Hitaci Loeder 70

ANT SAFETY NOTICE
For the operating procedure of the machine or equipment, see “OPERATION &
MAINTENANCE MANUAL”. Improper operation of the machine could result in bodily
injury or death to you or your fellow workers.
“ CAUTION”, “ DANGER”, “ WARNING”, labels have been put on the

machine to provide instructions and identify specific hazards etc, which if neglected may
cause bodily injury or death etc, to you or your fellow workers.
The basic safety instructions for servicing are described in “0. GENERAL DESCRIPTION:
01. SAFETY PRECAUTIONS” of this Shop Manual. Prior to attempting to service the
machine, read carefully the safety instructions and get familiar with the servicing
procedures completely. Failure to do so may cause bodily injury or death to you or your
fellow workers. The special instructions for each servicing are described in the relevant
chapters.
The person who wants to execute maintenance must know the machine system, parts,
repairing method and tools. It is required to read thoroughly the Shop Manual and Service
Manual so as to understand it comprehensively.
The warning symbol shown below used in this manual and put on the machine indicates
existence of hazard. Pay rigid attention.
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FOREWORD GENERAL
With our pursuit of technological researches and vast experiences, CONTENTS
we have been developing products of superior quality and reliability
for complete customer satisfaction. GENERAL
0. DESCRIPTION
To use the machines safely with its full performance for a long time,
proper handling and periodical inspections/maintenance are essential.
POWER
This manual describes mainly disassembly, inspection, assembly 1. TRAIN
and adjustment of the main components and systems of the wheel
loaders. For the structure and the principle of operation, refer to the
service manual. We hope this manual will be your good companion in
BRAKE
your servicing jobs. 2. SYSTEM
The values and descriptions given in this manual are subject to change
owing to change of design or some other reason.
STEERING
3. SYSTEM
HYDRAULIC
4. SYSTEM
ELECTRIC
5. UNIT
This shop manual applies to the following machines:

LX70-7 : No. 05101 and after
LX80-7 : No. 02101 and after
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AL KNOWLEDGE OF MAINTENANCE

$ %&

' ANDARD BOLT TIGHTENING TORQUE

-%. TION

/
ARTS TO BE REPLACED PERIODICALLY

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Maintenance requires utmost care of safety.
Below are described the fundamental requirements for maintenance. The person who intends to perform
maintenance must understand them thoroughly in advance.
1. Worker's safeguards.
The person who intends to perform maintenance must wear work clothes, helmet and safety shoes. Do not
wear torn or contaminated work clothes.
Wear neat work clothes. And while working, do not wear rings, bracelets and pendants which may be
caught by the machine and cause danger.
Use the safety goggles and gloves if necessary. When you use the grinder or hammer to hit parts (for
example, pins) of the machine or when foreign substance may scatter during work, be sure to wear the safety
goggles.
2. Keep the work site clean and in good order.

The place where the machine maintenance is executed must be always kept clean and dry.
Any oil or water spilt on the floor may cause slipping and electric shock if electric power is used.
The fuel oil, lubricating oil, hydraulic oil, waste cloth soaked with grease and other inflammables must be
put in vessels which must be stored in a safety place.
If waste oil or grease is disposed of improperly, contamination of the water quality and the soil may occur.
3. During maintenance, never attempt to use fire.

While checking the oil amount, filling oil or checking the battery, never smoke.
Before supplying the fuel oil, be sure to stop the engine.
You must know where a fire extinguisher is located, and how to use it.
4. Clean the machine before starting maintenance.

If the machine is contaminated by oil or dust, fire may occur. And it is difficult to find failures.
If any oil or grease is found on the operator's seat, handrail or step, wipe if off immediately. Otherwise,
you may slip and be in danger.
5. Before starting maintenance, stop the machine on a horizontal, stable place,

and execute maintenance while following the procedure described below.
1) Set the transmission change lever to the neutral position.
2) Put the bucket horizontally on the ground.
3) Apply the parking brake.
4) Stop the engine, and pull out the key switch.
5) Loosen the oil tank cap to discharge the internal pressure of the tank.
- 01-1 -
6) Move the loading-unloading lever forward, backward, leftward and rightward several times to discharge
the remaining pressure in the hydraulic line, then lock the loading-unloading lever.
7) Attach a proper caution sign such as “MACHINE NOT IN SERVICE NOW” or “MAINTENANCE”
to the steering wheel.
8) Block all of the tires.
9) Joint the front frame and the rear frame with a safety link.
6. Always check the maintenance tools, and use them correctly.

The required types and required number of tools for maintenance must be prepared. Use special tools if
necessary.
7. Before executing maintenance or part replacement of the electric system,

disconnect the negative terminal of the battery.
8. Just after the machine was stopped, be careful since some parts such as
the muffler are hot.
Be careful so as to prevent burn by hydraulic oil, lubricating oil and cooling water in piping and parts since
they are hot. When discharging oil, be careful to prevent burn by oil.
9. When running the engine in a poorly ventilated work site (room), provide
sufficient ventilation so as to prevent gas poisoning by exhaust gas.
10. When jacking up the machine, be sure to hold the machine with stands or
proper supports.
Never attempt to do maintenance while the machine is lifted by only a jack or crane without any other
support.
11. In removing or installing a heavy part (whose weight is 20 kg [44 lbs] or

more) or in uneasy posture, use a crane or hoist so that your spine or waist
is not injured.
When a crane, etc. is used, a qualified person must perform the work in conformance to the laws including
“Safety Rules for Cranes and Others”.
The weight of each part (whose weight is 10 kg [22 lbs] or more) is listed in the Shop Manual or the
Service Manual. When lifting a heavy part, use wire ropes and lifting devices having sufficient strength.
When removing parts with the aid of a crane, etc., confirm that bolts, nuts, piping, wire harnesses, etc.
have been completely removed.
- 01-2 -
12. When executing repair while the bucket or other attachments are lifted,
support the boom with a boom support.
13. When checking rotating parts and their vicinity, stop the engine in advance.
Especially, it is extremely dangerous to check the running fan belt and its vicinity.
14. When removing piping and parts in the oil pressure, air pressure or water
pressure system, discharge the inner pressure in advance.
15. When removing the cover plate which holds a spring, take due care.
Slowly loosen the last two bolts or nuts. After releasing the spring force, remove completely the cover
plate.
16. When removing the oil filling port cap, radiator cap, breather or plugs, take
due care.
Cover the cap or plug with waste cloth, and slowly remove the cap or plug.
Just after the machine was stopped, hot gas may spout out. Therefore, due care must be taken.
17. Leaking fuel oil, lubricating oil or hydraulic oil may cause fire. Fire is
strictly prohibited.
Never use uncovered fire (such as match and lighter) for illumination. Never attempt to check the oil
amount or check for oil leak while smoking.
18. When two or more persons have to work together, it is necessary that a
leader is appointed and every person confirms the work procedure in
advance.
Especially, when running of the engine is required, one person must sit on the operator's seat and confirm
safety, and other persons must execute the maintenance work.
19. To check the machine with the machine moving, only the operator must sit
on the operator's seat, and other persons must be located in distant places.
Absence of obstructions in the checking place must be confirmed in advance. A notice board must be put
up and a watching person must attend so that other persons and machines do not enter the machine moving
area.
20. After checking, repairing or adjusting the machine, be sure to check the
functions of the machine.
- 01-3 -
AL KNOWLEDGE OF

1. Mounting of Bearing
To fit the bearing to the shaft, hit the inner race as
shown in the figure. When fitting the bearing to the
case, hit the outer race.
When removing, follow the same procedure.
Fig. 02.1 Mounting of Bearing

2. Handling of “O”-ring
1) The “O”-ring must be free from molding defects and handling faults.
2) Thoroughly clean the “O”-ring and “O”-ring fitting part, and apply grease or hydraulic oil.
3) When fitting the “O”-ring, do not stretch it to such an extent that its permanent deformation may occur.
Do not fit the “O”-ring, rolling it (the “O”-ring
remains distorted, resulting in oil leak).
4) When an “O”-ring and a back-up ring are paired
(hydraulic oil pressure is high), fit the “O”-ring
at the side where pressure affects.
Fig. 02.2 Mounting of “O”-ring

3. Handling of Oil Seal
1) Fit the oil seal so that the seal lip is directed to the lubricating oil or hydraulic oil which seals the seal
lip.
2) When fitting the oil seal to the housing, apply thinly the packing cement to the oil seal outer ring and
inner surface of housing so as to prevent leak from the press-fit part.
When press-fitting, use the jig and uniformly press-fit.
Fig. 02.3 Fitting of Oil Seal
- 02-1 -
3) When fitting the oil seal to the shaft, apply the
lubricating oil or grease to the seal lip and shaft
surface.
When the dual lip type oil seal is used, fill the lip
gap with grease. (Proper amount of grease is
about 1/3 to 1/2 of lip gap capacity.)
When fitting the oil seal, use the conical sleeve
so as to protect the seal lip from being damaged.
Fig. 02.4 Mounting of Oil Seal

4. Application of LOCTITE
(1) Application Procedure
1) Clean (degrease) with trichlene, acetone, ether or alkali solution.
2) Sufficiently dry with air blow or natural drying.
3) Apply the specified LOCTITE.
(2) Removal of Parts

The part can be removed with the aid of ordinary tools, such as spanner, wrench and pulley remover.
If applied LOCTITE is too hard to remove, heat the fixing part with soldering iron or gas torch (200 to
250°C [392 to 482°F]), so that the part can be removed easily.
When work is executed after heating, take due care to avoid burn.
(3) Reassembling
1) Once broken LOCTITE bond remains on the threads as white power. New LOCTITE can be applied
to them.
Note: When the bolt was moved for torque check, remove the bolt, apply LOCTITE, and then tighten it.
2) When LOCTITE was used on the flange surface, remove the cured LOCTITE with iron brush. Otherwise
it may affect adversely the mounting dimension.
5. Using the Power Wrench

When using the power wrench for tightening the screws, refer to the manufacturer's specification, since it
has specific efficiency.
The output torque is not always equal to “(Torque wrench value) x (Factor of power wrench)”.
Take due care when the tightening torque is specified.
- 02-2 -
6. Attaching of Split Flange
1) Confirm that foreign substances such as dusts and abnormalities such as flaws are not present on the
attachment face for the flange and clamps of the split flange.
2) Put the flange with an “O”-ring on the attachment face, put the clamp on it, and temporarily tighten
four bolts by hand.
Note: If the hose is bent during piping or if the attachment face is not horizontal, temporarily tighten one
side of the clamp at first so that positioning will be easy when the flange will be attached.
3) Move the clamps inward by as much as the clearance of the bolt holes, and then tighten the both sides
evenly.
Note: During tightening, the split flange may be deviated outward by as much as the clearance of the bolt
holes of the clamp, the flange shoulder may come off, tightening may be uneven, and then oil leak
may occur. To prevent this nonconformity, move the clamp inward during attachment as shown in
the figures below.
Tighten the mounting bolts evenly, one by one in diagonal positions in turn. (The bolt numbers
indicate the tightening order.)
4) When tightening is finished, confirm that backlash is not present.
CLAMP CLAMP
3 2
A A
1 4
"O"-RING
Numbers indicate the tightening order

A-A CROSS SECTION VIEW
Fig. 02.5 Tightening of Split Flange
- 02-3 -
!"
1. Usual Metallic Parts
1) Immerse the parts in cleaning light oil (cleaning oil) or the like, and hold until the lubricant and foreign
substances are all removed from the parts. Then, slowly move the parts up and down to clean thoroughly.
2) Clean the castings with cleaning oil or steam cleaner.
3) If contamination is persistent, use wire brush, wooden spatula or metal piece to scrape off the sticking
contaminant to clean the parts roughly, and then clean them finally. However, do not use the wire
brush when cleaning the sliding parts and precisely finished surfaces.
4) Clean the lubricating oil passages with a steam cleaner. Check for clogging with a wire. Then, clean
with liquid or compressed air blow.
5) When cleaning the parts in weakly alkali solution, hold the parts in the heating solvent tank until they
are heated and cleaned sufficiently. Then throughly rinse the parts cleaned in the solvent tank with
flowing water or clean water so as to remove completely alkali.
When using solvent type cleaning agent or volatile cleaning agent such as trichlene, take due care
to protect your skin from them, do not use open fire, and be careful not to inhale solvent vapour.
6) Cleaning of parts made of two or more alloys like bearings and bushings in alkali solution may cause
electrolysis corrosion due to ionization. Hence, clean these parts with light oil, trichlene solvent vapour
or Magnus solution.
7) After cleaning, blow with compressed air to dry.
2. Bearings
1) To remove the solidified lubricating oil from the bearing, immerse the bearing into a cleaning solvent,
put it on a clean work table, and gently tap it with a soft hammer.
2) When drying, blow with compressed air at sides so that it is not rotated.
3. Rubber Parts
1) To clean the rubber parts, use alcohol, or merely wipe off the sticking contaminant.
2) In no case attempt to clean with gasoline, light oil, kerosine or the like. To clean the rubber parts, use
the oil which is allowed to be used for them.
- 03-1 -
# ANDARD BOLT TIGHTENING TORQUE
When using standard bolts for general tightening, tighten them to the applicable torques as shown in pages
04-3 to 04-6. The torques in that list, however, are not applicable to the following cases where particular
torques are mentioned in the Shop Manual and the Service Manual of each models so refer to those manual
for those torques.
1) If special nuts are used.
2) If plastics or rubber is used in tightening.
3) If a particular torque is mentioned for functional reasons.
• Strength classification
Strength classification Indication on bolt Material
SS400
4.6
(Number may be omitted.)
6.8 S45C
SCM435
8.8
Boron steel
(“B” may not be indicated.)
SCM435
10.9
Boron steel
(“B” may not be indicated.)
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FODVVLILFD

" WLRQ 45 Part No.
# #12 101-
#$ # #12 100-

#&' 21$ 103-
ellow
'#&(Boron steel $1$ 106-

% '#&(Boron steel 1 107-
/0 3 108-
# #12 112-
# #12 110-
' /
#&' 21$ ellow 113-

'#&(Boron steel 1 119-
# #12 115-
'44/
# #12 111-

ellow

#&' 21$ 114-

A

# #12 121-
! M4 to M8:
# #12 120-
Continuous Normal thread
#&' 21$ 123-
thread and ellow
(normal thread) '#&(Boron steel $1$ 126-
M10 to M39:
'#&(Boron steel 1 127-
Fine thread
/0 3 128-
M4 to M8: # #12 131-
Normal thread # #12 130-
Socket head and #&' 21$ ellow 133-
M10 to M39: '#&(Boron steel $1$ 136-
Fine thread '#&(Boron steel 1 137-
M4 to M8: # #12 161-
Normal thread # #12 160-
Hole in thread and #&' 21$ ellow 163-
M10 to M39: '#&(Boron steel $1$ 166-
Fine thread '#&(Boron steel 1 167-
•How to assign the part No.

In the part No., the nominal No. is added after the No. shown in the list below and hyphen.
Example: 01130-16050 (Hexagon head bolt, strength classification 4.6, M16 x 50 socket head)
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- 04-3 -
- 04-4 -
- 04-5 -
- 04-6 -
05. LUBRICATION
1. WATER/OIL REPLACEMENT CAPACITY
Unit: liters [U.S. gal.]
Fig. 05.1 Water/oil replacement capacity
- 05-1 -
2. GREASE UP
Fig. 05.2 Grease up
- 05-2 -
3. LIST OF LUBRICANTS
CAUTION
• Do not mix lubricants of different brands; otherwise the performance of the loader might be adversely
affected.
• Local refined oils and coolant, or anti-freeze do not allow for the same operation periods designated
in this manual.
Some must be changed more frequently.
• Multi-viscosity oils allow a wider temperature range for operation but must be changed more frequently
as the additive that provides the multi-viscosity gradually deteriorates lowering the viscosity.
Degradation of viscosity at the higher temperatures can be very detrimental to the hydraulic system.
- 05-3 -

ARTS TO BE REPLACED
Y
For operating the machine safely, it is important to securely perform periodical inspection and
maintenance. For enhancing the safety further more, it is required to periodically replace parts which
are playing especially important roles from the point of view of safety.
As the time passes, such parts can change in the properties or be easily damaged or deteriorated. In
normal inspection and maintenance, it is difficult to judge the degree of deterioration in the quality of
such parts.
Accordingly, even if no abnormality is detected in the appearance, such parts should be replaced
with new ones after they have been used for a specified period.
If any abnormality is detected in such parts, they should be repaired or replaced in the same way as
other parts even if the replacement timing has not come.
SAFETY PARTS LIST

Safety parts to be replaced at periodic intervals Replacement intervals
Fuel hose Every 2 years
Master cylinder rubber parts Every 2 years
Wet type brake rubber parts (“D”-ring) Every 4 years
Brake hose Every 2 years
Packing, seals and “O”-rings for steering cylinder Every 4 years
Steering cylinder hose Every 2 years
Boom cylinder hose (tail side) Every 2 years
Bucket cylinder hose (tail side) Every 2 years
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NOTE
- 06-2 -

%%$
1. DISASSEMBLY AND REASSEMBLY OF HST PUMP ...................................... 11-1

11.1 DISASSEMBLY OF HST PUMP ................................................................................................................... 11-3
11.2 REASSEMBLY OF HST PUMP ..................................................................................................................... 11-5
11.3 DISASSEMBLY AND REASSEMBLY OF COMBINATION VALVE 1 ...................................................... 11-7
11.4 DISASSEMBLY AND REASSEMBLY OF COMBINATION VALVE 2 .................................................... 11-10
11.5 STANDARD VALUES FOR MAINTENANCE ........................................................................................... 11-12
Y AND REASSEMBLY OF TRANSMISSION ........................ 12-1

12.1 DISASSEMBLY OF TRANSMISSION ......................................................................................................... 12-1
12.1.1 PREPARATION ....................................................................................................................................... 12-1
12.1.2 DISASSEMBLY OF TRANSMISSION CASE ....................................................................................... 12-1
12.1.3 DISASSEMBLY OF CLUTCH ASSEMBLY .......................................................................................... 12-6
12.1.4 DISASSEMBLY OF CONTROL VALVE ............................................................................................... 12-9
12.1.5 DISASSEMBLY OF OUTPUT SHAFT .................................................................................................. 12-9
12.2 ASSEMBLY OF TRANSMISSION .............................................................................................................. 12-11
12.2.1 REASSEMBLY OF OUTPUT SHAFT .................................................................................................. 12-11
12.2.2 REASSEMBLY OF CONTROL VALVE ............................................................................................... 12-12
12.2.3 REASSEMBLY OF CLUTCH ASSEMBLY ......................................................................................... 12-14
12.2.4 REASSEMBLY OF TRANSMISSION CASE ....................................................................................... 12-18
! Y AND REASSEMBLY OF DRIVE AXLE ................................. 13-1

13.1 DISASSEMBLY .............................................................................................................................................. 13-1
13.2 REASSEMBLY ............................................................................................................................................. 13-11
13.3 TROUBLESHOOTING ................................................................................................................................ 13-28
13.5 TIGHTENING TORQUE VALVES FOR MAIN BOLTS ............................................................................ 13-31
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1. DISASSEMBLY AND REASSEMBLY OF

