Kubota K7563-99360 User manual

ENGLISH
INSTRUCTION MANUAL
HYDRAULIC UTILITY VALVE KIT
(K7563-99360)
for KUBOTA UTILITY VEHICLE
RTV900
MANUEL D’INSTRUCTION
KIT DE SOUPAPE UTILITAIRE
HYDRAULIQUE (K7563-99360)
pour le véhicule utilitaire RTV900
KUBOTA
BEDIENUNGSANLEITUNG
HYDRAULIKNUTZVENTILSATZ
(K7563-99360)
für KUBOTA NUTZFAHRZEUG
RTV900
PRINTED IN U.S.A.
IMPRIMÉ AUX ÉTATS-UNIS ©KUBOTA Corporation 2005
IN DEN USA GEDRUCKT.
Code No.
N de code. K7563-9369-2
Code-Nr.
This kit has been prepared to add the function of hydraulic outlet to the hydraulic dumping equipped models of
RTV900. To upgrade, some parts should be replaced or added as follows.
ABefore installing this kit, you need to install a High Mount Air Cleaner kit (STANDARD MODEL: K7561-9986-0 /
EC HOMOLOGATED MODEL: K7563-9986-0) suitable for your RTV900. This kit cannot be installed without
relocating the air cleaner.
APlease check your serial number of the RTV900 first.
The machines with the following serial number range, need additional parts to be changed.
If it is in this range, please order the Aux. Pump unit (K7561-3412-0) and replace the original unit with it referring
to the section [4] Change AUX. PUMP UNIT.
READ ALL INSTRUCTIONS BEFORE CONVERTING PARTS.
BCHECKING PARTS
ACheck the component parts according to the parts list.
RTV900 STANDARD MODEL : 50001 - 50259
RTV900 EC HOMOLOGATED MODEL : 10001 - 10179

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1. AUXILIARY VALVE
REF. No. PART No. PART NAME Q'TY REMARKS
1
VALVE, ASSY AUXILIARY
YW166-0010-5 VALVE, ASSY AUXILIARY RFP 1
K7561-3981-3 BRACKET, COMP VALVE 2 1
01754-50816 BOLT, FLANGE 4 FLANGE, M8, L = 16 mm
K7561-3429-2 HOSE, PRESSURE 2 HYDRAULIC 1
75580-6180-0 ASSY ADAPTOR 1 1
K7561-3433-0 FITTING, 4601-10-8-NWO 1 3/4-16UNF, O.R.B
75532-6180-0 ASSY ADAPTOR 2 (#380-4-8) 2
7J243-6185-0 ASSY ADAPTER 3/8NPT 2
K2581-6632-0 1/4 COUPLER H2-62 2
K7561-3437-0 COUPLER, FF-371-6FP 1
K7561-3438-0 NIPPLE, FF-372-6FP 1
7J245-6634-0 1/4" PLUG, DUST (PDP-4W) 1
K7561-3439-0 PLUG, NR-50 1 Large
7J245-6632-0 1/4" PLUG, DUST (PDP-4YY) 1
K7561-3440-0 CAP, NR-37 1 Small
K7561-3985-2 ARM, VALVE 2
68021-3279-2 PIN 4 4.75 mm, L = 17.5 mm
04013-50050 WASHER, PLAIN 4 M5
05525-50500 PIN SNAP 4 FLANGE, M8, L = 16 mm

