REAR AXLE

Structure and Functions .............................................................................................................. 8 - 1

Procedures and Key Points for Removal and Installation .......................................................... 8 - 3

Rear Wheels ........................................................................................................................ 8 - 3
Rear Axle ............................................................................................................................ 8 - 4

Procedures and Key Points for Disassembly and Assembly ...................................................... 8 - 7

Disassembly ........................................................................................................................ 8 - 7
Assembly ............................................................................................................................ 8 - 8

Inspection and Adjustment ........................................................................................................ 8 - 14

Making sure of Minimum Turning Radius ........................................................................ 8 - 14

Service Data ................................................................................................................................ 8 - 15

8
 REAR AXLE

Structure and Functions

2
3
4

19
18

11 8
9
12
10
13
14
15
16
17
16 206811

1 Housing 7 Taper roller bearing 13 Oil seal

2 Pinion gear 8 Oil seal 14 Taper roller bearing
3 Rack gear 9 Steering axle 15 Taper roller bearing
4 Piston 10 Wheel hub 16 Nut
5 Cap 11 Hub bolt 17 Lock washer
6 Taper roller bearing 12 Hub nut 18 Hydraulic oil inlet (left wheel)
19 Hydraulic oil inlet (right wheel)
The rear axle is coupled with pinion gear and rack The steering axle connected to the pinion gear
gear. The rack gear is mounted with pistons on is linked to two symmetrically arranged rear
both ends, and converting the reciprocal motion wheels. The steering axle and the taper roller
generated by oil pressure to the pinion gear to bearing of the pinion gear support the rear
rotational movement. The pinion gear serves as a wheel load.
steering device.
8-1
REAR AXLE

Rear Wheels

Solid Pneumatic Tire Solid Tire

114.3 mm (4.5 in.)

127 mm (5 in.)

2 3

206812

1 Steering axle 3 Wheel nut

2 Rear wheel 4 Rim

15 ¥ 4.5 - 8
Tire size
(15 ¥ 5 ¥ 11.5)

Dimensions in parentheses ( ) are for solid tires.

8-2
 REAR AXLE

Procedures and Key Points for Removal and Installation

Rear Wheels
Removal
1 Wheel nut
2 Rear wheel

Removal sequence
1. Pull the hand brake lever, and place wheel
stoppers at the front wheels.
2. Turn the key switch ON, and turn the steering 1
wheel all the way to either right or left. 2
3. Locate the hub nut on one side of the vehicle
that is visible from the rear. Loosen the hub 206813
nut by turning it two or three rotations.
4. Turn the steering wheel to the opposite direction,
and loosen the hub nut on the opposite side by
turning it two or three rotations.
5. Turn the key switch OFF, and lift the rear side
of the vehicle (until the rear tires are off the
ground).
a. Place a jack at the rear center (under the
draw bar pin) of the counterweight, and
lift.
b. Attach a wire rope to the draw bar pin and
lift with a crane.
6. After the rear side of the vehicle is lifted, place
wood blocks under the frame on both sides at
the rear as a safety measure.
7. Turn the key switch ON, turn the steering
wheel, and remove the right and left tires.
8. Turn the key switch OFF.

206814
Installation
Follow the removal sequence in reverse.

NOTE
Tighten the wheel nuts evenly to the specified
torque.

Wheel nut 157 N·m

tightening torque (16 kgf·m)
[116 lbf·ft] 101212

8-3
REAR AXLE

Rear Axle
Removal (Part 1)

13
2

4 6
1
5
12
3
9

11
7

8
10

206815

Sequence
1 Battery cover, Gas spring, Seat 8 Hose (hydraulic suction)
2 Controller cover 9 Pipe (hydraulic delivery)
3 Battery 10 Motor, Hydraulic pump
4 Battery shield 11 Hose (hydraulic return)
5 Controller 12 Hose (rear axle return)
6 Bracket 13 Hydraulic tank
7 Hose (steering suction)
Preparation
1. Remove the rear wheels.
(Refer to Rear Wheel Removal procedure.)
2. Disconnect the battery plug located on the
right side of the foot area of the operator’s seat
to cut off power.

8-4
 REAR AXLE

Key points for removal

The rear axle is mounted to the counterweight.
To remove the rear axle, it is necessary to
remove all the surrounding components such
as the motor, hydraulic pump, hydraulic tank
and controller.

