Komatsu Avance Loader WA600-3 Shop Manual SEBMW01401 - PDF DOWNLOAD

SEBMW01402 SEBMW01401

©2020 ©2017 All Rights Reserved Printed in Japan 01-20 09-17 (01)

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00-2-5 (02)

FI NALDRI VEANDBRAKE 301574

( 02)

( 02)

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

REMOVAL OF FRONT AXLE k Stop the machine on level ground and install

the safety bar on the frame.

k Loosen the oil filler cap of the hydraulic tank

gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit".

1. Place the lift arm on support stands , then operate the work equipment control lever to raise the machine body and set blocks under the front frame. a Since the machine body moves forward, keep the parking brake turned off. a Remove the bucket. For details, see REMOVAL OF BUCKET. 2. Sling and remove tires (2).

4 Tires: 1,450kg

※1

3. Raise lift arm (1) slowly and put blocks under the rear wheels. a Raise the boom so that the front axle can be removed, then lock the work equipment control lever and apply the parking brake, then stop the engine.

4. Disconnect hose (3) for the parking brake.

5. Disconnect hose (4) for both front brake.

※2 6. Disconnect front drive shaft (5). a When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling.

4 Front drive shaft: 56kg

WA600-3

30-131 (01)

DISASSEMBLY AND ASSEMBLY

FRONT AXLE

7. Sling the front axle temporarily, then remove mounting bolt (6). ※3 8. Slowly sling and remove front axle (7). a Remove the front axle by operating the crane so that it will not interfere with the boom end.

4 Front axle: 3,500kg

INSTALLATION OF FRONT AXLE q

Carry out installation in the reverse order to removal.

※1

3 Hub nut: 736.0 - 912.0Nm {75.0 - 93.0kgm}

※2

3 Mounting bolt:

157.0 - 196.0Nm {16.0 - 20.0kgm} ※3

3 Mounting bolt:

2450.0 - 3038.0Nm {250.0 - 310.0kgm} q

Bleeding air from brake Bleed from front brake. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-132 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

REAR AXLE

REMOVAL OF REAR AXLE k Stop the machine on level ground and install

the safety bar on the frame and put blocks under the wheels. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit".

1. Set blocks on right and left sides of the rear axle. a Set these block to prevent the tires from jumping up when removed.

2. Raise the machine body with jacks (5ton) , then set support stand under the counter weight.

3. Adjusting jack

, set blocks

.

4. Sling tire (1) temporarily, then remove the hub nuts.

5. Sling and remove tires (1).

4 Tires: 1,450kg

※1

※2 6. Disconnect rear drive shaft (2). a When disconnecting the drive shaft, sling it with a rope, etc. to prevent it from falling.

4 Drive shaft: 57kg

7. Disconnect hose (3) from the brake valve.

8. Disconnect tubes (4) and (5) connected to right and left brakes from the slack adjuster. ※3

WA600-3

30-135 (01)

DISASSEMBLY AND ASSEMBLY

REAR AXLE

20. Remove rear support (15) from the rear axle.

4 Rear support: 230kg

21. Remove packing (19) from rear support (15).

22. Remove bushing (20) from the rear support. a Remove all dirt and oil from the bushings and rear support bushing fitting face.

INSTALLATION OF REAR AXLE q

Carry out installation in the reverse order to removal.

※1

3 Hub nut: 736.0 - 912.0Nm {75.0 - 93.0kgm}

※2

3 Mounting bolt:

157.0 - 196.0Nm {16.0 - 20.0kgm} ※3 a Bleed air from the slack adjuster. For details, see TESTING AND ADJUSTING, "Bleeding air". ※4

3 Support mounting bolt:

2450.0 - 3038.0Nm {250.0 - 310.0kgm} ※5

3 Mounting bolt:

98.0 - 123.0Nm {10.0 - 12.5kgm} ※6

※9

a Apply Loctite Prism 411 to the sticking face on the support side, then stick the bushing quickly. a The set time is 30 - 60 seconds. ※7

※8

3 Mounting bolt:

245.0 - 309.0Nm {25.0 - 31.5kgm}

30-138 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

DISASSEMBLY OF FINAL DRIVE AND BRAKE ASSEMBLY k Park the machine on a level surface, lower the

work equipment to the ground, and chock the wheels. k Disconnect the battery negative (-) terminal.