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2. LEVER
REF. No. PART No. PART NAME Q'TY REMARKS
2ASSY. CABLE 1
K7561-3993-2 ASSY CABLE, VALVE 1
K7561-3997-0 FORKED 2
3 K1042-6125-0 CLAMP, CORD 1
4 05122-50618 PIN JOINT 2 6 mm, L = 18 mm
5 04013-50060 WASHER, PLAIN 2 M6
6 05525-50600 PIN, SNAP 2
7 K7561-39961 STAY, LEVER UPPER 2 1
8 01153-50875 HEX. BOLT 1 M8, L = 75 mm
9 02751-50080 NUT, FLANGE 1 M8
10 K3211-6225-0 SWITCH, BRAKE (#6400-03) 1
11 K7561-4312-2 PLATE, M5 1 10 mm x 25.4 mm, t = 3.2 mm
12 K2561-6226-0 PLATE, SWITCH 1 10 mm x 22.7 mm, t = 1.0 mm
13 04512-50050 WASHER, SPRING LOCK 2 M5
14 03054-50516 SCREW, PAN HEAD (PHILLIPS) 2 M5
15 K7561-3988-2 LEVER, PTO 1
16 K2561-4266-0 GRIP, LEVER 1 YELLOW
17 K7561-6124-0 WIRE HARNESS, LEVER HYD. 1

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3. AUXILIARY TANK
REF. No. PART No. PART NAME Q'TY REMARKS
18
ASSY TANK, AUXILIARY 1
K7561-9343-0 TANK, KIT. LABEL AUXILIARY 1 WITH LABEL K7561-6584-0
K7561-6584-0 LABEL, NO STEP CAUTION 1ENGLISH
K7563-6584-0 LABEL, NO STEP CAUTION FRENCH, PUT IF NECESSARY
K7565-6584-0 LABEL, NO STEP CAUTION GERMAN, PUT IF NECESSARY
04717-02000 WASHER, SEAL 1 I.D. 20 mm
06331-45020 PLUG 1
E9151-3314-2 PLUG, OIL FILLER 1
04816-50300 O RING 1 I.D. 30 mm
63633-1139-0 OIL GAUGE 1
6C040-3607-0 PIPE, BREATHER 1
K7561-3447-2 BASE, FILTER 1
04816-50250 O RING 1 I.D. 25 mm
K7561-3448-0 JOINT 1
K7561-1407-2 FILTER, OIL 1
K7561-3344-0 PIPE, FILTER 1
04816-00160 O RING 2 I.D. 16 mm
01123-50816 BOLT, SEMS 1 M8, L = 16 mm
04717-01610 WASHERSEAL 1 I.D. 16 mm
19 17214-8304-0 SWITCH, TEMP. 1
20 K7561-3443-2 BASE, TANK 1
21 K7561-3445-2 U BOLT, M10 2
22 K7561-3444-3 SUPPORT, TANK 1

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23 K7561-3442-0 STAY, TANK 1
24 K7561-3446-0 CUSHION, TANK 1 L = 170 mm, t = 6.0 mm
25 K7561-3449-4 CUSHION, TANK 3 L = 260 mm, t = 2.0 mm
26 02116-50100 HEX, NUT 6 M10
27 02771-50100 NUT, FLANGE 6 FLANGE, M10
28 01125-50816 BOLT, W SEMS 2 WSEMS, M8, L = 16 mm
29 01125-50820 BOLT, W SEMS 2 WSEMS, M8, L = 20 mm
30 01754-50816 BOLT, FLANGE 2 FLANGE, M8, L = 16 mm
REF. No. PART No. PART NAME Q'TY REMARKS

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4. HOSE and BREATHER
REF. No. PART No. PART NAME Q'TY REMARKS
31 K7561-3456-2 HOSE, SUCTION HYDRAULIC 1 L = 860 mm, I.D. 15.9 mm
32 K7561-3457-0 HOSE, RETURN HYDRAULIC 1 L = 1050 mm, I.D. 15.9 mm
33 K7561-3458-2 HOSE, OIL COOLER 1
HYDRAULIC 1 L = 420 mm, I.D. 15 mm
34 K7561-3459-2 HOSE, OIL COOLER 2
HYDRAULIC 1 L = 170 mm, I.D. 15 mm
35 K7711-3325-2 SLEEVE, HOSE 1
36 K7561-3462-0 SLEEVE, OIL COOLER 1 1
37 K7561-3434-0 FITTING, 4601-10-10-NWO 1
38 36330-2120-0 PIPE, BREATHER 1 HOSE, I.D. 8 mm
39 K2561-3633-0 BREATHER (#10978) 1
40 K7561-8813-0 CLAMP, HOSE 2 Small
41 3G750-1742-2 JOINT 1
42 36919-5567-0 CLAMP 1
43 01754-50816 BOLT, FLANGE 1 FLANGE, M8, L = 16 mm
44 K1211-1117-0 CLAMP, HOSE 8 Large

