U-Cup Rod Seal
10 - O-Ring 21 - O-Ring 36 - Wiper Seal
W8R7-E-01(20160803) W3-3-6
Disassembly of Hoist Cylinder

(1030 lb)
1. Put the matching marks on cylinder head (5) and

cylinder tube (1).
CAUTION: Cylinder tube (1) weight: 110 kg

(243 lb)

(16 used) from cylinder tube (1). Slide out and
remove cylinder tube (1) from cylinder head (5),
cylinder rods (4, 3), and the piston rod (2) as-
sembly.
: 24 mm
3. Remove stopper ring (27) from the inner side of

cylinder rod (3).

(7 used) from piston rod (2).
：17 mm
5. Remove piston (6) from piston rod (2).
CAUTION: Piston rod (2) weight: 90 kg (198

lb)
6. Slide out and remove piston rod (2) from cylinder

rods (3, 4) and the cylinder head (5) assembly.
7. Remove stopper ring (28) from the inner side of

cylinder rod (4).
W8R7-E-01(20160803) W3-3-7
16 17 18 19 20 21 29, 30 31 32 33 34
35
36
28
27
37
15
42
41
40 39 38
2 3 4 5
Port at B Rod
12, 13 14
9, 10 7, 8 6 Trans Tube
Port at A Bottom
View A W8R7-03-03-003
W8R7-E-01(20160803) W3-3-8
CAUTION: Cylinder rod (4) + Cylinder head

(5) weight: 130 kg (287 lb)
8. Slide out and remove cylinder rod (4) and the

cylinder head (5) assembly from cylinder rods (3).
CAUTION: Cylinder head (5) weight: 22 kg

(49 lb)
9. Remove cylinder head (5) from cylinder rod (4).
10. Remove wear ring (31), rod seal (32), U-cup rod
seal (33), and wiper seal (34) from the inner side
of cylinder head (5). Discard wear ring and seal.
11. Remove backup ring (30) and O-ring (29) from the
outside of cylinder head (5). Discard O-ring.
12. Remove wear rings (15) (2 used) and piston ring

(18) from the outer side of piston (6).
13. Remove O-ring (21) from the outer side of piston

rod (2). Discard O-ring.
of cylinder rod (3). Discard wear ring and seal.

(19) from the outer side of cylinder rod (3).
of cylinder rod (4).Discard wear ring and seal.

(20) from the outer side of cylinder rod (4).
W8R7-E-01(20160803) W3-3-9
INSPECTION OF HOIST CYLINDER
2 3 4 5
Port at B Rod
14
6 Trans Tube Port at A Bottom
View A W8R7-03-03-003
W8R7-E-01(20160803) W3-3-10
INSPECTION OF HOIST CYLINDER
1. Clean all parts with proper detergent and wipe

with lint-free cloth. Clean all seals and ring
grooves. Confirm no foreign object is in the
grooves.
2. Blow compressed air to cylinder rods (3, 4), cyl-

inder tube (1), and piston rod (2) paths to remove
foreign objects.
3. Check there is no crack on welded section or

deep scratches on cylinder rods (3, 4), cylinder
tube (1), piston rod (2), cylinder head (5), and
piston (6).
Inspect inside of cylinder rods (3, 4) and cylinder
tube (1) by using a light.
Remove bump, dent, and scratch by using the oil
stone and wire brush. Then, clean the parts. If
repair is not possible, replace the part.
4. Check the holes and threads of bolts and screws.

If they are damaged, replace them.
5. Check that bushing (14) at the hoist cylinder

mounting section and mounting part are not se-
verely worn.
If necessary, replace or repair the part.
W8R7-E-01(20160803) W3-3-11
ASSEMBLY OF HOIST CYLINDER
16 17 18 19 20 21 29, 30 31 32 33 34
35
36
28
27
37
15
42
41
40 39 38
2 3 4 5
Port at B Rod
12, 13 14
9, 10 7, 8 6 Trans Tube
Port at A Bottom
View A W8R7-03-03-003
1- Cylinder Tube 12 - Bolt (16 Used) 27 - Stopper Ring 37 - Wiper Seal

2- Piston Rod 13 - Washer (16 Used) 28 - Stopper Ring 38 - U-Cup Rod Seal
3- Cylinder Rod 14 - Bushing 29 - O-Ring 39 - Rod Seal
4- Cylinder Rod 15 - Wear Ring (2 Used) 30 - Backup Ring 40 - Rod Seal
5- Cylinder Head 16 - Wear Ring (2 Used) 31 - Wear Ring 41 - Wear Ring
6- Pistons 17 - Wear Ring (2 Used) 32 - Rod Seal 42 - Wear Ring
7- Socket Bolt (7 Used) 18 - Piston Ring 33 - U-Cup Rod Seal
8- Washer (7 Used) 19 - Piston Ring 34 - Wiper Seal
9- Plug 20 - Piston Ring 35 - U-Cup Rod Seal
10 - O-Ring 21 - O-Ring 36 - Wiper Seal
W8R7-E-01(20160803) W3-3-12
Assembly of Hoist Cylinder
1. Install wear rings (17) (2 used) and piston ring

(20) to the outer side of cylinder rod (4).
2. Install wear ring (42), rod seal (40), U-cup rod

seal (35), and wiper seal (36) to the inner side of
cylinder rod (4).
Install all seals and rings at the correct position
and direction. Refer to the illustration on the right. Wear Ring Rod Seal
U-Cup Rod Seal
(19) to the outer side of cylinder rod (3). Wiper Seal

cylinder rod (3).
and direction. Refer to the illustration on the right.
5. Install O-ring (21) to outer side of piston rod (2).

W8DS-09-15-002
Typical Installation Position and Direction of Seals and Rings
(18) to the outer side of piston (6).
7. Install backup ring (30) and O-ring (29) to the

outside of cylinder head (5).

cylinder head (5).
and direction. Refer to the illustration on the right.
W8R7-E-01(20160803) W3-3-13
28
27
Cushion Range
2 3 4 5
Port at B Rod
12, 13
9, 10 7, 8 6 Trans Tube
Port at A Bottom
View A W8R7-03-03-003
W8R7-E-01(20160803) W3-3-14
CAUTION: Cylinder head (5) weight: 22 kg CAUTION: Cylinder tube (1) weight: 110 kg
(49 lb) (243 lb)
9. Install cylinder head (5) to cylinder rod (4). 16. Slide in and install cylinder tube (1) to cylinder
rods (4, 3) and piston rod (2). Align the matching
marks made when disassembling on cylinder
CAUTION: Cylinder rod (4) + Cylinder head
head (5) and cylinder tube (1).
(5) weight: 130 kg (287 lb)
10. Slide in and install cylinder rod (4) and the cylin- used).
der head (5) assembly to cylinder rod (3). Install cylinder head (5) to cylinder tube (1) with
11. Install stopper ring (28) to the inner side of cylin- : 24 mm
der rod (4). : 270 N·m (27 kgf·m, 199 lbf·ft)
CAUTION: Piston rod (2) weight: 90 kg (198 18. If plug (9) is removed, install O-ring (10) and plug
lb) (9) to cylinder tube (1).
: 19 mm
12. Slide in and install piston rod (2) to cylinder rods : 40 N·m (4.0 kgf·m, 30 lbf·ft)
(3, 4) and the cylinder head (5) assembly.
13. Install piston (6) to piston rod (2).
14. Apply LOCTITE #271 or equivalent screw lock

material to the thread part of socket bolts (7) (7
used).
Install piston (6) to piston rod (2) with socket bots
：17 mm
: 550 N·m (55 kgf·m, 406 lbf·ft)
15. Install stopper ring (27) to the inner side of cylin-

der rod (3).
W8R7-E-01(20160803) W3-3-15
(Blank)
W8R7-E-01(20160803) W3-3-16
HOIST DEVICE / Dump Body
REMOVAL AND INSTALLATION DUMP
BODY
1 2 5
Removal
1. Prepare a hoist that can handle weight over 80
tons.
CAUTION: When removing the dump body,
confirm that the dump body is completely
seated on the frame.
2. Operate the hoist lever and let dump body (1)
completely seated on frame (2).
3. Measure the clearance (X, X’) between dump W8DS-03-04-001
body hinge bracket (3) and frame hinge bracket 14

(4). Record the thickness of necessary shim (6)
pack. Inspect four sections at left and right sides. 1
NOTE: Clearances have been adjusted by using
2.3 mm (0.09) and 4.5 mm (0.18 in) thick-
3 4
ness shims as each clearance becomes 0.5
to 3 mm (0.02 to 0.12 in).
4. Remove lubrication hoses (8) (2 used) from el- 5

bows S (7) (2 used) of hinge pins (5) (2 used).
Remove elbows S (7) (2 used) when necessary.
: 17 mm, 19 mm
7, 8
5. Operate the hoist lever to lift dump body (1) for 0.6 6
m (24 in). Support the body with a wooden block.
Remove hoist cylinder (14) from mounting section
W8DS-03-04-002
of dump body (1). X X’
For removal of hoist cylinder (14), refer to “Hoist
Cylinder” section (W3-3). 9 1
6. Loosen bolts (10) (8 used) and remove exhaust

pipe (9) from dump body (1) with plates (12) (2
used), bolts (10) (8 used), and washers (11) (8
used).
Disconnect pipe (9) from the exhaust pipe end of
frame (2).
10, 11
Remove ring seals (13) (2 used) from pipe (9)
when necessary.
12
: 17 mm
7. Remove pipe (9) at the other side from frame (2) 2

and dump body (1) by taking the same procedure.
13
W8DS-03-04-003
W8R7-E-01(20160803) W3-4-1
8. Loosen nuts (17) (4 used) on ball joints (15) (2
used). Remove body angle sensor rod (18), ball
1
joints (15) (2 used), nuts (17) (4 used), and
15, 16, 17
washers (16) (2 used) from angle sensor attached
sections of dump body (1) and frame (2). 18
: 13 mm
CAUTION: Rock ejector (19) weight: 58 kg

W8DS-03-04-004
(128 lb)
9. Loosen lock nuts (22) (4 used) of rock ejectors 20, 21,

22
(19) (2 used).
Remove rock ejectors (19) (2 used) together with
bolts (20) (2 used), washers (21) (4 used), and
lock nuts (22) (4 used) from dump body (1). Detail of A
: 36 mm
19
W8DS-03-04-005
10. Remove mud shield rubbers (23, 24, 25, 26) and 23, 28,
(27) (2 used) by loosening bolts (28) (56 used), 29, 30
nuts (29) (56 used), and washers (30) (56 used).
: 17 mm
25, 28,
29, 30
27, 28,
29, 30
24, 28,
29, 30
26, 28,
29, 30
27, 28,
29, 30
W8DS-03-04-006
W8R7-E-01(20160803) W3-4-2
11. Remove lock nuts (32) (2 used) and bolt (31) from
hinge pin (5). 49
1 4
: 36 mm
CAUTION: Hinge pin (5) weight: 51 kg (112 lb)

3
12. Lightly tap hinge pin (5) with a hammer and re-
move from hinge bracket (3) of dump body (1).
Remove shim (6) packs (2 used). 5
13. Remove other hinge pin (5) in the same procedure 31, 32
by taking steps 11 and 12.
14. Inspect bushings (49) (2 used) of hinge bracket (4)

on frame (2) and remove if necessary.
W8DS-03-04-002
15. Install lifting tool hooks to four positions of lifting 6
brackets installed to dump body (1).
CAUTION: Dump body (1) weight: 26000 kg

(57300 lb)
1
16. Hoist and remove dump body (1) from frame (2).
Place dump body (1) on the holder with appropri-
2
ate strength and height.
W8DS-03-04-007
W8DS-03-04-008
a-Holder
W8R7-E-01(20160803) W3-4-3
IMPORTANT: Do not store the dump body for a
long period with body pads attached.
IMPORTANT: Before removing body pads (33) (18

used), put an alignment mark on
each body pads, shims, and dump
40, 41, 42
body. These marks are used when
33, 40,
re-assembling the body pads. 33
41, 42
17. If necessary, remove body pads (33) (18 used), by

taking the following steps.
Loosen bolts (36) (108 used) which secures body
pads (33) (18 used). Remove bolts (36) (108
used) and washers (37) (108 used) from dump
body (1).
Shim packs (40, 41, 42) (18 used) are removed A
together.
: 19 mm
A Section A-A
36, 37 36, 37
W8DS-03-04-009
W8R7-E-01(20160803) W3-4-4
Inspection
1. Clean the dump body thoroughly with steam.

Clean all of small metal parts with appropriate 33 33
solvent (mineral spirit).
2. Check condition of each dump body pad (33).

Replacement of body pads (33) is necessary
when rubber section of the body pad gets thinner
than 54.5 mm (2.15 in).
A
3. Check all welded sections for cracks and damage.
Make necessary repairs.
4. Check the dump body surface for sever wear. Section A-A
A
Check the entire dump body for warp of the plate W8DS-03-04-009
and holes.
Make a necessary repair such as replacement of
parts, correction of warp, enforcement, and
painting as required.
5. Check hinge pin (5) and bushing (49). If a com-

ponent is severely worn or damaged, replace it.
5
W8DS-03-04-002
49
W8R7-E-01(20160803) W3-4-5
Installation
IMPORTANT: When install the new dump body, not 40, 41, 42
use this manual. Refer to “On-Site
33, 40, 33
Assembly Manual”.
41, 42
1. Prepare a hoist that can handle weight over 80

tons.
2. Lubricate bolts (36) (108 used).

Align alignment marks and install body pads (33)
(18 used).
A
Install body pads (33) (18 used) and shim packs
(40, 41, 42) (18 used) to the original mounting
position of dump body with bolts (36) (108 used)
and washers (37) (108 used). A Section
断面 A A-A
Tighten bolts (36) (108 used) evenly. 36, 37 36, 37
W8DS-03-04-009
: 19 mm
: 90 N·m (9.0 kgf·m, 66 lbf·ft)
3. Install hoisting tool hooks to four positions of hoist

brackets installed to dump body (1). 1
CAUTION: Dump body (1) weight: 26000 kg

(57300 lb)
4. Hoist dump body (1), move to a position right a

above frame (2). Slowly lower down onto the
connecting position of frame (2).
W8DS-03-04-008
a-Holder
W8DS-03-04-007
W8R7-E-01(20160803) W3-4-6
5. Sufficiently apply anti-seize lubricant onto the in-
ner surfaces of dump body hinge bracket (3) and 4 49
bushing (49). 1
6. Align holes on hinge pins (5) on dump body hinge

bracket (3) and frame hinge bracket (4).
3
7. Adjust the shim (6) pack to the required thickness
as the clearance (X, X’) between dump body 5
hinge bracket (3) and frame hinge bracket (4)
becomes 0.5 to 3 mm (0.02 to 0.12 in) by referring
31, 32
the size when removing them.
8. Apply grease to hinge pin (5).
CAUTION: Hinge pin (5) weight: 51 kg (112 lb) 6

W8DS-03-04-002
X X’
9. Attach adjusted shim (6) packs to both sides of
dump body hinge brackets (3) and insert hinge pin
(5).
10. Align the bolt (31) hole on hinge pin (5) and bolt
(31) hole on dump body hinge bracket (3).
Install bolt (31) and lock nuts (32) (2 used).
: 36 mm
: 950 N·m (95 kgf·m, 700 lbf·ft)
11. Install other hinge pin (5) by taking above steps 5

to 10.
12. Hoist dump body (1) for 0.6 m (24 in). Support the
dump body with a wooden block. 14
Install hoist cylinders (14) (2 used) to dump body
(1).
Refer to “Hoist Cylinder” section (W3-3) for de-
tailed installation procedure.
13. Operate the hoist lever to lower dump body (1)

and let dump body (1) completely seated on frame
(2).
T8R7-03-09-001
W8R7-E-01(20160803) W3-4-7
14. Let dump body (1) seated on frame (2). In this
condition, measure the clearance between body 1 2
guide (50) of dump body (1) and body guide plate
(51) of frame (2). Confirm that the clearance is
within 3 to 6 mm (0.12 to 0.25 in).
If the clearance is not within this range, adjust by
using shims (52, 53).
: 36 mm
: 950 N·m (95 kgf·m, 700 lbf·ft)
15. Check and adjust body guide (50) at the other W8DS-03-04-001
side by taking the same procedure.
3 to 6 mm
52, 53
16. If mud shield rubbers (23, 24, 25, 26) and (27) (2
used) are removed, install mud shield rubbers (23,
24, 25, 26) and (27) (2 used) to the body with bolts 50 51 W8DS-03-04-012
(28) (56 used), nuts (29) (56 used), and washers

(30) (56 used).
: 17 mm 23, 28,
: 50 N·m (5.0 kgf·m, 37 lbf·ft) 29, 30
25, 28,
CAUTION: Rock ejector (19) weight: 58 kg 29, 30
(128 lb) 24, 28,
27, 28, 29, 30
29, 30
17. Install rock ejectors (19) (2 used) with bolts (20) (2
26, 28,
used), washers (21) (4 used), and lock nuts (22)
29, 30
(4 used).
: 36 mm 27, 28,
: 950 N·m (95 kgf·m, 700 lbf·ft) 29, 30
W8DS-03-04-006
20, 21,
22
Detail of A
A
A
19
W8DS-03-04-005
W8R7-E-01(20160803) W3-4-8
18. Install body angle sensor rod (18) and the ball
joint (15) (2 used) assemblies to angle sensor in-
stallation sections of dump body (1) and frame (2)
with nuts (17) (4 used) and washers (16) (2 used).
When the space between mounting cores of body
angle sensor rod (18) is 454±5 mm (17.9±0.2 in), 1
install as the length of angle sensor lever is less
than 50 mm as the bracket (50) dimension. Refer 454±5 mm *Less than 50 mm
to the illustration on the right for details.
: 13 mm
: 20 N·m (2.0 kgf·m, 15 lbf·ft) 2
Lever
50
W8R7-03-04-001
1
19. Install ring seals (13) (2 used) to exhaust pipe (9). 9
Connect pipe (9) to the exhaust pipe end at the 13
frame (2) side.
Install pipe (9) to dump body (1) with plates (12) (2
used), bolts (10) (8 used), and washers (11) (8 10, 11
used).
: 17 mm 12
: 50 N·m (5.0 kgf·m, 37 lbf·ft)
20. Connect pipe (9) at the other side to frame (2) and 2
dump body (1) by taking the same procedure.
W8DS-03-04-003
21. Install elbows S (7) (2 used) to hinge pins (5) (2

used).
Connect lubrication hoses (8) (2 used) to elbows
S (7) (2 used) of hinge pins (5) (2 used).
: 17 mm, 19 mm
: 30 N·m (3.0 kgf·m, 22 lbf·ft)
5
7, 8
W8DS-03-04-002
W8R7-E-01(20160803) W3-4-9
(Blank)
W8R7-E-01(20160803) W3-4-10
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
SECTION 4
AC DRIVE CONTROL DEVICE
CONTENTS
Group 1 Control Cabinet Removal and Installation of
Removal and Installation of DSC DC/DC Converters HDR10 ...... W4-1-9-31
Control Cabinet ............................... W4-1-1-1 Removal and Installation of
Removal and Installation of Control Power (CS) Unit .................. W4-1-10-1
Rectifier (REC) Unit ......................... W4-1-2-1 Removal and Installation of Control
Removal and Installation of Rectifier (REC) Power (CS) Unit Internal Parts ......... W4-1-11-1
Unit Internal Parts .............................. W4-1-3-1 Removal and Installation of Auxiliary Alternator
Removal and Installation of Field Regulator (AFR) Unit ............... W4-1-12-1
Inverter (INV) Unit ........................... W4-1-4-1 Removal and Installation of Auxiliary Alternator
Removal and Installation of Field Regulator (AFR) Unit
Inverter (INV) Unit Internal Parts .... W4-1-5-1 Internal Parts ................................... W4-1-12-5
Removal and Installation of Main Alternator Removal and Installation of Auxiliary Inverters
Field Regulator (MFR) Unit ................ W4-1-6-1 INV301 and INV302 ......................... W4-1-13-1
Removal and Installation of Main Alternator Removal and Installation of Relays .... W4-1-14-1
Field Regulator (MFR) Unit Removal and Installation of Coolant
Internal Parts ..................................... W4-1-6-5 Level Sensor WS301 ....................... W4-1-15-1
Removal and Installation of FAN Unit .. W4-1-7-1 Removal and Installation of Heater .... W4-1-16-1
Removal and Installation of Removal and Installation of Auxiliary
Drive System Controller (DSC) .......... W4-1-8-1 Excitation Unit Current Transformer
Removal and Installation of DSC CT301 ............................................. W4-1-17-1
Drive Control Board VDC06 ............... W4-1-9-1 Removal and Installation of Pump
Removal and Installation of DSC PUMP301 ...................................... W4-1-18-1
Communication Control Board Coolant Change Procedures ............ W4-1-19-1
VDC07 ............................................. W4-1-9-5
Removal and Installation of DSC Group 2 Grid Box
Interface Board VIO13 ..................... W4-1-9-9 Removal and Installation of Grid Box ...... W4-2-1
Removal and Installation of DSC
Interface Board VIO14 ................... W4-1-9-13 Group 3 Alternator Cooling Blower
Removal and Installation of DSC Removal and Installation of
Interface Board VIO15 ................... W4-1-9-15 Alternator Cooling Blower ..................... W4-3-1
Removal and Installation of DSC
DC/DC Converters AVR302 and Group 4 Wheel Motor Cooling Blower
AVR303 ........................................... W4-1-9-21 Removal and Installation of
Wheel Motor Cooling Blower ................. W4-4-1
W8R7-E-01(20160803) 8R7W-4-1
(Blank)
W8R7-E-01(20160803) 8R7W-4-2
AC DRIVE CONTROL DEVICE / Control Cabinet
CONTROL CABINET
Removal 1

surface.