1. Push up the machine with the work equipment, set a support stand under the axle, sling the wheel assembly, and remove the hub nuts.

Remove wheel assembly (1) while operating the crane.

4 Wheel assembly: 1450 kg 2. Remove the front axle assembly. For details, see "Removal and installation of front axle assembly".

3. Remove the rear axle assembly. For details, see "Removal and installation of rear axle assembly".

4. Fix the brake housing and wheel hub by using tools J1. a Install tools J1 to 3 places at even intervals. a Keep tools J1 installed until the brake assembly is removed.

5. Remove drain plug (2), and drain the oil.

6 Axle oil: 124 l a Set drain plug (2) at the bottom.

6. Remove bolts (3) (12 pieces), and remove cover (4).

7. Install bolt 1 to drive shaft (5) so that drive shaft (5) can be easily pulled out.

8. Pull out, sling, and remove drive shaft (5).

4 Drive shaft: 70 kg

9. Remove hexagonal socket head bolts (6) (3 pieces), and sling and remove planetary carrier assembly (7). a Use eyebolts 2. a Remove the assembly, while keeping it in parallel with the ring gear by using a bar, etc.

4 Planetary carrier assembly: 130 kg

WA600-3

30-153 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

10. Remove bolts (8) and retainer (9). a Check the thickness and quantity of the shims inserted on the inside of retainer.

11. Sling and remove ring gear (10).

4 Ring gear: 80 kg

12. Disassembly of planetary carrier assembly Disassembly of planetary gear assembly 1) Pull out shaft (11) by using a press machine, and remove pinion gear (12). a When the shaft is pushed out approximately 25 mm, the lock ball drops. Take care not to lose it. a Write a number on the case so that the removed parts are not mixed with others.

2) Remove bearings (13) (2 pieces) form pinion gear (12). a Keep the bearing, etc. fitted to the mating parts as a set so that they are not combined with parts of other sets.

13. Disassembly of ring gear assembly 1) Remove lock plate (15) from ring gear hub (14), and remove ring gear (16).

2) Remove bearing (17) from ring gear hub (14).

30-154 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

14. Remove bolts (20) (28 pieces), and sling and remove wheel hub and brake assembly (21). a After removing the assembly, place it with the brake side up.

4 Wheel hub and brake assembly: 800 kg

15. Remove bolts (23) (48 pieces), and sling and remove cylinder assembly (22).

4 Cylinder assembly: 100 kg

16. Disassembly of cylinder assembly 1) Remove cap (38).

2) Remove bleeder (39).

3) Remove plug (40).

4) Press guide (41) and project the cylinder from the guide bottom.

5) Remove pin (42).

6) Remove guide (41).

7) Remove spring (43).

WA600-3

30-155 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

8) Remove piston (50).

9) Remove O-ring (44).

10)Remove bolt (45), and remove sleeve (46).

11)Remove O-ring (47).

12)Remove pin (48) from cylinder (49).

13)Remove seal (51) from sleeve (46).

30-156 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

14)Remove seal (52) from piston (50).

17. Disassembly of brake assembly 1) Sling and remove brake assembly (24).

4 Brake assembly (24): 230 kg

2) Remove plates (30) and discs (31).

3) Reverse outer gear assembly (32).

4 Outer gear assembly (32): 130 kg

WA600-3

30-157 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

4) Remove oil seal (33).

5) Remove floating seal (34).

6) Remove bolts (35) (32 pieces), and remove retainer (36).

7) Remove O-ring (37).

30-157-1 30-158 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

18. Remove floating seal (25).

19. Remove bolts (26) (8 pieces), and remove retainer (27).

20. Remove outer race (28).

21. Reverse wheel hub (19).

22. Remove outer race (29).

WA600-3

30-157-2 30-159 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

23. Replacement of wheel hub stud bolts a Even if only 1 stud bolt is damaged or lengthened, replace all the stud bolts.

Removal of stud bolts (Double nut) q Remove stud bolts (18) (31 pieces) from wheel hub (18) according to the following procedure.

1) Install nuts (2 pieces) to the stud bolt.