Fig. 11.1 HST pump
- 11-1 -
1. PISTON 34. TRUNNION 69. SERVO RING
2. SPRING 35. GASKET 70. PLATE
3. PLUG 36. “O”-RING 71. SPRING RETAINER
4. PLUG 37. BEARING 72. RETAINING RING
5. “O”-RING 38. SHAFT 73. SPRING GUIDE
6. SHIM 39. BEARING 74. SPRING
7. CHECK VALVE 40. CAP 75. SPRING SEAT
8. ORIFICE 41. “O”-RING 76. SPRING
9. PLUG 42. BACK-UP RING 77. PIN
10. SHIM 43. RETAINING RING 78. CYLINDER BLOCK
11. GASKET 44. PIN 79. RETAINER GUIDE
12. BEARING 45. GASKET 80. RETAINER
13. PIN 46. PIN 81. PISTON
14. PLATE 47. COVER 82. THRUST PLATE
15. PLATE 48. WASHER 83. SWASH
16. PIN 49. BOLT 84. SNAP RING
17. “O”-RING 50. PLUG 85. BOLT
18. HOUSING 51. BOLT 86. BOLT
19. PLUG 52. RING 87. PLATE
20. PUMP COMBINATION 53. OIL SEAL 88. COUPLING
VALVE 1 54. “O”-RING 89. BOLT
21. ELBOW 55. SEAL CARRIER 90. BOLT
22. PIPE 56. RETAINING RING 91. BRACKET
23. SOLENOID VALVE 57. SCREW 92. BOLT
24. BOLT 58. RETAINER 93. GASKET
25. BOLT 59. SERVO SLEEVE 94. WASHER
26. “O”-RING 60. “O”-RING 95. BOLT
27. WASHER 61. “O”-RING 96. COVER
28. PUMP COMBINATION 62. SCREW 97. GASKET
VALVE 2 63. WASHER 98. BOLT
29. GASKET 64. SPRING GUIDE 99. GASKET
30. PLUG 65. SPRING 100. COVER
31. PLUG 66. SERVO PISTON 101. PLUG
32. BOLT 67. PIN
33. WASHER 68. RETAINING RING
- 11-2 -
1.1 DISASSEMBLY OF HST PUMP
[Cautions for Disassembly]
• Drain the pump and clean the exterior of the pump. Put a clean sheet of paper, cloth or rubber mat on the
work bench for disassembling and reassembling the unit.
• Exercise due care not to damage the parts or allow foreign material to enter the system.
• Do not try to disassemble the adjusting screws, other than necessary. If it is necessary to disassemble
them, record pre-disassemble dimensions surely.
• Do not try to disassemble components supplied as an assembly, other than necessary.
• Replace all seals with new ones before reassembly.
HST pump weight: 93 kg [205 lb]
1) Place the HST pump on a work stand with plate (87) facing upward. Put aligning marks on cover (47),
housing (18), cap (40), plate (87), pump combination valve 1 (20) and pump combination valve 2 (28).
2) Remove bolts (25 and 90) and washers (27 and 94) to remove pump combination valve 1 (20) and
pump combination valve 2 (28). Remove “O”-rings (41 and 26) and back-up ring (42) from cap (40).
Width across flat: 7/16 in., 1/2 in.
3) Remove coupling (88). Loosen socket bolts (92, 85, and 86) to remove plate (87) and gasket (93).
Width across flat: 6 mm, 12 mm
4) Loosen socket bolts (51) and washer (48) to remove cap (40) and gasket (11) from housing (18).
Width across flat: 5/16 in.
5) Remove valve plate (14) and plate (15) from housing (18).
6) Remove ring (52), roller bearing (12) outer race, and shim (10) from cap (40).
7) Using a bearing puller, remove the inner race of roller bearing (12) from shaft (38).
8) Remove plate (70), retainer (71), retaining ring (72), spring guide (73), spring (74), spring seat (75),
and pin (77) from shaft (38).
9) Turn housing (18) over so that cylinder block (78) can be pulled out from the side. Remove cylinder
block (78) sub-assembly (including guide (79), retainer (80), and pistons (81)) and thrust plate (82).
10) Remove retaining ring (56) to remove carrier (55), “O”-ring (54), and seal (53).
11) Loosen bolts (49) to remove cover (47), gasket (45), and shaft (38) from housing (18). Remove cover
(47) from shaft (38). The inner race and the outer race of roller bearing (39) will remain on shaft (38)
and in cover (47) respectively. Using a bearing puller, remove the inner race of roller bearing (39) from
shaft (38).
- 11-3 -
12) Measure height (a) of sleeves (59) and record
a
the measured values. After putting aligning
marks on sleeves (59) and housing (18), remove
retainers (58) and sleeves (59).
13) Loosen bolts (32) to remove trunnions (34).
Remove swash plate (83) assembly from
59
housing (18).
Fig. 11.2
Note: There is a slight discrepancy between the
center line (A) of servo piston (66) and the 66 69 C
center line (B) of the eccentric hole. Therefore, B
before removing servo piston (66) from swash

plate (83), record the eccentric hole direction
of servo piston (66) and the direction of 83
A
chamfer (C) on link (69) so that they can be Eccentric Hole
correctly reassembled.
14) Remove screws (62), washers (63), guide

springs (64), and springs (65) as necessary.
10.5 to 14.5 N-m {1.1 to 1.5 kgf-m}
[8.0 to 10.8 lbf-ft]
Fig. 11.3
- 11-4 -
1.2 REASSEMBLY OF HST PUMP
Note: Adjust the end play of shaft (38) to 0.15 to
83
0.41 mm [0.006 to 0.016 in.] by changing the
thickness of shim (10).
1) Install swash plate (83) assembly (including

screws (62) (2 pcs.), washers (63) (2 pcs.), guide
spring (64) (2 pcs.), springs (65) (2 pcs.), links
(69) (2 pcs.) and servo pistons (66) (2 pcs.)) into C
housing (18).
2) Install trunnion (34) assemblies (2 pcs.)
(including gaskets (35) (2 pcs.), “O”-rings (36)
(2 pcs.), roller bearing (37) inner races (2 pcs.)) Fig. 11.4
to housing (18) with bolts (32) (6 pcs.) and
washers (33) (6 pcs.).
Depth Gauge
49 N-m {5 kgf-m} [36 lbf-ft]
3) Attaching a spring balance to section (C) on
swash plate (83), check that swash plate (83) is
moved by a force of 13.3 to 26.5 N {1.36 to 2.7
kgf} [9.8 to 19.5 lbf]. Adjust force by changing
the number of gaskets (35).
82
4) Place housing (18) with cap (40) mounting
surface upward. 83
5) Place thrust plate (82) on swash plate (83).
6) Install “O”-rings (60) (4 pcs.) and (61) (2 pcs.) Fig. 11.5
onto sleeves (59) (2 pcs.). Then, install sleeves
(59) to housing (18). Adjust height (a) of sleeve a
(59) to the dimension recorded before

disassembling. Check that swash plate (83) is
not tilted when neutral using a depth gauge.
Install retainer (58) (2 pcs.), and socket bolts
(57) (4 pcs.). 59
4 to 5.4 N-m {0.41 to 0.55 kgf-m}

[3 to 4 lbf-ft]
7) Place housing (18) with cover (47) mounting
surface sideways.
Fig. 11.6
- 11-5 -
8) Install the outer race and the inner race of roller bearing (39) to cover (47) and shaft (38) respectively.
Install gasket (45) and pins (46) onto cover (47). Install cover (47) onto shaft (38) and secure cover (47)
to housing (18) with bolts (49) (12 pcs.) and washers (48) (12 pcs.).
49 N-m {5 kgf-m} [36 lbf-ft], Width across flat: 9/16 in.
9) Install seal (53), “O”-ring (54), and carrier (55) into cover (47). Install retaining ring (56).
10) Coat piston (81) and retainer (80) with hydraulic oil. Install springs (76) (6 pcs.), guide (79), pistons
(81) (9 pcs.), and retainer (80) in cylinder block (78). Check that pistons (81) move smoothly in cylinder
block (78).
11) Align the tooth less positions on shaft (38), cylinder block (78) and guide (79). Install cylinder block
(78) assembly in housing (18).
12) Lay the HST pump on work stand. Install spring seat (75), spring (74), spring guide (73), retaining ring
(72), retainer (71), and plate (70) on to shaft (38). Then, install them in cylinder block (78).
13) Using special tool, install the inner race of roller bearing (12) onto shaft (38).
14) Install the outer race of roller bearing (12) into cap (40). After coating valve plate (14) with grease,
install valve plate (14) to cap (40).
15) Install gasket (11) to housing (18). Then, coat gasket (11) with a sealing agent (any silicon rubber
sealant). While taking care not to drop valve plate (14), install cap (40) onto housing (18).
16) When installing socket bolts (51) (8 pcs.) and washers (48) (8 pcs.), evenly tighten two socket bolts
(51) which are located diagonally from each other. After cap (40) comes in contact with housing (18),
tighten other socket bolts (51).
24.5 N-m {2.5 kgf-m} [18 lbf-ft], Width across flat:5/16 in
17) Install gasket (93) to cap (40). Secure plate (87) to cap (40) with socket bolts (92) (3 pcs.), (85) (2 pcs.),
and (86) (2 pcs.).
Socket Bolts (92 and 86): Width across flat:12 mm
147 N-m {15 kgf-m} [108 lbf-ft]
Socket Bolt (85): Width across flat: 6 mm
24.5 N-m {2.5 kgf-m} [18 lbf-ft]
18) Install “O”-rings (41) (2 pcs.), back-up ring (42) (2 pcs.) and “O”-rings (26) (2 pcs.) to cap (40). Secure
pump combination valve 2 (28) to cap (40) with bolts (90) (6 pcs.) and washers (94) (6 pcs.).
21.5 to 28.5 N-m {2.2 to 2.9 kgf-m} [16 to 21 lbf-ft], Width across flat: 1/2 in.
19) Secure pump combination valve 1 (20) to housing (18) with bolts (25) (7 pcs.) and washers (27) (7
pcs.).
10.5 to 14.5 N-m {1.1 to 1.5 kgf-m} [8 to 10.5 lbf-ft], Width across flat: 7/16 in.
20) Install coupling (88) onto shaft (38).
- 11-6 -
1.3 DISASSEMBLY AND REASSEMBLY OF COMBINATION VALVE 1
Fig. 11.7 Pump combination valve 1 (1)
- 11-7 -
- 11-8 -
Tightening Torque
Part Name Quantity Wrench Size
N-m {kgf-m} [lbf-ft]
1 Housing 1
2 Cover 1
3 Gasket 1
4 Pin 1
5 Washer 1
6 Retaining ring 3
7 Valve 1
8 Sleeve 1
9 Seat 1
10 Spring 1
11 Spring seat 1
12 Screw 1
13 Nut 1 17 mm 47 to 62 4.8 to 6.3 35 to 46
14 "O"-ring 1
15 "O"-ring 1
16 Screw 4 7/16 in. 10.8 to 14.7 1.1 to 1.5 8.0 to 10.8
17 Washer 4
18 Plug 1 1-3/8 in. 94 to 230 9.6 to 23.5 69 to 170
19 Plug 4 9/16 in. 12.7 to 26.5 1.3 to 2.7 9.4 to 20
20 Plug 1
21 Stopper 1
22 Plug 14
23 Piston 2
24 Spring 1
25 "O"-ring 2
26 Plug 2 1 in. 54 to 135 5.5 to 13.8 40 to 100
27 Nut 2 17 mm 47 to 62 4.8 to 6.3 35 to 46
28 Screw 2
29 "O"-ring 2
30 Plunger 2
31 "O"-ring 1
32 Nut 1 19 mm 49 to 59 5 to 6 36 to 43
33 Adjusting screw 1
34 "O"-ring 1
35 Inching valve 1
36 Cover 1
37 Screw 2 5 mm 9.8 to 11.8 1 to 1.2 7.2 to 8.7
38 "O"-ring 1
39 Spring 1
40 Spring 1
41 Check valve 1
42 Stopper 1
43 Inching lever 1
44 Pin 1
- 11-9 -
1.4 DISASSEMBLY AND REASSEMBLY OF COMBINATION VALVE 2
- 11-10 -
Tightening Torque
1 Housing 1
2 Plug 2 9/16 in. 13.5 to 27.5 1.4 to 2.8 10.1 to 20.3
3 Plug 2 7/16 in. 36.7 to 44.9 3.6 to 4.4 20.0 to 31.8
4 Relief valve 2 1-3/8 in. 122 to 255 12.4 to 26.3 90 to 190
5 Ball 1
6 Seat 1
- 11-11 -
1.5 STANDARD VALUES FOR MAINTENANCE
1) Clearance between diameter (d) of piston (81)
81 78
and bore diameter (D) of cylinder block (78).
D-d Unit: mm [in.]

Standard Allowable
Limit d D
0.03 [0.0012] 0.06 [0.0024]
Fig. 11.11
2) Clearance (e) between piston (81) and the shoe
81
in the crimped section and shoe thickness (t).
e Unit: mm [in.]
Standard Allowable
Limit
e
0 to 0.15 0.35 t
[0 to 0.0059] [0.0138]
t Unit: mm [in.] Fig. 11.12
Standard Allowable
Limit
4.8 [0.189] 4.5 [0.177]
3) Heights of valve plate (14) and plate (15). 14
i Unit: mm [in.]
i
Standard Allowable
Limit
7.9 [0.311] 7.7 [0.303]
Fig. 11.13
j Unit: mm [in.] 15
Standard Allowable
Limit j
8.0 [0.315] 7.8 [0.307]
Fig. 11.14
- 11-12 -

Y AND REASSEMBLY OF

Y OF TRANSMISSION
12.1.1 PREPARATION
1) Wash the periphery of the transmission. Unit: mm [in.]
2) Remove the drain plug to drain the oil.
6.0 to 7.2 L [1.6 to 1.9 U.S. gal.]
3) Prepare parts which cannot be used again such
as gaskets and packing as well as periodically
replaced parts.
50 [1.97]
4) Prepare tools and jigs. 20 41 [1.61]
[0.79]
• Spanner
• Snap ring pliers (for shafts and holes) 41 [1.61]
• Puller
[0.08]
2
15 [0.59]
• Plastic hammer
[0.24]
6
115 [4.53]
• Scraper 55.2 [2.17]
66 [2.60]
Unit weight: 150 to 180 kg [330 to 71 [2.80]
400 lbs]
Fig. 12.1 jig
12.1.2 DISASSEMBLY OF TRANSMISSION CASE

1) Remove the suction tube from the lower portion
of the transmission case, and pull out the strainer. STRAINER
Note: Remove the gaskets from the mating surfaces.

"O"-RING
Do not use the “O”-ring again.
TUBE
Fig. 12.2
- 12-1 -
2) Remove the pipe between the brake and the brake
SOLENOID VALVE
solenoid valve, and remove the brake solenoid PIPE
valve.
Remove the “O”-ring from the solenoid valve.
Note: Do not use again the “O”-ring removed from
the mating surface.
Fig. 12.3
3) Remove the oil level gauge, pipe, stay and elbow.
OIL LEVEL
GAUGE
PIPE
ELBOW STAY
Fig. 12.4
4) Remove the plug, and remove the regulator SPRING
valve.
Note: Do not use the “O”-ring again.
PLUG
"O"-RING
VALVE PISTON
Fig. 12.5
5) Remove the control valve.
Note: Remove the gaskets from the mounting CONTROL VALVE
surfaces.
Fig. 12.6
- 12-2 -
6) Remove the speed sensor.
Remove the “O”-ring from the sensor.
Remove the shim also (only in the L16-3 and
SPEED SENSOR
LX80-7).
Note: Do not use the “O”-ring removed from the
mounting surface.
Fig. 12.7
7) Remove the output flange on the front side. OUTPUT FLANGE

Remove the output flange on the rear side.
WASHER
"O"-RING
SHIM
Fig. 12.8
8) Remove the seal retainer.
Remove the “O”-ring and the oil seal from the
seal retainer.
Note: Do not use the “O”-ring or oil seal again.
SEAL RETAINER
Fig. 12.9
9) Remove the snap ring from the bearing outer
race.
In the same way, remove the snap ring from the
bearing outer race of the clutch shaft. (Remove
the sleeve also.)
SNAP RING
Fig. 12.10
- 12-3 -
10) Remove all case cover mounting bolts, and attach
four bolts among them to screw holes in the
positions shown in Fig. 12.11.
Fig. 12.11
11) Alternately tighten the four bolts, and remove

the case cover.
Note: Completely remove liquid gasket from the
mating surfaces.
Case weight: 26 kg [57 lbs]
Fig. 12.12
12) Remove the distributor cap mounting bolts, then, SCREW HOLE
by using two bolts among them, remove the
distributor cap.
SCREW HOLE
Fig. 12.13
13) Remove the snap ring from the bearing outer
race. SNAP RING
Fig. 12.14
- 12-4 -
14) Remove the clutch assembly to the front side.
Clutch assembly weight:
17.5 to 18.5 kg [38.6 to 40.8 lbs]
Fig. 12.15
15) Remove the oil baffle.
OIL BAFFLE
Fig. 12.16
16) Remove six cover mounting bolts from the
parking brake, and remove the cover and spring.
Remove the oil seal from the cover.
Remove the “O”-ring from the brake housing.
Note: At this time, be careful not to miss the spring.
Do not use the “O”-ring or oil seal again.
Fig. 12.17
17) Remove two hexagon socket head cap screws,
and remove the housing, piston and end plate.
Next, remove the brake disk.
Remove the “O”-rings from the removed housing
and piston.
Note: Do not use the “O”-rings again.
Fig. 12.18
- 12-5 -
18) Remove the snap ring from the disk hub attached
to the output shaft, and remove the disk hub.
DISC HUB
SNAP RING
Fig. 12.19
19) Remove the output shaft assembly to the front

side.
Fig. 12.20
12.1.3 DISASSEMBLY OF CLUTCH ASSEMBLY

(1) Disassembling the clutch on the high gear side
1) Remove the snap ring, and pull the bearing out
of the shaft.
Fig. 12.21
- 12-6 -
2) Remove the snap ring, and pull out the high gear.
Fig. 12.22
3) Remove the snap ring from the durum, and take SNAP RING
out the end plate and clutch disks.
L13-3 and LX70-7: END PLATE
3 pairs of outer and inner disks

INNER DISK
L16-3 and LX80-7:
OUTER DISK
Fig. 12.23
4) Compress the spring using a jig and press, and
remove the snap ring from the groove. JIG (Refer to FIG.12.1)
Fig. 12.24
5) Release compression of the spring, and pull out
the snap ring, spring seat, spring and piston.
SNAP RING
SPRING SEAT
SPRING
Fig. 12.25
- 12-7 -
(2) Disassembling the clutch on the low gear side
1) Remove three seal rings from the shaft. LOW GEAR
SEAL RING
Fig. 12.26
2) Remove the snap ring, and pull out the bearing

using a puller.
BEARING
SNAPRING
Fig. 12.27
3) Remove two snap rings from the shaft, and pull
out the low gear.
LOW GEAR
SNAP RING
Fig. 12.28
4) In the same way as the high side, disassemble
the clutch on the low side.
Fig. 12.29
- 12-8 -
12.1.4 DISASSEMBLY OF CONTROL VALVE
1) Remove the solenoid valve.
SOLENOID VALVE
Fig. 12.30
2) Remove the cover, and take out the piston,
COVER
stopper, spring and spool.
PISTON
Note: Completely remove old gaskets. SPRING
STOPPER
SPRING
SPOOL
Fig. 12.31
12.1.5 DISASSEMBLY OF OUTPUT SHAFT

1) Pull out the bearing on the high gear side using a
puller.
HIGH GEAR
BEARING
Fig. 12.32
- 12-9 -
2) Remove the snap ring on the high gear side, and
pull out the high gear. HIGH GEAR
SNAP RING
Fig. 12.33
3) Pull out the low gear together with the bearing

LOW GEAR
using a puller.
BEARING
Fig. 12.34
- 12-10 -

Y OF TRANSMISSION
[Cautions to be taken when reassembling ]
• Clean all the disassembled parts in cleaning solvent, then dry with compressed air. In particular, remove
LOCTITE and gaskets thoroughly from the mating surfaces of the case and others.
• Make sure the cleaned parts are free from dirt or foreign matter. Handle them carefully so as not to cause
dent, score or scratches.
• Check the disassembled parts for wear or damage, replacing with new ones if defective. Refer to “12.3
STANDARD VALUES FOR MAINTENANCE.”
• Replace all the seals with new ones.
12.2.1 REASSEMBLY OF OUTPUT SHAFT

1) Attach snap rings for gear positioning to the shaft.
Attach them
in these position
Fig. 12.35
2) Attach the high gear, and fix it with the snap ring.
Fix it
HIGH GEAR
Fig. 12.36
- 12-11 -
3) Attach the low gear first, attach the bearing and
hub next, then fix them with the snap ring.
LOW GEAR
Fig. 12.37
4) Attach the bearing on the high gear side.