W8DS-04-01-001
A B E2R C E2L
3. Disconnect the grid box harness from control

cabinet (1) at connectors P1, P2, P3, P4, P5, N1,
N2, N3, N4, and N5.
：17 mm
Detail of Section A
W8R7-04-01-001
4. Disconnect the left wheel motor harness from For Right Wheel Motor For Left Wheel Motor
control cabinet (1) at connectors U2L, V2L, and
W2L. Disconnect ground harness at E2L.
：19 mm
5. Disconnect the right wheel motor harness from

control cabinet (1) at connectors U2R, V2R, and
W2R. Disconnect ground harness at E2R.
：19 mm
W8DS-04-01-003 W8DS-04-01-004
W2R V2R U2R U2L V2L W2L
Detail of Section B Detail of Section C
W8R7-E-01(20160803) W4-1-1-1
6. Disconnect all harnesses at external connectors
from terminal block TB3 on left side of control
cabinet (1). 2 3 4 5 6 7 8 9 10
2- Wheel Motor Cooling Blower Harness (U, V, W)
3- Alternator Cooling Blower Harness (U, V, W) 1
4- Auxiliary Alternator Excitation Winding (P, N)
5- Reduction Gear Cooling Motor Harness (U, V, W)
6- Grid Box Blower Harness R1 (U, V, W)
7- Grid Box Blower Harness R2 (U, V, W) D
9- Grid Box Blower Harness L1 (U, V, W)
10 - Grid Box Blower Harness L2 (U, V, W)
E
W8R7-04-01-002

high-voltage harnesses by using a voltage
detecting rod. Disconnect the main generator U11 V11 W11
N11
harnesses from left side of control cabinet (1) at P11
connectors P11 and N11. Disconnect the auxiliary
generator harnesses from left side of control
cabinet (1) at connectors U11, V11, and W11.
W8DS-04-01-007
Detail of Section D
8. Remove clamps of harness from left side of 12, 14, 19, 20

11, 13, 17, 20
control cabinet (1). 12, 14, 18, 20
11 - Bracket (8 Used) 16 - Bolt (4 Used)
13 - Clamp (14 Used) 18 - Bolt (8 Used)
15 - Clamp (2 Used) 20 - Washer (28 Used)
：17 mm
12, 15, 18, 20 11, 13, 16, 20
W8R7-04-01-003
Section E
W8R7-E-01(20160803) W4-1-1-2
9. Disconnect the harness from terminal block on
right side of control cabinet (1) at connectors CN1,
CN2, CN3, and CN4. CN2 CN3
CN1 CN4
10. Remove clamps of harness from right side of
control cabinet (1).
1
21 - Clip (2 Use) 25 - Spacer (4 Used)
22 - Clip (2 Use) 26 - Bolt (4 Used)
23 - Clip (2 Use) 27 - Washer (4 Used)
24 - Clip (2 Use)
：17 mm 21, 23,
22, 24, 25, 26,
25, 26, 27
27
W8R7-04-01-004

1
detecting rod. Disconnect the main generator F
harness from the left side of control cabinet (1) at
connectors U1, V1, and W1. Disconnect ground
E1
harness at E1. E
：19, 24 mm
12. Disconnect ground harness E from the right side

of control cabinet (1).
：19 mm
W8R7-04-01-005
U1 V1 W1
E1
W8DS-04-01-010
Detail of Section F
W8R7-E-01(20160803) W4-1-1-3
13. Disconnect hose (29) from elbow S (28) of control
cabinet (1). 28 29 1
：60 mm
14. Loosen hose clamps (31) (8 used). Remove

rubber hoses (30) (2 used). Disconnect air ducts
(40) (2 used) from control cabinet (1).
31
：7 mm or
30
40
W8R7-04-01-006
15. Loosen mounting bolts (32) (8 used) and nuts (38) 1

(8 used) of control cabinet (1). Remove bolts (32)
(8 used), washers (33) (8 used), washers (36) (8
used), washers (37) (8 used), and nuts (38) (8
used).
Remove the lower part of cushions (35) (8 used)
when necessary.
：32 mm
W8R7-04-01-007
32
33
35
36
38 37
W8R7-04-01-008
Detail of Section G
W8R7-E-01(20160803) W4-1-1-4
Wire Rope 1
CAUTION: Control cabinet (1) weight:
2400 kg (5290 lb)
16. Attach a lifting tool (a) onto control cabinet (1) with
bolts (b) (10 used).
：30 mm b
: 196 N·m (19.6 kgf·m, 145 lbf·ft)
17. Hoist control cabinet (1). Remove control cabinet
(1) from frame (39). Keep hoisted control cabinet
(1) horizontally.
18. Lower and place control cabinet (1) on an

appropriate holder.
W8DS-04-01-018
Shackle a
19. Remove plates (34) (4 used) and cushions (35) (8
used) from frame (39) when necessary.
34
35
39
W8R7-04-01-008
W8R7-E-01(20160803) W4-1-1-5
Installation
1. Set cushions (35) (8 used) and plates (34) (4

used) to eight installation positions on control
cabinet (1) on frame (39). 34
35
39
W8R7-04-01-008
CAUTION: Control cabinet (1) weight: Wire Rope 1

2400 kg (5290 lb)
2. Attach a lifting tool (a) onto control cabinet (1) with

bolts (b) (10 used).
：30 mm b
: 196 N·m (19.6 kgf·m, 145 lbf·ft)
3. Hoist and align control cabinet (1) with the

installation position on frame (39). Keep hoisted
control cabinet (1) horizontally.
IMPORTANT: When running while mounting a

lifting tool (a) to control cabinet (1), a W8DS-04-01-018
Shackle
there is a possibility that the crack in
control cabinet (1). After installation
of control cabinet (1), remove a
lifting tool (a).
W8R7-E-01(20160803) W4-1-1-6
used). Install control cabinet (1) to frame (39) with
bolts (32) (8 used), washers (33) (8 used),
washers (36) (8 used), washers (37) (8 used), and
nuts (38) (8 used).
: 32 mm
: 750 N·m (75 kgf·m, 550 lbf·ft)
W8R7-04-01-007
32
33
39
35
36
38 37
W8R7-04-01-008
Detail of Section G
5. Install rubber hoses (30) (2 used) with hose
clamps (31) (8 used). Connect air ducts (40) (2 28 29 1
used) to control cabinet (1).
：7 mm or
6. Connect hose (29) to elbow S (28) of control

cabinet (1). 31
：60 mm
：380 N·m (38 kgf·m, 280 lbf·ft) 30
40
W8R7-04-01-006
W8R7-E-01(20160803) W4-1-1-7
7. Connect main generator connectors U1, V1, and
W1 to right side of control cabinet (1). Connect
ground harness at E1. 1
F
Secure the harness to control cabinet (1).
：24 mm
：72 N·m (7.2 kgf·m, 53 lbf·ft) E1
E
：19 mm
：34 N·m (3.4 kgf·m, 25 lbf·ft)
8. Connect ground harness E of control cabinet (1).

：19 mm
：34 N·m (3.4 kgf·m, 25 lbf·ft)
W8R7-04-01-005
U1 V1 W1
E1
W8DS-04-01-010
Detail of Section F
9. Connect the terminal board harnesses on right
side of control cabinet (1) at connectors CN1, CN2,
CN3, and CN4. CN2 CN3
CN1 CN4
10. Install clamps of harnesses to the right side of
1
21 - Clip (2 Use) 25 - Spacer (4 Used)
22 - Clip (2 Use) 26 - Bolt (4 Used)
23 - Clip (2 Use) 27 - Washer (4 Used)
24 - Clip (2 Use)
：17 mm 21, 23,
：50 N·m (5.0 kgf·m, 37 lbf·ft) 22, 24, 25, 26,
25, 26, 27
27
W8R7-04-01-004
W8R7-E-01(20160803) W4-1-1-8
11. Connect main generator connectors P11 and N11
to control cabinet (1). Connect auxiliary generator
2 3 4 5 6 7 8 9 10
connectors U11, V11, and W11 to control cabinet
(1). 1
：17 mm
：14 N·m (1.4 kgf·m, 10 lbf·ft)
S
E
12. Connect external connectors to terminal block
TB3 on control cabinet (1). At this time, connect in
E
accordance with identification tags attached to
both ports and harnesses.
2- Wheel Motor Cooling Blower Harness (U, V, W)
3- Alternator Cooling Blower Harness (U, V, W)
4- Auxiliary Alternator Excitation Winding (P, N) W8R7-04-01-002
5- Reduction Gear Cooling Blower Harness (U, V, W)
9- Grid Box Blower Harness L1 (U, V, W) U11 V11 W11
N11
10 - Grid Box Blower Harness L2 (U, V, W) P11
W8DS-04-01-007
Detail of Section D
13. Install clamps of harness to the left side of control 12, 14, 19, 20
cabinet (1). 11, 13, 17, 20
11 - Bracket (8 Used) 16 - Bolt (4 Used) 12, 14, 18, 20
15 - Clamp (2 Used) 20 - Washer (28 Used)
：17 mm
Bolt (16), (17)
：12 N·m (1.2 kgf·m, 8.9 lbf·ft)
Bolt (18), (19) 12, 15, 18, 20 11, 13, 16, 20
：15 N·m (1.5 kgf·m, 11 lbf·ft) Section E W8R7-04-01-003
W8R7-E-01(20160803) W4-1-1-9
14. Connect right wheel motor connectors U2R, V2R,
and W2R to control cabinet (1). At this time, 1
connect in accordance with identification tags
attached to both ports and harnesses. Connect
ground harness to E2R.
：19 mm
Connectors U2R, V2R, W2R
：45 N·m (4.5 kgf·m, 33 lbf·ft)
Connectors E2R
：21 N·m (2.1 kgf·m, 15 lbf·ft)
15. Connect left wheel motor connectors U2L, V2L,

and W2L to control cabinet (1). At this time,
connect in accordance with identification tags
attached to both ports and harnesses. Connect
ground harness to E2L. W8DS-04-01-001
A B E2R C E2L
：19 mm
Connectors U2L, V2L, W2L
：45 N·m (4.5 kgf·m, 33 lbf·ft) For Right Wheel Motor For Left Wheel Motor
Connectors E2L
：21 N·m (2.1 kgf·m, 15 lbf·ft)
W8DS-04-01-003 W8DS-04-01-004
W2R V2R U2R U2L V2L W2L
Detail of Section B Detail of Section C
16. Connect grid box connectors P1, P2, P3, P4, P5,
N1, N2, N3, N4, and N5 to control cabinet (1). At
this time, connect in accordance with identification
tags attached to both ports and harnesses.
：17 mm
：14 N·m (1.4 kgf·m, 10 lbf·ft)
Detail of Section A
W8R7-04-01-001
W8R7-E-01(20160803) W4-1-1-10
REMOVAL AND INSTALLATION OF REC- 1
TIFIER (REC) UNIT
Removal 2
1. Open the front doors (upper right and lower right)
of control cabinet (1) by using the door open/close
handle.
2. Remove M8 bolts (4 used) to remove the access

cover (upper right).
: 13 mm
3. Remove M8 bolts (4 used) to remove the access

cover (lower right).
: 13 mm Control Cabinet (1) Front View T8R7-01-02-016
4. Remove bolts (4) (6 used in front and 2 used on

top) holding protection cover (3) at the front of
REC unit (2). Remove protection cover (3) from
REC unit (2).
: 13 mm
5. Remove M8 bolts (20 used) from the reverse side 2

cover (left) of control cabinet (1). Remove the re-
verse side (left) cover from control cabinet (1).
: 13 mm
6. Perform voltage detection.
REC Unit (2) W8DS-04-01-022
W8DS-04-01-023
W8R7-E-01(20160803) W4-1-2-1
5
7. Disconnect cooling pipe connection coupler (5) Ring
Socket (Machine Side)
from the reverse side of the control cabinet in the
following procedures.
7-1. Cut wire bundle band (6) used to prevent cou-
pler (5) from disconnecting.
7-2. Pull to slide the ring of coupler (5) straight
backward.
Slide W8DS-04-01-024
NOTE: When separating coupler (5), small amount Plug (REC Unit Side)
of antifreeze liquid may spill. Before sepa-
rating coupler (5), wrap coupler (5) with a
clean cloth. Thoroughly wipe off the spilled
antifreeze liquid.
8. Remove copper bar connection bolts (7) (3 used)

from the reverse side of the control cabinet. Re- 5
move copper bars (8) (3 used) from the reverse
side of the control cabinet.
: 19 mm
9. Remove bolts (2 used) holding REC unit (2) from

the reverse side of the control cabinet.
: 19 mm 7, 8 W8DS-04-01-025
Control Cabinet Reverse Side

6
W8DS-04-01-026
5
W8DS-04-01-027
W8R7-E-01(20160803) W4-1-2-2
IMPORTANT: When removing connection bar (10), 14, 17, 18 14, 17, 18
take care not to scratch the optical
cable.
10. Remove bolts (11) (4 used) and bolts (12) (4 used)
from the bottom and the top of control cabinet
front connection bars (10) (2 used) respectively.
Remove connection bars (10) (2 used) from the
control cabinet front. 14,
15,
: 17 mm, 19 mm 16
19
IMPORTANT: When cutting off wire bundle band
(14), take care not to cut the electri- 13
cal circuit wires.
11. Disconnect wires (15) connected to voltage sen-
sor DCPT (13) (3 used) in the following proce- 10, 11, 12
W8DS-04-01-028
20, 21
dures.
Control Cabinet Front Side
11-1. Cut to remove wire bundle band (14) from the
wires.
11-2. Remove screws (16) (6 used) holding wires (15)
connected to the top side terminals of voltage
sensor DCPT (13) (3 used). Remove wires (15)
from the terminals of voltage sensor DCPT (13)
(3 used).

(14), take care not to cut the electri-
cal circuit wires.
12. Separate wire bundle bands (14) (2 used) holding
wire connectors (18) (2 used) connected to cur-
rent sensors HCT (17) (2 used). Remove wire
connectors (18) (2 used) from current sensor HCT
(17) (2 used).
13. Remove connector CN1 (19).
14. Remove M5 screws (21) (2 used) from ground

lines (20) (2 used) on REC unit (2) side. Remove
ground lines (20) (2 used) from REC unit (2).
20, 21
W8DS-04-01-029
REC Unit (2) Lower-Right Front View
W8R7-E-01(20160803) W4-1-2-3
15. Remove bolts (22) (2 used) holding the upper 22 22
section of REC unit (2).
: 13 mm
16. Remove bolts (23) (2 used) holding the lower sec-

tion of REC unit (2) to the reverse side of the con-
trol cabinet.
: 19 mm
CAUTION: Weight of REC unit (2): 60 kg (132

lb)
17. While paying attention to the following points, take
REC unit (2) out of the front side of the control
cabinet. W8DS-04-01-028
• Be careful not to allow the REC unit to come in 23 23
contact with wires. Control Cabinet Front Side
• Be careful not to allow the REC unit to come in
contact with the front cover packing. The packing 22 22
may come off.
W8DS-04-01-030
W8R7-E-01(20160803) W4-1-2-4
Installation
CAUTION: Weight of REC unit (2): 60 kg (132

lb)
1. While paying attention to the following points, in- 2
stall REC unit (2) to control cabinet (1).
contact with wires.
contact with the front cover packing. The packing
REC Unit (2) W8DS-04-01-022
may come off.
1
2. Install the lower section of REC unit (2) to the front
side of the control cabinet with bolts (23) (2 used). 2
: 19 mm
3. Install REC unit (2) to the reverse side of the con-

trol cabinet with bolts (9) (2 used).
: 19 mm
4. Install copper bars (8) to the reverse side of the

control cabinet with bolts (7) (3 used).
Control Cabinet (1) Front View T8R7-01-02-016
: 19 mm
23 W8DS-04-01-028
Control Cabinet Front Side 23
7, 8 Control Cabinet Reverse Side W8DS-04-01-025
Detail A [Before Installing Coupler (5)] W8DS-04-01-027
W8R7-E-01(20160803) W4-1-2-5
5. Install connection bar (10) to the front of the con- 14, 17, 18 14, 17, 18
trol cabinet with bolts (11) (4 used) and bolts (12)
(4 used).
: 17 mm, 19 mm
6. Connect ground lines (20) (2 used) with screws

(21) (2 used). 14,
15,
7. Connect connector CN1 (19). 16
19
8. Connect wire connectors (18) (2 used) to current 13
sensors HCT (17) (2 used) in the following pro-
cedures.
8-1. Connect wire connectors (18) (2 used) to cur- W8DS-04-01-028
rent sensors (17) (2 used). 20, 21 10, 11, 12
8-2. Fasten wire connectors (18) (2 used) with wire
bundle band (14) (2 used).
9. Connect wires (15) (3 used) to voltage sensor

DCPT (13) (3 used) in the following procedures.
9-1. Connect wires (15) (3 used) to the terminals of 20, 21
voltage sensor DCPT (13) (3 used) with screws
(16) (6 used).
9-2. Fasten wires (15) (3 used) with wire bundle
band (14) (3 used).
W8DS-04-01-029
REC Unit (2) Lower-Right Front View
W8R7-E-01(20160803) W4-1-2-6
Ring 5
10. Install cooling pipe connection coupler (5) to the Socket (Machine Side)
reverse side of the control cabinet in the following
procedures.
10-1. Wipe off antifreeze liquid and foreign matter
remaining in the socket of coupler (5).
10-2. Clean the plug of coupler (5) with a workshop
towel.
Slide W8DS-04-01-024
10-3. After connecting coupler (5), attach coupler Plug (REC Unit Side)
disconnection prevention wire bundle band (13).
5 13
11. Install upper section of REC unit (2) to the control
cabinet with bolts (22) (2 used).
: 19 mm
12. Check that all circuit wire connectors are securely

connected.
13. After checking the connections of all circuit wire 5 W8DS-04-01-027 W8DS-04-01-026
connectors, put a tightening check mark (black) to

each screw or bolt.
14. Install front protection cover (3) to REC unit (2)

with bolts (4) (6 used in front and 2 used on top). 5
: 13 mm
15. Refill coolant according to the coolant change

procedures.
16. Bleed air according to the air bleeding proce-

dures.
Control Cabinet Reverse Side W8DS-04-01-025
22
22
W8DS-04-01-030
W8DS-04-01-023
W8R7-E-01(20160803) W4-1-2-7
17. Install reverse side cover (left) to control cabinet
(1) with M8 bolts (20 used).
: 13 mm
18. Install the lower-right cover to control cabinet (1)

with M8 bolts (4 used).
: 13 mm
19. Install the upper-right cover to control cabinet (1)

: 13 mm
20. Close the front doors (upper-right and lower-right)

handle.
W8R7-E-01(20160803) W4-1-2-8
REMOVAL AND INSTALLATION OF REC-
TIFIER (REC) UNIT INTERNAL PARTS
Removal and Installation of Rectifier (REC) Unit

Current Sensor HCT1 8 2 3 4
Removal
1. Remove REC unit (1) from the control cabinet by
following the REC unit remove and install proce-
dures (W4-1-2-1).
2. Remove nuts (2) (4 used) and bolts (3) (3 used) 6, 7

from copper bars (4) (2 used) and copper bar (5).
Remove copper bars (4) (2 used) and copper bar
(5) from REC unit (1). 5
: 17 mm, 13 mm
3. Remove screw (7) connecting wire (6) to the re-

sister. Disconnect wire (6) from copper bar (5). REC Unit (1) W8DS-04-01-031
4. Remove current sensor HCT1 (8) from REC unit

(1).
Installation
1. Install current sensor HCT1 (8) to REC unit (1).
9
2. Install copper bars (4) (2 used) and copper bar (5)
to REC unit (1) with nuts (2) (4 used) and bolts (3)
(3 used). Tighten copper bars (4) (2 used) and
copper bar (5) together with insulator (9) and bolts 4 or 5
(3) (3 used). Install the capper bars so that insu- W8DS-04-01-032
lator (9) does not become loose.