2) Tighten the 2 nuts against each other. (Turn the 1st one counterclockwise and turn the 2nd one clockwise.)

3) Turn only the 1st nut in the loosening direction (counterclockwise) and remove the stud bolt.

30-157-3 30-160 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

ASSEMBLY OF FINAL DRIVE AND BRAKE ASSEMBLY 1. Installation of stud bolts q Install stud bolts (18) (31 pieces) to wheel hub (19), avoiding galling, etc., according to the following procedure.

1) Check the tapped holes of wheel hub (19) for damage.

2) Check that the nut installation end has identification mark E or is shouldered. a When tighten, do not apply grease or oil to the threads.

3) Install the nuts (2 pieces) to the nut installation end of stud bolt.

4) Tighten the 2 nuts against each other (Turn the 1st one counterclockwise and turn the 2nd one clockwise).

5) Turn only the 2nd nut clockwise and install the stud bolt to the wheel hub.

6) Tighten the stud bolt to its incomplete thread portion. a Tightening dimension (protrusion): 78 to 80 mm 3 Stud bolt: 196 to 441 Nm {20 to 45 kgm} 2. Expansion fit outer race (29). a Do not cool outer race (29) below -40°C. a Check that there is no gap between outer race (29) and wheel hub.

3. Reverse wheel hub (19).

4. Expansion fit outer race (28). a Do not cool outer race (28) below -40°C. a Check that there is no gap between outer race (28) and wheel hub.

WA600-3

30-157-4 30-161 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

5. Tighten retainer (27) with bolts (26) (8 pieces).

3 Bolt: 98.1 to 122.6 Nm {10.0 to 12.5 kgm}

6. Install floating seal (25) by using tool J3. a Carefully install floating seal (25) since even a small damage to it caused by impacts, falling, etc. can cause oil leakage. a Remove all white-powdered blooming on the surface of O-ring on floating seal assembly (25) with alcohol. a Fully degrease the floating seal (25) and the O-ring contact surface of wheel hub. a Apply alcohol to the O-ring on floating seal (25) and the O-ring contact surface of wheel hub, and evenly push in with tool J3. a After installing floating seal (25), check that the O-ring is not twisted. a Be sure to use a push jig which pushes the O-ring.

7. Measure height (a) of floating seal (25) at 4 places on the periphery, and check that its variation is 1 mm or less. a Apply axle oil to the sealing surface of floating seal (25). a Check that the sealing surface of floating seal (25) if free from dirt.

2 Floating seal: Axle oil (AXO80)

8. Assembly of brake assembly 1) Install O-ring (37). a Check the O-ring for damage or dirt before installing.

30-157-5 30-162 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

2) Install retainer (36) and tighten it with bolts (35) (32 pieces).

2 Bolt: Adhesive (LT-2) 3 Bolt:

157.0 to 196.2 Nm {16.0 to 20.0 kgm}

3) Install floating seal (34) by using tool J3. a Carefully install floating seal (34) since even a small damage to it caused by impacts, falling, etc. can cause oil leakage. a Remove all white-powdered blooming on the surface of O-ring on floating seal assembly (34) with alcohol. a Fully degrease the floating seal (34) and the O-ring contact surface of retainer. a Apply alcohol to the O-ring on floating seal (34) and the O-ring contact surface of retainer, and evenly push in with tool J3. a After installing floating seal (34), check that the O-ring is not twisted. a Be sure to use a push jig which pushes the O-ring.

4) Measure height (a) of floating seal (34) at 4 places on the periphery, and check that its variation is 1 mm or less. a Apply axle oil to the sealing surface of floating seal (34). a Check that the sealing surface of floating seal (34) if free from dirt.

2 Floating seal: Axle oil (AXO80) 5) Install oil seal (33) by using tool J2. a Apply adhesive to the oil seal fitting surface of retainer (36). a Install oil seal (33) so that it is flush with the end face of retainer (36).

2 Mating faces of oil seal and retainer: Adhesive (Loctite 648) 6) Fill the lip surface of oil seal (33) with grease.

Filling amount of grease: 70% 2 Oil seal lip surface: Grease (G2-LI)

WA600-3

30-157-6 30-163 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

7) Sling and install outer gear assembly (32). a After installing outer gear assembly (32), check that the oil seal lip is not rolled up.