Note: Remove the snap ring from the bearing outer
HIGH GEAR
race in advance.
Fig. 12.38
12.2.2 REASSEMBLY OF CONTROL VALVE

1) Attach two snap rings, stopper and piston to the
body. SPRING
STOPPER
PISTON
Fig. 12.39
- 12-12 -
2) Attach the spool and spring to the body.
SPRING
SPOOL
Fig. 12.40
3) Attach the cover by way of a gasket with six COVER

bolts. GASKET
11.8 N-m {1.2 kgf-m} [8.7 lbf-ft]
Fig. 12.41
4) Attach the solenoid valve.
Valve: 20 to 29 N-m {2 to 3 kgf-m}
[14 to 22 lbf-ft]
Cap nut: 6.9 to 9.8 N-m {0.7 to 1
kgf-m} [5.1 to 7.2 lbf-ft]
SOLENOID VALVE
Fig. 12.42
- 12-13 -
12.2.3 REASSEMBLY OF CLUTCH ASSEMBLY
(1) Reassembling the clutch on the high gear side
1) Attach the seal ring to the shaft.
SEAL RING
Seal ring: Grease
Fix it to this groove
Fig. 12.43
2) Attach the seal ring to the piston, then attach the
PISTON
piston to the clutch drum on the high side.
Note: When attaching the seal ring to the piston, pay
SEAL RING
attention to the lip direction (so that it faces
inward).
Note: When attaching the piton to the clutch drum,
pay attention to the piston direction.
Seal ring: Grease
Fig. 12.44
3) Put the spring, spring seat and snap ring, then,

while gradually compressing snap ring using a SNAP RING
jig and press, fit the snap ring to the groove. SPRING SEAT
SPRING
JIG
(FIG.12.1)
Fig. 12.45
- 12-14 -
4) Alternately attach the outer disks and inner disks
to drum. INNER DISK
L13-3 and LX70-7:

L16-3 and LX80-7:
OUTER DISK
Fig. 12.46
5) Attach the end plate and snap ring.

SNAP RING
Note: Pay attention to the end plate direction.
END PLATE
Fig. 12.47
6) Attach the snap ring and two bearings to the high
gear. OUTER BEARING
Note: Be careful not to confuse the inner bearing and
HIGH GEAR
outer bearing. In addition, pay attention to the
outer bearing attaching direction. SNAP RING
INNER BEARING
Fig. 12.48
7) Attach the high gear assembly to the shaft. SNAP RING
At this time, attach it while turning the gear
clockwise and counterclockwise, and fix it with
the snap ring.
Fig. 12.49
- 12-15 -
8) Attach the bearing, and fix it with the snap ring.
SNAP RING
BEARING
Fig. 12.50
(2) Assembling the clutch on the low gear side

1) In the same way as the clutch on the high side,
attach the piston and clutch disk.
Refer to 1) to 4) in “(1)
Reassembling the clutch on
the high gear side.”
2) Attach the end plate, spring plate and snap ring. END PLATE
Note: Pay attention to the end plate and spring plate SNAP RING
attaching directions. SPRING PLATE
Fig. 12.51
3) Attach the snap ring and two bearings to the low
gear. OUTER BEARING INNER BEARING
Note: Be careful not to confuse the inner baring and

outer bearing. In addition, pay attention to the LOW GEAR
outer bearing attaching direction.
SNAP RING
Fig. 12.52
- 12-16 -
4) Attach the low gear assembly to the shaft.
At this time, attach it while turning the gear SNAP RING
clockwise and counterclockwise, and fix it with

the snap ring.
Fig. 12.53
5) Attach the bearing and two snap rings to the shaft.

Note: Pay attention to the bearing attaching direction. SNAP RING
BEARING
Fig. 12.54
6) Attach the seal rings (3 pcs.) to the shaft.
Seal ring: Grease
SEAL RING
Fig. 12.55
- 12-17 -
12.2.4 REASSEMBLY OF TRANSMISSION CASE
1) Attach the output shaft assembly to the case.
Fig. 12.56
2) Attach the oil baffle with the mounting bolts (2
pcs.).
18.8 N-m {1.92 kgf-m} [13.9 lbf-ft]
OIL BAFFLE
Fig. 12.57
3) Attach the clutch assembly while engaging it
with the gear of the output shaft with the low SNAP RING
gear side facing the case, then attach the snap

ring to the bearing outer race.
Fig. 12.58
- 12-18 -
4) Attach “O”-rings (1 large pc. and 3 small pcs.) DISTRIBUTOR CAP
to the distributor cap. "O"-RING
Attach the distributor cap with the mounting
bolts (4 pcs.).
52.1 N-m {5.32 kgf-m} [38.5 lfb-ft]
“O”-ring: Grease
"O"-RING
(3 pcs.)
Fig. 12.59
5) Attach one end plate and six pairs of outer and END OUTER DISK
PLATE
inner disks (alternately one by one from outer
disk), then insert the outer disk into the brake INNER
DISK
housing at the end.
6 SETS
OUTER DISK
Fig. 12.60
6) Attach “O”-rings to the case mounting surface
and cover mounting surface of the brake housing.
Attach the brake housing to the rear side of the
case with the hexagon socket head cap screws
(2 pcs.).
At this time, engage the inner disks with the hub "O"-RING
while turning the body clockwise and

counterclockwise. "O"-RING
Fig. 12.61
7) Attach “O”-rings (2 pcs.) to the piston.
Attach the piston to the brake housing, and put
"O"-RING
the springs (16 pcs.) into holes.
PISTON
Fig. 12.62
- 12-19 -
8) Assemble the oil seal into the cover. Align the
bolt holes and spring holes of the cover, then
tighten the mounting bolts (4 long pcs. and 2
short pcs. [located upward and downward])
alternately in diagonal lines.
Attach the flange on the rear side to the shaft.
Note: Assemble the cover with a dent of 7 mm [0.28
Dent of 7 mm [0.28 in.]
in.] or less in diameter facing downward. or less in diameter
Oil seal lip: Grease
Fig. 12.63
Oil seal outer periphery:
LOCTITE #262
52.1 N-m {5.32 kgf-m} [38.5 lbf-ft]
9) Apply linear coating of liquid gasket (LOCTITE

FMD127), while avoiding bolt holes, on the
transmission cover mounting surface of the
transmission.
Attach the cover with the mounting bolts (23
pcs.) while using the knock pins (2 pcs.) as the
guide.
52.1 N-m {5.32 kgf-m} [38.5 lbf-ft]
Fig. 12.64
10) Attach the snap ring to the bearing outer race on
the front side of the output shaft.
In the same way, attach the snap ring to the
bearing outer race of the clutch shaft, then attach
the sleeve.
SNAP RING
Fig. 12.65
- 12-20 -
11) Attach “O”-ring and oil seal to the seal retainer.
Attach the seal retainer with the mounting bolts
(3 pcs.).
52.1 N-m {5.32 kgf-m} [38.5 lbf-ft] "O"-RING
“O”-ring and oil seal lip: Grease

Oil seal outer periphery:
LOCTITE #262 OIL SEAL
Fig. 12.66
12) Attach the flange on the front side. At this time,

measure the dimension of the part X, and insert X
a shim thinner by 0.05 to 0.1 mm [0.002 to 0.004

in.] than the measured value into the part X.
Attach “O”-ring between the shaft and flange,
then attach the washer to the shaft with the bolt.
225.5 N-m {23.01 kgf-m}
[166.4 lbf-ft]
Fig. 12.67
13) Attach the control valve by way of a gasket with
the mounting bolts (4 long pcs. and 3 short pcs.).
26.1 N-m {2.66 kgf-m} [19.2 lbf-ft] GASKET
Fig. 12.68
14) Attach “O”-ring to the solenoid valve for parking
SOLENOID VALVE
brake.
Attach the solenoid valve for parking brake with
the mounting bolts (4 pcs.).
10.8 N-m {1.1 kgf-m} [8.0 lbf-ft]
Fig. 12.69
- 12-21 -
15) Attach the brake pipe.
If the connector is disconnected, apply LOCTITE
#572 on the thread area.
Fig. 12.70
16) Attach regulator valve.

Plug: 69 to 78 N-m {7 to 8 kgf-m}
[51 to 58 lbf-ft]
PLUG
"O"-RING
SPRING
PISTON
Fig. 12.71
17) Attach “O”-ring to the speed sensor, then attach
the speed sensor to the case.
10.6 N-m {1.08 kgf-m} [7.8 lbf-ft]
Note: In the L16-3 and LX80-7 attach the shims (2
pcs.) to the sensor, then attach the sensor to
the case.
Fig. 12.72
18) Attach the elbow, pipe, stay and oil level gauge
to the case.
OIL LEVEL
GAUGE
PIPE
ELBOW STAY
Fig. 12.73
- 12-22 -
19) Attach the strainer to the case, then attach the
suction pipe by way of a gasket with the bolts (4
pcs.).
18.8 N-m {1.92 kgf-m} [13.9 lfb-ft]
Fig. 12.74
20) Attach the drain plug.

58 to 74 N-m {5.9 to 7.5 kgf-m}
[43 to 54 lbf-ft]
Thread area: LOCTITE #572
DRAIN PLUG
Fig. 12.75
- 12-23 -
ANDARD VALUES FOR MAINTENANCE
HOUSING
• Transmission
1) Clearance between Bore (b) in Housing and a
Outer Diameter (a) of Regulator Valve Piston
b
b-a Unit: mm [in.]
Standard Dimension Allowable Limit
0.040 to 0.076 0.095
[0.00157 to 0.00299] PISTON
[0.00374]
Fig. 12.76
2) Free Length (c) of Regulator Valve Springs

Unit: mm [in.]
Standard
Allowable Limit
Dimension
Spring (S) 107.96 [4.25] 106.5 [4.19]
Spring (L) 98.58 [3.88] 97.2 [3.83]
Fig. 12.77
3) Oil Seal Sliding Outer Diameter (d) of Output d
Shaft Flanges
Unit: mm [in.]
Standard
Allowable Limit
Dimension
59.926 to 60.0 59.82
Front Flange
[2.359 to 2.362] [2.355]
54.926 to 55.0 54.82 Fig. 12.78 Front side
Rear Flange
[2.162 to 2.165] [2.158]
Fig. 12.79 Rear side
- 12-24 -
4) Inner Diameter (e) of Oil Seals in Output Shaft
Flange
Unit: mm [in.]
Standard e
Allowable Limit
Dimension
Oil Seal - 59 [2.32]
on Front Side
Oil Seal - 54 [2.13]
on Rear Side
Fig. 12.80
• Clutch Assembly
5) Free Length (f) of Springs for Moving Piston
Unit: mm [in.]
Standard
Allowable Limit
Dimension
Spring 42 [1.65] 40.3 [1.59]
Fig. 12.81
6) Seal Rings
Unit: mm [in.]
Standard Allowable h
h g
Dimension Limit
2.40 to 2.60 _ h
g
[0.0827 to 0.1024]
g g
Seal Ring 4.95 to 5.25 4.75 i i i
(X) h
[0.1949 to 0.2067] [0.1870]
45.20 to 46.20 _
i
[1.780 to 1.819]
2.4 to 2.6 _
g Z
[0.083 to 0.102] X Y
Seal Ring 5.45 to 5.85 5.1 Y
h X Z
(Y) [0.2146 to 0.2303] [0.2008]
116.7 to 118.3 _
i
[4.594 to 4.657]
1.95 to 2.05 1.72
g
[0.0768 to 0.0807] [0.0677]
Seal Ring 1.95 to 2.05 1.90
h
(Z) [0.0768 to 0.0807] [0.0748]
39.82 to 40.08 _
i
[1.568 to 1.578]
Fig. 12.82
- 12-25 -
7) Groove Width (j) on Piston and Shaft & drum
j
for Seal Rings
Unit: mm [in.]
Standard Allowable
Dimension Limit
Groove Width (j) 3.0 to 3.13 3.21 Y
X
for Seal Ring (X) [0.118 to 0.123] [0.126] Z
Groove Width (j) 2.70 to 2.90 2.996

for Seal Ring (Y) [0.1063 to 0.1142] [0.1180]
Groove Width (j) 2.10 to 2.15 2.25
for Seal Ring (Z) [0.0827 to 0.0846] [0.0886]
Fig. 12.83
8) Plate, Disk, and Clutch Release Amount (p)
n
Unit: mm [in.] k
Standard Allowable
Dimension Limit
1.54 to 1.66 1.44 DISK
Thickness (k) of Plate [0.0606 to PLATE
[0.0567]
0.0654]
2.32 to 2.47
2.17
Thickness (n) of Disk [0.0913 to
[0.0854]
0.0972]
Clutch 0.83 to 2.46 3.36
Disen-gage [0.0327 to [0.1322]
Stroke (p) L13-3 0.0972] (Hi) (Hi)
LX70-7 0.78 to 2.46 3.61
[0.0307 to [0.1421]
0.0972] (Lo) (Lo)
1.4 to 3.3 4.5
[0.0551 to [0.1772]
L16-3 0.1299] (Hi) (Hi) p
LX80-7 1.25 to 3.45 4.65
[0.0492 to [0.1831]
0.1358] (Lo) (Lo)
Fig. 12.84
- 12-26 -
9) Free Length (q) of Belleville Spring
Unit: mm [in.] q
4.95 to 5.25
4.75 [0.1870]
[0.1949 to 0.2067]
Fig. 12.85
- 12-27 -
• Control Valve
10) Outer Diameter (r) of Valve and Bore (s) in Body
s-r Unit: mm [in.]
0.020 to 0.061 r
0.080 [0.00315]
[0.00079 to 0.00240]
s
VALVE
BODY
Fig. 12.86
PISTON
11) Outer Diameter (t) of Piston and Bore (u) in Body
t
u-t Unit: mm [in.]
Standard Dimension Allowable Limit u
0.020 to 0.066
0.085 [0.00335]
[0.00079 to 0.00260]
BODY
Fig. 12.87
12) Free Length (v) of Springs
Unit: mm [in.]
Standard
Allowable Limit
Dimension
167.2 160.9
Spring (S)
[6.583] [6.335]
107.0 104.2
Spring (L)
[4.213] [4.102]
Fig. 12.88
- 12-28 -

Y AND REASSEMBLY OF

Y
[Cautions to be used when disassembling]
• When disassembling and reassembling the drive axle, it is good practice to place it on a unit table.
353 [778] 349 [770]

402 [886] 392 [864]
(1) Removing axle tube
1) Remove the drain plug and discharge gear oil.
Gear oil: 10 to 14 L
[2.6 to 3.7 U.S. gal.]
Fig. 13.1
2) Lift the axle tube with a crane temporarily,
holding the axle tube at the opposite side to
prevent it from lowering.
Axle tube: 100 to 120 kg
[220 to 265 lbs]
3) Remove 14 axle tube mounting bolts. Remove
the axle tube assembly from the differential body.
Fig. 13.2
Note that the differential body and the axle tube
are joined with dowel pins. Separate one from
the other by prying.
Fig. 13.3
- 13-1 -
(2) Disassembling axle tube
1) Secure the axle shaft by using 2 wheel bolt holes.
2) Loosen the retainer plate mounting bolt and

remove it.
Approx. 490 N-m {50 kgf-m} [362 lbf-ft] torque
is required to loosen the bolt because it is locked
with LOCTITE.
Fig. 13.4
3) Remove the final reduction gear assembly (planet

carrier), using a bar.
Remove any shim if attached to the axle shaft
end.
Planet carrier: 15 to 18 kg
[33 to 40 lbs]
Fig. 13.5
4) Remove the outer ring of the axle shaft oil seal
from the axle tube, using a screwdriver.
5) Drive the end of the axle shaft to remove the shaft

from the axle tube. If it is hard to remove the
axle shaft, use a press.
Axle shaft: 32 to 33 kg
[70 to 73 lbs]
Fig. 13.6
6) Remove the bearing cone from inside the axle
tube.
Fig. 13.7
- 13-2 -
7) Remove the bearing cone from the axle shaft,
using a bearing removing jig (separator).
8) Then, cut the axle shaft oil seal sleeve and remove
the oil seal.
Fig. 13.8
9) When replacing the axle shaft bearing, remove 2

bearing cups from the axle tube.
Fig. 13.9
10) When replacing the ring gear, remove it from the
axle tube, using a gear puller with a plate put
into the axle tube to support the gear puller shaft.
Fig. 13.10
(3) Disassembling final reduction gear assembly
1) Remove the snap ring from the planet gear shaft.
Do not use again the removed snap ring because
it is deformed.
Fig. 13.11
- 13-3 -
2) Remove the shaft by driving it out of the opposite
side. Use caution not to lose the shaft lock ball.
Fig. 13.12
3) Remove the planet gear and the 2 thrust washers.
Fig. 13.13
4) Remove the 56 needle rollers and the spacer from
inside the gear.
5) Disassemble the other two planet gear shafts,

using the same procedure as above.
Fig. 13.14
6) Remove the retainer plate from the carrier. Keep
any shim, if used.
Fig. 13.15
- 13-4 -
(4) Removing brake unit
1) Remove the end plate, brake disk, and brake ring
from the differential body in this order. Then,
remove the 8 pins.
Remove the sun gear.
Fig. 13.16
2) Install 2 puller bolts into the puller screw holes