: 17 mm, 13 mm
3. Connect wire (6) to copper bar (5) with screw (7).
4. Check that all wires are securely fastened. Put a

tightening check mark (black) to each screw or
bolt.
5. Install REC unit (1) to the control cabinet by fol-

lowing the REC remove and install procedures
(W4-1-2-1).
W8R7-E-01(20160803) W4-1-3-1
Current Sensor HCT2
Removal
following the REC unit remove and install proce- 4 5 3
dures (W4-1-2-1).
2
2. Remove nuts (2) (4 used) and bolts (3) (3 used)
from copper bars (4) (2 used) and copper bar (5).
Remove copper bars (4) (2 used) and copper bar
(5) from REC unit (1).
: 17 mm, 13 mm
8
3. Remove M5 screw (7) connecting wire (6) to the 10
resister. Disconnect wire (6) from copper bar (5).
6, 7
4. Remove screws (10) (2 used). Remove current
sensor HCT2 (8) from REC unit (1). REC Unit (1) W8DS-04-01-033
Installation
1. Install current sensor HCT2 (8) to REC unit (1) 3
with screws (10) (2 used).
2. Install copper bars (4) (2 used) and copper bar (5)

to REC unit (1) with nuts (2) (4 used) and bolts (3) 9
(3 used). Tighten copper bars (4) (2 used) and
copper bar (5) together with insulator (9) and bolts
(3) (3 used). Install the capper bars so that insu-
lator (9) does not become loose. 4 or 5
: 17 mm, 13 mm W8DS-04-01-032
3. Connect wire (6) to copper bar (5) with screw (7).

bolt.
5. Install REC unit (1) to the control cabinet by fol-

lowing the REC unit remove and install proce-
dures (W4-1-2-1).
W8R7-E-01(20160803) W4-1-3-2
Voltage Sensors DCPT1, 2, 3
Removal
following the REC unit remove and install proce-
dures (W4-1-2-1).
2. Spread a sheet under voltage sensors DCPT to

prevent loosing screws.
3. Disconnect wires (5, 6, or 7) that are connected to

voltage sensor DCPT1 (2), DCPT2 (3) or DCPT3
(4) to be replaced from the lower terminal.
4. Remove resistor (8) that is connected to voltage

sensors DCPT1 (2), DCPT2 (3) or DCPT3 (4) to REC Unit (1)
W8DS-04-01-022
be replaced. (M4 bolts (2 used))
5. Remove bolts (2 used) from the reverse side of

voltage sensor DCPT1 (2), DCPT2 (3) or DCPT3 2 4 3
(4). Remove voltage sensor DCPT1 (2), DCPT2
(3) or DCPT3 (4) from REC unit (1).
Installation 6, 8
1. Position to install voltage sensor DCPT 1 (2),
DCPT2 (3) or DCPT3 (4) as illustrated to REC unit
(1) with bolts (2 used). 5, 8 7, 8
2. Connect resistor (8) to the replaced voltage sen-

sor DCPT1 (2), DCPT2 (3) or DCPT3 (4). (M4
screws (9) (2 used))
3. Connect wire (5, 6 or 7) to the lower terminal of

the replaced voltage sensor DCPT1 (2), DCPT2
W8DS-04-01-034
(3) or DCPT3 (4).

3 4
bolt.
5. Install REC unit (1) in the control cabinet by fol-

lowing the REC unit remove and install proce-
dures (W4-1-2-1).
1 2
9
W8DS-04-01-035
Voltage Sensor Installation Direction
W8R7-E-01(20160803) W4-1-3-3
Resistors R9B, R9C, R10B 2 4 3
Removal
1. Refer to Removal and Installation of Rectifier

(REC) Unit (W4-1-2-1). Remove protection cover
from REC unit (1). A
2. Spread a sheet under REC unit (1) in order to

prevent loosing screws.

(b), take care not to cut wire har-
nesses.
3. Cut off wire bundle bands (b) (2 used) which se-

cure resistor R9B (5), R9C (6), or R10B (7).
W8DS-04-01-034
4. Remove screws (8) (2 used). Remove resistor 8

R9B (5), R9C (6), or R10B (7) from voltage sensor
DCPT 1 (2), DCPT 2 (3), or DCPT 3 (4).
b
Installation
c
IMPORTANT: Only resistor R10B (7) is different
from other resistance values.
NOTE: Resistance value of resistors R9B (5), R9C
(6): 2.2 kΩ W8R8-04-01-012
5 7 6
Resistance value of resistor R10B (7): 6.8
kΩ Detail A
1. Install resistor R9B (5), R9C (6), or R10B (7)
to voltage sensor DCPT 1 (2), DCPT 2 (3), or
DCPT 3 (4) with screws (8) (2 used).
IMPORTANT: When securing wire bundle band (b),

take care not to cut wire harnesses.
2. Secure resistor R9B (5), R9C (6), or R10B (7) to

wire harnesses (c) (2 used) with wire bundle
bands (b) (2 used).
3. Check that all wire harnesses are securely fas-

tened. Put a tightening check mark (black) on
each screw or bolt.
4. Remove a sheet from REC unit (1).

(REC) Unit (W4-1-2-1). Install protection cover to
REC unit (1).
W8R7-E-01(20160803) W4-1-3-4
2 3 4
Resistors R7A, R7B, R8A, R8B, R9A, R9D, R10A,
R10C
Removal
1. Refer to Removal and Installation of Rectifier 6, 7

(REC) Unit (W4-1-2-1). Remove REC unit (1).
6, 7
2. Remove nuts (2) (8 used) and bolts (3) (6 used)
from copper bars (4) (6 used). Remove copper
bars (4) (6 used) from REC unit (1). 5
: 17 mm, 13 mm
W8DS-04-01-031
REC Unit (1)

3. Remove screws (7) (2 used). Disconnect wire
harnesses (6) (2 used) from copper bars (5) (2
used). 8
4. Remove bolts (9) (4 used). Remove plate (8) from

REC unit (1).
: 13 mm
The removal and installation procedures of resis-
tors R7A (10), R7B (11), R8A (12), R8B (13), R9A
9
(14), R9D (15), R10A (16), and R10C (17) are
same. Then, the procedures of resistor R7A (10) 9
are explained here.
5. Remove screws (19) (2 used). Disconnect the

wire harnesses (2 used) which are connected to
resistor R7A (10).
6. Remove screws (18) (2 used). Remove resistor

W8R8-04-01-001
R7A (10) from plate (8).
10 11 14 16 17 15 13 12
19
18
W8R8-04-01-002
W8R7-E-01(20160803) W4-1-3-5
10 11 14 16 17 15 13 12
Installation
1. Install resistor R7A (10) to plate (8) with 8

screws (18) (2 used).
19
2. Connect the wire harnesses (2 used) to resistor
R7A (10) with screws (19) (2 used).
3. Install plate (8) to REC unit (1) with bolts (9) (4

used). 18
: 13 mm W8R8-04-01-002
4. Connect wire harnesses (6) (2 used) to copper

bars (5) (2 used) with screws (7) (2 used). 8
5. Install copper bars (4) (6 used) to REC unit (1)

with nuts (2) (8 used) and bolts (3) (6 used).
: 17 mm, 13 mm
6. Check that all wire harnesses are securely fas- 9

tened. Put a tightening check mark (black) on 9
each screw or bolt.

(REC) Unit (W4-1-2-1). Install REC unit (1).
W8R8-04-01-001
2 3 4
6, 7
6, 7
5
W8DS-04-01-031
REC Unit (1)
W8R7-E-01(20160803) W4-1-3-6
INVERTER (INV) UNIT 4 1
Removal
1. Open the front doors of control cabinet (1) by
using the door open/close handle.
• Open front door (lower center) when replacing
inverter (INV) R (2).
• Open front door (lower right) when replacing
inverter (INV) unit L (3).
• Open front door (lower center) when operating DC
short circuit bar (4).
Since almost common removal procedures are

applicable to both INV unit R (2) and L (3), the
2 3 W8DS-04-01-021
procedures for INV unit R (2) are explained hereafter.
Control Cabinet (1) Front View
2. Remove bolts (5) (4 used) to remove cover (6).
: 13 mm
W8DS-04-01-036
INV Unit R/L
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-4-1
4. Loosen bolt (7) to shift DC short circuit bar (4) 7 4
from OPEN position to the SHORT CIRCUIT
position.
: 13 mm
5. Remove main circuit copper bars (8, 9, 10 and 11)

from the front of inverter (INV) unit R (2) in the
5-1. Remove bolts (12) (8 used) and nuts (13) (8
used).
5-2. Remove main circuit copper bars (8, 9, 10 and
11).
: 19 mm
14
6. Disconnect wires from the printed boards in the
following procedures. 15
6-1. Remove connector CN1 (14).

6-2. Remove Connector CN2 (15).
6-3. Provisionally fasten disconnected wires to the
side wall with adhesive tape so that they do not
obstruct the removal of INV unit R (2).
7. Remove screw (17) to disconnect ground line (16) W8DS-04-01-038
from INV unit R (2). 16, 17

12, 13
10
8 11
W8DS-04-01-039
W8R7-E-01(20160803) W4-1-4-2
IMPORTANT: When handling the optical cable,
take care not to directly touch the 18 Hold both sides
optical cable. Hold the connector on
the both sides. (Refer to the
illustration.)
8. Disconnect optical cables (18) (7 used) from the
printed board. Install optical cable protection caps Do not touch W8DS-04-01-040
to the tip ends of optical cables (18) (7 used).

Install connector covers on printed board optical 20, 21
receiver (19) (7 used).
IMPORTANT: Optical cable is easy-to-break.

Handle the optical cables with
sufficient care. The minimum
bending radius of the optical cable is
50 mm.
IMPORTANT: The optical cables may accidentally

come off though they are
provisionally fastened with adhesive
tape. Use care not to allow the
optical cable to be loaded. 19 W8DS-04-01-041
9. Loosen bolts (21) (2 used) on optical cable

holding frame (20) with optical cables (18) (7 24, 25
used) keep attached. Remove optical cable
holding frame (20) and provisionally fasten optical
cable holding frame (20) to the side wall.
22
10. Remove main circuit copper bars (22 and 23) from
the upper section of INV unit R (2) in the following
procedures.
10-1. Remove bolts (24) (4 used) and nuts (25) (4
used).
10-2. Remove L-type main circuit copper bars (22 and
23).
23
IMPORTANT: When the coupler is disconnected, W8DS-04-01-042
small amount of coolant will spill.
Before disconnecting the coupler, Ring Socket (Machine Side)
wrap the coupler with a clean cloth.
Thoroughly wipe off the spilled
coolant.
11. Remove cooling pipe connection coupler (26) in
the following procedures.
11-1. Cut the disconnection prevention band of
W8DS-04-01-024
coupler (26). Slide
Plug (INV Unit Side)
11-2. While pulling to slide the ring on coupler (26)
straight, disconnect coupler (2). Coupler (26)
W8R7-E-01(20160803) W4-1-4-3
12. Remove metal fastener (27) (2 used) from the 27, 28, 29
upper section of INV unit R (2) in the following
procedures.
12-1. Remove bolts (28) (4 used) and bolts (29) (2
used).
12-2. Remove metal fastener (27) (2 used).
: 19 mm, 17 mm
13. Remove metal fastener (30) (2 used) from the

lower section of INV unit R (2) in the following
procedures.
13-1. Remove bolts (31) (6 used).
13-2. Remove metal fastener (30) (2 used). Metal Fastener at Upper-Left Section W8DS-04-01-043
: 19 mm
27, 28, 29
CAUTION: Weight of INV unit R (2): 226 kg

(498 lb)
14. Pull INV unit R (2) out of the control cabinet front
while taking care about the following points.
• Use an exclusively arranged support.
• Be careful not scratch wires and/or optical cables.
• Pull out INV unit R (2) while holding handles (32)
(2 used) on the front of INV unit R (2).
Metal Fastener at Upper-Right Section W8DS-04-01-044
32 32
30, 31 30, 31
Metal Fastener at Lower Section W8DS-04-01-045
W8R7-E-01(20160803) W4-1-4-4
Installation
1
CAUTION: Weight of INV unit R (2): 226 kg
(498 lb)
1. Install INV inverter (INV) unit R (2) for

replacement to the control cabinet (1) while taking
care about the following points.
• Use an exclusively arranged support.
• Be careful not scratch wires and/or optical cables.
• Push in INV unit R (2) while holding handles (32)
(2 used) on the front of INV unit R (2).
2. Install metal fastener (30) (2 used) to the right and

left lower sections of INV unit R (2) with bolts (31) Control Cabinet (1) Front View W8DS-04-01-021
(6 used).
: 19 mm
2
3. Install metal fastener (27) (2 used) to the right and
left upper sections of INV unit R (2) with bolts (28)
(4 used) and bolts (29) (2 used).
: 19 mm, 17 mm
W8DS-04-01-036
30, 31 32 32 30, 31
W8DS-04-01-045
Metal Fastener Lower Section
W8DS-04-01-043 W8DS-04-01-044
27, 28, 29 27, 28, 29
Metal Fastener at Metal Fastener
Upper-Left Section Upper-Right Section
W8R7-E-01(20160803) W4-1-4-5
4. Install main circuit copper bars (22 and 23) to the 24, 25
upper section of INV unit R (2) with bolts (24) (4 22
used) and nuts (25) (4 used).
: 17 mm
23
W8DS-04-01-042
Ring Socket (Machine Side)

5. Install cooling pipe connection coupler (26) in the
5-1. Remove coolant and foreign matter remaining in
the coupler (socket side) with workshop towel.
5-2. Clean the coupler (plug side) with workshop
towel.
5-3. Connect coupler (26). Install a coupler W8DS-04-01-024
disconnection prevention band. Slide
Plug (INV Side)
Coupler (26)
20, 21
50 mm.
IMPORTANT: The optical cables may accidentally

optical cable to be loaded.
6. Install optical cable holding frame (20) together
with optical cables (18) (7 used) with bolts (21) (2
used). 19 W8DS-04-01-041
IMPORTANT: When handling the optical cable, Hold both side

18
take care not to directly touch the
illustration.)
7. Connect optical cable (18) (7 used) to printed Do not touch W8DS-04-01-040
board optical receiver (19) (7 used).
W8R7-E-01(20160803) W4-1-4-6
8. Connect ground line (16) to INV unit R (2) with 7 4
screw (17).
IMPORTANT: When connecting connector CN2

(15), check that the connector claws
come to clasp. Refer to the
illustration.
9. Connect wires to the printed board in the following
procedures
9-1. Connect connector CN1 (14).
9-2. Connect connector CN2 (15).
10. Install main circuit copper bars (8, 9, 10 and 11) to

14 15
the front of INV unit R (2) with bolts (12) (8 used)
and nuts (13) (8 used).
: 19 mm
11. After checking that all wires and copper bars are
correctly tightened, put a tightening check mark
(black) to each screw or bolt.
12. Shift DC short circuit bar (4) from the SHORT

CIRCUT position to the OPEN position and install W8DS-04-01-038
bolt (7). 16, 17
Clasp Connector
: 13 mm Teeth
Push
W8DS-04-01-046
15
10
8 11
W8DS-04-01-039
W8R7-E-01(20160803) W4-1-4-7
13. Install cover (6) with bolts (5) (4 used)
: 13 mm
14. Close the front door of control cabinet (1) by using

the door open/close handle. 5
15. Refill coolant by following the coolant change

6
procedures.
16. Bleed air by following the air bleeding procedures.
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-4-8
INVERTER (INV) UNIT INTERNAL PARTS 4 1
Removal and Installation of inverter (INV) Unit

Current Sensors HCT11, HCT12, HCT13, and
HCT14
Removal
using the door open/close handle. 3
• Open the front center lower door when replacing

INV unit R (2).
2
• Open the front lower right door when replacing
INV unit L (3).
• Open the front center lower door when operating
DC short circuit bar (4). Control Cabinet (1) Front View T8R7-01-02-016
Since almost common removal procedures are

applicable to both INV unit R (2) HCT and INV unit L
(3) HCT, the procedures for INV unit R (2) HCT are
explained hereafter.

: 13 mm
Inverter (INV) Unit R/L W8DS-04-01-036
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-5-1
from the OPEN position to the SHORT CIRCUIT
position.
: 13 mm
5. Current sensors HCT11 (14), HCT12 (15), HCT 13

(16) and HCT14 (17) are connected to the front of
INV unit R (2) via main circuit copper bars (8, 9, 10
and 11). Remove only the copper bar that is
connected a current sensor to be replaced. The
procedures for removing current sensor HCT11
(14) is explained hereafter.
6. Remove bolts (12) (2 used) and nuts (13) (2

used).
: 19 mm
7. Remove main circuit copper bar (8).
8. Disconnect wire connector from current sensor

HCT 11 (14). W8DS-04-01-038
9. Remove screws (19) (2 used) holding current 14, 18, 19, 20

sensor HCT11 metal fastener (18). Take out 15, 18, 19, 20 16, 18, 19, 20
current sensor HCT11 (14) together with metal
fastener (18).
10. Loosen screws (20) (2 used) to remove current

sensor HCT11 (14) from metal fastener (18).
8
11
9
10
12, 13
17, 18, 19, 20

W8DS-04-01-039
W8R7-E-01(20160803) W4-1-5-2
Installation 14, 18, 19, 20
1. Current sensors HCT11 (14), HCT12 (15), HCT 13
15, 18, 19, 20 16, 18, 19, 20
(16) and HCT14 (17) are connected to the front of
INV unit R (2) via main circuit copper bars (8, 9, 10
and 11). Install only the copper bar that is
connected a current sensor to be replaced.
The procedures for installing current sensor
HCT11 (14) is explained hereafter.
8
2. Install current sensor HCT11 (14) to metal fastener
(18) with screws (20) (2 used).
11
3. Install metal fastener (18) to INV unit R (2) with M5 9
10
4. Connect the wire connector to current sensor
HCT11 (14).
5. Install main circuit copper bar (8) to INV unit R (2)

with bolts (12) (2 used) and nuts (13) (2 used).
: 19 mm
17, 18, 19, 20
W8DS-04-01-039
6. After checking that all wires and copper bars are
correctly tightened, put a tightening check mark 7 4
(black) to each screw or bolt.
7. Shift DC short circuit bar (4) from the SHORT

CIRCUIT position to the OPEN position and install
bolt (7).
: 13 mm
W8DS-04-01-038
W8R7-E-01(20160803) W4-1-5-3
: 13 mm
5
9. Close the front doors of control cabinet (1) by

• Close the front center lower door when INV unit R
(2) HCT was replaced.
• Close the front lower right door when INV unit L 6
(3) HCT was replaced.
• Close the front center lower door when DC short
circuit bar (4) was replaced.
W8DS-04-01-037
4 1
W8R7-E-01(20160803) W4-1-5-4
Removal and Installation of Inverter (INV) Printed
Boards
4 1
Removal
• Open the front center lower door when replacing
INV unit R (2) printed board.
• Open the front lower right door when replacing
INV unit L (3) printed board. 3
• Open the front center lower door when operating
DC short circuit bar (4).
2
Since most of the common removal procedures are
applicable to both INV unit R (2) printed board and
INV unit L (3) printed board, the procedures for INV
unit R (2) printed board (7) are explained hereafter. Control Cabinet (1) Front View T8R7-01-02-016
2, 3
7, 8
2. Remove bolts (5) (4 used) to remove cover (6). Inverter (INV) Unit R/L W8DS-04-01-036
: 13 mm
3. Perform voltage detection. 5
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-5-5
from the OPEN position to the SHORT CIRCUIT
position.
: 13 mm

illustration.)
5. Disconnect optical cables (10) from the printed

board. Put optical cable protection caps on the tip
ends of optical cables (10) (7 used). Put optical
unit connector covers on optical receiving units
(11) (7 used).