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5. OIL COOLER
REF. No. PART No. PART NAME Q'TY REMARKS
45
ASSY OIL COOLER 1
K7561-6165-0 FAN, ELECTRICAL 1
K7561-3455-0 OIL COOLER, 24 1
K7561-3453-2 NET, OIL COOLER 1
K7561-3451-3 BRACKET, OIL COOLER RH 1
K7561-3452-4 BRACKET, OIL COOLER LH 1
K7561-3454-0 SEAL, NET 2
01754-50812 BOLT, FLANGE 2 FLANGE, M8, L = 12 mm
01754-50612 BOLT, FLANGE 2 FLANGE, M6, L = 12 mm
04013-50060 WASHER, PLAIN 2 M6
04512-50060 WASHER, SPRING LOCK 2 M6
02014-50060 HEX. NUT 2 M6
01025-50616 BOLT 4 WSEMS, M6, L = 16 mm
46 01125-50820 BOLT, W SEMS 4 WSEMS, M8, L = 20 mm
47 K7561-9347-0 COVER, KIT. LABEL FAN 1
K1272-6558-0 LABEL, FAN WARNING 1 PUT ON FAN COVER
48 01754-50816 BOLT, FLANGE 2 FLANGE, M8, L = 16 mm

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6. SUPPORT for HARNESS and etc.
REF. No. PART No. PART NAME Q'TY REMARKS
49 K7561-6161-0 BASE, STAY 1
50 K7561-6162-0 STAY, FUSE BOX 2 1
51 K7561-6164-0 COVER, UNIT 2 1
52 K7561-6163-0 SUPPORT, STAY 1
53 01754-50816 BOLT, FLANGE 6 FLANGE, M8, L = 16 mm
54 K7561-6231-0 RELAY, CA 1
55 03714-50616 SCREW, TAPPING 1 M6, L = 16 mm
56 01125-50816 BOLT, W SEMS 2 WSEMS, M8, L = 16 mm
57 K7561-6166-0 STAY, CLAMP 1
58 03024-50416 SCREW, SEMS (PAN HEAD) 2 M4, L = 16 mm
59 K7561-9141-2 NUT, M6 TIN 2 M6, TIN Plated
60 K7561-9672-0 BOLT, CABLE BATTERY 2 M6, TIN Plated

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7. HARNESS, LABEL and etc.
REF. No. PART No. PART NAME Q'TY REMARKS
61 05511-50535 PIN, SPLIT 1 FOR CYLINDER PIVOT PIN
62 K7561-9671-0 ASSY, WIRE HARNESS T2
SERVICE 1
63 K1211-6123-0 CABLE, TIE 2 L = 292 mm
64 K1122-6123-0 CABLE, TIE 7 L = 190 mm
65 K7581-6583-0 LABEL, HYD. UTILITY VALVE 1 PUT ON CARGO GATE
66 K7561-6582-0 LABEL, AUX. CAUTION 1 ENGLISH
K7563-6582-0 LABEL, AUX. CAUTION 1 FRENCH
K7565-6582-0 LABEL, AUX. CAUTION 1 GERMAN
67 K7561-6520-6 LABEL SET, 1 1
68 K7563-7132-3 OPERATORS MANUAL RTV900,
T2 1
69 K7563-9369-2 MANUAL, HYD. UG T-TS 1