(M6) in the brake piston and remove the brake
piston, holding the 2 bolts.
Fig. 13.17
If the brake piston is too hard to remove, remove
it by supplying compressed air through the brake
piping port.
Warning!
Install a stopper plate on the differential body,
to prevent the piston from popping out. (See
the right figure.)
Fig. 13.18
3) Remove the “D”-ring from the outer diameter of
the brake piston.
4) Remove the brake unit at the opposite side, using

the same procedure.
Fig. 13.19
- 13-5 -
(5) Removing drive pinion (bearing cage)
1) Loosen the bolts securing the cover to the
differential body and remove the cover.
Number of bolts: 18 (L13-3, LX70-7)
20 (L16-3, LX80-7)
2) Check the ring gear for tooth contact pattern and

backlash. Refer to the steps (5) and (6) in “13.2
Reassembly”.
Fig. 13.20
3) Remove the companion flange lock nut. Remove

the washer and “O”-ring.
When loosening the lock nut, lock the companion
flange with the ring gear.
Fig. 13.21
4) Remove the companion flange.
If it is too hard to remove, use a gear puller.
Fig. 13.22
5) Remove the bearing cage mounting bolts.
Number of bolts:
Fig. 13.23
- 13-6 -
6) Install two of the mounting bolts removed, into
the puller screw holes in the bearing cage and
tighten them evenly. Remove the bearing cage
and the drive pinion as a unit, holding the bolts.
Fig. 13.24
7) Remove any shim from the bearing cage.
Fig. 13.25
(6) Disassembling drive pinion
1) Remove the drive pinion from the bearing cage,
using a press.
Remove the spacer from the pinion shaft.
Fig. 13.26
2) Remove the oil seal and bearing cone from the
bearing cage. To remove the oil seal, break it
with a screwdriver.
Remove the “O”-ring from the outer diameter of
the bearing cage.
Fig. 13.27
- 13-7 -
3) When replacing the bearing with a new one,
remove the bearing cone from the drive pinion
with a bearing puller.
Fig. 13.28
4) After that, remove the 2 bearing cups from inside

the bearing cage, using a pin or a tube.
Fig. 13.29
(7) Removing differential case
1) Lift the differential case with a crane temporarily.
Differential case: 35 to 36 kg
[77 to 79 lbs]
2) Remove the bearing retainer mounting 6 bolts.
Fig. 13.30
3) Install two of the mounting bolts removed, into
the puller screw holes in the bearing retainer and
tighten them evenly. Remove the bearing
retainer, holding the bolts. Then remove any
shim.
Remove the square ring and “D”-ring from the
bearing retainer.
Fig. 13.31
- 13-8 -
4) Remove the bearing retainer and shims at the
opposite side, using the same procedure as above.
Fig. 13.32
5) Remove the ring gear and differential case

assembly from the differential body.
Fig. 13.33
6) When replacing the differential bearing with a
new one, remove the bearing cup from inside the
bearing retainer.
Fig. 13.34
(8) Disassembling the differential case
1) Loosen the 12 ring gear mounting bolts and
remove the ring gear.
If the ring gear is hard to remove, remove it by
tapping its back with a mallet.
Fig. 13.35
- 13-9 -
2) Remove the 12 differential case mounting bolts
and disassemble the differential case.
Fig. 13.36
Tap the spider with a rod and mallet.
Fig. 13.37
3) Remove the 2 side gears, spider, 4 pinion gears
and 6 thrust washers from inside the differential
case.
Fig. 13.38
4) When replacing the differential bearing, remove
the bearing cone from the differential cases A
and B, using a bearing puller.
Fig. 13.39
- 13-10 -
[ Cautions to be used when reassembling the drive axle]
• Wash each disassembled part with a clean washing oil and dry it by blowing air.
• Handle the washed parts, with care not to damage or contaminate.
• Check the disassembled parts for wear or damage and replace any worn or damaged part. Refer to “13.4
STANDARD VALUES FOR MAINTENANCE.”
• Replace all the seals with new ones.
(1) Reassembling differential case

1) Place the flanged half case (differential case A)
on a work bench, and install the thrust washer
and the side gear.
Fig. 13.40
2) Install 4 pinion gears and 4 thrust washers on the
spider, and install them as a unit on the side gear,
engaging the gears.
Fig. 13.41
3) Direct the tooth surface of the side gear
downward so that the side gear engages with the
pinion gears. Install the side gear thrust washer.
Fig. 13.42
- 13-11 -
4) Install the plane half case (differential case B),
matching the marks. Tap the case with a soft
mallet to make sure that the case half is installed
without looseness.
Fig. 13.43
5) Install 12 case bolts and tighten them in the

diagonal order.
Apply LOCTITE#262 to the threaded area of
each bolt.
98 N-m {10 kgf-m} [72 lbf-ft]
Fig. 13.44
6) If the differential bearing was replaced with a
new one, press bearing cones on the differential
case halves A and B.
Fig. 13.45
7) Install the ring gear on the flanged half case
(differential case A) and tighten the 12 mounting
bolts. Tap the ring gear with a soft mallet to
install it without looseness.
98 N-m{10 kgf-m} [72 lbf-ft]
Bolt thread area: LOCTITE #262
Fig. 13.46
- 13-12 -
(2) Reassembling drive pinion (bearing cage)
1) If the drive pinion bearing was replaced, press 2
bearing cups into the bearing cage.
Fig. 13.47
2) Press the bearing cone into the drive pinion.
Fig. 13.48
3) Insert the spacer into the drive pinion, directing
the stepped area of the spacer upward.
Fig. 13.49
4) Put the bearing cage on the drive pinion.
Fig. 13.50
- 13-13 -
5) Press the bearing cone into the drive pinion.
After that, make sure that the bearing cage turns
smoothly without looseness.
Fig. 13.51
6) Apply a light coat of liquid seal on the outer

diameter of the oil seal and apply grease between
the lips.
Press the oil seal into the bearing cage.
After pressing the oil seal, attach the dust cover
(only in the front axle).
Fig. 13.52
7) Install the companion flange onto the drive
pinion. Slide the flange several times to eliminate
strain at the seal lip.
Fig. 13.53
8) Then, insert the “O”-ring and the washer and
tighten the lock nut. Before tightening the lock
nut, apply LOCTITE#262 on its threaded area.
When tightening the lock nut, lock the companion
flange with a monkey wrench.
539 N-m{55 kgf-m} [400 lbf-ft]
Make sure that the bearing cage turns smoothly
without binding.
Fig. 13.54
- 13-14 -
9) Apply grease to the “O”-ring. Install the “O”-
ring in the groove at the outer diameter of the
bearing cage.
Fig. 13.55
(3) Installing differential case

1) If the differential bearing was replaced with a
new one, press bearing cups on the 2 bearing
retainers.
Fig. 13.56
2) Lift the reassembled differential case with a crane
and put the case in the differential body, aligning
the ring gear with the notch in the differential
body.
Fig. 13.57
3) Install square rings and shims on the 2 bearing
retainers. Use shims of the same size as was
removed during disassembly.
Fig. 13.58
- 13-15 -
4) Install the bearing retainers at the right and left
sides of the differential body to hold the
differential case. Temporarily install the 16
bearing retainer mounting bolts.
Fig. 13.59
5) Make sure that the differential case has no

looseness in the right and left directions and turns
smoothly.
If any defect is found, adjust the shim thickness
of the bearing retainer.
Fig. 13.60
(4) Installing drive pinion (bearing cage)
1) Install bearing cage shims in the differential body.
Then, install the bearing cage and the drive pinion
assembly. Use the same size of shims as was
removed during disassembly. The shims are a
two-piece type, so divide them in the upper and
lower areas, respectively.
Fig. 13.61
2) Install the bearing cage mounting bolts FRONT AXLE Upper part of
temporarily and check the gear for backlash and the vehicle
tooth contact pattern. Refer to steps (5) and (6).
Fig. 13.62
- 13-16 -
Number of bolts: REAR AXLE Upper part of
the vehicle
L13-3, LX70-7 L16-3, LX80-7
Fig. 13.63
3) After positioning, remove the bolts which were

temporarily installed to the bearing cage, apply
LOCTITE#262 to the threaded area of each bolt
and retighten the bolts to the specified torque.
98 N-m{10 kgf-m} [72 lbf-ft]
Fig. 13.64
4) Remove the bolts temporarily installed to the
bearing retainer, apply LOCTITE#262 to the
threaded area of each bolt and retighten the bolts
to the specified torque.
49 N-m {5 kgf-m} [36 lbf-ft]
Fig. 13.65
(5) Adjusting backlash of ring gear
1) Set a dial gauge on the tooth profile outer edge
of the ring gear.
2) Fix the drive pinion, and turn the ring gear back
and forth to measure the backlash.
Standard size of Ring gear backlash:
0.20 to 0.28 mm [0.0079 to 0.0110 in.]
Fig. 13.66
- 13-17 -
3) Adjust the backlash by adding or omitting the
number of shims at the differential case bearing
retainer.
If the backlash is too large, move some shims Adjust the number of shims within
from the flanged half side to the plane half side the range of 0.55 to 1.55 mm [0.022 to
and bring the ring gear closer to the drive pinion. 0.061 in.](at both sides).
Do not change the total number of shims.
If the backlash is too small, adjust it in the
opposite procedure as above.
(6) Adjusting the tooth surface contact pattern of

ring gear
1) Apply a thin coat of red lead to several ring gear
teeth and turn the ring gear back and forth with a
hand to check the tooth surface contact pattern.
Fig. 13.67
2) Adjust the tooth surface contact pattern, referring
to the following steps a. to e.
3) After acquiring the normal tooth surface contact

pattern, check the backlash again.
Fig. 13.68 Pictorial nomenclature of tooth

a. Normal contact pattern (Fig. 13.69)
A normal contact pattern of the tooth surface is
from the toe to the heel and its length is approx.
80 % of the total tooth length.
Note: The following adjustment items (b. to e.) show
the procedures for checking the convex surface
side of the tooth. Remember that the concave
surface side has opposite contact conditions.
Fig. 13.69
- 13-18 -
b. Adjusting contact condition at toe (Fig. 13.70)
Move some shims from the plane half side to the
flanged half side and shift the ring gear away from
the drive pinion.
Then, reduce the shim thickness of the bearing
cage and bring the drive pinion closer to the ring
gear.
Fig. 13.70
c. Adjusting contact condition at heel (Fig. 13.71)

Move some shims from the flanged half side to
the plane half side and bring the ring gear closer
to the drive gear.
Then, increase the shim thickness of the bearing
cage and shift the drive pinion away from the
drive gear.
Fig. 13.71
d. Adjusting contact condition at face (Fig. 13.72)
Reduce the shim thickness of the bearing cage
and bring the drive pinion closer to the ring gear.
Then, move some shims from the plane half side
to the flanged half side and shift the ring gear
away from the drive pinion.
Fig. 13.72
e. Adjusting contact condition at frank (Fig. 13.73)
Increase the shim thickness of the bearing cage
and shift the drive pinion away from the ring gear.
Then, move some shims from the flanged half
side to the plane half side and bring the gear closer
to the drive pinion.
Fig. 13.73
- 13-19 -
(7) Installing brake unit
1) Install the “D”-ring of the brake piston on the
differential body (bearing retainer).
Fig. 13.74
2) Install the “D”-ring on the outer diameter of the

brake piston and insert the brake piston into the
piston groove in the differential body.
Fig. 13.75
3) Install two pins in the lower two grooves of the
eight grooves at the inner diameter of the
differential body.
4) Install the brake ring, brake disk, and the end plate
inside the differential body in this order.
Fig. 13.76
Ensure that the convex at the outer diameter of
PLUG HOLE BRAKE RING OR END PLATE
each of the brake ring and the end plate is in
alignment with the plug hole for measuring disk
thickness. (See Fig. 13.77)
5) Install pins in the remaining 6 pin grooves at the

inner diameter of the differential body.
6) Reassemble the brake unit at the opposite side,

using the same procedure as above. Fig. 13.77
- 13-20 -
(8) Reassembling axle tube
1) If the ring gear was replaced with a new one,
install the ring gear on the axle tube, securing
with 4 pins.
Fig. 13.78
2) If the axle shaft bearing was replaced, press the

bearing cup into the wheel side of the axle tube.
3) Then, put a proper bearing cone into the cup.
Fig. 13.79
4) Press the oil seal of the axle shaft into the axle
tube.
Fig. 13.80
5) Remove the inner sleeve from the pressed oil seal
and press the sleeve onto the axle shaft.
Fig. 13.81
- 13-21 -
6) Stand the axle tube, directing the wheel side up,
and insert the axle shaft from top.
Drive the axle shaft from top and press the
bearing cone which was inserted into the axle
tube, onto the shaft side.
7) Turn the reassembled axle tube and shaft upside

down.
If the axle shaft bearing was replaced, press the
bearing cup into the axle tube.
Fig. 13.82
8) Install the bearing cone onto the axle shaft,
pushing the cone lightly.
The location of the bearing cone will be adjusted
in the step “(9) Adjusting the preload of axle shaft
bearing.”
Fig. 13.83
(9) Adjusting the preload of axle shaft bearing
(shim adjustment)
1) Install the planet carrier on the axle shaft in order
to adjust the preload of the axle shaft bearing.
No gear is attached to the planet carrier.
Fig. 13.84
- 13-22 -
2) Put the retainer plate in the planet carrier and
tighten the mounting bolt to 49 N-m {5 kgf-m}
[36 lbf-ft] torque. Press the axle shaft bearing
cone into the axle shaft, turning the axle tube.
Fig. 13.85
3) Loosen the bolt and remove the retainer plate.

Measure the difference in height (Y) between the
axle shaft end surface and the planet carrier.
Fig. 13.86
The measurement position of the height
difference (Y) is shown in Fig. 13.87.
Fig. 13.87
4) Select a shim which is 0.03 to 0.10 mm [0.0012
to 0.0039 in.] thicker than the height difference
(Y).
Fig. 13.88
- 13-23 -
5) Install the selected shim on the axle shaft and
the retainer plate in this order. Tighten the bolt.
304 N-m{31 kgf-m} [224 lbf-ft]
(L13-3, LX70-7)
333 N-m{34 kgf-m} [246 lbf-ft]
(L16-3, LX80-7)
Fig. 13.89
6) Secure the axle shaft and hook a spring balancer

in the axle tube bolt hole, to measure the bearing's
rotational resistance.
7) Normal bearing's rotational resistance is 20 to
25 N {2 to 2.5 kgf} [4.4 to 5.5 lbf].
Adjust the shim thickness so that the bearing's
rotational resistance shows the value within the
range as above. If the rotational resistance is
smaller than the specified value, reduce the shim
Fig. 13.90
thickness, and if it is larger, increase the shim
thickness.
8) After the shim thickness is determined, loosen

the bolt securing the retainer plate and remove
the planet carrier which was temporarily installed.
Fig. 13.91
(10) Reassembling and installing final reduction
gear assembly
1) Install the needle bearings on the planet gear.
Each planet gear has 56 needle rollers and one
spacer.
Prevent the bearings from dropping off, by
applying grease properly.
Fig. 13.92
- 13-24 -
2) Install the reassembled planet gear (with the
thrust washers at top and bottom) in the planet
carrier.
Fig. 13.93
3) Install the lock ball in the planet shaft and press

the planet shaft into the planet carrier.
Fig. 13.94
4) Secure the planet shaft with a snap ring.
Fig. 13.95
5) Put the retainer plate in the planet carrier.
6) Reassemble the other 2 planet gears and install

them in the planet carrier, using the same
procedure as above.
Fig. 13.96
- 13-25 -
7) Install the selected shim on the axle shaft and
install the reassembled planet carrier on the shaft.
Fig. 13.97
8) Apply LOCTITE#262 to the threaded area of the

retainer plate mounting bolt and tighten the bolt
to the specified torque to secure the planet carrier.
304 N-m{31 kgf-m} [224 lbf-ft]
(L13-3, LX70-7)
333 N-m{34 kgf-m} [246 lbf-ft]
(L16-3, LX80-7)
Fig. 13.98
(11) Installing axle tube
1) Apply LOCTITE FMD-127 to the axle tube
surface which will mate with the differential
body. Make sure that the bead of LOCTITE is
applied, without a break, on the tube surface
inside row of the bolt holes.
Bead width: 2 to 3 mm [0.08 to 0.12 in.]
Fig. 13.99
2) Lift the axle tube assembly and install it on the
differential.
Apply LOCTITE#262 to the threaded area of 14
mounting bolts and tighten them.
206 N-m{21 kgf-m} [152 lbf-ft]
3) Install the axle tube assembly at the opposite side,

using the same procedure as above.
Fig. 13.100
- 13-26 -
4) Fill the differential with gear oil.
Gear oil:
10 [2.6] 10 [2.6]
14 [3.7] 14 [3.7]
Fig. 13.101
5) Apply LOCTITE FMD-127 to the cover

mounting area of the differential. Note that
LOCTITE should be applied to the inside of the
row of bolt holes.
6) Install the cover on the differential and tighten
the mounting bolts.
Number of bolts: 18 (L13-3, LX70-7)
20 (L16-3, LX80-7)
29 N-m{3 kgf-m} [22 lbf-ft]
Fig. 13.102
- 13-27 -

Trouble Problem Cause Remedy
Gear worn, damaged or broken. Replace.
Excessive backlash of each gear. Adjust or replace.
Bearing worn, damaged or broken. Replace bearing.

Noisy differential.
Loose engagement of side gear and shaft splines. Replace.
Loose bolts. Retighten.
Low gear oil. Add oil to specified level.
Gear (final reduction gear) worn, damaged or broken. Replace.
Excessive backlash of each gear. Replace.
Bearing worn, damaged or broken. Replace bearing.

Noisy axle tube.
Loose planet carrier holding bolt (retainer plate Retighten (Adjust shims).
mounting bolt).
Improper preload of axle shaft bearing. Adjust shims.
Low gear oil. Add oil to specified level.
Broken liquid packing of differential cover. Apply liquid packing.
Broken liquid packing of axle tube. Apply liquid packing.

Oil leakage from
differential. Worn or damaged “O”-ring of bearing cage. Replace “O”-ring.
Oil seal worn or damaged. Replace oil seal.
Loose bolt. Retighten.
Oil leakage from Oil seal worn or damaged. Replace oil seal.
axle shaft.
Oil seal installed improperly. Repair or replace.
- 13-28 -
Trouble Problem Cause Remedy
Brake piston seal (“D”-ring) deteriorated or damaged.
Brake disk or brake ring worn or damaged.

Overhaul and replace.
Poor braking. Brake piston rusted.
Foreign matter caught on brake disk.
Loose or damaged bleeder screw of disk brake. Retighten or replace.
Brake disk or brake ring run-out or worn unevenly.

Erratic braking. Overhaul and replace.
Worn parallel pin of disk brake.
Rusted brake piston.