Removing battery cover

Before removal, open the battery cover and
disconnect the seat switch terminal. Remove
the gas spring from the frame, and remove the
hinge bolts located on the counterweight. The
seat does not have to be removed.

Removing controller
Remove all cables connected to the controller.
During removal, record cable connecting
locations so that they can be reconnected to
the original positions. Disconnect all harness
connectors, and bind them to keep them out of
the way during rear axle removal.

Removing motor and hydraulic pump

Disconnect the cables and harness connectors
of the motor.
Arrange an oil pan to receive drained oil, and
remove hoses 7, 8 and pipe 9. Do not remove
the pipe on the suction side.

Removing hydraulic tank

Disconnect hoses 11, 12, then remove the
hydraulic tank. Since the tank contains oil,
keep the tank balanced during removal.

8-5
REAR AXLE

Removal (Part 2)

15

16

14

17

206816

Sequence
14 Connector 16 Steering hose
15 Overflow hose 17 Rear axle assembly and Steering axle
assembly

Key points for removal

A steering sensor is mounted on the top of the
rear axle. Be careful not to damage the sensor
when lifting the assembly.
Installation
Follow the removal sequence in reverse.
Key points for installation
Tighten the rear axle assembly mounting bolts
to the specified torque.

Bolt tightening torque 436 N·m (44.5 kgf·m) [322 lbf·ft]

8-6
 REAR AXLE
Procedures and Key Points for Disassembly and Assembly
Steering axle
Disassembly

7
8

6
5
4
3
2

206817

Sequence
1 Cap 6 Wheel hub, Hub bolt
2 Nut 7 Oil seal
3 Lock washer 8 Taper roller bearing
4 Nut 9 Steering axle
5 Taper roller bearing

Key points for disassembly

1. Removing wheel hubs
Use a puller to remove the wheel hubs from
the steering axle.

206818

8-7
REAR AXLE
Assembly

1
2

8
7
4 6
3 5
206819

Sequence
1 Steering axle 6 Nut
2 Wheel hub 7 Lock washer
3 Taper roller bearing 8 Nut
4 Oil seal 9 Cap
5 Taper roller bearing
Key points for assembly
1. Assembling wheel hubs
(1) Insert the inner races of the taper roller
bearings using the bearing installer A
(special tool). A

Special tool needed

Bearing installer A 91268-01500

206820

8-8
 REAR AXLE

(2) Filling insides of rear axle hubs with

grease
Supply grease into the rear axle hubs. See the
diagram for proper grease filling condition.
Supply grease to the roller holding devices.
Fill grease to approximately 80% of the
cavity. Do not supply grease to full level.
Filling grease to maximum level causes
excessive generation of heat and quickly
deteriorates the grease. When coating oil seal
lips with grease, be careful not to use too Refilling with grease
206821
much grease, since an excess amount of
grease can cause leaks.
2. Preload adjustment and lock nut
Adjust the inside nut first, then tighten the
outside nut (lock nut) to the specified torque.
Then, check the preload. To measure preload,
attach a spring balance to a hub bolt, then read
the force generated when the hub starts
rotating.
Use the following allowable ranges when
readjusting used bearings.
Outside nut
49 to 490 N·cm Inside nut 206821
Preload of hub bearing (5 to 50 kgf·cm)
[0.36 to 3.6 lbf·ft]
6.5 to 65 N
Tangential force on hub bolt (0.67 to 6.7 kgf)
[1.5 to 14.7 lbf]
157 N·m
Lock nut tightening torque (16 kgf·m)
[116 lbf·ft]

8-9
REAR AXLE

Rear Axle Assembly

Disassembly

14 2

17

Section A
4

10 11 12
9
7

8
A 1 3

15

16

6
207204
13 4

Sequence
1 Bolt 10 Bolt, washer
2 Plate 11 Piston assembly
3 Shim 12 Rack gear
4 Pinion gear 13 Oil seal
5 Taper roller bearing (inner) 14 Oil seal
6 Taper roller bearing (inner) 15 Taper roller bearing (outer)
7 Bolt, washer 16 Taper roller bearing (outer)
8 Cap 17 Housing
9 Seal, O-ring

8-10
 REAR AXLE

Key points for disassembly

Press
1. Removal of the pinion gear
Remove bolt 1, plate 2 and shim 3. Position
housing 17 on a base, and use a press to 17
remove pinion gear 4.