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BWHOLE VIEW
Fig.12 cargo loaded / Fig.13 cargo unloaded
(1) CARGO BED (6) PUMP
(2) AUXILIARY OIL TANK (7) ENGINE
(3) AUXILIARY VALVE (8) TRANSMISSION
(4) OIL COOLER (9) FRAME
(5) HIGH MOUNT AIR CLEANER

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BASSEMBLY PROCEDURE
A< > : Ref. No. of PARTS LIST.
To avoid personal injury:
APark the machine on firm and level surface.
AApply the parking brake.
AStop the engine and remove the key.
AFor safety, disconnect negative(-) cable at the
battery terminal before assembling.
ACLEAN THE HYDRAULIC EQUIPMENT AND
SURROUNDING AREA BEFORE INSTALLING THIS
KIT.
[1] Prepare safe position
Raise the cargo box. Place the range shift lever in the
neutral position.
[2] Remove cargo box and LIFT CYLINDER ASSY
Disconnect wire harness connector toward tail lamps.
Remove JOINT PIN at the top of LIFT CYLINDER
ASSY with another person's help and lower the cargo
box (Fig.14). Remove the cargo box and exterior
plastic covers around the seat.
[3] Dismount OLD AUXILIARY TANK
1. Loosen a drain plug of OLD AUXILIARY TANK at rear
side of the vehicle and drain hydraulic oil completely.
2. Disconnect OLD RETURN HOSE from the valve.
Disconnect OLD SUCTION HOSE and OLD FITTING
at the pump side. (Fig.15)
3. Dismount OLD AUXILIARY TANK and BRACKETs
from the vehicle (Fig.16).
(1) JOINT PIN
(2) LIFT CYLINDER ASSY
(1) OLD AUXILIARY TANK
(2) OLD SUCTION HOSE
(3) OLD RETURN HOSE
(4) OLD FITTING
(1) OLD LH BRACKET
(2) OLD RH BRACKET
(3) OLD AUXILIARY TANK
(4) OLD BOLTs (WITH LOCK AND PLAIN WASHER) x 8

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4. Install FITTING (4601-10-10-NWO) to PUMP ASSY
8CC as shown in Fig.17 (angle 45 degrees).
[4] Change AUX. PUMP UNIT (if necessary: target
serial number information is described in the
beginning of this manual)
ABE CAREFUL NOT TO ALLOW DUST OR DEBRIS
TO ENTER TRANSMISSION.
1. Disconnect HYDRAULIC PRESSURE HOSE 2 from
PUMP ASSY 8CC (Fig.18).
2. Remove OLD AUX. PUMP UNIT and PUMP ASSY
8CC from TRANSMISSION.
(1) PUMP ASSY 8CC
(2) FITTING (4601-10-10-NWO) <37>
(1) OLD AUX. PUMP UNIT
(2) PUMP ASSY 8CC
(3) STUD BOLT x 2
(4) HEX. NUT x 2
(5) PRESSURE HOSE 2
(6) TRANSMISSION
(7) STRAIGHT PINs x 2