Dragging brake. Overhaul and replace.
Brake disk and brake ring seized.
- 13-29 -
ANDARD VALUES FOR MAINTENANCE
Unit: mm [in.]
Item Standard Size Useful limit Remarks
0.1, 0.2, 0.25 _

Thickness of bearing cage shim [0.004, 0.008, 0.010]
30.429 to 30.479 _
L13-3, LX70-7
Length of bearing [1.1978 to 1.1200]
cage spacer 30.454 to 30.474 _
L16-3, LX80-7
[1.1990 to 1.1998]
Inner diameter of differential pinion 23.85 to 23.88

gear [0.9390 to 0.9402]
Clearance
23.72 to 23.75 0.2 [0.008]
Diameter of differential spider pin [0.9339 to 0.9350]
Thickness of differential pinion gear 1.562 to 1.613 1.45

thrust washer [0.06150 to 0.06398] [0.0571]
Thickness of differential side gear 2.31 to 2.36 2.15

thrust washer [0.0909 to 0.0929] [0.0846]
Backlash between drive pinion and 0.20 to 0.28 _ Shim adjustment

ring gear [0.0079 to 0.0110]
Adjusting shim thickness within Shim thickness:

Shim adjustment of differential the range of 0.55 to 1.55 mm 0.1, 0.2, 0.25 mm
bearing retainer [0.022 to 0.061 in.] (at both sides). [0.004, 0.008, 0.010 in.]
Shim adjustment
Rotational resistance of axle shaft 19.6 to 24.5 N _
bearing [on pitch circle of tube {2.0 to 2.5 kgf} Shim thickness:
mounting bolt] [14.5 to 18.1 lbf] 0.1, 0.2, 0.25, 0.5 mm
[0.004, 0.008, 0.010,
0.020 in.]
5.9 to 6.5 5.3
Brake disk thickness [0.23 to 0.26] [0.21]
4.9 to 5.1 4.3

Brake ring thickness [0.19 to 0.20] [0.17]
- 13-30 -
" ORQUE VALUES FOR MAIN BOLTS
Tightening torque
Item Remarks
Ring gear mounting bolt 98 {10} [72] Apply LOCTITE#262.
Differential case mounting bolt 98 {10} [72] Apply LOCTITE#262.
Differential bearing retainer mounting bolt 49 {5.0} [36] Apply LOCTITE#262.
Bearing cage mounting bolt 98 {10} [72] Apply LOCTITE#262.
Flange nut 539 {55} [400] Apply LOCTITE#262.

L13-3
Planet carrier holding bolt LX70-7 304 {31} [224]
Apply LOCTITE#262.
(Retainer plate mounting bolt) L16-3 333 {34} [246]
LX80-7
Axle tube mounting bolt 206 {21} [152] Apply LOCTITE#262.
Differential cover mounting bolt 29 {3.0} [22]
- 13-31 -
NOTE
- 13-32 -

%%$

Y AND REASSEMBLY OF BRAKE VALVE

21.1 DISASSEMBLY ........................................................................................................................................... 21-2
21.2 REASSEMBLY ............................................................................................................................................ 21-3
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28
3
7
8 37
4
5
12 31
13
32
33
35
36 34
40
38 39
23
24
22
26. PUSH ROD
21
27. NUT
25
28. JOINT
14. COVER 29. WASHER
15. OIL SEAL 30. SNAP RING
2 16. PLATE 31. BODY
17. “C”-RING 32. PRIMARY PISTON
18. “O”-RING 33. PACKING
1 7. THRUST WASHER 19. “C”-RING 34. STOPPER
1. BODY 8. “C”-RING 20. DUST COVER 35. SECONDARY PISTON
2. PLUG 9. SPRING 21. VALVE 36. “C”-RING
3. CONNECTOR 10. SPRING 22. SPRING 37. CONNECTOR
4. SPRING 11. SPRING SEAT 23. PLUG 38. “O”-RING
5. ROD 12. PISTON 24. “O”-RING 39. WASHER
6. SPOOL 13. “O”-RING 25. SET SCREW 40. BOLT
Fig. 21.1 Brake valve
- 21-1 -

Y
Don’t disassemble valve (21), spring (22), “O”-ring (24), and plug (23) as they have been assembled
to a specified value. If disassembled, the specified value will change, resulting in malfunction of
the machine.
1) Remove dust cover (20) and push rod (26) from cover (14). While pushing cover (14), remove “C”-
ring (19).
2) Remove spool (6), spring seat (11), spring (10), and spring (9) from body (1). (When spool (6) is
removed, cover (14), piston (12) and connector (3) will be removed along with spool (6) as they are
assembled as a unit via spool (6).)
3) Remove cover (14) and piston (12) from spool (6). Remove “C”-ring (17), plate (16), oil seal (15), and
“O”-rings (18) (2 pcs.) from cover (14). Remove “O”-ring (13) from piston (12).
4) Remove “C”-ring (8) and thrust washer (7) from connector (3) to separate spool (6) from connector (3).
Remove rod (5) and spring (4) from connector (3).
5) Remove bolts (40) and plain washers (39) to separate body (31) from body (1). Remove “O”-ring (38)
from body (31).
Width across flat: 17 mm
6) While pushing piston assembly (35) into body (31), remove “C”-ring (36) from body (31).
7) Remove stopper (34) and packing (33). Remove piston assemblies (35 and 32) from body (31). Remove
“O”-ring from piston assembly (32).
Width across flat: 10 mm
- 21-2 -

Y
Notes: 1. Note that entry of foreign materials, etc. during assembly causes operational malfunction.
2. Since the rubber parts in the brake valve is specified as a regular replacement maintenance part,
even if no abnormalities are found in appearance, those parts shall be replaced every 2 years.
1) Install “O”-ring onto piston assembly (32). Install piston assemblies (32 and 35) into body (31) in this
order. Then, install packing (33) and bolt (34).
8.8 to 12.7 N-m {0.9 to 1.3 kgf-m} [6.5 to 9.4 lbf-ft], Width across flat: 10 mm
2) While pushing piston assembly (35) into body (31), install “C”-ring (36) in body (31).
3) Install “O”-ring (38) onto body (31). Connect body (1) and body (31) with plain washers (39) (4 pcs.)
and bolts (40) (4 pcs.).
29.4 to 34.3 N-m {3 to 3.5 kgf-m} [21.7 to 25.3 lbf-ft], Width across flat: 17 mm
4) Install spring (4) and rod (5) into connector (3). Install spool (6), thrust plate (7), and “C”-ring (8) into
connector (3).
5) Install spring (9), and spool (6) and connector (3) assembly into body (1). Install spring (10) and spring
seat (11) into body (1).
6) Install “O”-ring (13) onto piston (12). Install piston (12) into body (1). Install “O”-rings (18) (2 pcs.)
onto cover (14). Install cover (14) into body (1).
7) Install oil seal (15) and plate (16) onto spool (6). Install “C”-ring (17) in cover (14).
8) While pushing cover (14) in body (1), install “C”-ring (19) in body (1). Install dust cover (20) and push
rod (26) onto cover (14).
- 21-3 -
NOTE
- 21-4 -

%%$

Y AND REASSEMBLY OF ORBITROL

31.1 DISASSEMBLY ........................................................................................................................................... 31-2
31.2 REASSEMBLY ............................................................................................................................................ 31-5

Y AND REASSEMBLY OF STEERING CYLINDER

32.1 DISASSEMBLY ........................................................................................................................................... 32-2
32.2 INSPECTION ............................................................................................................................................... 32-3
32.3 REASSEMBLY ............................................................................................................................................ 32-4

Y AND REASSEMBLY OF PRIORITY VALVE

33.1 DISASSEMBLY ........................................................................................................................................... -2
33.2 REASSEMBLY ............................................................................................................................................ -2
(blank page)

Y AND REASSEMBLY OF ORBITROL
1
14
2
15
4
5
6
16
5
17
18
25
8
9 24 19
11
10 20
12
13 21
12
22
23
1. DUST SEAL 10. SLEEVE 18. DRIVE SHAFT B

2. RETAINING RING 11. CROSS PIN (COUPLED DRIVE)
3. SEAL GLAND BUSHING 12. CENTERING SPRING 19. GEROTOR (ROTOR SET) B
4. OIL SEAL 13. FLAT SPRING 20. SPACER
5. BEARING RACE 14. SPOOL 21. END CAP
6. NEEDLE 15. SPACER PLATE 22. SCREW
7. HOUSING 16. DRIVE SHAFT A 23. RETAINER SCREW
8. BALL 17. GEROTOR (ROTOR SET) A 24. ORIFICE PLATE
9. ADAPTER SCREW 25. INLET CHECK VALVE
Fig. 31.1 Orbitrol
- 31-1 -

Y
The Orbitrol needs to be repaired in clean work areas. Before disconnecting the piping, remove dusts,
mud and the like from the area around the port of the product main body. Remove dusts and dirt adhered on
joints on the outer periphery of the product main body using a wire brush. Handle the Orbitrol with rigid care
so as to prevent dents, flaws, etc. caused by dropping and contact of parts.
Note: Be careful not to be injured by edges, etc. of machined areas of the sleeve, spool and housing.
(1) Disassembling the rotor set side

1) With the rotor set side of the Orbitrol upward,
Put matchmark
lightly hold the port side of the housing in a vise.
Put a copper plate, etc. on the vise so that the RETAINER
SCREW
housing is not tightened excessively. (1 pc.)
2) Remove the end cap mounting screws (6 pcs.)

and retainer screw (1 pc.), then remove the end
cap, “O”-ring, rotor sets (2 sets), “O”-rings (2
pcs.) and drive shaft B. SCREW (6 pcs.)
Note: Before removal, put matchmarks on the

housing, rotor sets and end cap.
Fig. 31.2
Be careful not to drop the star from the ring
located on the outer periphery of the rotor sets.
3) Remove the spacer from the spline of the star in
the rotor set B.
4) Remove the spacer plate, the “O”-ring and the

drive shaft A from the housing.
5) Remove the housing from the vise.
Fig. 31.3
- 31-2 -
6) Remove the adapter screw by using a screwdriver.
7) Put the housing upside down, and take out the
ball.
Note: Pay attention not to drop or miss the ball. In
addition, confirm the hole position in which
the ball was located.
Fig. 31.4
(2) Disassembling the control valve side
1) With the flange surface of the housing facing
upward, place the housing on cloth carefully so
as not to damage the finished surface.
Remove the retaining ring from the housing.
Be sure to wear protective goggles since the
retaining ring may jump out from housing.
Fig. 31.5
2) Place the housing so that its shaft line direction
becomes horizontal. Turn the spool-and-sleeve
assembly until the cross pin becomes horizontal,
then, while pushing the spool and sleeve, remove
the seal gland bushing from the housing.
3) Remove the oil seal and the dust seal from the
seal ground bushing.
Note: Pay attention not to damage the seal ground
bushing.
Fig. 31.6
4) Remove the bearing from the spool. Remove
the races (2 pcs.) and needle.
5) Gently turning the spool-sleeve assembly to the
right and left, push it in the direction opposite to
the flange to remove it from the housing.
Note: Use extra cautions not to let the sleeve outer
diameter section caught on the housing inner
diameter.
Fig. 31.7
- 31-3 -
6) Remove the cross pin.
Note: Before removing the cross pin, put matchmarks
on the spool-and-sleeve assembly with an oil-
based pen.
Fig. 31.8
7) Pushing the spool a little forward in the sleeve,

remove the centering springs (4 pcs.) and flat
springs (2 pcs.) from the spool.
Because the spring may jump, pay rigid
attention. Be sure to wear protective goggles.
8) As gently turning the spool, push it out toward
the rear of sleeve.
9) Remove the “O”-ring from the housing.
10) Note that the inlet check valve incorporated into
the P-port is attached to the housing with an Fig. 31.9
adhesive, which does not enable you to remove
it.
11) Remove the orifice plate from the LS port using

a screwdriver.
Fig. 31.10
- 31-4 -

Y
Check the mating surfaces in all parts. Replace a part with flaws or burrs with a new one because such a
part may cause oil leakage. Wash all metallic parts with clean solvent, and dry them with air blow. If washed
metallic parts are dried with cloth or paper, its dusts may be adhered on the parts, enter the product main
body, contaminate the hydraulic system, and cause problems. Do not use cloth or paper in drying parts. Do
not file parts. Do not polish parts with rough sandpaper.
Notes: 1. Be careful not to be injured by edges, etc. of machined parts of the sleeve, spool and housing.
2. After disassembly, use new “O”-rings and seals in reassembly in principle. Before reassembly,
apply thin coating of clean grease on “O”-rings, etc.
3. The dimension is extremely similar between the “O”-rings before and after the spacer plate. Before
opening the seal kit, confirm them carefully, and pay rigid attention so as not to confuse them.
(1) Assembling the spool and the sleeve

1) Put the spool and the sleeve together with their
spring grooves aligned.
Note: Holding the splined section of the spool, check
the spool easily turns in the sleeve.
2) Align the matchmarks made on the spool and
sleeve.
Fig. 31.11
3) Install two flat springs in the intermeditae
position and two centering springs on each side
as shown in the figure. Put together six springs
and insert them into a spring inserting tool
(special tool) with their both-end notches facing
downward.
4) While slightly lifting the spool from the sleeve
and compressing with fingers the end on the
opposite side of the centering spring, push the
centering spring into the groove of the spool and
sleeve. At this time, slide the insertion tool at Fig. 31.12
the same speed with the spring pushing speed.
After insertion, align the end of the spring with
the outer periphery of the sleeve.
Be sure to wear protective goggles since the
spring may jump out.
5) Insert the cross-pin and make the outer diameter
of the sleeve the same height as that of both pin
ends.
- 31-5 -
(2) Assembling of control valve side
1) Place the housing so that its shaft line direction
becomes horizontal. While keeping the pin in
the almost horizontal status and turning
clockwise and counterclockwise little by little the
spool-and-sleeve assembly, insert the spool-and-
sleeve assembly from the housing end cap side
into the housing surface.
Note: Install the assembly, noting that too deep an
Fig. 31.13
insertion of it may cause the cross-pin to drop
out.
2) Make sure that the spool-and-sleeve assembly
smoothly turns in the housing.
3) With the housing's end cap side down, place the
housing on a work table, and install the “O”-ring.
4) Attach the bearing to the spool, in the order of

bearing race, needle and bearing race.
5) Install the dust seal and the oil seal to the seal
ground bushing.
Note: Make sure that the flat surface of the dust seal
is located on the seal gland bushing side. Pay
attention so that the oil seal is not distorted or
deformed.
6) While turning the seal gland bushing, insert it
into the spool, then, pat it with a soft hammer Fig. 31.14
until it gets into contact with the bearing.
7) Install the retaining ring.
Note: Make sure to wear protective goggles because
the retaining ring may jump out of the housing.
Widen the retaining ring with a screw driver so
that its entire periphery is securely fitted into
the groove in the housing.
8) Attach the orifice plate to the LS port using a
screwdriver.
- 31-6 -
(3) Assembling the rotor set side
1) Insert the ball into the hole in which it was
located.
2) Install the adapter screw to the hole in which the
ball is inserted.
Note: Be careful not to drop or lose the ball.
3) Fix lightly the flange section of the housing with
a vise, with the rotor mounting side upward.
Attach a copper plate, etc. on the vise, and be
Fig. 31.15
careful not to fix the flange section too strongly.
4) Install the “O”-ring and the spacer plate.
Align the bolt hole positions of the spacer plate.
Note: The pitch circle diameter is different between
the bolt holes and the oil holes.
5) By turning the spool-and-sleeve assembly, put
the cross pin in parallel with the housing port
surface. Insert the drive shaft A, and fit its yoke
to the cross pin.
Note: For positioning the drive shaft, mark a line on
the spline end face to show the position of the Fig. 31.16
cross pin, as shown in Fig. 31.17.
6) Install the “O”-ring to the spacer plate side of

the rotor set A.
7) While aligning the bottoms of the star in the rotor
set A (as indicated by the line W in Fig. 31.17)
with the mark on the drive shaft A (as indicated
by the line X in Fig. 31.17) with the “O”-ring
side toward the spacer plate, put the rotor set A
on the spacer plate.
Note: Make sure that the lines W, X, Y and Z in Fig.
31.17 showing the individual positions and
surfaces are all in parallel with one another.
Turn the rotor set ring to align the bolt holes
without detaching the drive shaft A from the
star in the rotor set A.
Note: Since the steps 5) to 7) are important ones for
determining the valve timing of the unit,
assemble them while paying extra attentions. Fig. 31.17
- 31-7 -
Note: The pitch circle diameter is different between
the bolt holes and the oil holes.
8) Install the drive shaft B (coupling drive) to the
star in the rotor set A.
9) Install the “O”-ring to the rotor set B. Assemble
two star gears with the “O”-ring side toward the
rotor set A.
10) Insert the spacer into the spline inside the rotor
set B.
11) Fit the “O”-ring on the end cap, and then install
the end cap on the rotor set B.
Note: Tighten each of the mounting screws (7 pcs.)
with a torque of 14.7 N-m {1.5 kgf-m} first,
then fully tighten them in the order shown in
Fig. 31.18 at the end.
Attach the retainer screw (1 pc.) while
confirming its hole. (In Fig. 31.18, No. 7
Fig. 31.18
indicates the retainer screw position.)
End cap mounting screws:
14.7 28.4 N-m {1.5 2.9 kgf-m}
[10.9 21.0 lbf-ft]
Thread: Hydraulic oil
12) After assembling the Orbitrol, install the steering
shaft and the steering wheel to the spool, and then
confirm that the spool and the sleeve rotate
smoothly.
- 31-8 -

Y AND REASSEMBLY OF

16
15
16
12
11
12
14
13
10
7
8
5
4
9
16
15
2
9. “O”-RING
10. PISTON
16 11. SEAL RING & “O”-RING
12. SLIDE RING
1. CYLINDER TUBE 5. “U”-RING 13. SCREW
2. PISTON ROD 6. WIPER RING 14. BALL
3. CYLINDER HEAD 7. “O”-RING 15. PIN BUSHING
4. BUSHING 8. BACK-UP RING 16. WIPER RING
Fig. 32.1 Steering cylinder
- 32-1 -

Y
1) Discharge oil from the cylinder, and vertically or
horizontally secure the cylinder. At this time,
stop rotation, and fix the cylinder in the shaft
direction.
2) Straighten the tongue of cylinder head lock
washer by using a chisel, etc.
3) Loosen the cylinder head by using a hook wrench.
Fig. 32.2
4) Put a oil pan under the port. Completely pull out
the piston rod, loosen the screws remaining on
the cylinder head, and remove the piston from
the tube.
Note: Put sleepers under the piston because it may
drop immediately after it is pulled out.
Fig. 32.3
5) Stop rotation of the piston rod by attaching the
tip of the piston rod to a jig, for example, then
fix the piston rod.
Because the cylinder head freely slides on the
piston rod, pay rigid attention so that your
fingers are not caught.
6) Cut off the punched area in the caulked area of Fig. 32.4
the set screw of the piston by using a drill, etc.,
then loosen the set screw. Remove the set screw,
then take the steel ball out of the innermost
position.
7) Remove the piston from the rod by using a power

wrench, etc. After removing the piston from the
rod, remove the cylinder head.
Fig. 32.5
- 32-2 -
8) Remove the slide ring, seal ring and “O”-ring
from the piston. The slide ring can be easily
removed by hand. As to the seal ring, however,
put up a screwdriver as shown in the right figure,
hit the screwdriver with a hammer, etc., then cut
and take out the seal ring.
Note: Removed seal parts and slide ring cannot be
used any more.
Fig. 32.6
9) Remove the “U”-ring, “O”-ring and back-up ring

from the cylinder head by using a screwdriver,
etc.
10) As to the wiper ring, put up a screwdriver to the
rubber area, then hit the screwdriver to remove
the wiper ring.
Note: Removed seal parts cannot be used any more.
Fig. 32.7
11) Remove the bushing from the inside of the
cylinder head by using a jig.
Note: Removed bushing cannot be used any more.
Fig. 32.8