bending radius of the optical cable is W8DS-04-01-038
50 mm.
10
IMPORTANT: The optical cables may accidentally Hold both side
tape. Use care not to allow the Do not touch
optical cable to be loaded.
Optical Cable (10) W8DS-04-01-040
6. Remove bolts (13) on optical cable holding frame
(12) with optical cables (10) (7 used) kept
attached. Remove optical cable holding frame (12) 11 12, 13 25 23 24
and provisionally fasten optical cable holding
frame (20) to the side wall.
: 8 mm
IMPORTANT: When cutting off wire bundle band,

take care not to cut the optical
cables.
7. Disconnect wires from the printed boards in the

7-1. Disconnect connectors CN1 (14), CN2 (15),
CN3 (16), CN4 (17), CN5A (18), CN5B (19),
CN5C (20), CN5D (21), CN5E (22), CN5F (23) 14 18 19 20 21 22 16, 17 15
W8DS-04-01-041
and CN5G (24).
7-2. Cut off wire bundle bands (25) (7 used) from
connectors CN5A (18), CN5B (19), CN5C (20),
CN5D (21), CN5E (22), CN5F (23) and CN5G
(24).
W8R7-E-01(20160803) W4-1-5-6
8. Remove screws (25) (8 used) to remove printed 25
board unit (7) from INV unit R (2).
W8DS-04-01-047
7
W8DS-04-01-048
Printed Board Unit (7)
W8R7-E-01(20160803) W4-1-5-7
Installation
7
1. Install printed board unit (7) to INV unit R (2) with

50 mm.
The optical cables may accidentally
optical cable to be loaded. W8DS-04-01-048
2. Install optical cable holding frame (12) together Printed Board Unit (7)
with optical cables (10) (7 used) with bolts (13) (2 25
used) to INV unit R (2).
: 8 mm 7
IMPORTANT: When handling the optical cable, W8DS-04-01-047

optical cable. Hold the connector on 10
the both sides. (Refer to the Hold both side
illustration.)
3. Connect optical cable (10) to the printed board.
Do not touch
W8DS-04-01-040
4. Connect wires to the printed boards in the

following procedures. 11 12, 13 25 23 24
4-1. Connect connectors CN1 (14), CN2 (15), CN3
(16), CN4 (17), CN5A (18), CN5B (19), CN5C
(20), CN5D (21), CN5E (22), CN5F (23) and
CN5G (24).
4-2. Connect connectors CN5A (18), CN5B (19),
CN5C (20), CN5D (21), CN5E (22), CN5F (23)
and CN5G (24) with wire bundle bands (25) (7
used).
14 18 19 20 21 22 16, 17 15
W8DS-04-01-041
W8R7-E-01(20160803) W4-1-5-8
5. Shift DC short circuit bar (4) from the SHORT 9 4
CIRCUIT position to the OPEN position and install
bolt (9).
: 13 mm

: 13 mm
7. Close the front doors of control cabinet (1) by

• Close the front center lower door when INV unit R
(2) printed board is replaced.
• Close the front lower right door when INV unit L
(3) printed board is replaced.
• Close the front center low door when operating
DC short circuit bar (4).
W8DS-04-01-038
W8DS-04-01-037
4 1
Control Cabinet (1) Front View W8DS-04-01-021
W8R7-E-01(20160803) W4-1-5-9
Removal and Installation of Inverter (INV) Unit 7 2
Plate and Capacitor Unit
3
Removal 3
1
1. Remove inverter (INV) unit (8).
Refer to Removal and Installation of Inverter (INV)
Unit (W4-1-4). 6
2. Remove bolts (1) (8 used) and remove copper

bars (2) (2 used). 4
: 17 mm
5
CAUTION: INV unit plate (6) weight: 110 kg
(243 lb) TQEB-01-02-013
Inverter (INV) Unit (8)

CAUTION: Capacitor unit (7) weight: 120 kg
(265 lb)
3. Hoist and hold INV unit plate (6). Remove bolts (3,
4) (2 used for each) and bolts (5) (4 used). Hoist
and remove inverter unit plate (6) from capacitor
unit (7).
: 13 mm, 17 mm, 19 mm
Installation
CAUTION: INV unit plate (6) weight: 110 kg
(243 lb)
CAUTION: Capacitor unit (7) weight: 120 kg
(265 lb)
1. Hoist and install inverter unit plate (6) to capacitor
WQHA-04-01-051
unit (7) with bolts (3, 4) (2 used for each) and bolts Inverter (INV) Unit Plate (6)
(5) (4 used).
: 13 mm, 17 mm, 19 mm
2. Install copper bars (2) (2 used) with bolts (1) (8

used).
: 17 mm
3. Install inverter (INV) unit (8).

Unit (W4-1-4).
WQHA-04-01-052
Capacitor Unit (7)
W8R7-E-01(20160803) W4-1-5-10
Removal and Installation of Inverter (INV) Unit 2
IGBT Unit
Removal
1. Refer to Removal and Installation of Inverter (INV)

Unit Plate and Capacitor Unit (W4-1-5-10).
Remove inverter (INV) unit plate (1) from capacitor 1
unit (2).
2. Refer to Removal and Installation of Inverter

Driver Board (VPA20) of Inverter (INV) Unit
(W4-1-5-5). Remove printed board (3) from IGBT
unit (4).
TQEB-01-02-013
Inverter (INV) Unit (8)

Unit Current Sensors HCT11, HCT12, HCT13, and
HCT14 (W4-1-5-1). Remove Current Sensors
HCT11, HCT12, HCT13, and HCT14 from inverter
(INV) unit plate (1).
Installation
1. Refer to Removal and Installation of Inverter (INV) 3

Unit Current Sensors HCT11, HCT12, HCT13, and
HCT14 (W4-1-5-1). Install Current Sensors 4
HCT11, HCT12, HCT13, and HCT14 to Inverter
(INV) unit plate (1).
2. Refer to Removal and Installation of Inverter

Driver Board (VPA20) of Inverter (INV) Unit
(W4-1-5-5). Install printed board (3) to IGBT unit WQHA-04-01-051
Inverter (INV) Unit Plate (1)

(4).

Unit Plate and Capacitor Unit (W4-1-5-10). Install
inverter (INV) unit plate (1) to capacitor unit (2).
W8R8-04-01-003
IGBT Unit (4)
W8R7-E-01(20160803) W4-1-5-11
Removal and Installation of Capacitor Unit
Resistors R11A, R11B, R12A and R12B 1
Removal
7
1. Remove capacitor unit (1). 2

2. Remove screws (2) (2 used for each) and

disconnect the wire harnesses from resistors
R11A (3), R11B (4), R12A (5), and R12B (6).
3. Remove screws (7) (2 used for each) and remove

resistors R11A (3), R11B (4), R12A (5), and R12B 3 4 5 6 WQHA-04-01-052
(6) from capacitor unit (1).

Capacitor Unit (1)
Installation 2
1. Install resistors R11A (3), R11B (4), R12A (5), and

R12B (6) to capacitor unit (1) with screws (7) (2
used for each).
2. Connect the wire harnesses to resistors R11A (3), WQHA-04-01-071

R11B (4), R12A (5), and R12B (6) with screws (2) 3, 4, 5, 6
(2 used for each).
3. Install capacitor unit (1).

WQHA-04-01-075
3 4 5 6
W8R7-E-01(20160803) W4-1-5-12
ALTERNATOR FIELD REGULATOR (MFR) 4
B 1
UNIT
Removal
A A
1. Open the front door (upper left) of control cabinet
(1) by using the door open/close handle.
T8R7-01-02-016

: 13 mm 2
3. Turn breaker CB302 (4) OFF.
4. Remove M8 bolts (20 used) from the right reverse 3

cover of control cabinet (1). Remove the right re-
verse cover from control cabinet (1).
W8DS-04-01-037
View A-A
13
W8R7-04-01-010 W8DS-04-01-050
Main Alternator Field Regulator (MFR) Unit
Detail B
T8R7-01-02-017
W8R7-E-01(20160803) W4-1-6-1
6. Remove bolts (6) (2 used) and wire connector (7) 6 7 12 11
to disconnect a wire harness from IGBT stack (5).
: 13 mm
7. Remove screws (8) (3 used) to disconnect a wire

harness from diode (9). Remove cable fastening
hook (10).
8. Remove nut (11) to disconnect a wire harness

from panel pass (12).
: 13 mm
9. Remove screw (15) to remove ground line (14)

from main alternator field regulator (MFR) unit W8DS-04-01-052
(13). 5
10. Remove bolts (16) (6 used) that are fastening

MFR unit to the control cabinet.
: 13 mm
10
11. Remove MFR unit (13) from control cabinet (1).
9 8 14 15 W8DS-04-01-053
A A
13
View A-A
16
W8R7-04-01-010 W8DS-04-01-050
Main Alternator Field Regulator (MFR) Unit
W8R7-E-01(20160803) W4-1-6-2
Installation
1
1. Install main alternator field regulator (MFR) unit
(13) to control cabinet (1).
A A
2. Secure main alternator field regulator (MFR) unit
(13) with bolts (16) (6 used).
: 13 mm
3. Connect ground line (14) to MFR unit with screw

(15).
4. Connect wire to panel pass (12) with nut (11).

: 13 mm
IMPORTANT: Check the wire harness No. to avoid Control Cabinet (1) Front View T8R7-01-02-016
incorrect wiring.
5. Connect the wire harness to diode (9) with screws View A-A 13
(8) (3 used). Install cable fastening hook (10). 16
IMPORTANT: Check that the connector claws

correctly come to clasp.
IMPORTANT: Check the wire harness No. to avoid

incorrect wiring.
6. Connect the wire harness to IGBT stack (5) with W8DS-04-01-049 W8DS-04-01-050
bolts (6) (2 used) and connector (7). Main Alternator Field Regulator (MFR) Unit
: 13 mm
7. After checking that all wire harnesses are cor-

rectly tightened, put a tightening check mark
(black) to each screw or bolt. 10
W8DS-04-01-053
9 8 14 15
6 7 12 11
W8DS-04-01-052
5
W8R7-E-01(20160803) W4-1-6-3
8. Install the right reverse cover to control cabinet (1)
1
: 13 mm

T8R7-01-02-016
4
9. Turn breaker CB302 (4) ON.
T8R7-01-02-017
2
10. Install cover (3) with bolts (2) (4 used).
: 13 mm
11. Close the front door (upper left) of control cabinet 3

W8DS-04-01-037
W8R7-E-01(20160803) W4-1-6-4
ALTERNATOR FIELD REGULATOR (MFR)
UNIT INTERNAL PARTS
Removal and Installation of Main Alternator Field
Regulator (MFR) Unit Rectifier STK301
Removal
1. Refer to Removal and Installation of Main

Alternator Field Regulator (MFR) Unit (W4-1-6-1). W8DS-04-01-050
Remove MFR unit (1). Main Alternator Field Regulator (MFR) Unit (1)
2. Remove nuts (3) (2 used). Disconnect wire

harnesses (4) (2 used) from rectifier STK301 (2).
: 10 mm
3
3. Remove screws (6) (4 used). Remove covers (5) 4

(2 used).
4. Remove screws (8) (4 used). Remove rectifier

2
STK301 (2) from MFR unit (1).
5. Remove nuts (9) (8 used). Remove adapters (7)

(2 used) and bolts (10) (8 used) from rectifier
STK301 (2).
: 7 mm W8DS-04-01-053
8 5 6
2
7
9, 10
7 8 6 W8R8-04-01-004
Lower Side of Main Alternator Field Regulator (MFR) Unit (1)
W8R7-E-01(20160803) W4-1-6-5
Installation
1. Install bolts (10) (8 used) to T-slots (A) of rectifier

STK301 (2). Install adapters (7) (2 used) to
rectifier STK301 (2) with nuts (9) (8 used).
: 7 mm
2. Install rectifier STK301 (2) to main alternator field

regulator (MFR) unit (1) with screws (8) (4 used).
A A
3. Install covers (5) (2 used) with screws (6) (4
used).
4. Connect wire harnesses (4) (2 used) to rectifier

STK301 (2) with nuts (3) (2 used).
: 10 mm W8R8-04-01-005
5. Check that all wire harnesses are securely

fastened. Put a tightening check mark (black) on 8 5 6
each screw or bolt. 8

Alternator Field Regulator (MFR) Unit (W4-1-6-1). 2
Install MFR unit (1). 7
9, 10
7 8 5 6 W8R8-04-01-004
W8DS-04-01-053
W8R7-E-01(20160803) W4-1-6-6
Regulator (MFR) Unit Capacitors C301A, C301B
Removal
1. Refer to Removal and Installation of Main 2

Turn OFF breaker CB302. Perform voltage
detection.
1
2. Remove nuts (2) (2 used) and nut (3). Disconnect 3
wire harnesses (3 used) from panel pass (1).
: 13 mm
W8R8-04-01-015
Main Alternator Field Regulator (MFR) Unit (6)

3. Remove bolts (4) (4 used) and screws (5) (4 used).
Remove panel pass (1) from MFR unit (6).
4
: 10 mm
1
4. Remove screws (8) (6 used). Remove capacitors
C301A (7) and C301B (9) from MFR unit (6). A
Installation
1. Install capacitors C301A (7) and C301B (9) to 7

MFR unit (6) with screws (8) (6 used).
2. Install panel pass (1) to MFR unit (6) with bolts (4) W8R8-04-01-006
(4 used) and screws (5) (4 used). 6 8
: 10 mm
3. Connect wire harnesses (3 used) to panel pass

(1) with nuts (2) (2 used) and nut (3).
: 13 mm
4. Check that all wire harnesses are securely 7

fastened. Put a tightening check mark (black) on 9
each screw or bolt.

Alternator Field Regulator (MFR) Unit (W4-1-6-1).
Turn ON breaker CB302. Close the door.
W8R8-04-01-014
View A
W8R7-E-01(20160803) W4-1-6-7
Regulator (MFR) Unit Resistor R301
Removal

Turn OFF breaker CB302. Perform voltage
detection.
2. Remove screws (2) (2 used). Disconnect wire 3

harnesses (4) (2 used) from resistor R301 (3). WQEB-04-01-026

3. Remove screws (5) (2 used). Remove resistor
R301 (3) from MFR unit (1).
Installation 4
1. Install resistor R301 (3) to MFR unit (1) with

2. Connect wire harnesses (4) (2 used) to resistor 2

R301 (3) with screws (2) (2 used).
3. Check that all wire harnesses are securely 3

fastened. Put a tightening check mark (black) on
each screw or bolt.

W8R8-04-01-007
Turn ON breaker CB302. Close the door.
W8R7-E-01(20160803) W4-1-6-8
Regulator (MFR) Unit Main Alternator Field
Excitation Module STK302
Removal
2
1. Refer to Removal and Installation of Main 5
Remove MFR unit (6).
1
2. Remove nuts (2) (2 used) and nut (3). Disconnect 3
wire harnesses (3 used) from panel pass (1).
: 13 mm
W8R8-04-01-015

3. Remove bolts (4) (4 used) and screws (5) (4 used).
Remove panel pass (1) from MFR unit (6).
: 10 mm
4. Remove screws (8) (4 used). Remove main

alternator field excitation module STK302 (7) from
MFR unit (6).
Installation
4
8
1. Install STK302 (7) to MFR unit (6) with screws (8) 1
(4 used).
2. Install panel pass (1) to MFR unit (6) with bolts (4) 7
(4 used) and screws (5) (4 used).
: 10 mm
3. Connect wire harnesses (3 used) to panel pass

(1) with nuts (2) (2 used) and nut (3).
: 13 mm W8R8-04-01-006
8 6
4. Check that all wire harnesses are securely
fastened. Put a tightening check mark (black) on
each screw or bolt.

Install MFR unit (6).
W8R7-E-01(20160803) W4-1-6-9
(Blank)
W8R7-E-01(20160803) W4-1-6-10
REMOVAL AND INSTALLATION OF FAN 6
UNIT 1
Removal
1. Open the front door (upper center) of control
cabinet (1) by using the door open/close handle.
2. Remove bolts (4 used) to remove cover (3).

: 13 mm
3. Remove screws (5) (6 used). Remove fan unit

cover (4) from control cabinet (1).
4. Disconnect connector (7) from fan unit (6). Control Cabinet (1) Front View
T8R7-01-02-016
5. Remove screw (9) holding ground line. Remove

ground line (8).
6. Remove bolts (10) (4 used) holding fan unit (6).

2
: 13 mm
7. Remove fan unit (6) from control cabinet (1).

3
W8DS-04-01-037
5
8, 9
W8DS-04-01-054
10
W8DS-04-01-055
W8R7-E-01(20160803) W4-1-7-1
Installation 6
1. Install fan unit (6) to control cabinet (1). 1
2. Secure fan unit (6) to control cabinet (1) with bolts

(10) (4 used).
: 13 mm
3. Connect ground line (8) with screw (9).
4. After checking that ground line (8) is correctly

tightened with screw (9), put a tightening check
mark (black) to screw (9).
5. Connect connector (7) to fan unit (6). Control Cabinet (1) Front View
T8R7-01-02-016
6. Install cover (4) on control cabinet (1) with screws

(5) (6 used). 10
7. Install cover (3) with bolts (2) (4 used). 6

: 13 mm
8. Close the front door (upper center) of control

W8DS-04-01-055
5
8, 9
W8DS-04-01-054
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-7-2
REMOVAL AND INSTALLATION OF DRIVE DSC
SYSTEM CONTROLLER (DSC)
Removal
1. Conduct the following transaction in accordance
with the System Monitor Operation Manual.
1-1. Take the records of the program version SAM
values. (CPU1, CPU2, CPU3, CPU4, CPU5,
DIO. PWM, COM)
1-2. Save the parameters.
1-3. Save the traceback data.
2. Turn the key switch and the battery switch OFF.

T8R7-01-02-016
3. Open the front door (upper right) of control cabinet DC/DC Converter
(1) by using the door open/close handle. AVR303 Interface Board
VZT26
DC/DC Converter AVR302

Interface Board VIO13
Drive Control Board VDC06
Communication Control Board VDC07 W8DS-02-04-011
Drive System Controller (DSC)
M8R8-07-017
Battery Switch
M146-07-062
W8R7-E-01(20160803) W4-1-8-1
: 13 mm
5. Remove M8 bolts (20 used) from the reverse

cover (left). Remove the reverse cover (left) from
2
6. To prevent generation of static electricity, use a

3
pair of cotton gloves and connect a ground band
or touch the vehicle frame to release static elec-
tricity.
7. Disconnect the following connectors from each

board.
7-1. Disconnect connectors [CN3 (4), CN4 (5), CN5
(6) and CN6 (7)] from interface board VIO13.
7-2. Disconnect connectors [CN3 (8), CN4 (9), CN5
(10), CN6 (11), CN7 (12), CN8 (13) and CN9 W8DS-04-01-037
(14)] from interface board VIO14.
7-3. Disconnect connectors [CN3 (15), CN4 (16),
CN5 (17), CN6 (18), CN7 (19) and CN8 (20)] 10 9 8 14 13
from interface board VIO15. VI013 VI014
7-4. Disconnect connector CN4 (21) from commu- 31
nication control board VDC07.
IMPORTANT: When loosening the screw, rotate a

screwdriver while tightly pressing it
down to prevent screw head col-
lapse.
8. After removing screws (22) (4 used) holding drive
control board VDC06 to PI case (31), remove W8DS-04-01-056
VDC06. Keep the removed VDC06 in an an- 4 6 7 5 11 12

ti-static electricity bag to prevent damage to the
VDC06 due to static electricity.
22 18 15 16
VDC06 VI015
31
21
W8DS-04-01-056
20 19 17
W8R7-E-01(20160803) W4-1-8-2
9. Remove screws fastening D-sub connector from
drive control board VDC06 and communication
control board VDC07.
9-1. Remove screws (25) (2 used) from the lower
side section of VDC06.
9-2. Remove screws (25) (2 used) from the upper 23
side section of VDC07.
VDC06 W8DS-04-01-057
10. Disconnect D-sub connector from drive control

board VDC06 and communication control board 25
VDC07.
10-1. Disconnect connector CN4 (23) from VDC06.
10-2. Disconnect connector CN6 (24) from VDC07.
25
23
W8DS-04-01-058
25
24
W8DS-04-01-059
VDC07 W8DS-04-01-060
W8R7-E-01(20160803) W4-1-8-3
IMPORTANT: To avoid damage to VDC06 guide rail,
B A 22
install VDC06 only after checking 31
that VDC06 is correctly seated on the
upper and lower guide rails.
IMPORTANT: When tightening the screw, rotate 24

the screwdriver while tightly press-
ing it down to prevent screw head
collapse.
23
11. Install drive control board VDC06 into PI case (31)
in drive system controller DSC. Fasten VDC06 VI013 W8DS-04-01-056
with screws (22) (4 used).