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3. Remove OLD AUX. PUMP UNIT from PUMP ASSY
8CC.
4. Apply the special grease into gear shaft of NEW
PUMP UNIT ASSY. (Fig.19 (B). Use the disulfide
molybdenum mixing grease).
5. Install NEW PUMP UNIT ASSY (K7561-3412-0) to
PUMP ASSY 8CC with STUD BOLTs and HEX. NUTs.
(NEW PUMP UNIT ASSY has a washer unlike OLD
AUX. PUMP UNIT)
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
6. After removing liquid sealant remaining on the base
face and in the groove completely, apply new liquid
sealant continuously along the groove (A). (Liquid
sealant should be equivalent to Three bond 1208D.)
7. Install the NEW AUX. PUMP UNIT with BOLTs (WITH
LOCK WASHER).
[Tightening torque: 39.2 to 44.1 N-m (4.0 to 4.5 kgf-m)]
8. Connect the HYDRAULIC PRESSURE HOSE 2 to the
PUMP ASSY 8CC. (Fig.18)
[Tightening torque: 35 to 41 N-m (4.8 to 5.5 kgf-m)]
[5] Reverse the direction of HYDRAULIC HOSE 1
1. Disconnect HYDRAULIC HOSE 1 and HYDRAULIC
HOSE 2 from the AUXILIARY VALVE ASSY and
CYLINDER (Fig.20).
2. Remove ADAPTER (6CTX-S) (5) from HYDRAULIC
HOSE 1.
3. Remove 1/4" NIPPLE 72N4-4F (3), 1/4" DUST CAP
(72PDC-4W) (4) and ADAPTER 2 (2) from
HYDRAULIC HOSE 1 (1).
4. Loosen TIE CABLEs and pull out HYDRAULIC HOSE
1 from the (B) side through LIFT SLEEVE.
5. Reverse the direction of HYDRAULIC HOSE 1 and
pass it through LIFT SLEEVE. (Fig.21)
6. Install HYDRAULIC HOSE 2 as it was before removal.
[Tightening torque: 22 to 25 N-m (2.2 to 2.6 kgf-m)]
7. Install ADAPTER 2 to CYLINDER with SEAL TAPE.
(Fig.21 (5)) (Remaining one or two threads, wind in
SEAL TAPE).
[Tightening torque: 47 to 54 N-m (4.8 to 5.5 kgf-m)]
8. Connect (B) side of HYDRAULIC HOSE 1 (1) to
ADAPTER 2. (5)
[Tightening torque: 22 to 25 N-m (2.2 to 2.6 kgf-m)]
9. Install ADAPTER (6CTX-S) (4) to HYDRAULIC HOSE
1. (1)
[Tightening torque: 22 to 25 N-m (2.2 to 2.6 kgf-m)]
10.Install 1/4" NIPPLE 72N4-4F (2) with 1/4" DUST CAP
(72PDC-4YY) (3) to ADAPTER (6CTX-S) (4) with
SEAL TAPE. (Remaining one or two threads, wind in
SEAL TAPE)
[Tightening torque: 47 to 54 N-m (4.8 to 5.5 kgf-m)]
11.Connect the NIPPLE to AUXILIARY VALVE ASSY.
(1) AUX. PUMP UNIT (NEW)
(K7561-3412-0)
(2) STRAIGHT PIN x 2
(3) BOLT (WITH LOCK
WASHER)
(4) FITTING
(4601-10-10-NWO) <37>
(5) WASHER
(A) Apply liquid sealant
(B) Apply special grease
* Before Re-assembly
(1) HYDRAULIC HOSE 1
(2) ADAPTER 2
(3) 1/4" NIPPLE 72N4-4F
(4) 1/4" DUST CAP (72PDC-4W)
(5) ADAPTER (6CTX-S)
(6) TIE CABLE x 2
(7) LIFT SLEEVE
(8) AUXILIARY VALVE ASSY
(9) CYLINDER
(10) HYDRAULIC HOSE 2

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12.Tighten TIE CABLEs so the HOSEs don't shift. [6] AUXILIARY VALVE
1. Remove VALVE CABLE and VALVE ARM (1) from
OLD VALVE ASSY. (Fig.22)
2. Remove BRACKET CLAMP (3) and CLAMP
CUSHION (4) and four FLANGE BOLTs. (5)
3. Remove HYDRAULIC PRESSURE HOSE 1 (6) at
PUMP side.
4. Remove OLD VALVE ASSY and OLD BRACKET from
vehicle.
5. Disconnect VALVE CABLE ASSY from LIFT LEVER
and remove OLD STAY. (Fig.23)
* After Re-assembly
(1) HYDRAULIC HOSE 1
(2) 1/4" NIPPLE 72N4-4F
(3) 1/4" DUST CAP (72PDC-4W)
(4) ADAPTER (6CTX-S)
(5) ADAPTER 2
(6) TIE CABLE x 2
(1) VALVE ARM
(2) OLD VALVE ASSY
(3) BRACKET CLAMP
(4) CLAMP CUSHION
(5) FLANGE BOLTs x 4
(6) HYDRAULIC PRESSURE HOSE 1
(7) OLD BRACKET
(1) VALVE CABLE ASSY
(2) LIFT LEVER
(3) OLD STAY