Inspect each disassembled part, and replace it with a new one in the following cases:
1) Bushing: When a 1/4 of the circumference has worn out and changed into red-copper color (Check it
before removal.)
2) Seal: When the cylinder is disassembled
3) Piston rod: When it is bent by 0.5 mm [0.020 in.] / 1 m [39.37 in.] or more
- 32-3 -

Y
1) Press-fit the bushing into the cylinder head.
Inside of cylinder head: Hydraulic oil
Note: After press-fit, confirm that the bushing is flush.
Fig. 32.9
2) Attach the “U”-ring to the inside of the cylinder

head.
Note: Pay attention to the “U”-ring mounting
direction.
Fig. 32.10
3) Attach the wiper ring to the cylinder head.
Fig. 32.11
4) Attach the back-up ring and “O”-ring to the

cylinder head.
Fig. 32.12
- 32-4 -
5) Attach the “O”-ring of the seal ring assembly to
the piston. Press-fit the seal ring by using a jig.
Fig. 32.13
6) Immediately after attaching the seal ring, attach

the piston to a sizing jig to adjust the size of the
seal ring.
7) Attach the slide ring to the piston.
Fig. 32.14
8) Fix the piston rod, and insert the cylinder head
to the piston rod.
Note: Take care so that the seals fitted to the inner
periphery of the cylinder head are not caught
by the stepped section of piston rod.
9) Attach the piston to the piston rod by using a
power wrench.
613 N-m {62.5 kgf-m} [452 lbf-ft]
Fig. 32.15
10) After tightening the piston, attach the steel ball
and set screw. After that, punch and caulk in
two positions on the periphery.
Set screw: 6.9 N-m {0.7 kgf-m}
[5.1 lbf-ft]
Fig. 32.16
- 32-5 -
11) Fix the cylinder tube, and insert the piston rod to
the cylinder.
Note: Take care so that the slide ring does not drop.
When inserting the piston into the tube, take
care so that the piston packing is not caught by
the stepped section of the tube.
Fig. 32.17
12) Tighten the cylinder head to the cylinder tube by

using a hook wrench.
Cylinder head: 304 N-m {31 kgf-m}
[224 lbf-ft]
Thread area: Three Bond #1901
13) Bend the lock washer of the cylinder tube toward
the cylinder head to prevent rotation.
Fig. 32.18
- 32-6 -
3. DISASSEMBLY AND REASSEMBLY OF PRIORITY VALVE
7
13 11
8
14
12
3
9
16
4
10
2
5
6
17
1. HOUSING
2. SPOOL 14
3. SPRING
4.-11. RELIEF VALVE ASSY
15
4. BODY
5. RING
6. SCREEN 10. “O”-RING 14. “O”-RING
7. SCREW 11. GUIDE 15. PLUG
8. SPRING 12. POPPET 16. SCREW
9. VALVE SEAT 13. PLUG 17. SCREW
Fig. 33.1 Priority valve
- 33-1 -

Y
Note: The priority valve needs to be repaired in clean work areas. Before disassembly, remove external dirt
using a wire brush and wipe off the surface with a waste.
1) Hold the housing (1) with a vise to fix it. Touch soft materials such as a wooden piece, aluminium,
copper with the vise.
2) Loosen the plug (15) to remove the “O”-ring (14).
3) Loosen the plug (13) to remove the “O”-ring (14).
4) Pull off the spool (2) and spring (3) from the housing (1). (The screws (16 and 17) cannot be disassembled
from the spool (2).)
5) Loosen the body (4) to remove the relief valve assembles (4 to 12). And then remove the “O”-ring (10).
6) Detach the screw (7) of the relief valve and remove the guide (11), spring (8), poppet (12) and valve
seat (9) from the body (4). (The screen (6) and the ring (5) cannot be disassembled from the body (4).)

Y
Note: Degrease and clean the metallic parts and then dry it with compressed air.
1) Attach the “O”-ring (10) to the body (4), insert the valve seat (9), poppet (12), spring (8), guide (11)
and screw (7) and tighten the screw.
2) Attach the relief assemblies (4 to 12) assembled in step 1) to the housing (1).
21 N-m {2.1 kgf-m} [15 lbf-ft]
3) Insert the spool (2) and the spring (3) into the housing (1).
Note: Pay attention to the spool direction. After insertion, confirm that the spool moves smoothly when
pressed by fingers.
4) Attach the “O”-ring (14) into the plug (13), then assemble the plug into the housing (1).
44 N-m {4.5 kgf-m} [32 lbf-ft]
5) Attach the “O”-ring (14) into the plug (15), then assemble the plug into the housing (1).
44 N-m {4.5 kgf-m} [32 lbf-ft]
6) After reassembly, turn the screw (7), and adjust the steering relief pressure. One turn of the screw
corresponds to 6.9 MPa {70 kgf/cm2} [996 psi] (reference value).
- 33-2 -

%%$

Y AND REASSEMBLY OF MAIN PUMP

Y AND REASSEMBLY OF MAIN VALVE

42.1 DISASSEMBLY ........................................................................................................................................... 42-2
42.2 TREATMENT AFTER DISASSEMBLY..................................................................................................... 42-3
42.3 REASSEMBLY ............................................................................................................................................ 42-4

Y AND REASSEMBLY OF BOOM CYLINDER
!
"#$%!#& '!()!*+,-

43A.1 DISASSEMBLY ........................................................................................................................................ -2
43A.2 INSPECTION ............................................................................................................................................ -3
43A.3 REASSEMBLY ......................................................................................................................................... -4

Y AND REASSEMBLY OF BUCKET CYLINDER
(0)!*1,-

43B.1 DISASSEMBLY ........................................................................................................................................ -2
43B.2 INSPECTION ............................................................................................................................................ -3
43B.3 REASSEMBLY ......................................................................................................................................... -4

Y AND REASSEMBLY OF TRAVEL DAMPER VALVE
!23'!!4!(OPTION-

44.1 DISASSEMBLY ........................................................................................................................................... -2
44.2 TREATMENT AFTER DISASSEMBLY ..................................................................................................... -4
44.3 REASSEMBLY ............................................................................................................................................ -4
44.4 ADJUSTMENT OF PRESSURE REDUCING VALVE SET PRESSURE ................................................. -6
44.5 MAINTENANCE PROCEDURE OF SOLENOID VALVE ........................................................................ -7
(blank page)
. DISASSEMBLY AND REASSEMBLY OF

10
9
8
7
6
2
1 5
14
7
4
6
3
8
9 16
10
13 15
15
30
1
29
28
27
11 26
25
24
12 18
19
20
23
21 37
20 17
19 18
32 39
18
33
17
22 36 38
34
33
32
18
24
25 35
31
Fig. 41.1 Main pump
- 41-1 -
Tightening Torque
1 Socket bolt 8 8 mm 56 to 63 5.7 to 6.4 41 to 46
2 Seal washer 5
3 Retaining ring 1
4 Oil seal 1
5 Cover 1
6 Bearing 2
7 "O"-ring 2
8 Gasket 2
9 Seal 2
10 Side plate 2
11 Drive gear 1
12 Driven gear 1
13 Body 1
14 Adapter plate 1
15 Spring washer 11
16 Socket bolt 8 8 mm 56 to 63 5.7 to 6.4 41 to 46
17 Gasket 2
18 Seal 4
19 Bearing 2
20 Side plate 2
21 Drive gear 1
22 Driven gear 1
23 Body 1
24 Gasket 2
25 Gasket 2
26 Adapter plate 1
27 "O"-ring 1
28 Coupling 1
29 Retaining ring 1
30 Oil seal 1
31 Adapter plate 1
32 Bearing 2
33 Side plate 2
34 Drive gear 1
35 Driven gear 1
36 Body 1
37 Cover 1
38 Washer 4
39 Bolt 4 17 mm 38.3 to 43.2 3.9 to 4.4 28.2 to 31.8
- 41-2 -
Fig. 41.2
[Cautions for Disassembly]

• Face the concavo side of the gasket (17) toward the
bottom side of the groove of the adapter plate (14)
and assemble them.
• Assemble the parts as distributing the left and right
length of the seal (18) equally from the reference
point “A” of the groove of the adapter plate (14).
Fig. 41.3
Fig. 41.4
- 41-3 -

Y AND REASSEMBLY OF MAIN VALVE
1
4 5 6
2
7 8 9 10 11
3
5
4 6 27
13 8 9 10 11
10 9
14
12
28
8 40
15 42
15
41
17
4
19 16
21 9 8
30 10
23 29 43
31
18
24 20 30
25
26
22
33
32
34
35
36
37
38
39
24. SLEEVE 34. NUT

1. NUT 13. SPACER 25. SPACER 35. PIN
2. OUTLET HOUSING 14. SPOOL 26. SNAP RING 36. NUT
3. TIE ROD BOLT 15. SPRING SEAT 27 . HOUSING 37. PLATE
4. “O”-RING 16. SPRING (BUCKET) 38. SOCKET HEAD
5. SPRING 17. DETENT PIN 28 . PORT RELIEF BOLT
6. POPPET 18. SHIM VALVE 39. COIL TUBE
7. HOUSING (BOOM) 19. SPRING 29. SPOOL 40. MAIN RELIEF
8. SEAL 20. BALL 30. SPRING SEAT VALVE
9. WIPER 21. BALL 31. SPRING 41. “O”-RING
10. PLATE 22. SOCKET HEAD 32. SOCKET HEAD 42. PLUG
11. SCREW BOLT BOLT 43. INLET HOUSING
12. “O”-RING 23. CAP 33. CAP
Fig. 42.1 Main valve
- 42-1 -

Y
Notes 1: During disassembly, sufficiently clean the work site so that foreign substances do not enter the
valve.
2: Replace all disassembled seals (“O”-rings, back-up rings, seals and wipers) with new ones.
(1) Disassembling the valve assembly
1) Remove the main relief valve (40) and port relief valve (28).
Note: Each of relief valves is to be replaced in the unit of assembly in principle. Accordingly, do not
disassemble them as far as abnormality is not detected. When removing them, see to it that the
assembly position of each part will be clear at the time of assembly.
2) Remove the nuts (1) (3 pcs.) from the tie rod bolts (3).
Note: Put a mark identifying the relationship to each section.
3) Remove the plug (42) and then remove the “O”-ring (41).
4) Disassemble the valve into sections.
5) Remove the spring (5) and poppet (6) of the load check valve from each spool section.
Note: Put an identification tag to each poppet and spring.
6) Remove the “O”-rings (4) (3 pcs.) from the mating face of each section.
(2) Disassembling the bucket spool section

1) Secure the housing (27) with a vise by way of a wooden chip, aluminum mouth ring or copper mouth
ring. Because the coil tube (39) is tightened together with the lock nut (34), loosen the nut and remove
the coil tube.
Note: Though the adhesive agent is applied on the thread area, heating is not required during disassembly.
And do not heat the coil tube because electrical parts should not be heated.
2) Loosen the socket head bolts (32). Pull the spool (29) with the cap (23) out of the housing (27). At the
same time, remove the seal plate (10).
3) Hold the spool assembly with a wooden plank
(Fig. 42.2) so that the periphery of the spool
assembly is not damaged, and secure it with a
vise. Heat the engagement area between the pin
(35) and socket head bolt (38) at 200 to 250 °C
[392 to 482 °F]. Then, loosen the nut (36), and
separate the pin from the socket head bolt.
4) Heat the engagement area between the spool (29)
and pin (35) in the same way as the step 3), then
Fig. 42.2 Wooden plank
separate them.
Note: If the engagement area is heated to remove the adhesive agent, do not use the spring again. If it is
estimated that the plate (37) was heated at high temperature, replace it with a new one also.
5) Remove the screws (11). Remove the seal plate (10), wiper (9) and seal (8).
6) Remove the wiper (9) and seal (8) from the spool hole on the port relief side of the housing.
- 42-2 -
(3) Disassembling the boom spool section
1) Secure the housing (7) with a vise by way of a wooden chip, aluminum mouth ring or copper mouth
ring. Loosen the socket head bolts (22). Pull out the spool (14) together with the spacer (13).
2) Hold the spool assembly with a wooden plank (Fig. 42.2) so that the periphery of the spool assembly is
not damaged, and secure it with a vise. Remove the snap ring (26). Remove the spacer. (25).
3) By using a hexagon wrench of 3 mm [0.12 in.]
or less, while pushing the detent ball (20), remove
the detent ball together with the sleeve (24) and
cap (23).
Note: Do not apply any load to hole at the edge side.
Since the deformation of the hole may lead to
the decrease in the detent function.
4) Remove the balls (20)(21) as well as spring (19) Fig. 42.3
and shim (18) inside the detent pin (17).
Note: The balls may jump out. Be careful not to miss them.
5) Head the fitted section of the detent pin (17) and

spool up to 200 through 250 °C [392 to 482 °F],
insert 5.5 to 6 mm [0.22 to 0.24 in.] round bar
into the lateral hole to loosen the detent pin and
remove it from the spool (14).
Note: When applying heat, the heated spring shall not
be used.
Spring force is applied on the detent pin.
Loosen the detent pin while applying a force
by hand to reduce the spring tension, and then Fig. 42.4
remove the pin.
6) Remove the spring seat (15), spring (16), plate (10) and spacer (13) from the spool (14).
Remove the wiper (9), seal (8) and “O”-ring (12) from the spacer (13).
7) Remove the screw (11). Remove the seal plate (10), wiper (9) and seal (8).

TMENT AFTER DISASSEMBLY
1) Cleaning
Completely clean all disassembled parts with clean mineral oil. Dry them with compressed air. Put
each part on clean paper or cloth for inspection.
2) Inspection
Check all surfaces of each part for burrs, scars, flaws and other defects.
a) If dents, flaws, etc. are detected on the load check face of the valve housing, remove them by
lapping. Take care not to leave the lapping agent.
- 42-3 -
b) Confirm that scars, dents, etc. are not present on the outer periphery of the spool. If small scars, etc.
are detected, remove them with oil stone or cloth on which the lapping agent is applied.
c) Confirm that all sliding parts move smoothly. Confirm all grooves and passages are free from
foreign substances.
d) If a spring is broken, is deformed or has worn out, replace it with a new one.
e) Replace all “O”-rings and oil seals with new ones.
f ) After removing a cap or plug, confirm that paint flakes are not present around the body hole or plug
seat.

Y
Notes 1: Handling of spools
• An excessive torque applied on the thread area will cause malfunction of the spool. Make sure to
observe the specified torque.
• Pay attention so that each spool, spring and spool end are assembled to the former status before
disassembly.
2: Adhesive agent application method (on male and female thread areas of parts to be adhered)
a) Cleaning (degreasing)
Degrease required parts with steam of acetate, ether, etc. Or clean them with the alkali detergent.
Do not use gasoline and kerosene.
b) Drying
Blow clean air to them or let them be dry naturally so that the adhesion faces are dry. If they are
not dry completely, the adhesion effect is deteriorated.
c) Applying the primer
Lightly spray the hardening accelerator “LOCTITE PRIMER T” on the adhesion faces. Leave
them for at least approximately 3 to 5 minutes to make them dry.
d) Applying the adhesive agent
Apply a small amount of adhesive agent (equivalent to LOCTITE #271) on two to three threads
at the entrance of the thread area of the spool. At this time, take care so that the area on which the
adhesive agent is applied is not adhered on the spring seat.
The operation shall be completed within 5 minutes after applying adhesive.
(1) Assembling the boom spool section

1) Secure the spool (14), with its thread area upward, to a vise by way of a wooden plank (Fig. 42.2).
Attach the “O”-ring (12), seal (8) and wiper (9) to the inside and outside of the spacer (13). Then,
insert them into the spool (14). Next, insert the plate (10), spring seat (15), spring (16) and spring seat
(15). Attach the detent pin (17) to the spool (14), and tighten the pin while utilizing its cross hole.
Detent pin: 14.7 to 19.6 N-m {1.5 to 2.0 kgf-m} [10.9 to 14.5 lbf-ft]
- 42-4 -
2) Insert the shim (18) into the hole of the detent pin (17). Apply grease, then insert the spring (19) and
balls (20)(21). When inserting the balls, insert the larger one (20) first, then insert the smaller one (21)
into the cross hole of the detent pin (in the reverse order of disassembly). In this status, attach the cap
(23) and sleeve (24). Insert the spacer (25) into the cap, and attach the snap ring (26).
3) Insert the spool assembly assembled in the step 2) into the housing (7). Tighten the socket head bolts
(22).
8.8 to 9.8 N-m {0.9 to 1.0 kgf-m} [6.5 to 7.2 lbf-ft]
Thread area: Hydraulic oil
4) Fit the seal (8), wiper (9) and seal plate (10) on the spool head side, and fix them with the screw (11).
(2) Assembling the bucket spool section

1) Remove dust such as adhesive agent chips from the thread areas of the spool (29) and pin (35), and
completely degrease them. Secure the spool (29), with its thread area upward, with a vise by way of a
wooden plank (Fig. 42.2). Insert the spring seat (30), spring (31) and spring seat (30) into the spool
(29), then tighten the pin (35).
Pin: 14.7 to 19.6 N-m {1.5 to 2.0 kgf-m} [10.9 to 14.5 lbf-ft]
2) Insert the cap (33). Attach the plate (37) with the socket head bolt (38) and nut (36). At this time, insert
a clearance gauge of 0.5 mm [0.0197 in.] between the nut and the plate. After screwing the bolt
completely, tighten the nut together to the pin.
Thread area of pin: LOCTITE #271
Nut: 2.0 to 2.9 N-m {0.2 to 0.3 kgf-m} [1.5 to 2.1 lbf-ft]
Remove the clearance gauge. Confirm that the clearance between the nut (36) and plate (37) is 0.46 to
0.63 mm [0.0181 to 0.0248 in.].
3) Attach the seal (8), wiper (9) and plate (10) to the housing (27). Insert the assembled spool assembly,
and fix it with the socket head bolts (32).
4) Fit the seal (8), wiper (9) and seal plate (10) on the spool head side, and tighten them with the screws
(11).
- 42-5 -
(3) Assembling the valve assembly
1) Align the outlet section (2), spool section assembly and inlet section assembly which have been assembled
in the unit of each section with the same positions as those before disassembly. Insert the tie rod bolts
(3), and attach the nut (1).
Nut on cylinder port side: 101 N-m {10.3 kgf-m} [74.5 lbf-ft]
Nut on valve mounting face side:65 N-m {6.6 kgf-m} [48.0 lbf-ft] (2 positions)
Note: Take care so that the “O”-ring is not protruded from the mating face and that the check valve poppet
(6) and spring (5) do not come off.
2) Attach the relief valve to each port.
78 to 88 N-m {8 to 9 kgf-m} [58 to 65 lbf-ft]
3) Attach the “O”-ring (41) to the plug (42), then attach them to the inlet housing (43).
88 to 98 N-m {9 to 10 kgf-m} [65 to 72 lbf-ft]
4) Screw the lock nut (34) into the innermost position of the cap (33), then screw the coil tube (39). When
the coil tube (39) is slowly screwed, it reaches the plate (37). Withdraw the coil tube (39) by 1/4 turn
(approximately 0.3 mm [0.012 in.]) from the contact position, then tighten it with the lock nut (34).
60.8 N-m {6.2 kgf-m} [44.9 lbf-ft], Thread area: Hydraulic oil
Thread area of coil tube: LOCTITE #242