LG7
IMPORTANT: When handling the optical cable, LG14
LG6
take care not to directly touch the LG13
LG5 LG12
LG4 LG11
the both sides. LG3 LG10
LG9
LG2
IMPORTANT: Optical cable is easy-to-break. Han- LG1 LG8
dle the optical cables with sufficient
care. The minimum bending radius
of the optical cable is 50 mm.
12. Disconnect optical cable connector (LG1 to LG14)
(14 used) from interface board VIO13. Put a pro-
tection cap on each connector tip. Install con- Detail A W8DS-04-01-061
nector covers (14 used) on VIO13 optical trans-

Hold both side
mitter unit.
IMPORTANT: Spread a sheet under the DC/DC in-

verters.
13. Disconnect wire harnesses from the DC/DC in-
Do not touch W8DS-04-01-040
verter.
13-1. Remove M3 screws (3 used) to disconnect
24
wires #P24B (25), #N24B (26), and ground line
(27) from DC/DC inverter AVR302 (23).
13-2. Remove M3 screws (3 used) to disconnect
wires #P24B (28), #N24B (29), and ground line
(30) from DC/DC inverter AVR303 (24). 28
29
30 23
27
25
26
Detail B W8DS-04-01-062
W8R7-E-01(20160803) W4-1-8-4
14. Remove bolts (32) (4 used) fastening PI case (31)
31
on the DSC reverse face to control cabinet (1).
: 13 mm
15. Remove screws (33) (4 used) fastening PI case

(31) on the DSC front face to control cabinet (1).
IMPORTANT: Fasten optical cables and wires to

the upper or lower sections of the
control cabinet with adhesive tape to
prevent DSC from scratching optical 32 W8DS-04-01-063
cables and wires. DSC Reverse Side
16. Remove DSC from control cabinet (1).
33
33
W8DS-04-01-062 W8DS-04-01-064
DSC Front-Left Side DSC Front-Right Side
W8R7-E-01(20160803) W4-1-8-5
Installation
1 DSC
IMPORTANT: Fasten optical cables and wires to
the upper or lower sections of the
control cabinet with adhesive tape to
prevent DSC from scratching optical
cables and wires.
1. Install DSC to control cabinet (1).
2. Tighten screws (33) (4 used) to fasten PI case

(31) to the control cabinet front face.
3. Tighten bolts (32) (4 used) to fasten PI case (31)

to the control cabinet reverse face.
: 13 mm Control Cabinet (1) Front View T8R7-01-02-016
DC/DC Converter 31
AVR303 Interface Board
VZT26

Communication Control Board VDC07 W8DS-02-04-011
33
33
W8DS-04-01-062 W8DS-04-01-064
DSC Front-Left Side DSC Front-Right Side
32
32
DSC Reverse Side W8DS-04-01-063
W8R7-E-01(20160803) W4-1-8-6
IMPORTANT: Check that the connection polarity is
correct after connecting wire har-
nesses. 24
4. Connect wire harnesses to the DC/DC inverter.
4-1. Connect wire #P24B (25), #N24B (26) and
ground line (27) with M3 screws (3 used) to
DC/DC inverter (AVR302) (23). 28
4-2. Connect wire #P24B (28), #N24B (29) and 29
ground line (30) with M3 screws (3 used) to
DC/DC inverter (AVR303) (24). 30 23
IMPORTANT: When loosening the screw, rotate the

screwdriver while tightly pressing it 27
lapse. 25
5. After removing screws (22) (4 used) holding drive
control board VDC06 to PI case (31). Keep the
removed VDC06 in an anti-static electricity bag to 26
prevent damage to the VDC06 due to static elec-
W8DS-04-01-062
tricity.
31
DC/DC Converter 22
AVR303 Interface Board
VZT26
W8DS-02-04-011
W8R7-E-01(20160803) W4-1-8-7
6. Connect D-sub connector to drive control board
VDC06 and communication control board VDC07.
6-1. Connect D-sub connector CN4 (23) to VDC06.
6-2. Connect D-sub connector CN6 (24) to VDC07.
7. Connect D-sub connector to drive control board 23

VDC06 and communication control board VDC07
with fastening screws.
7-1. Tighten screws (25) (2 used) to the side face
lower section of VDC06.
7-2. Tighten screws (25) (2 used) to the side face
upper section of VDC07. VDC06 W8DS-04-01-057
IMPORTANT: To avoid damage to the VDC06 guide

rail, insert VDC06 only after checking 25
that VDC06 is correctly seated on the
IMPORTANT: When tightening the screw, rotate 25

ing it down to prevent the screw 23
head collapse.
8. Install VDC06 into PI case (31). Secure VDC06
with screws (22) (4 used)
W8DS-04-01-058
25
24
W8DS-04-01-059
VDC07 W8DS-04-01-060
W8R7-E-01(20160803) W4-1-8-8
optical cable. Hold the connector on LG7
LG14
the both sides. LG6
LG13
LG5 LG12
LG4 LG11
IMPORTANT: Optical cable is easy-to-break. Han-
LG3 LG10
dle the optical cables with sufficient LG2
LG9
care. The minimum bending radius LG1 LG8
IMPORTANT: Check that connectors have been

correctly connected.
9. Connect optical cable connectors (LG1 to LG14)
(14 used) to interface board VIO13. W8DS-04-01-061
VI013
Hold both side
10. Connect connectors to each board.
10-1. Connect four connectors CN3 (4), CN4 (5), CN5
(6) and CN6 (7) to interface board VIO13.
10-2. Connect seven connectors CN3 (8), CN4 (9), Do not touch
W8DS-04-01-040
CN5 (10), CN6 (11), CN7 (12), CN8 (13) and Optical Cable
CN9 (14) to interface board VIO14.
10-3. Connect six connectors CN3 (15), CN4 (16), 10 9 8 14
CN5 (17), CN6 (18), CN7 (19) and CN8 (20) to
VI013 VI014 VI015 VDC07
interface board VIO15.
10-4. Connect one connector CN4 (21) to communi-
31
cation control board VDC07.
11. After checking that all wires are correctly tightened,

put a tightening check mark (black) to each screw
or bolt.
W8DS-04-01-056
4 6 7 5 11 12 13
18 15 16
VI015 VDC07
21
20 19 17
W8DS-04-01-056
W8R7-E-01(20160803) W4-1-8-9
12. Install the left reverse cover to the control cabinet
: 13 mm

2
: 13 mm
14. Close the front door (upper right) of control cabinet

3
15. Turn the battery switch ON. Turn the key switch
ON.
W8DS-04-01-037
Battery Switch
M146-07-062
W8R7-E-01(20160803) W4-1-8-10
REMOVAL AND INSTALLATION OF DSC DSC
DRIVE CONTROL BOARD VDC06 1
Removal
values. (CPU1, CPU2, CPU3, CPU4, DIO,
PWM)
1-3. Save the trouble history records.

3. Open the front door (upper right) of control cabinet 22

W8DS-02-04-011
M8R8-07-017
Battery Switch
M146-07-062
W8R7-E-01(20160803) W4-1-9-1
: 13 mm 2
5. To prevent generation of static electricity, use a

or touch the vehicle frame to release static elec- 3
tricity.

lapse.
6. Remove screws (22) (4 used) to remove drive
controller board VDC06 from PI case (31). Keep W8DS-04-01-037
the removed VDC06 in an anti-static electricity

bag to prevent damage to the VDC06 due to static 22 VDC06 VI015
electricity.
31
7. Remove screws (25) fastening connector CN4
(D-sub connector) to the side lower section of
VDC06.
8. Disconnect connector CN4 (D-sub connector) (23)

from VDC06.
W8DS-04-01-056
23
W8DS-04-01-057
25
23
25
W8DS-04-01-058
W8R7-E-01(20160803) W4-1-9-2
Installation
1. Connect connector CN4 (D-sub connector) (23) to
the side lower section of drive control board
VDC06. 23
2. Fasten connector CN4 (D-sub connector) (23) to

VDC06 with screws (25) (2 used).
IMPORTANT: Before installing VDC06 into DSC,

check that dipswitches 1 and 2 are
turned OFF.
IMPORTANT: To avoid damage to the VDC06 guide VDC06 W8DS-04-01-057
rail, install VDC06 only after check-

ing that VDC06 is correctly seated on 25
the upper and lower guide rails.
IMPORTANT: When tightening the screw, rotate

ing it down to prevent the screw
head collapse.
3. Install VDC06 into PI case (31). Secure VDC06 to
PI case (31) with screws (22) (4 used) 23
25
W8DS-04-01-058
31
22
Drive System Controller (DSC) W8DS-02-04-011
W8R7-E-01(20160803) W4-1-9-3
: 13 mm 2
5. Close the front door (upper right) of control cabi-

net (1) by using the door open/close handle.
3
W8DS-04-01-037

ON.
Battery Switch
values. (CPU1, CPU2, CPU3, CPU4, DIO,
PWM) M146-07-062
In case different values from those recorded
before replacing VDC06 are recorded, replace
the program.
7-2. Input the parameters save before replacing
VDC06 to reset the parameters.
8. Turn the key switch OFF and wait for more than 5
seconds. Then, turn the key switch ON again.
Check that no abnormality is present.
W8R7-E-01(20160803) W4-1-9-4
1
COMMUNICATION CONTROL BOARD
VDC07
Removal
values. (CPU5, COM)
1-3. Save the trouble history records.
22
Communication Control Board VDC07

W8DS-02-04-011
3. Open the front door (upper right) of control cabinet

M8R8-07-017
Battery Switch
M146-07-062
W8R7-E-01(20160803) W4-1-9-5
: 13 mm
35
5. To prevent generation of static electricity, wear a
tricity.
6. Disconnect connector CN4 (35) from VDC07. VDC07 22 W8DS-04-01-065

lapse.
7. Remove screws (22) (4 used) to remove VDC07
from PI case (31). Keep the removed VDC07 in an
anti-static electricity bag to prevent damage to the
VDC07 due to static electricity.
8. Remove screws (25) (2 used) fastening connector 35

W8DS-04-01-066
CN6 (D-sub connector) (24) to the side upper

section of VDC07.
24
25
W8DS-04-01-059
9. Disconnect connector CN6 (D-sub connector) (24)
from VDC07.
VDC07 W8DS-04-01-060
W8R7-E-01(20160803) W4-1-9-6
Installation
1. Connect connector CN6 (D-sub connector) (24) to
the side upper section of communication control
board VDC07.
2. Fasten connector CN6 (D-sub connector) (24) to

VDC07 with screws (25) (2 used).
24
25
W8DS-04-01-059
IMPORTANT: Before installing VDC07 into PI case

(31), check that dipswitches 1 is
turned OFF.
IMPORTANT: To avoid damage to the VDC07 guide

ing that VDC07 is correctly seated on

VDC07 W8DS-04-01-060
head collapse.
3. Install VDC07 into PI case (31). Secure VDC07 to
35
PI case (31) with screws (22) (4 used)
4. Connect connector CN4 (35) to VDC07.
W8DS-04-01-065
22
VDC07
35 W8DS-04-01-066
W8R7-E-01(20160803) W4-1-9-7
: 13 mm
6. Close the front door (upper right) of control cabi- 2

3
ON.

values. (CPU5, COM).
W8DS-04-01-037
8-2. In case different values from those recorded
before replacing VDC07 are recorded, replace
the program.
Battery Switch
9. Turn the key switch OFF and wait for more than 5
seconds. Then, turn the key switch ON again.
Check that no abnormality is present.
M146-07-062
W8R7-E-01(20160803) W4-1-9-8
REMOVAL AND INSTALLATION OF DSC 1 DSC
INTERFACE BOARD VIO13
Removal

: 13 mm
W8DS-02-04-011
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-9
3. Disconnect connectors CN3 (4), CN4 (5), CN5 (6) 22 VIO13
and CN6 (7) from interface board VIO13.

optical cable. Hold the connector on 31
the both sides.

dle the optical cables with sufficient
care. The minimum bending radius 4 6 7 5 W8DS-04-01-056
of the optical cable is 50 mm. Drive System Controller (DSC)

4. Disconnect optical cable connectors (LG1 to
LG14) (14 used) from interface board VIO13. Put
a protection cap on each connector tip. Install 22
connector covers (14 used) on VIO13 light trans-
LG7
mitter unit. LG14
LG6
LG13
LG5 LG12
IMPORTANT: When loosening the screw, rotate the LG4 LG11
screwdriver while tightly pressing it LG3 LG10
down to prevent screw head col- LG2
LG9
lapse. LG1 LG8

5. Remove screws (22) (4 used) to remove VIO13
from PI case (31). Keep the removed VIO13 in an
anti-static electricity bag to prevent damage to 4 5
VIO13 due to static electricity.
6 7
W8DS-04-01-061
Detail VIO13
Hold both side
Do not touch
Optical Cable W8DS-04-01-040
W8R7-E-01(20160803) W4-1-9-10
Installation VIO13 22
IMPORTANT: To avoid damage to the VIO13 guide
rail, install VIO13 only after checking 31
that VIO13 is correctly seated on the

head collapse.
1. Install interface board VIO13 into PI case (31). 4 6 7 5 W8DS-04-01-056
Secure VIO13 to PI case (31) with screws (22) (4 Drive System Controller (DSC)
used)
22
2. Connect connectors CN3 (4), CN4 (5), CN5 (6)
LG7
and CN6 (7) to VIO13. LG14
LG6
LG13
LG5 LG12
IMPORTANT: When handling the optical cable, LG4 LG11
take care not to directly touch the LG3 LG10
optical cable. Hold the connector on LG2
LG9
the both sides. LG1 LG8

dle the optical cables with sufficient 4 5
care. The minimum bending radius
6 7
IMPORTANT: Check that all connectors are cor- Detail VIO13 W8DS-04-01-061
rectly connected
3. Connect optical cable connectors (LG1 to LG14)
(14 used) to VIO13 light transmitter unit. Hold both side
Do not touch
Optional Cable W8DS-04-01-040
W8R7-E-01(20160803) W4-1-9-11
: 13 mm
2
net (1) by using the door open/close handle. 3
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-12
1
Removal

T8R7-01-02-016
W8DS-02-04-011

: 13 mm 2
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-13
3. Disconnect 7 connectors CN3 (8), CN4 (9), CN5
(10), CN6 (11), CN7 (12), CN8 (13) and CN9 (14) VIO14
10 9 8 22 14 13
from interface board VIO14.

screwdriver while tightly pressing it 31
lapse.
anti-static electricity bag to prevent damage to
VIO14 due to static electricity. DSC W8DS-04-01-056
11 12
W8R7-E-01(20160803) W4-1-9-14
Installation VIO14
10 9 8 22 14 13
rail, install VIO14 only after checking
31
head collapse.
1. Install interface board VIO14 into PI case (31). DSC W8DS-04-01-056
11 12
Secure VIO14 to PI case (31) with screws (22) (4
used).
2
2. Connect 7 connectors CN3 (8), CN4 (9), CN5 (10),
CN6 (11), CN7 (12), CN8 (13) and CN9 (14) to
VIO14.
3
: 13 mm

W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-15
(Blank)
W8R7-E-01(20160803) W4-1-9-16
1
Removal

W8DS-02-04-011

: 13 mm 2
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-17
3. Disconnect 6 connectors CN3 (15), CN4 (16), VIO15
18 15 16
CN5 (17), CN6 (18), CN7 (19) and CN8 (20) from
interface board VIO15.
IMPORTANT: When loosening the screw, rotate the 31

lapse. 17
anti-static electricity bag to prevent damage to DSC 22 20 19
VIO15 due to static electricity. W8DS-04-01-056
W8R7-E-01(20160803) W4-1-9-18
Installation VIO15
18 15 16
upper and lower guide rails. 31

the screwdriver while tightly press- 17
head collapse.
1. Install interface board VIO15 into PI case (31). DSC 22 20 19
Secure VIO15 to PI case (31). with screws (22) (4 W8DS-04-01-056
used).
2. Connect 6 connectors CN3 (15), CN4 (16), CN5

(17), CN6 (18), CN7 (19) and CN8 (20) to VIO15.
2
: 13 mm
4. Close the front door (upper right) of control cabi- 3

W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-19
(Blank)
W8R7-E-01(20160803) W4-1-9-20
REMOVAL AND INSTALLATION OF DSC 1 DSC
DC/DC CONVERTERS AVR302 AND
AVR303 (Serial No.: 10001-10022)
Removal of DSC DC/DC converter AVR302


: 13 mm

pair of cotton gloves and connect a ground band Control Cabinet (1) Front View
or touch the vehicle frame to release static elec- T8R7-01-02-016
tricity.
5. Remove interface board VIO13 and drive control

board VDC06 while referring to the following
group pages.
• REMOVAL AND INSTALLATON OF DSC IN-
TERFACE BOARD VIO13
• REMOVAL AND INSTALLATION OF DSC DRIVE
CONTROL BOARD VDC06 DSC DC/DC Converter AVR302
Drive System Controller (DSC) W8DS-02-04-011
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-21
IMPORTANT: Spread a sheet under DSC DC/DC
converter AVR302 to prevent screws
from missing.
6. Remove M3 screws (10 used) to disconnect wire
harnesses (10 used) from DSC DC/DC converter
AVR302 (23).
Remove wire harnesses (10 used) of AVR302
(23).
23
W8DS-04-01-062
7. Remove screws (41) (4 used) from metal holder

(40). Remove AVR302 (23) from metal holder
(40). 40
23
41
W8DS-04-01-067
W8R7-E-01(20160803) W4-1-9-22
Installation of DSC DC/DC converter AVR302
1. Install DSC DC/DC converter AVR302 (23) to
metal holder (40) with screws (41) (4 used).
IMPORTANT: After making connections, make

sure that each harness polarity is
correct.
2. Connect wire harnesses (10 used) to AVR302 (23) 23
with M3 screws (10 used).

rectly tightened, put a tightening check mark 40
(black) to each screw. 41
W8DS-04-01-067
Harnesses
23 (10 Used)
W8DS-04-01-062
W8R7-E-01(20160803) W4-1-9-23
4. While referring to the following group pages, in-
31
stall interface board VIO13 to PI case (31).
22
• REMOVAL AND INSTALLATION OF DSC IN-
TERFACE BOARD VIO13
5. Adjust DSC DC/DC converter AVR302 (23) by

following the procedures below.
5-1. Connect a voltmeter cables to check pins VCC
and GD on VDC06.
DSC DC/DC Converter AVR302
IMPORTANT: To avoid damage to the VDC06 guide Drive Control Board VDC06
ing that VDC06 is correctly seated on
W8DS-02-04-011
5-2. Slowly install VDC06 into PI case (31) Drive System Controller (DSC)
5-3. Turn the key switch ON. Adjust VR on AVR302
(23) so that voltage between check pins VCC
and GD on VDC06 becomes to 5.00 V.
5-4. Turn the key switch OFF. Remove VDC06 from Check Pin GD
PI case (31).
Check Pin VCC
Battery Con-
IMPORTANT: When tightening the screw, rotate nector CN6
head collapse.
5-5. Disconnect the tester cables. Install VDC06 into VDC 06 W8DS-04-01-068
PI case (31) again. Secure VDC06 to PI case

VCC
VCC
Ground Line
Adjust VR GD
GD
P12C
N12C
COMC
P24B
N24B
W8DS-04-01-069
AVR 302
W8R7-E-01(20160803) W4-1-9-24
: 13 mm 2

3
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-25
Removal of DSC DC/DC converter AVR303
1 DSC

: 13 mm

tricity.
5. Remove interface board VIO13 and drive control Control Cabinet (1) Front View
board VDC06 while referring to the following T8R7-01-02-016
group pages. DSC DC/DC Converter

AVR303
TERFACE BOARD VIO13
CONTROL BOARD VDC06


W8DS-02-04-011
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-26
IMPORTANT: Spread a sheet under DSC DC/DC
converter AVR303 to prevent screws
from missing.
6. Remove M4 screws (7 used) to disconnect wire 24
harnesses (7 used) from DSC DC/DC converter
AVR303 (24).
Remove wire harnesses (7 used) of AVR303 (24).
7. Remove screws (41) (4 used) from metal holder

(40). Remove AVR303 (24) from metal holder
(23).
8. Remove screws (43) (4 used) from AVR303 (24)

mounting adaptor (42) (2 used). Remove AVR303 W8DS-04-01-062
41
(24) mounting adaptor (42) (2 used).
24
40 42, 43
W8DS-04-01-067
W8R7-E-01(20160803) W4-1-9-27
Installation of DSC DC/DC converter AVR303
41
1. Install DSC DC/DC converter AVR303 (24)
mounting adaptor (42) (2 used) to DSC DC/DC
converter AVR303 (24) with screws (43) (2 used).
2. Install AVR303 (24) to metal holder (40) with

24
40 42, 43
W8DS-04-01-067
IMPORTANT: After making connections, make

sure that each harness polarity is Wire Harness
24
correct. (7 Used)
3. Connect wire harnesses (7 used) to AVR303 (24)
with M4 screws (7 used).