4 Outer gear assembly (32): 130 kg

8) Insert discs (31) and plates (30) alternately. a Apply axle oil to each of them before inserting.

2 Disc and plate: Axle oil (AXO80)

9. Assembly of cylinder assembly 1) Install seal (52) to piston (50). a Check the seal contact surface of piston is free from dirt before installing.

2 Piston: Grease (G2-LI)

2) Install seal (51) to sleeve (46). a Check the seal contact surface of sleeve is free from dirt before installing.

30-157-7 30-164 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

3) Insert pin (48) into cylinder (49).

4) Install O-ring (47).

5) Install sleeve (46) and tighten it with bolt (45). a Apply grease to piston and sleeve assembly.

2 Piston and sleeve assembly: Grease (G2-LI) 6) Install O-ring (44).

7) Install piston (50). a Align the guide hole in cylinder with the guide hole in piston.

8) Insert spring (43).

9) Insert guide (41) into spring (43).

10)Press guide (41) and project its bottom from the cylinder.

11)Insert pin (42) into the hole of guide (41).

WA600-3

30-157-8 30-165 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

12)Install plug (40).

2 Plug: Liquid gasket (LG-5) 13)Install bleeder (39) to plug (40).

14)Install cap (38) to bleeder (39).

10. Sling and install cylinder assembly (22), and tighten it with bolts (23) (48 pieces).

4 Cylinder assembly: 100 kg 3 Bolt: 245.3 to 309 Nm {25.0 to 31.5 kgm}

11. Fix wheel hub and brake assembly (21) by using tools J1. a Install tools J1 to 3 places at even intervals.

12. Sling and install wheel hub and brake assembly (21), and tighten it with bolts (20) (28 pieces).

4 Wheel hub and brake assembly (21): 800 kg 3 Bolt: 824.0 to 1030 Nm {84.0 to 105 kgm}

30-157-9 30-166 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

13. Assembly of ring gear assembly 1) Install bearing (17) to ring gear hub (14). a When shrink fitting the bearing, do not heat it to 80°C or more. a After installing the bearing, check that there is no gap between it and hub.

2) Fit ring gear hub (14) to ring gear (16), and install lock plate (15). a Install the lock plate with its wider end inside. a Thoroughly degrease the threaded holes. a Check that there is clearance between lock plate (15) and ring gear hub (14). q Clearance: 0.1 to 0.3 mm 3 Bolt: 27.5 to 34.3 Nm {2.8 to 3.5 kgm} 2 Bolt: Adhesive (LT-2) 14. Assembly of planetary carrier assembly 1) Set pinion gear (12) and bearing (13) to carrier case.

2) Align the ball installation location on carrier case with the ball installation location of shaft.

3) Set ball (11a) on shaft (11), and expansion fit shaft (11) into the carrier case while holding ball (11a). a Do not cool shaft (11) below -40°C. a Check that shaft (11) is not projecting from the cover installation location. a Check that the gear light turns after shaft (11) is installed.

15. Adjustment procedure for wheel bearing 1) Insert ring gear assembly (10) into the tube and wheel hub.

WA600-3

30-157-10 30-167 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

2) Install retainer (9) with no shim inserted, and lightly tighten it with bolts (8) (3 pieces).

3) Remove tools J1.

4) Evenly tighten bolts (8) until they are stabilized at the torque below, while turning the hub wheel 20 to 30 turns.

3 Tightening torque: 57.9 to 67.7 Nm {5.9 to 6.9 kgm}

5) Measure dimension (a) from retainer (9) to the tube end with a depth micrometer through the measurement hole in retainer (9). a Measure the distances at 2 places and obtain the average.

6) Fix the wheel hub with tools J1, and remove retainer (9). a Be sure to fix the wheel hub, then remove retainer (9).

7) Measure retainer thickness (b) with micrometer.

8) Calculate clearance (c) between the retainer and tube. c=a-b 9) Select shims so that their thickness (t) is clearance (c) + 0.3 mm. t = c + 0.3

30-157-11 30-168 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

10)Install selected shims and retainer (9), and tighten bolts (8) (8 pieces).

2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt:

245.3 to 309.0 Nm {25.0 to 31.5 kgm} 11)Remove tools J1. a Turn the wheel hub and check it for abnormality.

