REAR AXLE
Structure and Functions ....................................................................... 5 – 1
Rear Wheels ............................................................................................. 5 – 2
Procedures and Suggestions for Removal and Installation ........ 5 – 3
Rear Wheels ............................................................................................. 5 – 3
Rear Axle .................................................................................................. 5 – 4
Procedures and Suggestions for Disassembly and
Reassembly ............................................................................................. 5 – 7
5
Steering Axle ............................................................................................ 5 – 7
Rear Axle Assembly .................................................................................. 5 – 10
Inspection and Adjustment ................................................................. 5 – 14
Making sure of Minimum Turning Radius .................................................. 5 – 14
Service Data ............................................................................................ 5 – 15
REAR AXLE
Structure and Functions
2
3
4
19
18
11 8
10 12
13
14
15
16
17
16 206811
1 Housing 8 Oil seal 15 Taper roller bearing
2 Pinion gear 9 Steering axle 16 Nut
3 Rack gear 10 Wheel hub 17 Lock washer
4 Piston 11 Hub bolt 18 Hydraulic oil inlet (left
5 Cap 12 Hub nut wheel)
6 Taper roller bearing 13 Oil seal 19 Hydraulic oil inlet (right
7 Taper roller bearing 14 Taper roller bearing wheel)
The rear axle is coupled with the pinion gear and rack The steering axle connected to the pinion gear is linked
gear. The rack gear is mounted with pistons on both to two symmetrically arranged rear wheels. The
ends, and converts the reciprocal motion generated by steering axle and the taper roller bearing of the pinion
oil pressure to the rotational movement of the pinion gear support the rear wheel load.
gear. The pinion gear serves as a steering device.
5-1
REAR AXLE
Rear Wheels
Solid Pneumatic Tire Solid Tire
φ292.1 mm (11.5 in.)
φ203.2 mm (8 in.)
φ381 mm (15 in.)
φ381 mm (15 in.)
4
114.3 mm (4.5 in.)
127 mm (5 in.)
2 3
206812
1 Steering axle 3 Wheel nut
2 Rear wheel 4 Rim
Truck Model
1 ton class 2 ton class
Item
15 × 4.5 × 8 140/55-9
Tire size
(15 × 5 × 11.5) (15 × 5 × 11.5)
Dimensions in parentheses ( ) are for solid tires.
5-2
REAR AXLE
Procedures and Suggestions for Removal and Installation
Rear Wheels
Removal
1 Wheel nut
2 Rear wheel
Sequence
1. Pull the hand brake lever, and place wheel stoppers at
the front wheels.
1
2. Turn the key switch ON, and turn the steering wheel all 2
the way to either the right or the left.
3. Locate the hub nut on the one side of the vehicle where 206813
it is visible from the rear. Loosen the hub 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 back 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 back of the vehicle is lifted, place jack stands
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.
211050
Installation
Follow the removal sequence in reverse.
NOTE
Tighten the wheel nuts evenly to the specified torque.
Wheel nut 157 N·m
101212
tightening torque (16 kgf·m)
[116 lbf·ft]
5-3
REAR AXLE
Rear Axle
Removal (Part 1)
11
2
12
10
4
1 7
5
213037
Sequence
1 Battery cover, Gas spring, Seat 7 Hose (hydraulic suction)
2 Controller cover 8 Pipe (hydraulic delivery)
3 Battery 9 Motor, Hydraulic pump
4 Battery shield 10 Hose (hydraulic return)
5 Controller 11 Hose (rear axle return)
6 Suction hose 12 Hydraulic tank
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.
5-4
REAR AXLE
Suggestions 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
6,7 and pipe 8. Do not remove the pipe on the suction side.
Removing hydraulic tank
Disconnect hoses 10, 11, then remove the hydraulic tank.
Since the tank contains oil, keep the tank balanced during
removal.