2. Inspect taper roller bearing (inner) 6 which is

press-fit in pinion gear 4 and taper roller 4 207205
bearings 15, 16 which are press-fit in housing
17. If the roller bearings are in good condition,
they do not have to be removed.

Inspection after disassembly

1. Housing
Inspect the sliding surface of piston assembly
11 for damage.
If there are small scratches on the surface, use
sandpaper to remove the scratches.

2. Pinion gear and rack gear

Inspect the tooth surfaces for damage. Inspect
the steering axle mounting screw at the lower
pinion gear section for damage. Inspect the
contact section of the oil seal at the lower
pinion gear section for damage.

3. Taper roller bearing

Inspect the rolling contact surface of the
bearing.

4. Inspect the contact section of the oil seal of

plate 2 for damage.

5. Oil seal, O-ring and other parts

Replace oil seals 4, 5, other seals, O-ring 9,
and piston seal of piston assembly 11 with
new parts.

8-11
REAR AXLE
Assembly

4 16

Section A
12

8 7 6
9

11

10
A 17 15 B

14

13

5 12 207204

Sequence
1 Housing 10 Cap
2 Taper roller bearing (outer) 11 Bolt, washer
3 Taper roller bearing (outer) 12 Pinion gear
4 Oil seal 13 Taper roller bearing (inner)
5 Oil seal 14 Taper roller bearing (inner)
6 Rack gear 15 Shim
7 Piston assembly 16 Plate
8 Bolt, washer 17 Bolt
9 Seal, O-ring B Overflow port

For assembly, follow the disassembly sequence in

reverse.
Key points for assembly
1. When knocking oil seals 4, 5 into housing 1,
use a backing plate and strike the oil seals
uniformly to set the seals evenly into position.
8-12
 REAR AXLE

2. Before installing piston assembly 7, apply

sealant 1E2200J on the periphery of the piston
and the sliding surface of housing 1.

3. When installing taper roller bearings (inner)

13, 14, coat them with hydraulic oil.

4. Coat the lips of oil seals 4, 5 with hydraulic oil

and install the seals.

5 To adjust the bearing end play after the

installation of taper roller bearings 13, 14, 14 Clearance
measure clearance between pinion gear 12
and taper roller bearing 14. Subtract a value
of 0.01 to 0.035 mm (0.0004 to 0.0014 in.)
from the measured value, and insert a shim
having the thickness of the calculated value,
then tighten plate 16.

12
Clearance – 0.01 to 0.035 mm= Shim thickness
(0.0004 to 0.0014 in.) 207206

6. Tighten bolt 17 to the specified torque.

Bolt tightening torque
N.m 45 ± 7
(kgf.m) (4.5 ± 0.7)
[lbf.ft] [99 ± 15]

7. After assembly, pour hydraulic oil into

overflow port B until the oil surface reaches
the overflow port. Cover the overflow port
with tape.

8-13
REAR AXLE

Inspection and Adjustment

1. Making sure of Minimum Turning Radius
(1) While operating the vehicle at low speed,
turn the steering wheel all the way to the
right, then to the left, and check the
diameter of the tire tracks in both turning
operations.
(2) Calculate minimum turning radius R by
dividing the turning diameter by two then
adding the distance between the center of
R
the outside rear wheel and the outside
edge of the counterweight.

206822

Unit : mm (in.)
Item
Minimum turning radius
Models
EP16KT 1517 (59.7)
EP18KT 1620 (63.8)
EP20KT 1645 (64.8)

8-14
 REAR AXLE
Service Data
A: Standard value
Truck Models
EP16KT, EP18KT EP20KT
Item
Preload of hub bearing 1
A 49 to 490 (5 to 50) [0.36 to 3.6]
N·cm (kgf·cm) [lbf·ft]
Tangential force on hub bolt
A 6.5 to 65 (0.67 to 6.7) [1.5 to 14.7]
N (kgf) [lbf]
Lock nut 2 A 157 (16) [116]
Tightening
torque Rear axle tightening bolt 3 A 436 (44.5) [322]
N·m Steering axle tightening bolt 4 A 224 (22.9) [166]
(kgf·m) Wheel nut 5 A 157 (16) [116]
[lbf·ft]
Plat bolt 6 A 45 ± 7 (4.5 ± 0.7) [99 ± 15]

6
3

5
4

206823

8-15