16. Fit O-ring to planetary carrier assembly (7), and sling and install them to the ring gear by using eyebolts 2. a Insert the assembly while matching it to the stud bolts and keeping it in parallel with the ring gear with a bar, etc.

17. Tighten hexagonal socket head bolts (6) (3 pieces).

3 Mounting bolt: 98.1 to 122.6 Nm {10.0 to 12.5 kgm}

18. Insert drive shaft (5) into the planetary carrier assembly, and install it to the spline of differential assembly. a Project the shaft a little from the planetary carrier. a Install to both right and left sides.

19. Install spacer (5a).

20. Install sun gear (5b).

21. Install snap ring (5c) to drive shaft (5), and insert drive shaft (5) to the end. a Check that snap ring (5c) is securely fitted to the groove in drive shaft (5).

4 Drive shaft: 70 kg

WA600-3

30-157-12 30-169 (02)

DISASSEMBLY AND ASSEMBLY

FINAL DRIVE AND BRAKE

22. Fit the O-ring, install final drive case cover (4), and tighten it with bolts (3) (12 pieces).

3 Mounting bolt: 98.0 to 123.0 Nm {10.0 to 12.5 kgm} 23. Tighten drain plug (2).

3 Drain plug: 59.0 to 78 Nm {6.0 to 8.0 kgm} 24. Install the rear axle assembly. For details, see "Removal and installation of rear axle assembly".

25. Install the front axle assembly. For details, see "Removal and installation of front axle assembly".

26. Sling and install wheel assembly (1) to the wheel hub. a Align the stud bolts with wheel installation holes while turning the wheel on the opposite side.

3 Hub nut: 736.0 to 912.0 Nm {75.0 to 93.0 kgm}

27. Add oil 1) Remove level plug (18) and oil filler plug (19).

Add oil until it flows out of the level plug hole, then install the plugs.

3 Plug: 127.0 to 176.0 Nm {13.0 to 18.0 kgm}

30-157-13 30-170 (02)

WA600-3

DISASSEMBLY AND ASSEMBLY

ORBITROL

REMOVAL OF ORBITROL

k Stop the machine on level ground and lower the

work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Set the safety bar on the frame. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery.

1. Remove boot (1).

※1

2. Remove joint lock bolt (2).

3. Disconnect drain hose (3).

4. Disconnect hose (4) of the left-hand stop valve.

5. Disconnect hose (5) of the accumulator.

6. Disconnect hose (6) of the right-hand stop valve.

7. Remove mounting bolt (7), then remove orbitrol (8).

8. Remove 4 lock bolts (9), then remove joint (10).

9. Remove mounting bolt (11), then remove bracket ※2 (12) from orbitrol (8).

INSTALLATION OF ORBITROL Carry out installation in the reverse order to removal. ※1 3 Joint lock bolt: 55.9 ± 7.8Nm {5.7 ± 0.8kgm}

q

※2

3 Bracket mounting bolt:

q

51.9 ± 7.8Nm {5.3 ± 0.8kgm} After installing the orbitrol, check the operation of the steering system.

30-158 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

REMOVAL OF STEERING CYLINDER

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Set the safety bar on the frame. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery.

1. Set safety bar (1).

2. Remove side cover (2).

3. Disconnect grease tube (3).

4. Disconnect bottom hose (4).

5. Remove mounting bolt (5), then pull out pin (6).

6. Disconnect head hose (7).

7. Remove mounting bolt (8), then pull out pin (9).

8. Sling and remove steering cylinder (10). ※1 4 Steering cylinder: 78kg a Check the number of shims installed on both head and bottom sides.

WA600-3

30-159 (01)

DISASSEMBLY AND ASSEMBLY

STEERING CYLINDER

INSTALLATION OF STEERING CYLINDER q

Carry out installation in the reverse order to remove.

k When aligning the position of the pin hole, use

a bar. Never put your fingers in the pin hole. ※1

a Adjust the shims so that the clearance on the bottom side will be the specified value.

Specified values: a + b = 0.5mm max.

a Adjust the shims so that the clearance on the head side will be the specified value.