!"#

#$ALVE
(1) Adjusting the main relief valve
1) Attach a pressure gauge to the inlet circuit.
2) Operate the pump at the rated number of rotations.
3) Change over the spool of the control valve, and read the value indicated by the pressure gauge when the
cylinder is located at the stroke end.
4) Adjust the adjuster so that the required pressure is achieved.
Turning the adjuster by one turn increases the pressure by 17.8 MPa {182 kgf/cm2} [2589 psi] (reference
value).
5) When the specified pressure is achieved, hold the adjuster so that it does not turn, then tighten the lock
nut.
27 to 31 N-m {2.8 to 3.2 kgf-m} [20 to 23 lbf-ft]
6) Increase the pressure again, and confirm that the specified pressure is achieved.
(2) Adjusting the port relief valve

The port relief valve cannot be adjusted.
Replace the existing port relief valve assembly with a preset one.
- 42-6 -

Y AND REASSEMBLY OF BOOM
!"#$%&'
17
1 16
17
13
10 14
12 15
11
12
4
5
7
8
9
3
6
Note: Although the figure shows the boom

cylinder for the L16-3, LX80-7, the
boom cylinder and bucket cylinder
2 for L13-3, LX70-7 are similar in the
internal structure to the former one.
(Boom cylinder for L13-3, LX70-7 has
an one-piece structure combining
piston with nut.)
1. TUBE 7. “O”-RING 13. NUT

2. PISTON ROD 8. BACK-UP RING 14. SET SCREW
3. CYLINDER HEAD 9. “O”-RING 15. STEEL BALL
4. “U”-RING 10. PISTON 16. BUSHING
5. BUSHING 11. SEAL RING & “O”-RING 17. WIPER RING
6. WIPER RING 12. SLIDE RING
Fig. 43A.1 Boom cylinder (L16-3, LX80-7)
- 43A-1 -

Y
1) Discharge oil from the cylinder, and vertically or
horizontally secure the cylinder. At this time,
stop rotation, and fix the cylinder in the shaft
direction.
2) Straighten the tongue of cylinder head lock
washer by using a chisel, etc.
3) Loosen the cylinder head by using a hook wrench.
Fig. 43A.2
the tube.
Fig. 43A.3
tip of the piston rod to a jig, for example, then
fix the piston rod.
Fig. 43A.4
6) Cut off the punched area in the caulked area of
the set screw of the piston nut or nut section by
using a drill, etc., then loosen the set screw.
Remove the set screw, then take the steel ball
out of the innermost section.
7) Loosen the nut or nut section by using a power
wrench, etc., and remove the piston from the rod.
After removing the piston from the rod, remove
Fig. 43A.5
the cylinder head.
- 43A-2 -
used any more.
Fig. 43A.6

etc.
10) As to the wiper ring, put up a screwdriver to the
the wiper ring.
Fig. 43A.7
11) Remove the bushing from the inside of the
cylinder head by using a jig.
Fig. 43A.8

before removal.)
- 43A-3 -

Y
Fig. 43A.9
2) Attach the “U”-ring to the inside of the cylinder

head.
Note: Pay attention to the “U”-ring mounting
direction.
Fig. 43A.10
Fig. 43A.11
4) Attach the back-up ring and “O”-ring to the

cylinder head.
Fig. 43A.12
- 43A-4 -
Fig. 43A.13

seal ring.
Fig. 43A.14
to the piston rod.
9) Insert the piston into the piston rod, and tighten
the nut or nut section.
Nut: N-m {kgf-m} [lbf-ft]
1320 {135} [980]
Fig. 43A.15
(Boom cylinder for L13-3, LX70-7)
2350 {240} [1740]
2450 {250} [1810]
(Bucket cylinder for L13-3, LX70-7)
- 43A-5 -
10) After tightening the piston or nut, attach the steel
ball and set screw. After that, punch and caulk in
two positions on the periphery.
Set screw: N-m {kgf-m} [lbf-ft]
16.2 {1.65} [11.9]
31.5 {3.21} [23.2]
(Boom cylinder for L16-3, LX80-7,
Bucket cylinder for L13-3, LX70-7)
Fig. 43A.16
the cylinder.
Fig. 43A.17
12) Tighten the cylinder head to the cylinder tube by
using a hook wrench.
Cylinder head: N-m {kgf-m} [lbf-ft]
530 {54} [391]
833 {85} [615]
(Boom cylinder for L16-3, LX80-7,
Bucket cylinder for L13-3, LX70-7)
Thread area: Three Bond #1901
13) Bend the lock washer of the cylinder tube toward Fig. 43A.18
the cylinder head to prevent rotation.
- 43A-6 -

Y AND REASSEMBLY OF

!"#$%&'(
2
18
17
15 16
18
14
11
13
12
13
5
4
7
8
18
17
18
10
9
9. BOLT
10. WASHER
11. PISTON
12. SEAL RING & “O”-RING
1 13. SLIDE RING
14. NUT
1. CYLINDER TUBE 5. “U”-RING 15. SET SCREW
2. PISTON ROD 6. WIPER RING 16. STEEL BALL
3. CYLINDER HEAD 7. “O”-RING 17. BUSHING
4. BUSHING 8. BACK-UP RING 18. WIPER RING
Fig. 43B.1 Bucket cylinder (L16-3, LX80-7)
- 43B-1 -

Y
1) Discharge oil from the cylinder, and vertically or horizontally secure the cylinder. At this time, stop
rotation, and fix the cylinder in the shaft direction.
2) Loosen and remove the cylinder head mounting
bolts (8 pcs.) by using a hexagon rod spanner,
etc. (Fig. 43B.2).
Fig. 43B.2
the tube.
Fig. 43B.3
tip of the piston rod to a device, for example,
then fix the piston rod.
Fig. 43B.4
5) Cut off the punched area in the caulked area of
the set screw of the piston by using a drill, etc.,
then loosen the set screw. Remove the set screw,
then take the steel ball out of the innermost
position.
6) Loosen the nut by using a power wrench, etc.,

and remove the piston from the rod. After
removing the piston from the rod, remove the Fig. 43B.5
cylinder head.
- 43B-2 -
used any more.
Fig. 43B.6

etc.
As to the wiper ring, put up a screwdriver to the
the wiper ring.
Fig. 43B.7
9) Remove the bushing by using a jig from the inside
of the cylinder head.
Fig. 43B.8

before removal.)
- 43B-3 -

Y
Fig. 43B.9
2) Attach the “U”-ring to the “U”-ring groove inside

the cylinder head.
Note: Pay attention to the “U”-ring assembly
direction.
Fig. 43B.10
Fig. 43B.11
4) Attach the back-up ring (outer) and “O”-ring to

the cylinder head.
Fig. 43B.12
- 43B-4 -
Fig. 43B.13

seal ring.
Fig. 43B.14
to the piston rod.
9) Attach the nut to the piston rod by using a power
wrench.
2890 N-m {295 kgf-m} [2130 lbf-ft]
Fig. 43B.15
10) After tightening the nut, attach the steel ball and
set screw. After that, punch and caulk in two
positions on the periphery.
Set screw: 56.9 N-m {5.80 kgf-m}
[42.0 lbf-ft]
Fig. 43B.16
- 43B-5 -
the cylinder.
Fig. 43B.17
12) Assemble the cylinder head into the tube by

tightening the bolts in the order shown in the right
figure.
442 N-m {45.1 kgf-m} [326 lbf-ft]
Fig. 43B.18
- 43B-6 -

Y AND REASSEMBLY OF TRAVEL
ALVE FOR APS (OPTION)
19. SLEEVE
1. VALVE HOUSING 10. PLUG 20. “O”-RING
2. SPOOL ASSEMBLY 11. ADJUSTER KIT 21. BACK-UP RING
3. SPRING 12. “O”-RING 22. SPRING
4. PLUG 13. PLANGER 23. POPETTE
5. “O”-RING 14. SPRING 24. PLUG ASSEMBLY
6. “O”-RING 15. SPRING SEAT ASSEMBLY 25. PLUG ASSEMBLY
7. CAP 16. SPOOL 26. SPRING
8. SOCKET HEAD BOLT 17. PLUG ASSEMBLY 27 . PLUG ASSEMBLY
9. SOLENOID VALVE 18. VALVE ASSEMBLY 28 . SPOOL
Fig. 44.1 Travel damper valve
- 44-1 -

Y
Notes 1: Before disassembly, loosen the valve assembly (18) of the travel damper valve to release the
accumulator pressure.
2: During disassembly, sufficiently clean the adjacent area so that foreign substances do not enter the
valve.
3: See to it that the assembly position will be clear at the time of reassembly for each disassembled
part.
4: Replace all removed seals (“O”-rings and back-up rings) with new ones.
1) Loosen the mounting bolts (9-24) of the solenoid valve (9), and remove the solenoid valve (9) from the
valve housing. At this time, remove the “O”-rings (9-19) from the mating face also. (Refer to Fig.
44.6.)
Note: The solenoid valve should be replaced in the unit of assembly in principle. Do not disassemble the
solenoid valve unless abnormality is suspected. For disassembly, refer to “44.5 ADJUSTMENT OF
SOLENOID VALVE”.
2) Remove the plug (24). Remove the “O”-ring from the plug.
3) Remove the plug (4), and remove the spring (3). Remove the “O”-ring (5) from the plug.
4) Remove the plug (17), and pull out the sleeve (19), spring (22) and poppet (23) from the valve housing.
Remove the “O”-ring from the plug (17). Remove the “O”-ring (20) and back-up ring (21) from the
sleeve (19).
Note: When pulling out the sleeve (19), utilize a screw hole of M6 x 1 provided on the end face.
5) Remove the valve assembly (18).
Remove the nut (18-3) and poppet (18-2) from
the plug (18-1).
At this time, remove the “O”-ring (18-4) from
the plug, and the “O”-ring (18-5) from the
poppet. (Refer to Fig. 44.2.)
Fig. 44.2 Valve assembly
6) Remove the adjuster kit (11) from the plug (10).

7) Remove the plug (10) from the valve housing, and pull out the plunger (13), spring (14) and spring seat
assembly (15).
Note: Because the steel ball in the spring seat assembly is press-fitted, do not disassemble the spring seat
assembly any more.
8) Remove the plug (27), and remove the spring (26).
Note: Loosen the plugs or caps at the both ends before starting the spool pullout work.
9) Loosen the socket head bolts (8), and remove the cap (7) and “O”-ring (6) on the mating face.
10) Remove the plugs (17) (in two positions). Remove the “O”-ring from each plug.
- 44-2 -
11) Remove the spool assembly (2) from the valve housing.
12) Remove the spool (16) from the valve housing.
13) Remove the spool (28) from the valve housing.
Note: When taking out each spool, take rigid care so that dents and scars are not made.
14) Hold the spool assembly (2) with a wooden plank
(Fig. 44.4) so that the periphery of the spools in
the spool assembly is not damaged, secure it with
a vise, loosen the plug (2-2), and then remove
the spool (2-3) and spring (2-4). (Refer to Fig.
44.3.)
Note: See to it that the assembly position and
direction will be clear at the time of reassembly
for each disassembled part.
Fig. 44.3 Spool assembly
Fig. 44.4 Wooden plank
- 44-3 -
TMENT AFTER DISASSEMBLY
1) Cleaning
Completely clean all disassembled parts with clean mineral oil. Dry them with compressed air, and
then put each part on clean paper or cloth for inspection.
2) Inspection
Check all surfaces of each part for burrs, scars, flaws and other defects.
a) If dents, scars or flaws are detected on the load check seat surface and shut-off valve seat surface of
the valve housing, remove them with the lapping agent. Take care so that the lapping agent does
not remain inside the valve.
Check and treat the seat surface of the poppet in the same way.
b) Check the periphery of the spools for scars, dents, etc. If small scars are detected, remove them
with oil stone or cloth on which the lapping agent is applied.
c) Confirm that all sliding parts move smoothly. Confirm all grooves and passages are free from
foreign substances.
d) If a spring is broken, is deformed or has worn out, replace it with a new one.
e) Foreign substances shall not be present in the orifice of the spools (2-1, 2-3) and the orifice of the
spool (16) in the spool assembly (2).
f) Replace all “O”-rings and back-up rings with new ones.
g) After removing a cap or plug, confirm that paint flakes are not present around the body hole or plug
seat.

Y
Note: Handling of the spools
· An excessive torque applied on the thread area will cause malfunction of the spool. Make sure to
observe the specified torque.
· Make sure that each spool, spring and spool end make a combination equivalent to the combination
before disassembly.
1) Reassemble the main spool assembly.
Assemble the spring (2-4) and flow control spool (2-3) into the spool (2-1), fix them to the wooden
plank used during disassembly, and tighten the plugs (2-2) (width across flat: 10 mm) at the specified
torque. (Refer to Fig. 44.3.)
Note: Note that an excessive torque may deform the spools and cause malfunction.
2) Slowly insert each spool (2, 16, 28) into the position before disassembly.
Note: After inserting each spool, slide it, and confirm that it moves smoothly.
- 44-4 -
3) Attach an “O”-ring to the plug (17), and tighten the plug (17) to the valve housing.
106 to 141 N-m {10.8 to 14.4 kgf-m} [78 to 104 lbf-ft], width across flat of hexagon socket:
10 mm
4) Attach the “O”-ring (6) to the groove in the cap (7), and tighten the cap (7) with the socket head bolts
(8).
69.8 to 77 N-m {7.12 to 7.86 kgf-m} [51.5 to 56.9 lbf-ft], width across flat of hexagon
socket: 8 mm
Note: Confirm that foreign substances, protrusions, etc. are not present on the mating faces of the valve
housing and cap.
5) Attach an “O”-ring to the plug (24), and tighten it to the valve housing.
31.4 to 41.2 N-m {3.20 to 4.20 kgf-m} [23.1 to 30.4 lbf-ft], width across flat of hexagon
socket: 6 mm
6) Assemble the spring (29) into the valve housing, and tighten the plug (30) in which an “O”-ring is
attached.
10 mm
Note: Note that a seat (dented area) for spring is provided in the plug (30), which is different from the plug
(17) of the same size.
7) Temporarily assemble the adjuster kit (11) in which the “O”-ring (12) is attached and the plunger (13)
into the plug (10).
8) Assemble the spring seat assembly (15) and spring (14), and tighten the plug (10) (width across flat: 38
mm) assembled in the step 7) to the valve housing.
9) Into the valve housing, assemble the sleeve (19) in which the poppet (23), spring (22), “O”-ring (20)
and back-up ring (21) are attached and tighten the plug (17) in which an “O”-ring is attached.
10 mm
10) Assemble the valve assembly (18).
Temporarily assemble the poppet (18-2) in which the “O”-ring (18-5) is attached and the nut (18-3)
into the plug (18-1) in which an “O”-ring is attached. (Refer to Fig. 44.2.)
- 44-5 -
11) Tighten the valve assembly (18) assembled in the step 10) to the valve housing.
For the tightening method and torque, refer to Fig. 44.5.
Fig. 44.5 Assembling the valve assembly
12) Assemble the spring (3), and tighten the plug (4) in which the “O”-ring (5) is attached.
149 to 165 N-m {15.2 to 16.8 kgf-m} [110 to 122 lbf-ft], width across flat of hexagon
socket: 32 mm
13) Tighten the solenoid valve (9) in which the “O”-rings (9-19) is attached on the mating face with the
bolts (9-24), and attach them to the valve housing. (Refer to Fig. 44.6.)
5.9 to 7.9 N-m {0.6 to 0.8 kgf-m} [4.3 to 5.8 lbf-ft], width across flat of hexagon socket: 4
mm
Note: Confirm that foreign substances, protrusions, etc. are not present on the mating faces of the valve
housing and solenoid valve.

!"#$ %!&'ALVE SET
$
Adjust the pressure reducing valve set pressure for the travel damper valve assembled in Paragraph 44.3.
1) Attach an accurate pressure gauge to the port SP. At this time, connect the port T to the tank, and attach
plugs to the ports A and B.
2) Supply “flow rate: 20 L/min, pressure: 20.6 MPa {210 kgf/cm2} [2990 psi]” from the port P, and turn
the adjuster (11-1) in the adjuster kit (11) so that the pressure at the SP port becomes the set pressure.
Turning the adjuster by one turn increases the pressure by 1.02 MPa {10.4 kgf/cm2} [148 psi] (reference
value).
3) When the specified pressure is achieved, hold the adjuster so that it does not turn any more, and then
tighten the lock nut.
4) Increase the pressure again, and confirm that the specified pressure is achieved.
- 44-6 -
)
! !% $"% "#" !"'ALVE
1. BODY 10. SPRING 19. “O”-RING

2. SPOOL 11. “O”-RING 20. SNAP RING
3. SOLENOID 12. RETAINER 21. SHEET
4. SNAP RING 13. SNAP RING 22. SNAP RING
5. “O”-RING 14. SPRING SEAT 23. PIN RETAINER
6. SPRING 15. PUSH ROD 24. HEXAGON SOCKET BOLT
7. SPRING SEAT 16. SPACER 25. “O”-RING
8. “O”-RING 17. CAP 26. WASHER
9. “O”-RING 18. PLUG
Fig. 44.6 Solenoid valve
- 44-7 -
Notes 1: Before disassembly, release the pressure from each part in the same way as Paragraph 44.1 even if
the solenoid valve is removed from the travel damper valve main body during the work.
2: During disassembly, sufficiently clean the adjacent area so that foreign substances do not enter the
valve.
3: Note that the solenoid valve may be hot if it has been used for a long time. During the work, make
sure to disconnect the connectors so that the lead wires are free from the load.
4: See to it that the assembly position will be clear at the time of reassembly for each disassembled
part.
5: Replace all disassembled “O”-rings and snap rings with new ones.
Note: For the part numbers in the text below, refer to Fig. 44.6.
(1) Disassembly
1) Remove the cap (17) and spacer (16) from the solenoid (3) side.
2) Remove the solenoid fixing nuts (width across flat: 22 mm), and remove the coil. At this time, it is
recommended for facilitating loosening of the nuts to fix the slotted area on the end face of the solenoid
iron core with a screwdriver, etc.
3) Remove the snap ring (4), and remove the spool assembly (2) from the body. Remove the “O”-ring (5)
from the spool assembly.
Note: When removing the snap ring, take care so that the body is not damaged by prying the snap ring.
Note: When taking out the spool, take rigid care so that dents and scars are not made.
And when the spool is taken out, the land comes off unavoidably. Slowly take out the spool while
taking rigid care so that burrs are not made in the land. Burrs may cause defective disassembly or
malfunction.
Note: The spool assembly (combination of solenoid iron core and parts around the spool) is connected with
the snap ring (20). It should not be disassembled any more because dedicated jigs are required in
reassembly.
4) Remove the cap (17) and spacer (16), and then remove the retainer (12) and seat (21) assembled into
one.
At this time, remove the “O”-rings (9, 11).
Note: Because the spring (10) and push rod (15) are connected to the retainer (12) with the snap ring (13),
they should not be disassembled any more.
5) Because the plug (18) is a pipe plug, it should not be disassembled unless nonconformity is suspected.
(2) Treatment after disassembly