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6. Mount the NEW AUXILIARY VALVE ASSY to rear
pipe of Mainframe and clamp with BRACKET CLAMP,
CLAMP CUSHION and four FLANGE BOLTs. (Fig.24)
[Tightening torque: 17.6 to 20.6 N-m (1.8 to 2.1 kgf-m)]
7. Connect the HYDRAULIC PRESSURE HOSE 2 to the
PUMP ASSY.
[Tightening torque: 35 to 41 N-m (3.6 to 4.5 kgf-m)]
8. Install UPPER LEVER STAY 2 to left side of the
parking brake lever (Fig.25).
[Tightening torque: 17.6 to 20.6 N-m (1.8 to 2.1 kgf-m)]
9. Connect VALVE CABLE ASSY to the lever and set the
adjustment thread on cable to LOWER LEVER STAY.
(Taking in slack of VALVE CABLE ASSY)
10.Connect VALVE CABLE ASSY to VALVE ARM and
set the adjustment thread on cable. (Set them to the
notches in the middle of their adjusting thread)
(1) AUXILIARY VALVE ASSY <1>
(2) BRACKET CLAMP
(3) CLAMP CUSHION
(4) FLANGE BOLTs x 4
(5) HYDRAULIC PRESSURE HOSE 2
(6) PUMP ASSY
(7) Rear pipe of Mainframe
(1) UPPER LEVER STAY 2 <7>
(2) LOWER LEVER STAY
(3) VALVE CABLE ASSY <2>
(4) CORD CLAMP <3>
(5) VALVE ARM
(6) JOINT PIN <4>
(7) PLAIN WASHER <5>
(8) SNAP PIN <6>
(9) FLANGE BOLTs
(10) PTO LEVER <15>
(11) LEVER GRIP <16>
(12) HEX. BOLT <8>
(13) FLANGE NUT <9>

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11.Install all exterior plastic covers. Confirm whether the
neutral position of LIFT LEVER is positioning in the
notch of LEVER LOCK. If not, adjust the location of
VALVE CABLE ASSY on LOWER LEVER STAY.
(Fig.26)
12.Adjust HEX. BOLT length so that bolt head is slightly
contacting the PTO LEVER and secure FLANGE
NUT. After adjustment, the levers should be kept in
their neutral position. (For protection of BRAKE
SWITCH. Fig.27)
13.Install BRAKE SWITCH to UPPER LEVER STAY 2.
Adjust the switch position sliding in the slot so that the
push rod of switch is depressed approximately 3 to 5
mm. (Fig.28)
Connect HYD. LEVER WIRE HARNESS to Main
harness (under the parking brake lever) and BRAKE
SWITCH. Clamp HYD. LEVER WIRE HARNESS to a
hole made in LOWER LEVER STAY. (Fig.25 (2))
14.Put HYD. LEVER LABEL on CENTER COVER LH as
shown in Fig.29.
(This label is in LABEL SET, 1 <67>. P/N is K7561-
6539 )
(1) CENTER COVER LH
(2) LEVER LOCK
(3) GRIP
(4) WASHER (BLACK)
(5) SPRING NUT
(6) SNAP PIN
(1) HEX. BOLT <8>
(2) FLANGE NUT <9>
(1) UPPER LEVER STAY 2 <7>
(2) BRAKE SWITCH <10>
(3) M5 PLATE <11>
(4) SWITCH PLATE <12>
(5) SPRING LOCK WASHER <13> x 2
(6) PAN HEAD SCREW (PHILLIPS) <14> x 2
(7) HYD. LEVER WIRE HARNESS <17>
(1) HYD. LEVER LABEL (In LABEL SET, 1 <67>)
(2) CENTER COVER LH