Specified values: c + d = 0.5mm max. q

Bleeding air Bleed air from the steering cylinder. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-160 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

STEERING VALVE

REMOVAL OF STEERING VALVE k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Set the safety bar on the frame. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery.

1. Remove the mounting bolt, then remove cover (1).

2. Sling and remove fender (2).

4 Fender: 40kg 3. Remove inspection cover (3).

4. Remove step (4).

5. Remove bracket (5), then remove tube (6) between the left hand cut-off valve and the right hand cut-off valve.

6. Disconnect the hose between the left hand steering cylinder head and the right hand steering cylinder head, then remove tube (7). a Be careful not to drop the check valve and orifice (8). a Before removing the tubes, disconnect the parts fixed with bracket and U-bolt.

7. Remove the U-bolt, then remove brackets (9) and (10).

8. Disconnect the hose between the left hand steering cylinder bottom and the right hand steering cylinder bottom, then remove tube (11). a Take care not to drop the check valve and orifice (12).

9. Remove U-bolt (13), then remove tube (14) between the left hand switch pump and the right hand switch pump and tube (5) between the left hand steering pump and the right hand steering pump. a Disconnect the hoses of each pump in advance.

WA600-3

30-165 (01)

DISASSEMBLY AND ASSEMBLY

STEERING VALVE

10. Disconnect drain tube (16).

11. Disconnect hose (17) of the right-hand stop valve and hose (18) of the left-hand stop valve.

12. Sling and remove the steering valve (19).

4 Steering valve: 35kg

INSTALLATION OF STEERING VALVE q

Carry out installation in the reverse order to removal.

q

When installing the check valve and orifice, confirm that their front and rear directions are aligned properly.

After installing the all parts, secure the tubes with the bolts.

When installing the tubes and valves, check that the O-rings are no damage and deterioration, then fit the tubes and the valves securely.

q

q

q

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from the steering circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-166 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

CUT-OFF VALVE

REMOVAL OF CUT-OFF VALVE

k Stop the machine on level ground and fully steer

to the right and lower the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery.

1. Disconnect hose (1) between the cut-off valve and steering valve.

2. Disconnect hose (2) between the cut-off valve and intermediate block of the work equipment valve.

3. Disconnect drain hose (3).

4. Disconnect drain tube (4).

5. Remove the mounting bolts, then remove cut-off valve (5).

4 Cut-off valve: 8kg

INSTALLATION OF CUT-OFF VALVE q

Carry out installation in the reverse order to removal.

q

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

WA600-3

30-167 (01)

DISASSEMBLY AND ASSEMBLY

BRAKE VALVE

REMOVAL OF BRAKE VALVE

k Stop the machine on level ground and lower the

work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery.

1. Disconnect transmission cut-off switch connector (1) (L12).

2. Disconnect hose (2) from the accumulator.

3. Disconnect drain hose (3).

4. Disconnect pilot tube (4).

5. Pull out pin (5). a Be careful not to lose L-pin.

6. Remove pedal (6).

7. Remove plunger (7), then remove boot (8).

8. Remove 4 mounting bolts (9), then remove brake valve (10).

INSTALLATION OF BRAKE VALVE q

Carry out installation in the reverse order to removal.

q

After installing the brake valve, check the operation of the brake.

q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-168 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

SLACK ADJUSTER

REMOVAL OF SLACK ADJUSTER

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery.

1. Disconnect hose (1) of the brake valve.

2. Disconnect tubes (2) and (3) of right and left brakes. ※1 3. Remove mounting bolt (4), then remove slack adjuster (5).

INSTALLATION OF SLACK ADJUSTER q

Carry out installation in the reverse order to removal.

※1

3 Tube sleeve nut:

68.6 ± 9.8Nm {7.0 ± 1.0kgm} q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

WA600-3

30-177 (01)

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TANK

REMOVAL OF HYDRAULIC TANK

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the filler cap to release the pressure from the hydraulic tank. k Release remaining pressure in work equipment circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery.

1. Sling and remove ladder floor (1).

4 Ladder floor: 120kg 2. Loosen hydraulic tank drain valve (2), and drain oil.

6 Hydraulic oil: 326l 3. Remove mounting bolt (3) from the bottom of the ※1 hydraulic tank.

4. Disconnect 4-unit pump suction tube (4). (Serial No.: 50001 - 52000) Disconnect pump suction tube (4). (Serial No.: 52001 and up) 5. Disconnect tube (5) of the hydraulic oil cooler.