Clean all disassembled parts with clean mineral oil, dry them with compressed air, and then check each part.
1. Confirm that the seat surfaces on the periphery of the spools and the periphery of the retainers are free
from scars, etc.
2. Confirm that each spring is not broken, is not deformed or has not worn out.
3. Replace all “O”-rings and snap rings with new ones. Do not use them again.
- 44-8 -
4. Confirm that paint flakes are not present around the body holes.
If paint flakes enter the valve, they may cause catching, clogging etc., and may cause malfunction and
oil leakage in the end.
If slight scars or flaws are detected by the above checks, remove them with the lapping agent.
If an abnormal part is detected, replace the entire solenoid valve assembly.
(3) Reassembly
1) Into the body, assemble the retainer assembly (12) in which the seat (21) and “O”-rings are attached
(1), and fix them with the snap ring (22).
2) Slowly insert the spool assembly (2) in which the “O”-ring is attached into the body (1), and fix them
with the snap ring (4).
Note: When the spool is inserted, the land comes off unavoidably. Slowly insert the spool while taking
rigid care so that burrs are not made in the land. Burrs may cause defective disassembly or malfunction.
After inserting the spool, slide it, and make sure that it moves smoothly.
3) Attach the coil, and fix it by tightening the solenoid fixing nuts (width across flat: 22 mm). At this
time, it is recommended for facilitating tightening of the nuts to fix the slotted area on the end face of
the solenoid iron core with a screwdriver, etc.
Note: An excessive torque may damage the groove in the body snap ring. Make sure to observe the specified
torque.
4) Attach the spacers (16) and caps (17) at the both ends.
- 44-9 -
5. ELECTRIC UNIT
CONTENTS
51. ELECTRICAL EQUIPMENT LAYOUT DRAWING .............................................. 51-1
52. WIRE HARNESS (REFERENCE) ..................................................................................... 52-1
53. STARTING SYSTEM ELECTRIC CIRCUIT .............................................................. 53-1
54. ELECTRIC CIRCUIT DIAGRAM ........................................................................................ 54-1

(blank page)

YOUT DRAWING
1. GLOW RELAY
2. BATTERY RELAY
3. REAR COMBINATION LAMP
4. REAR WORKING LAMP
5. BACK BUZZER
6. SENDER UNIT
7. LICENSE LAMP
8. SPEED SENSOR
9. QOS SENSOR
Fig. 51.1 Electrical Equipment Layout Drawing
- 51-1 -
1. PROXIMITY SWITCH (BUCKET LEVER)
2. HORN
3. FRONT COMBINATION LAMP
4. HEAD LAMP
- 51-2 -
1. NEUTRAL START RELAY
2. ENGINE STOP MOTOR RELAY
3. PARKING RELAY (2)
4. PARKING RELAY (1)
5. HEAD LAMP (Lo) RELAY
6. HORN RELAY
7. F-N-R F RELAY
8. F-N-R R RELAY
9. BACK LAMP RELAY
10. F-N-R SOLENOID GND RELAY 16. QOS TIMER
11. HEAD LAMP (Hi) RELAY 17. FUSE BOX
12. STOP LAMP SWITCH 18. TRANSMISSION CONTROLLER
13. STARTER SWITCH 19. PARKING BRAKE SWITCH
14. SWITCH 20. WORKING LAMP SWITCH
15. FLASHER UNIT 21. CLUSTER METER
- 51-3 -
1. PRESSURE SWITCH (PARKING)
2. BRAKE OIL TANK (LEVEL SWITCH)
3. BATTERY
4. ENGINE STOP MOTOR
5. FUEL SENDER UNIT
- 51-4 -
1. WORK LIGHT
2. RADIO
3. ROOM LAMP
4. REAR WIPER
5. FRONT WIPER
6. FRONT WIPER SWITCH
7. REAR WIPER SWITCH
8. LEFT WORK LIGHT RELAY
9. RIGHT WORK LIGHT RELAY
10. WORK LIGHT RELAY
(OPTION)
- 51-5 -
- 51-6 -
1. WARNING LAMP 21. FUSE (ROOM LAMP, CLOCK [RADIO])
(ENGINE OIL PRESSURE) 22. FUSE (MONITOR POWER SUPPLY)
2. WARNING LAMP (BATTERY VOLTAGE) 23. FUSE (PARKING BRAKE RELEASE)
3. PILOT LAMP (PARKING BRAKE) 24. FUSE (HEAD LAMP, POSITION LAMP)
4. PILOT LAMP (GLOW) 25. FUSE
5. PILOT LAMP (WORK LIGHT) (TURN SIGNAL LAMP, STOP LAMP,
6. PILOT LAMP (HIGH GEAR) BACK LAMP)
7. PILOT LAMP (APS, OPTION) 26. FUSE (CUT-OFF SWITCH)
8. WARNING LAMP (BRAKE OIL LEVEL) 27. FUSE (SPEED RANGE SWITCH)
9. WARNING LAMP 28. FUSE (HORN, LEVELER)
(EMERGENCY STEER, OPTION) 29. FUSE (GLOW)
10. ENGINE WATER THERMO METER 30. FUSE (REAR WORK LIGHT)
11. FUEL METER 31. FUSE (A/C CONTROL POWER SUPPLY)
12. SPEED METER 32. FUSE (BLOWER MOTOR)
13. HOUR METER 33. FUSE
14. TURN SIGNAL (LEFT) (A/C CONDENSER,
15. PILOT LAMP (HIGH-BEAM) COMPRESSER POWER SUPPLY)
16. TURN SIGNAL (RIGHT) 34. FUSE (FRONT WIPER, WASHER)
17. HORN SWITCH 35. FUSE (REAR WIPER, WASHER)
18. QUICK SHIFT SWITCH 36. FUSE (RADIO)
19. FUSE (BATTERY VOLTAGE) 37. FUSE (FRONT WORK LIGHT)
20. FUSE (HAZARD) 38. FUSE (OPTION)
- 51-7 -

Note: Latest wire harnesses are described here for reference.
[How to see the wire harness]

1) For each wire harness, the wire size, the wire color and the connection procedure are described in the
list.
2) In connection in wiring, if one end is 1A , the other end is 1B . In the same way, if one end is 1C , the
other end is 1D . If one end is 1E , the other end is 1F .
3) At a terminal of each wire harness, the connector type is indicated in a symbol.
4) Wire size
Example: AV1.25 ... Low voltage wire for car (AV), nominal cross-sectional area = 1.25 mm2 [0.019 in.2]
- 52-1 -
5) Wire color
The wire color is indicated in a color symbol. In a combined color symbol, the first color indicates the
wire background color, and the second color indicates the marking color.
: : BG:
B: Black
ellow Black and Green
:
W: White
ellow
W: Y:
R: Red
ellow
: : GB:
:
ellow Green and Black
:
:ellow
ellow and Red ellow and Black ellow and Green ellow and Blue ellow and White
: :
:
ellow
W: Y:
:
ellow
Light Green : Light Green
:

:
:
:
Before servicing the electric system or replacing a part in the electric system, disconnect terminals
of the battery. When disconnecting terminals of the battery, disconnect the terminal on the
ground side first to shut down electricity, then disconnect other terminals.
- 52-2 -
1. WIRE HARNESS, FRONT FRAME
2. WIRE HARNESS, COCKPIT
3. WIRE HARNESS, WORK LIGHT SWITCH
(ONLY AWNING SPECIFICATION )
4. WIRE HARNESS, REAR FRAME
5. WIRE HARNESS, ENGINE
6. WIRE HARNESS, T/M • HST
Fig. 52.1 Wire Harness Layout Drawing
- 52-3-
1) WIRE HARNESS, ENGINE
- 52-4 -
Notes 1: A number in the wiring indicates the length (mm).
2: The terminal position of a multi-pole connector is seen
from the counterpart connector side.
Fig. 52.2 Wire Harness, Engine

2) WIRE HARNESS, T/M • HST
- 52-5 -
Notes 1: A number in the wiring indicates
the length (mm).
2: The terminal position of a multi-
pole connector is seen from the
counterpart connector side.
Fig. 52.3 Wire Harness, T/M • HST

3) WIRE HARNESS, FRONT
- 52-6 -
2: The terminal position of a multi-pole connector is seen
from the counterpart connector side.
Fig. 52.4 Wire Harness, Front

4) WIRE HARNESS, WORK LIGHT SWITCH (ONLY AWNING SPECIFICATION)

2: The terminal position of a multi-pole connector
is seen from the counterpart connector side.
Fig. 52.5 Wire Harness, Work Light Switch (only awning specification)
- 52-7 -
5) WIRE HARNESS, COCKPIT
- 52-8 -
(blank page)
- 52-9 -
5) WIRE HARNESS, COCKPIT

Fig. 52.6 Wire Harness, Cockpit
- 52-10 -
6) WIRE HARNESS, REAR FRAME

Fig. 52.7 Wire Harness, Rear Frame
- 52-11 -
ARTING SYSTEM ELECTRIC CIRCUIT
Fig. 53.1 Starting System Electric Circuit
- 53-1 -
1. Main switch ON
When the main switch is set from OFF to ON, the terminal B is connected to the terminals ACC and BR.
By this connection, the current flows in the battery relay terminal BR, and the power line is connected
(arrow A ). The current flows from the ACC to the glow timer and the glow relay, and preheating is
performed by the glow plug (arrow B ).
If the cooling water is at 10 °C [50 °F] or less, preheating is performed for 8 seconds by the timer. If the
cooling water is at 10 °C [50 °F] or more, preheating is not performed. The water temperature is detected by the
QOS switch.
2. Main switch start (ST)

When the switch is set from ON to ST, the terminal B is connected to the terminal C. The current flows in
the starter motor safety relay terminal S by way of the neutral relay, the current flows from the relay terminal
C to the starter motor terminal S, then the starter is rotated (arrow C ). At this time, if the transmission
control lever is located in the F or R position, the neutral relay is not activated, and the signal is not transmitted
to the safety relay terminal C. As a result, the starter is not rotated.
When the starter is rotated and the engine is started up, the generator starts to generate power, and the
signal is transmitted from the terminal L to the safety relay terminal R (arrow D ). When the signal is input
to the terminal R, the pinion gear of the starter motor is pulled back, and rotation is stopped.
Before the engine is started up, the voltage at the terminal R of the safety relay is approximately 0 V. As a
result, the current flows in the charging lamp in the meter, and the lamp lights. When the engine is started
and the alternator starts to generate power, the voltage is output from the terminal L. As a result, there is no
difference in the electric potential with the line No. (3), and the lamp is extinguished.
3. Main switch stop (OFF)

The stop motor is activated when the main switch is set to ON or OFF, rotated by 180° at each time, and set
to the startup or stop position.
When the main switch is set to ON, the signal is transmitted from the terminal BR to the engine relay, and
the engine relay is activated. As a result, the terminals A and P2 of the relay are connected each other, and the
stop motor is rotated by 180 degrees.
On the contrary, when the main switch is set to OFF, the engine relay is pulled back, the terminals A and P1
are connected each other, and the stop motor is rotated by 180 degrees. As a result, the stop lever of the
injection pump is pulled back, and the engine is stopped.
- 53-2 -

Note: Cord colors:
The cords are classified by color. The first symbol shows the cable color and the 2nd the making color.
Wire diameter
Wire diameters are shown in the circuit diagram. Unless otherwise specified, the wire diameter is 0.85
mm2 [0.00132 in.2]
- 54-1 -
(blank page)
- 54-2 -
SECTION 6
ENGINE AND ACCESSORY
(For LX110-7 and LX70-7/80-7 Only)
—CONTENTS—
General Information Major Components ................................................ 3-7
General Repair Instructions .............................. 1-2 Rocker Arm and Rocker Arm Shaft
Notes on The Format of This Manual................ 1-2 Disassembly Steps .......................................... 3-12
Main data and Specifications ............................ 1-6 Cylinder Head Disassembly Steps .................. 3-13
External View..................................................... 1-9 Piston and Connecting Rod Disassembly
Tightening Torque Specifications.................... 1-15 Steps ................................................................ 3-14
Angular nut and Bolt tightening method .......... 1-17
Major Parts Fixing Nuts and Bolts................... 1-19 Engine Assembly II
Identifications .................................................. 1-13 (Inspection and Repair)
Cylinder Head .................................................... 4-2
Maintenance Valve Guide ...................................................... 4-3
Lubricating System............................................ 2-2 Valve Spring....................................................... 4-6
Fuel System....................................................... 2-3 Tappet................................................................ 4-7
Cooling System ................................................. 2-7 Push Rod ........................................................... 4-8
Valve Clearance Adjustment............................. 2-7 Rocker Arm Shaft and Rocker Arm ................... 4-8
Injection Timing ................................................. 2-9 Idler Gear and Idler Gear Shaft ......................... 4-9
Compression Pressure Measurement ............ 2-15 Camshaft.......................................................... 4-10
Turbocharger Inspection ................................. 2-16 Cylinder Body and Liner .................................. 4-11
Engine Repair Kit ............................................ 2-17 Piston and Piston Ring .................................... 4-17
Recommended Lubricants .............................. 2-19 Piston Pin......................................................... 4-19
Engine Oil Viscosity Cart................................. 2-19 Connecting Rod ............................................... 4-20
Crankshaft........................................................ 4-22
Flywheel and Flywheel Housing ...................... 4-29
Engine Assembly I
Timing Gear Case Cover ................................. 4-29
(Disassembly)
External Parts Disassembly Steps .................... 3-2
NOTE: Refer to AA-4BG1T, BB-6BG1, BB-4BG1T,
BB6BG1T engine manual.
1
Engine Assembly III Air Compressor
(Reassembly) General Description ......................................... 10-2
Piston And Connecting Rod Reassembly Disassembly steps ........................................... 10-3
Steps ................................................................. 5-2 Inspection and repair ....................................... 10-4
Cylinder Head Reassembly Steps .................... 5-4 Reassembly steps ........................................... 10-6
Rocker Arm and Rocker Arm Shaft
Reassembly Steps ............................................ 5-8 Engine Electricals
Major Component Reassembly Steps I............. 5-9 Starter Identification ......................................... 11-2
Major Component Reassembly Steps II.......... 5-14 Starter Main Data and Specifications .............. 11-3
External Parts Reassembly Steps Starter Motor Sectional View ........................... 11-4
(Left-Hand Side) .............................................. 5-19 Performance .................................................... 11-4
External Parts Reassembly Steps Alternator Identification .................................... 11-5
(Right-Hand Side)............................................ 5-23 Main Data and Specifications .......................... 11-6
Engine Turning Operation ............................... 5-27 Alternator Sectional View................................. 11-7
Engine Sectional View..................................... 5-29 Charging Circuit ............................................... 11-7
Lubricating System Troubleshooting

General Description........................................... 6-2 Hard Starting.................................................... 12-2
Oil Pump............................................................ 6-3 1) Starter Inoperative..................................... 12-2
Oil Cooler........................................................... 6-5 2) Starter Operates but Engine Does Not

Turn Over .................................................. 12-3
Cooling System 3) Engine Turns Over but Does Not Start Fuel
General Description........................................... 7-2 Is Being Delivered to the Injection Pump .. 12-4
Thermostat ........................................................ 7-3 4) Engine Turns Over but Does Not Start...... 12-5
Unstable Low Idling ......................................... 12-6
Fuel Systems Insufficient Power............................................. 12-9
General Description........................................... 8-2 Excessive Fuel Consumption ........................ 12-12
Injection Nozzle ................................................. 8-3 Excessive Oil Consumption ........................... 12-14
Injection Pump Calibration Data........................ 8-8 Overheating ................................................... 12-15
White Exhaust Smoke ................................... 12-17
Turbocharger
Dark Exhaust Smoke ..................................... 12-18
General Description........................................... 9-2
Oil Pressure Does Not Rise........................... 12-19
Turbocharger Identification ............................... 9-3
Abnormal Engine Noise ................................. 12-21
Inspection and Repair ....................................... 9-4
2
Special Tool List
Special Tool List .............................................. 13-2
Repair Standards
General Rules ................................................. 14-1
Conversion Table
Length.............................................................. 15-2
Area ................................................................. 15-3
Volume ............................................................ 15-3
Mass ................................................................ 15-5
Pressure .......................................................... 15-6
Torque ............................................................. 15-7
Temperature .................................................... 15-8
3
(Blank)
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MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
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FAX: revisions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
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ANT SAFETY NOTICE

“ CAUTION”, “ DANGER”, “ WARNING”, labels have been put on the

This shop manual applies to the following machines:

2. Keep the work site clean and in good order.

3. During maintenance, never attempt to use fire.

4. Clean the machine before starting maintenance.

5. Before starting maintenance, stop the machine on a horizontal, stable place,

6. Always check the maintenance tools, and use them correctly.

7. Before executing maintenance or part replacement of the electric system,

11. In removing or installing a heavy part (whose weight is 20 kg [44 lbs] or

Fig. 02.1 Mounting of Bearing

Fig. 02.2 Mounting of “O”-ring

Fig. 02.3 Fitting of Oil Seal

Fig. 02.4 Mounting of Oil Seal

(2) Removal of Parts

5. Using the Power Wrench

Numbers indicate the tightening order

Fig. 02.5 Tightening of Split Flange

Strength classification Indication on bolt Material

•How to assign the part No.

Fig. 05.1 Water/oil replacement capacity

Fig. 05.2 Grease up

SAFETY PARTS LIST

1. DISASSEMBLY AND REASSEMBLY OF HST PUMP ...................................... 11-1

 Y AND REASSEMBLY OF TRANSMISSION ........................ 12-1

! Y AND REASSEMBLY OF DRIVE AXLE ................................. 13-1

Fig. 11.1 HST pump

HST pump weight: 93 kg [205 lb]

before removing servo piston (66) from swash

14) Remove screws (62), washers (63), guide

1) Install swash plate (83) assembly (including

(59) to the dimension recorded before

4 to 5.4 N-m {0.41 to 0.55 kgf-m}

Fig. 11.7 Pump combination valve 1 (1)

Fig. 11.9 Pump combination valve 2 (1)

Fig. 11.10 Pump combination valve 2 (2)

D-d Unit: mm [in.]

0.03 [0.0012] 0.06 [0.0024]

3) Heights of valve plate (14) and plate (15). 14

Fig. 12.1 jig

12.1.2 DISASSEMBLY OF TRANSMISSION CASE

Note: Remove the gaskets from the mating surfaces.

3) Remove the oil level gauge, pipe, stay and elbow.

7) Remove the output flange on the front side. OUTPUT FLANGE

11) Alternately tighten the four bolts, and remove

15) Remove the oil baffle.

19) Remove the output shaft assembly to the front

12.1.3 DISASSEMBLY OF CLUTCH ASSEMBLY

3 pairs of outer and inner disks

2) Remove the snap ring, and pull out the bearing

12.1.5 DISASSEMBLY OF OUTPUT SHAFT

3) Pull out the low gear together with the bearing

12.2.1 REASSEMBLY OF OUTPUT SHAFT

4) Attach the bearing on the high gear side.

12.2.2 REASSEMBLY OF CONTROL VALVE

3) Attach the cover by way of a gasket with six COVER

11.8 N-m {1.2 kgf-m} [8.7 lbf-ft]

Fix it to this groove

3) Put the spring, spring seat and snap ring, then,

L13-3 and LX70-7:

5) Attach the end plate and snap ring.

(2) Assembling the clutch on the low gear side

Note: Be careful not to confuse the inner baring and

ANT SAFETY NOTICE

Y AND REASSEMBLY OF TRANSMISSION ........................ 12-1

! Y AND REASSEMBLY OF DRIVE AXLE ................................. 13-1