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[7] Install AUXILIARY TANK and HOSEs
1. Put TANK CUSHION (t = 6 mm) and two TANK
CUSHIONs on TANK BASE. (Location of cushion is as
shown in Fig.30)
2. Install two FLANGE BOLTs (Fig.31 (6)) and M10 U
BOLTs (7) to fix the TANK BASE.
3. Tighten FLANGE BOLTs (6) firmly.
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
4. Tighten M10 U BOLTs equally with FLANGE NUT
(Fig.33 (2)). Then lock with HEX. NUT (3).
[Tightening torque: 17.6 to 19.6 N-m (1.8 to 2.0 kgf-m)]
5. Put a TANK CUSHION (t = 2 mm) (Fig.31 (10)) on the
underside of TANK SUPPORT.
And set AUXILIARY TANK ASSY with TANK
SUPPORT (8) on TANK BASE.
6. Install TANK STAY and BOLTs (WITH LOCK AND
PLAIN WASHER) to fix the position of AUXILIARY
TANK (Fig.32). Do not tighten bolts.
(1) TANK CUSHION (t = 6 mm) <24>
(2) TANK CUSHIONs (t = 2 mm) <25> x 2
(1) AUXILIARY TANK ASSY <18>
(2) HYDRAULIC RETURN HOSE <32>
(3) HYDRAULIC SUCTION HOSE <33>
(4) TIE CABLE <64>
(5) HOSE CLAMP <44> x 2
(6) FLANGE BOLTs <30> x 2
(7) M10 U BOLTs <21> x 2
(8) TANK SUPPORT <22>
(9) TANK BASE <20>
(10) TANK CUSHION (t = 2 mm) <25>
(11) TANK STAY <23>
(12) TEMP. SWITCH <19>
(1) TANK STAY <23>
(2) BOLTs (WITH LOCK AND PLAIN WASHER)
(L=20) <29> x 2
(3) BOLTs (WITH LOCK AND PLAIN WASHER)
(L=16) <28> x 2

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7. Tighten TANK SUPPORT equally with FLANGE
NUTs. Then lock with HEX, NUT. (Fig.33 (4) (5))
[Tightening torque: 17.6 to 19.6 N-m (1.8 to 2.0 kgf-m)]
8. Set TANK STAY and tighten BOLTs (WITH LOCK
AND PLAIN WASHER) firmly. (Fig.32)
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
9. Connect HYDRAULIC SUCTION HOSE and
HYDRAULIC RETURN HOSE to AUXILIARY TANK
ASSY with HOSE CLAMPs respectively. (Fig.31)
[Tightening torque: 4.0 to 5.0 N-m (0.41 to 0.51 kgf-m)]
10.Install TEMP. SWITCH to FILTER BASE with SEAL
WASHER. (Fig.31 (12))
[Tightening torque: 2.9 to 3.9 N-m (0.30 to 0.40 kgf-m)]
[8] Assembly of BREATHER HOSE ASSY
1. Insert BREATHER (#10978) into BREATHER HOSE,
then clamp them with HOSE CLAMPS. (Fig.34)
2. Connect BREATHER HOSE ASSY. (Fig.35 (1)) to
BREATHER PIPE (3) with HOSE CLAMP. (Set HOSE
CLAMP 5 mm from the end)
3. Clamp hoses to INTAKE AIR PIPE, with TIE CABLE
(LONG).
(1) TANK BASE <20>
(2) FLANGE NUTS <27> x 4
(3) HEX. NUTS <26> x 4
(4) FLANGE NUTS <27> x 2
(5) HEX. NUTS <26> x 2
(1) BREATHER (#10978) <39>
(2) BREATHER HOSE <38>
(3) HOSE CLAMP <40> x 2
(1) BREATHER HOSE ASSY <38 to 40>
(2) HOSE CLAMP <40>
(3) BREATHER PIPE
(4) TIE CABLE (LONG) <63>
(5) INTAKE AIR PIPE
(6) TANK STAY <23>