(black) to each screw.
W8DS-04-01-062
W8R7-E-01(20160803) W4-1-9-28
5. While referring to the following group pages, in-
22 31
stall interface board VIO13 and drive control
DSC DC/DC Converter
board VDC06 to PI case (31). AVR303
CONTROL BOARD VDC06
TERFACE BOARD VIO13
6. Adjust DSC DC/DC converter AVR303 (24) by

6-1. Remove screw (22) (4 used) to remove VIO14 Drive Control Board VDC06
from PI case (31). Interface Board VIO14
6-2. Connect the test cables to the check pin P24C
and check pin COMC of VIO14. W8DS-02-04-011

upper and lower guide rails. Check Pin COMC
6-3. Slowly install VIO14 into PI case (31).
6-4. Turn the key switch ON. Adjust VR on AVR303
(24) so that voltage between check pins P24C
and COMC on VIO14 becomes to 24.00 V. Check Pin P24C
6-5. Turn the key switch OFF. Remove VIO14 from
PI case (31).
VIO14 W8DS-04-01-070

ing it down to prevent the screw P24C
head collapse. P24C
6-6. Disconnect the tester cables. Install VIO14 into COMC
Adjust VR
PI case (31) again. Secure VIO14 to PI case COMC
P24B
N24B
Ground Line
AVR 303 W8DS-04-01-071
W8R7-E-01(20160803) W4-1-9-29
: 13 mm 2

3
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-9-30
REMOVAL AND INSTALLATION OF DSC
1 4
DC/DC CONVERTER (HDR10) (Serial No.:
10023 and Up)
Removal
1. Open front door (upper right) of control cabinet (1)
by using the door open/close handle.
T8R7-01-02-016
2. Remove bolts (2) (5 used) and remove cover (3).

: 13 mm
2

4. To prevent generation of static electricity, use a 3
to release static electricity.
WQHA-04-01-041
5. Remove interface board VIO13 (5), drive control
board VDC06 (6), and interface board VIO14 (21)
while referring to the following group pages.
• Removal and Installation of DSC Interface Board 4 5 6 21
VIO13
• Removal and Installation of DSC Drive Control
Board VDC06
• Removal and Installation of DSC Interface Board
VIO14
WQHA-04-01-035
W8R7-E-01(20160803) W4-1-9-31
6. Remove M4 screws (3 used) and disconnect the 7
wire harnesses (6 used) from TB1 (8) of DC/DC
converter HDR10 (7).
7. Remove M3 screws (3 used) and disconnect the

wire harnesses (5 used) from TB2 (9) of HDR10
(7).
8. Disconnect connecter CN3 (10) from HDR10 (7).
WQHA-04-01-035
8 9 10
WQEB-04-01-044
W8R7-E-01(20160803) W4-1-9-32
9. Remove screws (12) (6 used) and remove metal
holder (23) with HDR10 (7) from holder (22).
10. Disconnect connecter CN2 (13) from HDR10 (7).
11. Remove screws (14) (3 used), (15) (2 used) and

remove holders (11, 23) from metal holder (11). 22
12
23
WQHA-04-01-044
23
14
15
13
11 WQHA-04-01-045
W8R7-E-01(20160803) W4-1-9-33
Installation
1. Install DC/DC converter HDR10 (7) to metal 23
holder (11) with screws (14) (3 used), (15) (2
used).
2. Connect connecter CN2 (13) to HDR10 (7).
3. Install metal holder (23) with HDR10 (7) to holder 14

(23) with screws (12) (6 used). 15
13
4. Connect connecter CN3 (10) to HDR10 (7).
5. Connect the wire harnesses (6 used) to TB1 (8) of

HDR10 (7) with M4 screws (5 used).
11 WQHA-04-01-045
6. Connect the wire harnesses (3 used) to TB2 (9) of

HDR10 (7) with M3 screws (3 used).

22
12
23
WQHA-04-01-044
8 9 10
WQEB-04-01-044
W8R7-E-01(20160803) W4-1-9-34
8. If interface board VIO13 (5), drive control board 4 7 5 6 21
XDC01 (6) and interface board VIO14 (21) are
removed, install them while referring to the fol-
lowing group pages.
VIO13
• Removal and Installation of DSC Drive Control
Board VDC06
VIO14
18 WQHA-04-01-035
Drive System Controller (DSC) (4)
: 13 mm
10. Close front door (upper right) of control cabinet (1)
by using the door open/close handle.
WQHA-04-01-041
W8R7-E-01(20160803) W4-1-9-35
(Blank)
W8R7-E-01(20160803) W4-1-9-36
REMOVAL AND INSTALLATION OF CON-
TROL POWER (CS) UNIT 1
Removal
1. Turn the key switch and battery switch (2) OFF.


T8R7-01-02-016
Control Power CS Unit (5) W8DS-04-01-072
M8R8-07-017
M146-07-062
W8R7-E-01(20160803) W4-1-10-1
: 13 mm 3
4. Remove M4 screws (17 used) from terminal board

TBZ6 (6). Disconnect wire harnesses (7) (17
used) from terminal board TBZ6 (6).
NOTE: Remove wire harness that are connected to 4
terminal board TBZ6 (6) from outside be-
sider control power CS unit (5).
5. Remove M4 screws (2 used) from wire harnesses

(9) (2 used) that are connected to overvoltage
protection module VAX03 (8). Disconnect wire W8DS-04-01-037
harnesses (9) (2 used) that are connected from 8
outside besider CS unit (5) to VAX03 (8) (6). 11
6. Remove M5 screw from ground line (10) of CS

unit (5).
6, 7
7. Remove CS unit (5) mounting bolts (11) (4 used). 10
: 13 mm
11
8. Remove CS unit (5) from control cabinet (1).
9 W8DS-04-01-073
CS Unit (5)
11
CS Unit (5) W8DS-04-01-072
W8R7-E-01(20160803) W4-1-10-2
Installation 5
1. Install control power CS unit (5) in control cabinet
(1).
11
2. Secure CS unit (5) to control cabinet (1) with bolts
(11) (4 used).
: 13 mm
3. Install M5 screw to ground line (10) of CS unit (5).

8
IMPORTANT: Check the harness number. Be
careful not to make incorrect con- 6
nection of wire harnesses.
4. Connect wire harnesses (9) (2 used) that are Control Power CS Unit (5) W8DS-04-01-072
connected to overvoltage protection module

VAX03 (8) with M4 screws (2 used). 8
11
careful not to make incorrect con-
5. Connect wire harnesses (7) (17 used) that are 6, 7
connected from outside besider CS unit (5) to
10
terminal board TBZ6 (6) with M4 screws (17
used). 11

(black) to each screw. 9 W8DS-04-01-073
CS Unit (5)
W8R7-E-01(20160803) W4-1-10-3
: 13 mm 3

9. Turn battery switch (2) and the key switch ON.

4
W8DS-04-01-037
M146-07-062
W8R7-E-01(20160803) W4-1-10-4
REMOVAL AND INSTALLATION OF CON-
1
TROL POWER (CS) UNIT INTERNAL
PARTS
Removal and Installation of CS Unit Overvoltage
Protection Module VAX03
Removal
1. Turn the key switch and battery switch (2) OFF.


T8R7-01-02-016
CS Unit (5) W8DS-04-01-072
M8R8-07-017
M146-07-062
W8R7-E-01(20160803) W4-1-11-1
3. Remove bolts (4 used) to remove cover (3).
: 13 mm 3

(12) (6 used) that are connected to overvoltage
protection module VAX03 (8). Disconnect wire 4
harnesses (12) (6 used) from VAX03 (8).
5. Remove screws (13) (4 used) securing VAX03 (8)

to control power (CS) unit (5).
6. Remove VAX03 (8) from CS unit (5).
W8DS-04-01-037
12
12
13
W8DS-04-01-074
12 8
VAX03 (8)
13
W8R7-E-01(20160803) W4-1-11-2
Installation 5
1. Install overvoltage protection module VAX03 (8) in
control power CS unit (5).
2. Secure VAX03 (8) to CS unit (5) with bolts (13) (4

used).
13
careful not to make incorrect con- 8
3. Connect wire harnesses (12) (6 used) to over-
voltage protection module VAX03 (8) with M4
screws (6 used).

12
12
13
W8DS-04-01-074
12 8
VAX03 (8)
W8R7-E-01(20160803) W4-1-11-3
: 13 mm 3

4
7. Turn battery switch (2) and the key switch ON.
W8DS-04-01-037
M146-07-062
W8R7-E-01(20160803) W4-1-11-4
Removal and Installation of CS Unit Line Filter
FLT301 A
Removal
1. Refer to Removal and Installation of Control
Power (CS) Unit (W4-1-10-1). Remove CS
unit (1).

harnesses (4) (5 used) from line filter FLT301 (2).
3. Remove screws (5) (4 used). Remove line filter TQEB-01-02-010
FLT301 (2) from CS unit (1). CS Unit (1)
Installation
4. Install line filter FLT301 (2) to CS unit (1) with
IMPORTANT: Check the wire harness number. Do

not make incorrect connection of
wire harnesses. 5
5
5. Connect wire harnesses (4) (5 used) to line filter 3, 4
FLT301 (2) with screws (3) (5 used). 3, 4

5
tened. Put a tightening check mark (black) on
each screw.
W8R8-04-01-008
5 2
View A
Power (CS) Unit (W4-1-10-1). Install CS unit (1).
W8R7-E-01(20160803) W4-1-11-5
Removal and Installation of CS Unit Diodes D301,
D305
Removal
Power (CS) Unit (W4-1-10-1). Remove CS unit 6
(1).
The procedures of diodes D301 (2) and D305 (3)
are same. Then, the procedures of diode D301 (2)
are explained here.
A

harnesses (5) (3 used) from diode D301 (2). TQEB-01-02-010
CS Unit (1)
3. Remove screws (7) (2 used). Remove diode D301
(2) from fin (6).
7
Installation
1. Apply silicone grease to diode D301 (2). Install
diode D301 (2) to fin (6) with screws (7) (2 used).

not make incorrect connection of 4, 5 4, 5
wire harnesses.
2. Connect wire harnesses (5) (3 used) to diode

D301 (2) with screws (4) (3 used). 2 3
3. Check that all wire harnesses are securely fas- 7

tened. Put a tightening check mark (black) on W8R8-04-01-009
each screw. View A

Power (CS) Unit (W4-1-10-1). Install control pow-
er (CS) unit (1).
W8R7-E-01(20160803) W4-1-11-6
Removal and Installation of CS Unit Capacitors
C302A, C302B
Removal
A
2
Power (CS) Unit (W4-1-10-1). Remove control
power (CS) unit (1). 3
The procedures of capacitors C302A (2) and
C302B (3) are same. Then, the procedures of
capacitor C302A (2) are explained here.
2. Remove bolts (4) (2 used). Disconnect wire har-

nesses (5) (2 used) from capacitor C302A (2).
: 8 mm
TQEB-01-02-010
3. Remove screws (6) (3 used). Remove capacitor CS Unit (1)

C302A (2) from CS unit (1).
Installation 6
3
1. Install capacitor C302A (2) to control power (CS)
unit (1) with screws (6) (3 used).

wire harnesses.
2. Connect wire harnesses (5) (2 used) to capacitor

C302A (2) with bolts (4) (2 used).
: 8 mm

2 4, 5
tened. Put a tightening check mark (black) on W8R8-04-01-013
each bolt. View A

Power (CS) Unit (W4-1-10-1). Install CS unit (1).
W8R7-E-01(20160803) W4-1-11-7
(Blank)
W8R7-E-01(20160803) W4-1-11-8
REMOVAL AND INSTALLATION OF AUX-
ILIARY ALTERNATOR FIELD REGULATOR 1
(AFR) UNIT
Removal
4

T8R7-01-02-016
10
Auxiliary Alternator Field Regulator AFR Unit (4)

W8DS-04-01-075
2. Remove bolts (2) (4 used) to remove cover (3). 2

: 13 mm
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-12-1
3. Spread a sheet under auxiliary alternator field
regulator AFR unit (4).

(6) (5 used) that are connected to terminal board
TBZ1 (5). Disconnect wire harnesses (6) (5 used)
8
that are connected to terminal board TBZ1 (5).
5. Disconnect connectors CN11 (8) and CN12 (9) of

9
wire harness that are connected to printed board
VPM08 (7).
6. Remove screws (10) (4 used) securing AFR unit.

Some screws (10) are used to fasten ground line 10, 11
(11) together with AFR. Therefore, ground line
(11) is also disconnected.
W8DS-04-01-076
7. Remove AFR unit (4) from control cabinet (1). 5, 6
5
U14
U11
F0110D
F0110C
W14
W8DS-04-01-077
10
Auxiliary Alternator Field Regulator (AFR) Unit (4)

W8DS-04-01-075
W8R7-E-01(20160803) W4-1-12-2
Installation 1
1. Install AFR unit (4) in control cabinet (1).
2. Secure AFR unit (4) to control cabinet (1) with

screws (10) (4 used). Fasten ground line (11) with
screws (10) together with AFR unit (4). 4
IMPORTANT: Check the cable number. Be careful

not to make incorrect connection of
wire harnesses.
3. Connect wire harnesses (6) (5 used) that are
connected to terminal board TBZ1 (5) with M4
screws (5 used).
4. After checking that wire harnesses (6) of terminal T8R7-01-02-016
board TBZ1 (5) and the ground line are correctly

tightened, put a tightening check mark (black) to
each screw. 10
5. Connect connectors CN11 (8) and CN12 (9) of

wire harnesses that are connected to printed
board VPM08 (7).
6. Remove a sheet spread under AFR unit (4). 7
Auxiliary Alternator Field Regulator (AFR) Unit

W8DS-04-01-075
10, 11
W8DS-04-01-076
5, 6
5
U14
U11
F0110D
F0110C
W14
W8DS-04-01-077
W8R7-E-01(20160803) W4-1-12-3
: 13 mm 2
8. Close front door (Upper center) of control cabinet

W8DS-04-01-037
W8R7-E-01(20160803) W4-1-12-4
ILIARY ALTERNATOR FIELD REGULATOR 1
(AFR) UNIT INTERNAL PARTS
Removal and Installation of Auxiliary Alternator

Field Regulator (AFR) Unit Printed Board VPM08
Removal 4

T8R7-01-02-016
10
Auxiliary Alternator Field Regulator AFR Unit (4)

W8DS-04-01-075
2. Remove bolts (2) (4 used) and remove cover (3). 2

: 13 mm
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-12-5
3. Spread a sheet under auxiliary alternator field 12
11
regulator AFR unit (4) to prevent loosing screws. 12
4. Disconnect connecters CN1 (8), CN11 (9), CN12 12

(10), and CN13 (11) from printed board VPM08 8
(7). 7 9
IMPORTANT: Do not disconnect the wire har-

nesses except wire harness (13)
10
from terminal box TBZ1 (6).
12
5. Remove screw (5).Disconnect wire harness (13)
from terminal box TBZ1 (6).
6. Remove screws (12) (8 used).Remove printed 12
board VPM08 (7) from auxiliary alternator field
regulator (AFR) unit (4).
W8DS-04-01-076
6
13
5
W8DS-04-01-077
W8R7-E-01(20160803) W4-1-12-6
Installation
IMPORTANT: Install wire harness (13) through
hole connector (14) on the back of
printed board VPM08 (7) before in- 13
stalling wire harness (13) to terminal 14
box TBZ1 (6).
wire harnesses. 7
1. Install wire harness (13) through hole connector

(14) on the back of printed board VPM08
(7).Install printed board VPM08 (7) to auxiliary
alternator field regulator (AFR) unit (4) with 6
W8R8-04-01-011
2. Connect wire harness (13) to terminal box TBZ1

(6) with screw (5). Check that all wire harnesses
are securely fastened. Put a tightening check
mark (black) on screw (5).
13
6
W8R8-04-01-010
13
5
W8DS-04-01-077
W8R7-E-01(20160803) W4-1-12-7
3. Connect connecters CN1 (8), CN11 (9), CN12 11
(10), and CN13 (11) to printed board VPM08 (7).
4. Remove the sheet which is spread under auxiliary

alternator field regulator (AFR) unit (4). 8
9
: 13 mm
10
6. Close front door (Upper center) of control cabinet
W8DS-04-01-076
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-12-8
4 5 6 1
ILIARY INVERTERS INV301 AND INV302
Removal A A

T8R7-01-02-016
W8R7-04-01-009
View A-A
5 6
: 13 mm 2
3. Turn breaker CB301 (4) OFF. W8DS-04-01-037
W8R7-E-01(20160803) W4-1-13-1
4. Loosen M4 screws (2 used) fastening respective
covers (7) for auxiliary inverter INV301 (5) and
INV302 (6)
5. Remove respective covers (7) for auxiliary inverter

INV301 (5) and INV302 (6) in the following pro-
cedures. While supporting the near side of the
cover, remove the cover by holding the inner side
of the cover. 7 7
7. Loosen screws from the following wire harnesses

routed in INV301 (5) and INV302 (6) and remove W8DS-04-01-079
the wire harnesses.

7-1. Main circuit wire harness (8) with M6 screws (6
used)
7-2. Control wire harness (9)
• INV301 (5) with M3 screws (8 used) 9
• INV302 (6) with M3 screws (7 used)
8. Loosen M5 screw from ground lines (1) of INV301

(5) and INV302 (6). Remove ground lines (10).
8 8
9. Remove bolts (11) (6 used) securing INV301 (5)
and INV302 (6) to control cabinet (1).
: 13 mm
10. Remove INV301 (5) and INV302 (6) from control

cabinet (1).
W8DS-04-01-080
10
W8DS-04-01-081
11
W8R7-E-01(20160803) W4-1-13-2
Installation
1. Install INV301 (5) and INV302 (6) in control cabi-
net (1).
2. Secure INV301 (5) and INV302 (6) to control

cabinet (1) with bolts (11) (6 used).
: 13 mm
10
3. Connect ground lines (10) to INV301 (5) and
INV302 (6) with M5 screw.
4. Connect the following wire harnesses in INV301

(5) and INV302 (6).
W8DS-04-01-081
4-1. Main circuit wire harness (8) with M6 screws (6 11
used)
Tightening torque: 5.8 N-m ± 10 %
4-2. Control wire harness (9)
: 0.7 N-m ± 10 % 9

8 8
6. Install covers (7) on INVC301 (5) and INV 302 (6).
7. Fasten covers (7) to INVC301 (5) and INV 302 (6)

with M4 screws (2 used)
W8DS-04-01-080
7 7
W8DS-04-01-079
W8R7-E-01(20160803) W4-1-13-3
8. Turn breaker CB301 (4) ON.
4
T8R7-01-02-017
9. Install cover (3) with bolts (2) (4 used). 2

: 13 mm
10. Close the front door (upper left) of control cabinet

(1) by using the door open/close handle. 3
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-13-4
REMOVAL AND INSTALLATION OF RE- A 1
LAYS
Removal and Installation of Relays RY302, 23E
Removal
2. Remove bolts (2)(4 used) to remove cover (3).