6. Disconnect joint tube (6) between the steering valve and hydraulic oil cooler.

7. Disconnect hydraulic tank breather hose (7).

8. Disconnect emergency steering suction tube (8).

9. Disconnect return tube (9) of the diverter valve.

10. Disconnect tube (10) of the block.

11. Disconnect return block (11) and tube (10) of each part together, then shift them toward the machine body. Disconnect return hose (12) of the brake valve.

12. Sling the hydraulic tank temporarily, then remove ※2 4 mounting bolts (13).

30-190 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

PPC VALVE

REMOVAL OF PPC VALVE

k Stop the machine on level ground and lower the

work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in PPC circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery.

1. Remove cover (1), then loosen plug (2) on the hydraulic tank to release the residual pressure in ※1 the hydraulic circuit.

2. Remove console box cover (3).

3. Disconnect control rod (4).

4. Disconnection of hoses from PPC valve.

1) Disconnect bucket tilt hose (5).

2) Disconnect bucket dump hose (6).

3) Disconnect boom raise hose (7).

4) Disconnect boom lower hose (8).

5) Disconnect hose (9) of the accumulator charge valve.

6) Disconnect drain hose (10).

5. Remove 6 mounting bolts (11), then remove PPC valve (12) and bracket together.

INSTALLATION OF PPC VALVE q

Carry out installation in the reverse order to removal.

※1

3 Plug: 9.8 - 12.7Nm {1.0 - 1.3kgm}

WA600-3

30-193 (01)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT VALVE

REMOVAL OF WORK EQUIPMENT VALVE k Stop

the machine on level ground and put blocks under the wheels and set the boom on the support stand, then confirm that the boom will not lower by itself. k Release remaining pressure in work equipment circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery.

1. Remove cover (1) under the dump cylinder.

2. Remove step (2).

3. Disconnect dump cylinder head hose (3) from tube (5).

4. Disconnect dump cylinder bottom hose (4) from tube (6). a Before disconnecting, confirm that no pressure is remaining.

5. Remove clamp U-bolts (7) and (8) of tubes (5) and (6).

6. Remove mounting bolt, then remove tube (5) of the bucket cylinder head.

7. Remove mounting bolt, then remove tube (6) of the dump cylinder bottom.

8. Disconnect the hose of the loader pump, then disconnect clamp U-bolt (9).

9. Remove the mounting bolt, then remove tube (10) of the loader pump.

10. Remove clamp (11), then disconnect bucket dumping PPC tube (12).

11. Disconnect boom lowering PPC tube (13).

12. Disconnect boom rising PPC tube (14).

13. Disconnect drain hose (15).

14. Disconnect bucket tilting PPC hose (16).

WA600-3

30-195 (01)

DISASSEMBLY AND ASSEMBLY

WORK EQUIPMENT VALVE

15. Disconnect boom raising hose (17).

16. Disconnect boom lowering hose (18).

17. Disconnect drain tube (19). a Disconnect the clamp.

18. Sling and remove the work equipment valve.

4 Work equipment valve: 90kg

INSTALLATION OF WORK EQUIPMENT VALVE q

Carry out installation in the reverse order to removal.

q

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from the work equipment circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-196 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

REMOVAL OF FLOOR FRAME

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in PPC circuit.

For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (-) terminal of the battery. a Collect the air conditioner refrigerant.

1. Remove ROPS (1), cab (2), right and left ladders (3) and side cover (4). For details, see REMOVAL OF CAB.

2. Disconnect 2 heater hoses (5). a Plug the holes to prevent the engine coolant water from flowing out.

3. Disconnect 2 air conditioner hoses (6). a Be sure to use 2 spanners to disconnect the hoses.

4. Disconnect connector (7).

Connector: (LR1.2.3.4.5.6), (TL1), (FR1.2) (Serial No.: 50001 - 52000) : (LR1.2.3.4.5.6.7), (TL1), (FR1.2) (Serial No.: 52001 and up) ※1 5. Disconnect accelerator cable (8). a Disconnect the accelerator cable clamped along the frame.