5-5
REAR AXLE
Removal (Part 2)
14
15
13
16
206816
Sequence
13 Connector 15 Steering hose
14 Overflow hose 16 Rear axle assembly and Steering axle
assembly
Suggestions 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.
Suggestions 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]
5-6
REAR AXLE
Procedures and Suggestions for Disassembly and Reassembly
Steering Axle
Disassembly
6
5
4
3
2
1 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
Suggestions for Disassembly
1. Removing wheel hubs
Use a puller to remove the wheel hubs from the steering
axle.
5-7
REAR AXLE
Reassembly
3 2 5 6 7
211051
Sequence
1 Steering axle 6 Nut
2 Taper roller bearing 7 Lock washer
3 Oil seal 8 Nut
4 Wheel hub 9 Cap
5 Taper roller bearing
Suggestions for Reassembly
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
5-8
REAR AXLE
(2) Filling insides of rear axle hubs with grease
Insert grease into the rear axle hubs. See the diagram
for proper grease filling condition. Add grease to the
roller holding devices. Fill grease to approximately
80% of the cavity. Do not add grease to the full level.
Adding grease to the maximum level causes excessive
heat generation and quickly deteriorates the grease.
When coating oil seal lips with grease, be careful not to
apply too much grease, as an excessive amount of
grease can cause leaks.
Refilling with grease 206821
2. Preload adjustment and lock nut
First, adjust the inside nut, next tighten the outside nut
(lock nut) to the specified torque, and then, check the
preload. To measure the preload, attach a spring
balance to one of the hub bolts, then read the force to
start the rotation of hub.
Use the following allowable ranges when readjusting
used bearings.
Outside nut
0.5 to 5 N·m Inside nut
206821
Preload of hub bearing (0.051 to 0.51 kgf·m)
[0.37 to 3.7 lbf·ft]
6.5 to 65 N
Tangential force on hub bolt (0.66 to 6.6 kgf)
[1.46 to 14.6 lbf]
157 N·m
Lock nut tightening torque (16 kgf·m)
[116 lbf·ft]
5-9
REAR AXLE
Rear Axle Assembly
Disassembly
14 2
17
Section A
4
10 11
12 9
7
A 1 3
15
16
6
13 4
207204
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
5-10
REAR AXLE
Suggestions for Disassembly Press
1. Removal of the pinion gear
17
Remove bolt 1, plate 2 and shim 3. Position housing
17 on a base, and use a press to remove pinion gear 4.
2. Inspect taper roller bearing (inner) 6 which is press-fit
in pinion gear 4 and taper roller bearings 15, 16 which 4 207205
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.
5-11
REAR AXLE
Reassembly
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 reassembly, follow the disassembly sequence in
reverse.
Suggestions for Reassembly
1. When inserting oil seals 4, 5 into housing 1, use a
backing plate and strike the oil seals uniformly to set
the seals evenly into position.
5-12
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, measure clearance 14 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.
45 ± 7 N·m
Bolt tightening torque (4.6 ± 0.7 kgf·m)
[33.2 ± 5.2 lbf·ft]
7. After reassembly, pour hydraulic oil into overflow port
B until the oil surface reaches the overflow port. Cover
the overflow port with tape.
5-13
REAR AXLE
Inspection and Adjustment
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
R
between the center of the outside rear wheel and the
outside edge of the counterweight.
Unit : mm (in.)
206822
Item
Minimum turning radius
Truck Model
FB16NT 1517 (59.7)
FB18NT 1620 (63.8)
FB20NT 1645 (64.8)
5-14
REAR AXLE
Service Data A: Standard value
Truck Model
1 ton class 2 ton class
Item
Preload of hub bearing 1
N·m (kgf·m) [lbf·ft] A 0.5 to 5.0 (0.051 to 0.51) [0.37 to 3.7]
Tangential force on hub bolt
N (kgf) [lbf] A 6.5 to 65 (0.66 to 6.6) [1.46 to 14.6]
Rear axle 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 (4.6 ± 0.7) [33.2 ± 5.2]
211052
5-15