: 13 mm
4. Slightly lower the holding lever located under re- Control Cabinet (1) Front View T8R7-01-02-016
lays RY 302 (4) and 23 E (5). Remove relays RY

302 (4) and 23 E (5).
4 5
Detail A W8DS-04-01-082
Installation 2
1. Install relays RY 302 (4) and 23 E (5).

: 13 mm
3
W8DS-04-01-037
5
4
Detail B W8DS-04-01-083
W8R7-E-01(20160803) W4-1-14-1
(Blank)
W8R7-E-01(20160803) W4-1-14-2
1
Removal and Installation of Relays RY303, RY304,
RY305
Removal

Perform voltage detection.
: 13 mm
3. Pull fuse holders (7) of respective relay RY303 (4),

RY304 (5) and RY305 (6).
4. Loosen screws fastening the wire harnesses to

relays RY304 (4), RY304 (5) and RY305 (6) to
disconnect the wire harnesses.
4-1. RY303 with screws (8) (6 used)
5. After loosening screws (10) (2 each used) secur-

ing relay metal holders (9), slide metal holders (9)
sideways to remove them.
4 5 6
6. While sliding relays RY304 (4), RY304 (5) and Detail of Section A T8R7-01-02-017
RY305 (6) sideways, remove them.
W8DS-04-01-037
5, 7, 9, 10 6, 7, 9, 10
4, 7, 9, 10
SV
HIS
W8DS-04-01-084
W8R7-E-01(20160803) W4-1-14-3
Installation 5, 7, 9, 10 6, 7, 9, 10
1. Confirm that the following setting values in each
relay of RY303 (4), RY304 (5) and RY305 (6) are 4, 7, 9, 10
as follows: 8
SV: 60 %
HYS: 5 %
T: 5s
SV
2. Install each relay of RY303 (4), RY304 (5) and
HIS
RY305 (6).
T
3. Install relay metal holders (9) with screws (10) (2
each used).
4. Connect wire harness to each relay of RY303 (4), W8DS-04-01-084
RY304 (5) and RY305 (6) and tighten wire har-

ness fastening screws.
: 0.49 N⋅m
5. Securely install fuse holders (7) to the original po-

sition in respective relay RY303 (4), RY304 (5)
and RY305 (6).

: 13 mm
7. Close the front door (upper left) of control cabinet 2

W8DS-04-01-037
W8R7-E-01(20160803) W4-1-14-4
A 1
Removal and Installation of Sockets for Relays
RY302, 23E
Removal

: 13 mm
4. Remove M3.5 screws to disconnect wire har-

nesses that are connected to sockets (6 and 7) for Control Cabinet (1) Front View T8R7-01-02-016
relays RY302 (4) and 23E (5) respectively.

4-1. Socket (6) for RY302 with screws (8) (6 used)
4-2. Socket (7) for 23E with screws (8) (4 used)
5. Slightly lower the holding lever located under re-

lays RY 302 (4) and 23 E (5). Remove relays
RY302 (4) and 23 E (5).
6. Remove screws (9) securing sockets (6 and 7) for B

relays RY302 (4) and 23E (5).
Detail of Section A W8DS-04-01-082
W8DS-04-01-037
8 8
5
4
6, 9
7, 9
Detail of Seaction B W8DS-04-01-083
W8R7-E-01(20160803) W4-1-14-5
Installation
IMPORTANT: Beware of the socket installation di-
rection. Face the relay holding lever
8 8
side downward.
1. Install sockets (6 and 7) for relays RY302 (4) and 5
23E (5) with M3 screws (9).
4
2. Install relays RY302 (4) and 23 E (5). 7, 9
6, 9
3. Connect wire harnesses to socket (6 and 7) for
relays RY302 and 23E with M3.5 screws.
3-1. Socket (6) for RY302 with screws (8) (6 used)
3-2. Socket (7) for 23E with screws (8) (4 used)

(black) to each screw. W8DS-04-01-083
5. Install cover (3) with bolts (2) (4 used). Terminal Layout/Inboard Wiring
: 13 mm

W8DS-04-01-085
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-14-6
1
REMOVAL AND INSTALLATION OF 5
COOLANT LEVEL SENSOR WS301
Removal
1. In accordance with the coolant change procedure
manual, drain the coolant from the coolant tank
until the coolant level is lowered down to the L line.
And then, drain the coolant further by approxi-
mately 1300 mL to 1350 mL.
2. Open the front door (upper left) of control cabinet

3. Remove bolts (2) (4 used) to remove cover (3). Control Cabinet (1) Front View T8R7-01-02-016
: 13 mm
2
4. Disconnect relay connector CNZ3 (4).
5. Cut to remove a wire bundle band used for hold-

ing the lead line of coolant level sensor (5). 3
IMPORTANT: When removing coolant level sensor

(5), directly grasp the sensor. Do not
pull on the lead line itself.
IMPORTANT: Completely wipe off the spilt coolant.

6. Remove screws (7) (2 used) to remove coolant
level sensor (5) and metal holder (6) from tank (8). W8DS-04-01-037
5 W8DS-04-01-086
4
5 6
View A W8DS-04-01-087
W8R7-E-01(20160803) W4-1-15-1
Installation
1. As illustrated, check that O-rings (9) (2 used) are 8
A
provided on each coolant level sensor (5). Install 6
5
coolant level sensors (5) (2 used) in tank (8) by
1-1. Install coolant level sensor (5) with the red lead
line to the left side.
1-2. Install coolant level sensor (5) with the black
lead line to the right side. 9
NOTE: The following parts are supplied together

with a new coolant level sensor.
⋅ Coolant level sensor metal holder (6) Install the sen-
View A
Install the sen- W8DS-04-01-087
⋅ Lead line with relay connector CNZ3 (4) sor with a red sor with a black
⋅ O-ring (9) lead line to the lead line to the
left side. right side.
2. Install metal holder (6) to tank (8) with screws (7)

(2 used).
3. Connect relay connector CNZ3 (4). 7
4. Fasten the lead line of coolant level sensor (5)

with a wire bundle band.

6
: 13 mm

5 W8DS-04-01-086
4
7. In accordance with the coolant change procedure
manual, refill coolant into the tank.
8. In accordance with the air bleeding procedure 2

manual, bleed air.
W8DS-04-01-037
W8R7-E-01(20160803) W4-1-15-2
HEATERS 1 4
Removal and Installation of Heater H302

A A
Removal
1. Remove M8 bolts (20 used) securing the reverse
cover (center) on control cabinet (1) and remove
the reverse cover (center).
: 13 mm
3. Loosen screws (3) (2 used) on circuit cable (2) to

terminal board TB in control cabinet (1). Discon- Reverse Side of Control Cabinet (1) W8R7-04-01-011
nect inboard circuit cable (2) from TB equipped

heater H302 (4).
4, 5
4. Remove bolt (5) from heater H302 (4) equipped
with TB. Remove heater H302 (4) equipped with
TB from control cabinet (1).
: 13 mm
Installation
1. Install heater H302 (4) equipped with TB to control
cabinet (1) with bolt (5).
: 13 mm View A-A W8R7-04-01-012
2. Connect inboard circuit cable (2) to heater H302

(4) equipped with TB with screws (3) (2 used). 4

rectly tightened, put a tightening check mark 5
4. Install the reverse cover (center) to control cabinet

: 13 mm 2, 3
W8DS-04-01-090
W8R7-E-01(20160803) W4-1-16-1
4 1
Removal
A A
cover (left) on control cabinet (1) and remove the
reverse cover (left).
: 13 mm
3. Loosen screws (3) (2 used) on inboard circuit ca-

ble (2) to terminal board TB. Disconnect inboard
circuit cable (2) from heater H303 (4) equipped
with TB.
Reverse Side of Control Cabinet (1) W8R7-04-01-011
4. Remove bolt (5) from TB equipped heater H303

(4) with TB. Remove heater H303 (4) equipped
with TB from control cabinet (1).
: 13 mm
4, 5 View A-A W8R7-04-01-012
Installation
: 13 mm
2. Connect inboard circuit cable (2) to heater H302 5

(4) equipped with TB with screws (3) (2 used).

rectly tightened, put a tightening check mark 2, 3
4
4. Install the reverse cover (left) to control cabinet (1) W8DS-04-01-091

: 13 mm
W8R7-E-01(20160803) W4-1-16-2
1 4
Removal
A A
cover (center) on control cabinet (1) and remove
the reverse cover (center).
: 13 mm

ble (2) to terminal board TB in control cabinet (1).
Disconnect inboard circuit cable (2) from heater
H304 (4) equipped with TB.

with TB. Remove TB equipped heater H304 (4)
from control cabinet (1).
: 13 mm
Installation
: 13 mm
2. Connect inboard circuit cable (2) to heater H304 4, 5 View A-A W8R7-04-01-012

4. Install the reverse cover (center) to control cabinet

: 13 mm 5
4 2, 3
W8DS-04-01-090
W8R7-E-01(20160803) W4-1-16-3
4 1
Removal
cover (left) on control cabinet (1) and remove the A A
reverse cover (left).
: 13 mm

ble (2) to terminal board TB in control cabinet (1).
Disconnect inboard circuit cable (2) from heater
H305 (4) equipped with TB.
with TB. Remove TB equipped heater H305 (4)
from control cabinet (1).
: 13 mm
Installation 4, 5
: 13 mm
2. Connect inboard circuit cable (2) to heater H305

View A-A W8R7-04-01-012
4
(black) to each screw. 5
4. Install the reverse cover (left) to control cabinet (1) 2, 3

: 13 mm
W8DS-04-01-091
W8R7-E-01(20160803) W4-1-16-4
ILIARY EXCITATION UNIT CURRENT 1 2
TRANSFORMER CT301
Removal
cover (right) on control cabinet (1) and remove the
reverse cover (right).
: 13 mm
3. Cut to remove wire bundle band (6) used for

holding wire (3).
4. Remove bolt (5) tightening wire (3) routed through

current transformer CT301 (2) to copper bar V11
(4) and disconnect wire (3) from copper bar V11 6
(4). Disconnect wire (3) from CT301 (2).
: 19 mm
NOTE: Remove only wires (3) (2 used) (onected to 3, 4, 5

copper ber V11 (4) of the middle.
5. Remove screw (8) to disconnect wire (7) from

CT301 (2).
6. Remove screws (9) (2 used) to remove CT301 (2)

W8DS-04-01-092
from control cabinet (1). 9
7, 8
W8DS-04-01-093
4
W8R7-E-01(20160803) W4-1-17-1
Installation 9
1. Install CT301 (2) to control cabinet (1) with screws
(9) (2 used).
7, 8
2. Route wire (3) through current transformer CT301
(2) and tighten wire (3) to copper bar V11 (4) with
bolt (5).
: 19 mm
2
3. After checking that wire (3) is correctly tightened
to copper bar V11 (4), put tightening check mark
(black) on the bolt head.
4. Fasten wire (3) with wire bundle band (6). W8DS-04-01-093

4
5. Connect wire (7) to CT301 (2) with screws (8) (2

used).
6
6. After checking that wire (7) is correctly tightened
to CT301, put tightening check mark (black) on
the bolt head.
3, 4, 5
7. Install the reverse cover (right) on control cabinet
: 13 mm
W8DS-04-01-092
W8R7-E-01(20160803) W4-1-17-2
REMOVAL AND INSTALLATION OF PUMP
PUMP301 1
Removal
1. Open the louver equipped front door (center left)
handle.
2. Remove coolant according to the coolant change

procedures (W4-1-19-1). 2
3. Remove nuts (4) (4 used) to remove cover (3)

from the electric power connector on pump
PUMP301 (2). Control Cabinet (1) Front View T8R7-01-02-016
: 13 mm 16
11
5. Loosen screws (6) (3 used) to disconnect wires

13
(5) (3 used) from the wire connection terminal.
6. Loosen nut (8) on bushing (7) at wire routing port. 4

Remove wires (5) (3 used) from pump PUMP301 11
(2). 3
: 41 mm
7. Remove bolt (10) to remove ground line (9) from

pump PUMP301 (2). 7, 8 12 W8DS-04-01-094
: 13 mm
8. Remove bolts (11) (8 used) from pump PUMP301

(2). 5
: 24 mm
9. Remove pump mounting bolts (12) (4 used).

: 17 mm
CAUTION: Weight of Pump PUMP301 (2): 52

kg
10. Remove pump PUMP301 (2) from control cabinet 6 7, 8 W8DS-04-01-095
(1).
11. Clean the flange surface of pipes (13, 16) with a

shop towel.
10
W8DS-04-01-096
W8R7-E-01(20160803) W4-1-18-1
Installation
2 14, 16 11
CAUTION: Weight of Pump PUMP301 (2): 52
kg
1. Place pump PUMP301 (2) on the mounting posi- 13, 14

tion of control cabinet (1).
2. Install pump PUMP301 (2) to control cabinet (1)

and temporarily tighten bolts (12) (4 used). 11
: 17 mm
3. Install pipes (13, 16) to the flanges of pump

PUMP301 (2) and temporarily tighten bolts (11) (2
used). Install new packings (14) (2 used) on the W8DS-04-01-094
flange surfaces of pipes (13, 16). 12
4. Install pipes (13, 16) to pump PUMP301 (2) with

bolts (11) (8 used).
: 24 mm
5. After checking that bolts (11) (8 used) are correctly

tightened, put tightening check mark (black) on
each bolt head.
6. Tighten bolts (12) (4 used).

: 17 mm
W8R7-E-01(20160803) W4-1-18-2
7. Connect ground line (9) to pump PUMP301 (2)
with bolt (10).
8. Insert wires (5) (3 used) into pump PUMP301 (2)

via the wire routing port. Then connect wires (5) (3 10
used) to the connection terminal with screws (6) (3
used). 9
9. After checking that wires (5) (3 used) are correctly

connected to the connection terminal, put tight-
ening check mark (black) to each connection ter-
minal.
10. Tighten nut (8) on bushing (7) at wire routing port. W8DS-04-01-096
: 41 mm
11. Install cover (3) on the electric power connector of 2

PUMP301 (2) with nuts (4) (4 used).
5
: 13 mm
12. Close the louver equipped front door (center left)

handle.
13. Refill coolant according to the coolant change

procedures (W4-1-19-1).
6 7, 8
14. Bleed air according to the air bleeding procedure W8DS-04-01-095
manual.
W8DS-04-01-094
7, 8 2
W8R7-E-01(20160803) W4-1-18-3
(Blank)
W8R7-E-01(20160803) W4-1-18-4
COOLANT CHANGE PROCEDURES 1
Coolant drain procedures

1. Remove bolts (3) (6 used) to remove drain cover
(2) on the left side of control cabinet (1).
: 13 mm
2. Check that drain valves (5) (2 used) on the left

side bottom of radiator (4) are closed.
3. Place a tray and shop towel under the drain ports

of valves (5) (2 used).
IMPORTANT: Wind seal tape around the screw Control Cabinet (1) Front View T8R7-01-02-016
threads on the coolant drain jig be-

fore connecting the coolant drain jig.
4. Remove plug caps (6) (2 used) from the drain
ports of valves (5) (2 used). Connect a coolant
drain jigs to valves (5) (2 used).
5. Place the drain hose end outside the control cab-

inet. Open valve (5) (2 used) to allow coolant to
drain.
3
IMPORTANT: In case coolant that was remaining 2
in the coolant drain hose spatters,
sufficiently wipe the spattered cool-
ant with shop towels.
W8DS-04-01-097
6. After draining coolant, close valves (5) (2 used). Control Cabinet (1) Left-Side View
Remove the coolant drain jig.
7. Reinstall plug cap (6) to the drain ports of valves

(5) (2 used).
8. Reinstall drain cover (2) with bolts (3) (6 used).

: 13 mm 4
: 12 Nm (1.2 kgfm, 8.9 lbfft) 5
5
9. Dispose the used coolant in accordance with the
rule specified in the local regulation.
6
Shop
Towels
W8DS-04-01-098
Coolant Draining
W8R7-E-01(20160803) W4-1-19-1
Coolant refill procedures
1. Remove bolt (9) to open top cover (8) on reservoir 9
8
cover (7).
: 13 mm
2. After opening cap (10) on reservoir (12), refill

coolant until coolant level reaches the height be-
tween [H] and [L] marks on coolant level gauge
(11).
NOTE: Use anti-freeze liquid as coolant.
Recommended coolant: SHADN A55 % di-
lution, Maker: Otsuka Chemical Co., Ltd 7 11
3. Close cap (10) on reservoir (12).
4. Bleed air according to the air bleeding procedure W8DS-04-01-100
manual. 10
5. Install top cover (8) on reservoir cover (7) with bolt

(9).
7 12
: 13 mm
W8DS-04-01-101
W8R7-E-01(20160803) W4-1-19-2
AC DRIVE CONTROL DEVICE / Grid Box
REMOVAL AND INSTALLATION OF GRID
BOX Grid Box Front
Assembly
Removal
Grid Box Rear 3
1. Park the machine in the service position on a level Assembly
surface.
2. Raise the dump body. Insert the body prop pins to 2

IMPORTANT: Do not hoist the grid boxes (3 used)

together. Hoisting position and 1
connecting position do not have
strength to hoist them together.
3. Disassemble the grid boxes (R1, R2, R3) (3 used)

of the grid box front assembly into a upper part
and two lower parts, and remove them. Remove
the grid box rear assembly with two grid boxes (L1,
L2) together. W8R7-04-02-001
4 6, 7, 8
<Removal of Grid Box Front Assembly>
4. Disconnect ground harness R3 (4) from grid box
R3 (3). Remove clip (6), bolt (7), and washer (8) 3
securing ground harness R3 (4) to grid box R3 (3).
：19, 17 mm
5. Disconnect ground harness R1 (5) from grid box

R1 (1). Remove clip (6), bolt (7), and washer (8) 1
securing ground harness R1 (5) to grid box R1 (1). 5 6, 7, 8
：19, 17 mm
6. Disconnect harnesses (9, 10, and 11) of

differential pressure switch and temperature
switch from grid boxes R1 (1), R2 (2), and R3 (3).
Remove clips (12) (4 used), clip (13), bolts (14) (3
used), and washer (15) (3 used) securing W8R7-04-02-002
differential pressure switch and temperature

switch to the grid boxes. Bind harnesses to frame 3
(28).
12, 14, 15 11
: 17 mm
12, 14, 15 10
12
13, 14, 15 9
W8R7-04-02-006
W8R7-E-01(20160803) W4-2-1
used). Remove covers (16, 17) of high voltage Grid Box
harnesses from the grid box front assembly. Front Assembly
：17 mm
16
8. Remove the covers (3 used) of terminal box (A).
Disconnect blower motor harnesses R1 (20), R2
18, 19
(21), and R3 (22) from grid boxes R1 (1), R2 (2),
and R3 (3).
17
9. Remove brackets (23) (4 used), clamps (24) (6 18, 19

used), rubbers (57) (6 used), bolts (25) (4 used),
bolts (26) (4 used), and washers (27) (8 used).
Remove blower motor harnesses R1 (20), R2 (21),
and R3 (22) from the grid box front assembly. Bind
harnesses to frame (28).
：17 mm
W8R7-04-02-001
10. Remove the covers (3 used) of terminal box (B)

3 B 22
from grid boxes R1 (1), R2 (2), and R3 (3). A
：10 mm R3
N5P5
23, 24,
25, 27,
11. Check that there is no residual voltage on 57
high-voltage harnesses by using a voltage 2
B A 21
detecting rod. Remove high voltage harnesses 33, 34,
R2
R1-N3, R1-P3, R2-N4, R2-P4, R3-N5, and R3-P5 35, 36, 23, 24,
38 N4P4
26, 27,
from grid boxes R1 (1), R2 (2), and R3 (3).
57
：17 mm 1
B
A 20
33, 34,
12. Remove brackets (29) (6 used), clamps (30) (6 R1
35, 37,
used), bolts (31) (12 used), and washers (32) (12 38 N3 P3
used).
：17 mm
28
13. Remove brackets (33) (8 used), rubbers (34) (12 W8R7-04-02-003
used), clamps (35) (12 used) bolts (36) (8 used),

bolts (37) (8 used), and washers (38) (16 used). B
Remove high voltage harnesses from the grid box
front assembly. Bind harnesses to frame (28).
R1-P3,
R1-N3,
R2-P4,
R2-N4,
R3-P5
R3-N5
31, 32
29
30
W8R7-04-02-008
W8R7-E-01(20160803) W4-2-2
14. Remove bolts (39) (12 used), bolts (40) (4 used),
bolts (41) (4 used), and washers (42) (20 used).
Remove brackets (43) (4 used) and bars (44) (2
used).
：19 mm
CAUTION： Grid Box R3 (3) weight:

403 kg (888 lb)
15. Install the hoisting tool to grid box R3 (3).
41, 42 44
16. Hoist and remove grid box R3 (3) from grid box R2
3
(2). Keep the hoisted grid box horizontally.
17. Lower and place grid box R3 (3) on an appropriate 39, 42

holder.
43
used) securing brackets (45) (4 used) of grid box 40, 42 2
R1 (1) to frame (28).
： 19 mm
1
CAUTION: Grid box front assembly weight:
806 kg (1775 lb) 46, 47
19. Install the hoisting tool to the grid box (R2) (2). 45
28 W8R7-04-02-007
20. Hoist and remove the grid box R1 (1) and R2 (2)
assembly from the installation position of frame
(28).
Keep the hoisted grid box horizontally.
21. Lower and place the grid box R1 (1) and R2 (2)
assembly on an appropriate holder.
22. Remove ground harness R2 harness when

necessary.
W8R7-E-01(20160803) W4-2-3
<Removal of Grid Box Rear Assembly>
23. Remove ground harness L1 (50) from grid box L1
(48).
：19 mm
50 48
W8R7-04-02-004
24. Disconnect harnesses (51, 52) of differential

pressure switch and temperature switch from grid
boxes L1 (48), L2 (49). Remove clips (12) (3
used), bolts (14) (2 used), and washer (15) (2
used) securing differential pressure switch and 49
temperature switch to the grid boxes. Bind 12, 14, 15
：17 mm 52
48
12, 14, 15
28
51 W8R7-04-02-006
25. Remove the covers (2 used) of terminal box (A). 49 A 54

Disconnect blower motor harnesses L1 (53), L2
(54) from grid boxes L1 (48) and L2 (49). 23, 24,
25, 27,
48 57
26. Remove brackets (23) (4 used), clamps (24) (4 A 53
used), rubbers (57) (4 used), bolts (25) (8 used)
and washers (27) (8 used). Remove blower motor 23, 24,
harnesses L1 (53) and L2 (54) from the grid box 25, 27,
rear assembly. Bind harnesses to frame (28). 57
：17 mm 28
W8R7-04-02-005
W8R7-E-01(20160803) W4-2-4
used). Remove cover (16) of high voltage Grid Box
Rear Assembly
harnesses from the grid box rear assembly.
：17 mm
16
18, 19
W8R7-04-02-001
28. Remove the covers (2 used) of terminal box (B)

from grid boxes L1 (48) and L2 (49).
49 B
：10 mm
L2
29. Check that there is no residual voltage on N2 P2

detecting rod. Remove high voltage harnesses 48
B
L1-N1, L1-P1, L2-N2, and L2-P2 from grid boxes 33, 34,
L1
L1 (48) and L2 (49). 35, 36,
38 N1 P1
：17 mm
30. Remove brackets (29) (4 used), clamps (30) (4

28
used).
：17 mm W8R7-04-02-005
31. Remove brackets (33) (4 used), rubbers (34) (4

B
used), clamp (35), bolts (36) (8 used), and
washers (38) (8 used). Remove high voltage
harnesses from the grid box rear assembly. Bind
：17 mm
L1-N1, L1-P1,
L2-N2 L2-P2
31, 32
29
30
W8R7-04-02-008
W8R7-E-01(20160803) W4-2-5
used) that secure brackets (45) (4 used) of the
grid box rear assembly to frame (28).
：19 mm Grid Box
Rear Assembly
CAUTION： Grid box rear assembly weight:

806 kg (1777 lb)
33. Install the hoisting tool to the grid box rear
assembly.
34. Hoist and remove the grid box rear assembly from
the installation position of frame (28).
35. Lower and place the grid box rear assembly on an

appropriate holder.
46, 47
36. Remove ground harness L2 harness when
necessary. 45
28 W8R7-04-02-007
W8R7-E-01(20160803) W4-2-6
Installation
<Installation of Grid Box Rear Assembly>

1. If ground harness L2 (55) of the grid box rear
assembly is removed, connect harness L2 (55) to
the grid box rear assembly and secure with clips
(6) (3 used), bolts (7) (3 used), and washers (8) (3 55
used). 6, 7, 8
：19 mm
：56 N·m (5.6 kg·m, 41 lbf·ft)
：17 mm
：50 N·m (5.0 kg·m, 37 lbf·ft)
CAUTION： Grid box rear assembly weight:

806 kg (1777 lb) W8R7-04-02-004
2. Install the hoisting tool to the grid box rear

assembly. Grid Box
Rear Assembly
3. Hoist and align the grid box rear assembly to the
installation position of frame (28).
4. Install brackets (45) (4 used) of the grid box rear

assembly to frame (28) with bolts (46) (8 used)
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft)
5. Connect blower motor harnesses L1 (53) and L2

(54) to terminal box (A) of grid boxes L1 (48) and
L2 (49). Number tags are attached to both ports 46, 47
and harnesses. Match the numbers when
connecting harnesses. 45
28 W8R7-04-02-007
49 A 54
48
A 53
W8R7-04-02-005
W8R7-E-01(20160803) W4-2-7
6. Secure blower motor harnesses L1 (53) and L2
(54) to grid box rear assembly with brackets (23) B A 54
(4 used), clamps (24) (4 used), rubbers (57) (4 L2
used), bolts (25) (8 used) and washers (27) (8 N2 P2
23, 24,
used). 25, 27,
：17 mm 48 57
B
：15 N·m (1.5 kgf·m, 11 lbf·ft) A 53
33, 34,
L1
35, 36,
7. Install the covers (2 used) of terminal box (A). 38 N1P1 23, 24,
25, 27,
57
8. Connect high voltage harnesses L1-N1, L1-P1,

L2-N2, and L2-P2 to grid boxes L1 (48) and L2
(49). Number tags are attached to both ports and W8R7-04-02-005
harnesses. Match the numbers when connecting
harnesses.
：17 mm B
：32 N·m (3.2 kgf·m, 24 lbf·ft)
9. Install brackets (29) (4 used), clamps (30) (4

used) to inside of terminal box (B). L1-N1, L1-P1,
：17 mm L2-N2 L2-P2
：15 N·m (1.5 kgf·m, 11 lbf·ft)
10. Install the covers (2 used) of terminal box (B).

：10 mm
：4 N·m (0.4 kgf·m, 3 lbf·ft) 31, 32
29
11. Secure high voltage harnesses to grid box rear 30
assembly with brackets (33) (4 used), rubbers
(34) (4 used), clamps (35) (4 used), bolts (36) (8
：17 mm
：15 N·m (1.5 kgf·m, 11 lbf·ft) W8R7-04-02-008
Grid Box
12. Install cover (16) of high voltage harnesses to the Rear Assembly
grid box rear assembly with bolts (18) (4 used)
：17 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft)
16
18, 19
W8R7-04-02-001
W8R7-E-01(20160803) W4-2-8
13. Connect harnesses (51, 52) of differential
pressure switch and temperature switch to grid
boxes L1 (48) and L2 (49). Number tags are
attached to both ports and harnesses. Match the
numbers when connecting harnesses.
49
14. Secure harnesses (51, 52) of differential pressure 12, 14, 15
switch and temperature switch to grid box rear
assembly with clip (12) (3 used), bolts (14) (2 52
：17 mm 48
：50 N·m (5.0 kgf·m, 37 lbf·ft) 12, 14, 15
28
51 W8R7-04-02-006
15. Connect ground harness L1 (50) to grid box L1

(48).
：19 mm
：56 N·m (5.6 kg·m, 41 lbf·ft)
50 48
W8R7-04-02-004
<Installation of Grid Box Front Assembly>

16. If ground harnesses R2 (56) and R3 (4) of the grid
box R1 (1) and R2 (2) assembly are removed,
connect ground harnesses R2 (56) and R3 (4) to 2
the grid box R1 (1) and R2 (2) assembly with clips
4
(6) (5 used), bolts (7) (5 used), and washers (8) (5 6, 7, 8
used).
：19 mm
1
：56 N·m (5.6 kg·m, 41 lbf·ft)
：17 mm 56 6, 7, 8
：50 N·m (5.0 kg·m, 37 lbf·ft)
W8R7-04-02-002
W8R7-E-01(20160803) W4-2-9
CAUTION: The grid box R1 (1) and R2 (2)

17. Install the hoisting tool to grid box R2 (2).
41, 42 44
18. Hoist and align grid box R1 (1) and R2 (2)
3
assembly with the installation position on frame
(28). Keep the hoisted grid box horizontally.
39, 42
19. Install brackets (45) (4 used) of the grid box R1 (1)
to frame (28) with bolts (46) (8 used) and washers 43
(47) (8 used).
：19 mm 40, 42 2
：90 N·m (9.0 kgf·m, 66 lbf·ft)
CAUTION： Grid Box R3 (3) weight: 1

403 kg (888 lb)
20. Install the hoisting tool to grid box R3 (3). 46, 47
21. Hoist and install grid box R3 (3) to grid box R2 (2). 45
Keep the hoisted grid box horizontally. 28 W8R7-04-02-007
22. Install brackets (43) (4 used) and bars (44) (2

used) to the grid box with bolts (39) (12 used), 3 A 22
bolts (40) (4 used), bolts (41) (4 used), and
wawshers (42) (20 used).
：19 mm
：90 N·m (9.0 kgf·m, 66 lbf·ft) 2
A 21
23. Connect blower motor harnesses R1 (20), R2 (21),
and R3 (22) to terminal box (A) of grid boxes R1
(1), R2 (2), and R3 (3). Number tags are attached
to both ports and harnesses. Match the numbers 1
A 20
when connecting harnesses.
W8R7-04-02-003
W8R7-E-01(20160803) W4-2-10
24. Secure blower motor harnesses R2 (21) and R3
(22) to grid box front assembly with brackets (23) 3 B A 22
(4 used), clamps (24) (6 used), rubbers (57) (6 R3
used), bolts (25) (4 used), bolts (26) (4 used), and 23, 24,
N5P5
washers (27) (8 used). 25, 27,
：17 mm 2 57
B A 21
：15 N·m (1.5 kgf·m, 11 lbf·ft) 33, 34,
R2
35, 36, 23, 24,
25. Install the covers (3 used) of terminal box (A). 38 N4P4
26, 27,
57
1
B
A
26. Connect high voltage harnesses R1-N3, R1-P3, 33, 34,
R1
R2-N4, R2-P4, R3-N5, and R3-P5 to grid boxes 35, 37,
38 N3 P3
R1 (1), R2 (2), and R3 (3). Number tags are
numbers when connecting harnesses. 28
：17 mm
W8R7-04-02-003
：32 N·m (3.2 kgf·m, 24 lbf·ft)
B
27. Install brackets (29) (6 used), clamps (30) (6
used) to inside of terminal box (B).
：17 mm
R1-P3,
：15 N·m (1.5 kgf·m, 11 lbf·ft) R1-N3,
R2-P4,
R2-N4,
R3-P5
R3-N5
28. Install the covers (3 used) of terminal box (B).
：10 mm
：4 N·m (0.4 kgf·m, 3 lbf·ft)
29. Secure high voltage harnesses to grid box front

31, 32
assembly with brackets (33) (8 used), rubbers 29
(34) (12 used), clamps (35) (12 used), bolts (36)
30
(8 used), bolts (37) (8 used), and washers (38) (16
used).
：17 mm
：15 N·m (1.5 kgf·m, 11 lbf·ft)
W8R7-04-02-008
30. Install covers (16, 17) of high voltage harness to

the grid box front assembly with bolts (18) (8 Grid Box
used) and washers (19) (8 used). Front Assembly
：17 mm
：50 N·m (5.0 kgf·m, 37 lbf·ft) 16
18, 19
17
18, 19
W8R7-04-02-001
W8R7-E-01(20160803) W4-2-11
31. Connect harnesses (9, 10, and 11) of differential
pressure switch and temperature switch to grid 3
boxes R1 (1), R2 (2), and R3 (3). Number tags are
12, 14, 15 11
numbers when connecting harnesses.
2
32. Secure harnesses (9, 10, and 11) of differential
pressure switch and temperature switch to grid
12, 14, 15 10
box front assembly with clips (12) (4 used), clip
(13), bolts (14) (3 used), and washers (15) (3
used). 1
：17 mm
12
：50 N·m (5.0 kgf·m, 37 lbf·ft) 13, 14, 15 9
33. Connect ground harnesses R3 (4) to grid box R3

(3). Secure ground harnesses R3 (4) to grid box W8R7-04-02-006
R3 (3) with clip (6), bolt (7), and washer (8).
：19 mm
：56 N·m (5.6 kg·m, 41 lbf·ft) 4 6, 7, 8
：17 mm
：50 N·m (5.0 kg·m, 37 lbf·ft)
3
34. Connect ground harnesses R1 (5) to grid box R1
(1). Secure ground harnesses R1 (5) to grid box
R1 (1) with clip (6), bolt (7), and washer (8).
：19 mm
1
：56 N·m (5.6 kg·m, 41 lbf·ft)
：17 mm 6, 7, 8
：50 N·m (5.0 kg·m, 37 lbf·ft)
5 W8R7-04-02-002
W8R7-E-01(20160803) W4-2-12
AC DRIVE CONTROL DEVICE / Alternator Cooling Blower
ALTERNATOR COOLING BLOWER
Removal
1. Park the machine in the service position on a level ←Front 1

surface.


detecting rod. Remove high voltage harnesses U,
V, and W (2) from the terminal box of blower (1). 3 2 W8R7-04-03-001
Bind harness to frame (3). Blower Installation Section (From Frame Bottom Surface)
CAUTION: Duct (16) weight: 33.5 kg (73.9 lb)

1 16
used), nuts (19) (20 used), and washers (18) (20
used). Remove duct (16) from the wheel motor
cooling blower piping.
: 17 mm
5. Remove band (4), bolts (6) (12 used), washers (7)

(12 used), nuts (8) (12 used), and washers (9) (12
used). Remove duct (5) from blower (1).
: 17 mm
CAUTION: Blower (1) weight: 290 kg (639 lb) 17, 18, 19 W8R7-04-03-002
6. Hold blower (1) by using a suspension lug of

blower (1).
4 5 6, 7, 8, 9 1
(12 used). Remove blower (1) from duct (13).
: 17 mm
8. Remove bolts (10) (6 used) and washers (11) (6 10, 11

used). Remove blower (1) from bracket (12).
: 19 mm
12
9. Hoist blower (1).
Lower and place blower (1) on an appropriate
holder.
14, 15
13
W8R7-04-03-003
W8R7-E-01(20160803) W4-3-1
AC DRIVE CONTROL DEVICE / Alternator Cooling Blower
Installation
4 5 6, 7, 8, 9 1
CAUTION: Blower (1) weight: 290 kg (639 lb)
1. Hoist blower (1) with a suspension lug. Align
blower (1) to bracket (12) and duct (13). Hold
blower (1) at that position.
2. Install blower (1) to duct (13) with bolts (14) (12 10, 11
: 17 mm
: 50 N·m (5 kgf·m, 36 lbf·ft) 12
3. Install blower (1) to bracket (12) with bolts (10) (6

: 19 mm
: 90 N·m (9 kgf·m, 65 lbf·ft) 14, 15
4. Install blower (1) to duct (5) with band (5) (2 used), 13

bolts (6) (12 used), washers (7) (12 used), nuts (8) W8R7-04-03-003
(12 used), and washers (9) (12 used).

: 17 mm 1 16
: 50 N·m (5 kgf·m, 36 lbf·ft)
CAUTION: Duct (16) weight: 33.5 kg (73.9 lb)

5. Install duct (16) to the wheel motor cooling blower
piping with bolts (17) (20 used), washers (18) (20
used), nuts (19) (20 used), and washers (18) (20
used).
: 17 mm
: 50 N·m (5 kgf·m, 36 lbf·ft)
6. Install high voltage harness U, V, and W (2) to the

terminal box of blower (1). 17, 18, 19 W8R7-04-03-002
←Front 1
7. Remove body prop pins from dump body. Let the
dump body be seated on the frame (3).
3 2 W8R7-04-03-001
Blower Installation Section (From Frame Bottom Surface)
W8R7-E-01(20160803) W4-3-2
AC DRIVE CONTROL DEVICE / Wheel Motor Cooling Blower
WHEEL MOTOR COOLING BLOWER
Removal
1. Park the machine in the service position on a level ←Front 1

surface.


detecting rod. Remove high voltage harnesses U,
V, and W (2) from the terminal box of blower (1). 3 2 W8R7-04-03-001
Bind harness to frame (3).
4. Remove bands (4) (2 used), bolts (6) (12 used),
washers (7) (12 used), nuts (8) (12 used), and
washers (9) (12 used). Remove duct (5) from
blower (1). 5 6, 7, 8, 9 1
: 17 mm
4
5. Hold blower (1) by using a suspension lug of
blower (1).
10, 11
(16 used). Remove duct (13) from blower (1).
: 17 mm 14, 15
12
13
used). Remove blower (1) from bracket (12).
: 19 mm
8. Hoist blower (1).

Lower and place blower (1) on an appropriate W8R7-04-04-001
holder.
W8R7-E-01(20160803) W4-4-1
AC DRIVE CONTROL DEVICE / Wheel Motor Cooling Blower
Installation
1. Install duct (13) to blower (1) with bolts (14) (16

used) and washers (15) (16 used). 5 6, 7, 8, 9 1
: 17 mm
: 50 N·m (5 kgf·m, 36 lbf·ft)
4
2. Hoist blower (1) with a suspension lug. Align
blower (1) to bracket (12) installation position. 10, 11
Hold blower (1) at the position.
3. Install blower (1) to bracket (12) with bolts (10) (6 14, 15

used) and washers (11) (6 used). 12
13
: 19 mm
: 90 N·m (9 kgf·m, 65 lbf·ft)
4. Install duct (5) to blower (1) with band (4) (2 used),

bolts (6) (12 used), washers (7) (12 used), nuts (8)
(12 used), and washers (9) (12 used).
: 17 mm W8R7-04-04-001
: 50 N·m (5 kgf·m, 36 lbf·ft)

←Front 1
5. Install high voltage harnesses U, V, and W (2) to
the terminal box of blower (1).
6. Remove body prop pins from dump body. Let the

dump body be seated on frame (3).
3 2 W8R7-04-03-001
W8R7-E-01(20160803) W4-4-2
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
W8R7-E-01(20160803)
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

W8R7-E-01(20160803)
W8R7-E-01(20160803)

Work Shop Manual

Uploaded by

Copyright:

Available Formats

Work Shop Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Work Shop Manual

Uploaded by

Copyright:

Available Formats

PART NO.

RIGID DUMP TRUCK

Service Manual consists of the following separate Part No.

• Please refer to the other materials (operator’s

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

• These are the SAFETY ALERT SYMBOLS.

• When you see these symbols on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the

• DANGER indicates an imminently hazardous situa-

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the machine

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or missing,

• Learn how to operate the machine and its controls cor-

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may im-

• The safety messages in this SAFETY chapter are in-

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Wear close fitting clothing and safety equipment appro-

You may need:

Be sure to wear the correct equipment and clothing for

• Avoid wearing loose clothing, jewelry, or other items

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

• In the walk-around inspection, be sure to cover all

• Before entering the cab, thoroughly remove all dirt

USE HANDHOLDS AND STEPS

• When you get on and off the machine, always face

• Do not step or climb on surfaces, which are not in-

• A poorly adjusted seat for either the operator or for the

• The seat should be adjusted whenever changing the

ity is obtained from the operator’s seat. If the mirror is

FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may be-

• Prior to operating the machine, thoroughly examine

• Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm

nals before starting the machine.

HANDLE STARTING AIDS SAFELY

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Inappropriate engine starting procedures may cause the

• Start the engine only from the operator’s seat.

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to follow

could result in a battery explosion or a runaway ma-

KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being

• Only allow the operator on the machine. Keep riders

• Never attempt to open any electrical component covers

INVESTIGATE JOB SITE BEFOREHAND