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[9] Install OIL COOLER ASSY
1. Install OIL COOLER ASSY to MISSION FRAME
COMP with BOLTs (WITH LOCK AND PLAIN
WASHER) (Fig.36, 37)
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
ACONFIRM ENOUGH CLEARANCE BETWEEN OIL
COOLER ASSY AND PARTS AROUND IT.
APASS THE HOSES IN FRONT OF THE FAN
SHROUD ("FRONT" means forward direction of
vehicle.) (Fig.38 (A))
2. Install FAN COVER to REAR TM GUARD with
FLANGE BOLTs. (Fig.39)
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
For the models which have the plate for LICENCE
PLATE, install FAN COVER with the plate. (FAN
COVER is upper.)
(1) OIL COOLER ASSY <45>
(2) BOLTs (WITH LOCK AND PLAIN WASHER) <46> x 2
(3) MISSION FRAME COMP
(1) OIL COOLER ASSY <45>
(2) BOLTs (WITH LOCK AND PLAIN WASHER) <46> x 2
(3) MISSION FRAME COMP
* Correctly assembled
(1) FAN COVER <47>
(2) FLANGE BOLTs <48> x 2
(3) REAR TM GUARD
(4) PLATE (LICENCE PLATE) (if equipped)

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ENGLISH
[10] Connect HOSEs
1. Pass OIL COOLER HOSE 1 through SLEEVE and
connect it between OIL COOLER ASSY and FITTING
(4601-10-8-NWO) with HOSE CLAMP (Fig.40). Screw
head of HOSE CLAMP (4) should be as shown in the
figure. (Bolt is rearward and bolt head is facing up)
[Tightening torque: 4.0 to 5.0 N-m (0.41 to 0.51 kgf-m)]
2. Drill (6.8 mm in diameter) and tap an M8 x 1.25 hole at
the location shown in Fig.41 (This hole will be used for
the clamp shown in Fig.43).
ABEFORE DRILLING, REMOVE OR MOVE WIRE
HARNESS, CABLES AND HOSES OUT OF THE
WAY.
TAKE CARE NOT TO DAMAGE THEM.
3. Insert JOINT to OIL COOLER HOSE 2 and connect it
to OIL COOLER with HOSE CLAMP. (Fig.42)
[Tightening torque: 4.0 to 5.0 N-m (0.41 to 0.51 kgf-m)]
4. Connect OIL COOLER HOSE 2 to HYDRAULIC
RETURN HOSE with JOINT and HOSE CLAMPs.
Screw head of HOSE CLAMP should be as shown in
Fig.42 (3).
[Tightening torque: 4.0 to 5.0 N-m (0.41 to 0.51 kgf-m)]
5. Clamp hoses to MAIN FRAME with TIE CABLE (Do
not include WIRE HARNESS). (Fig.43 (5))
6. Clamp HYDRAULIC RETURN HOSE to MAIN
FRAME with CLAMP (1) and FLANGE BOLT (2).
[Tightening torque: 23.5 to 27.5 N-m (2.4 to 2.8 kgf-m)]
(1) HYDRAULIC OIL COOLER HOSE 1 <33>
OIL COOLER SLEEVE 1 <36>
(2) OIL COOLER ASSY <45>
(3) FITTING (4601-10-8-NWO)
(4) HOSE CLAMP <44>
(5) HOSE CLAMP <44>
(1) An added screw hole (M8 x 1.25)
(1) HYDRAULIC OIL COOLER HOSE 2 <34>
(2) JOINT <41>
(3) HOSE CLAMP <44> x 3
(4) HYDRAULIC RETURN HOSE <32>
(1) CLAMP <42>
(2) FLANGE BOLT <41>
(3) HYDRAULIC RETURN HOSE <32>
(4) HYDRAULIC SUCTION HOSE <31>
(5) TIE CABLE (Long) <63>
(6) TIE CABLE (Short) <64>