6. Disconnect 2 washer hoses (9). a If any cleaning water is in the washer tank, bend the hoses and tie them with tape.

30-230 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

7. Disconnect hose (10) between the right-hand brake valve and rear brake, and hose (11) between the right-hand brake valve and front brake.

8. Disconnect hose (12) of the left-hand brake valve accumulator.

9. Disconnect hose (13) between the orbitrol and accumulator, drain hose (14), hose (15) of right-hand stopper valve and hose (16) of the left-hand stop valve.

10. Disconnect hose (17) between the accumulator charge valve and PPC valve.

11. Disconnect PPC valve drain hose (18).

12. Disconnect hoses (19) (Dump bucket), (20) (Tilt bucket), (21) (Raise lift arm) and (22) (Lower lift arm) between the PPC valve and work equipment valve. a Each hose is connected by means of quick coupler. It is disconnected easily by pushing it up a little and turning it.

13. Disconnect hoses (23) and (24) between the righthand brake valve and accumulator. a These hoses must be disconnected since there is a hanging clamp on the floor frame.

14. Disconnect right-hand brake valve drain hose (25).

15. Disconnect left-hand brake valve drain hose (26).

WA600-3

30-231 (01)

DISASSEMBLY AND ASSEMBLY

FLOOR FRAME

16. Disconnect ground cable (27).

17. Remove 4 nuts of floor frame mount (28).

※2

18. Sling and remove floor frame (29). a Sling carefully, checking that each clamp, wire, etc. is disconnected securely.

4 Floor frame: 290kg

INSTALLATION OF FLOOR FRAME q

Carry out installation in the reverse order to removal.

※1

a Adjust the length of the accelerator cable. For details, see TESTING AND ADJUSTING. ※2

3 Mounting bolt:

277.3 ± 32.3Nm {28.3 ± 3.3kgm} q

Refilling air conditioner with refrigerant Using tool X1, refill the air conditioner with refrigerant (R134a).

q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-232 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

STOP VALVE

REMOVAL OF STOP VALVE

k Stop the machine on level ground and lower the

work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Disconnect the cable from the negative (-) terminal of the battery.

1. Disconnect hose (1) connected to orbitrol.

2. Disconnect hose (2) connected to steering valve.

3. Disconnect return hose (3).

4. Remove the mounting bolt, then remove stop valve (4).

INSTALLATION OF STOP VALVE q

Carry out installation in the reverse order to removal.

WA600-3

30-239 (01)

DISASSEMBLY AND ASSEMBLY

ACCUMULATOR

REMOVAL OF ACCUMULATOR k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (–) terminal of the battery.

1. Remove covers (1) and (2).

2. Disconnect connectors (3) (C01), (4) (C02), (5) (C03) and (6) (C04).

3. Disconnect hose (7) between the rear brake accumulator and accumulator charge valve.

4. Disconnect hose (8) between the front brake accumulator and accumulator charge valve.

5. Disconnect hose (9) connected to parking brake solenoid valve.

6. Disconnect tube (10) connected to left-hand brake valve.

7. Disconnect tube (11) connected to right-hand brake valve. a Loosen 2 clamps of tubes (10) and (11).

8. Remove bands (12).

9. Remove mounting bolts, then remove rear brake accumulator (13) and front accumulator (14). a Each accumulator is secured with 2 mounting bolts at its bottom.

30-240 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

ACCUMULATOR

INSTALLATION OF ACCUMULATOR q

Carry out installation in the reverse order to removal.

q

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

WA600-3

30-240-1 (01)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE SOLENOID VALVE

REMOVAL OF ACCUMULATOR CHARGE VALVE

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (–) terminal of the battery.

1. Remove cover (1).

2. Disconnect hose (2) connected to PPC pump.

3. Disconnect hose (3) between the accumulator charge valve and rear accumulator block for the front brake.

4. Disconnect hose (4) between the accumulator charge valve and block.

5. Disconnect hose (5) from hydraulic tank.

6. Disconnect tube (6) between the accumulator charge valve and PPC accumulator.

7. Disconnect tube (7) connected to PPC valve.

8. Remove accumulator charge valve (8).

INSTALLATION OF ACCUMULATOR CHARGE VALVE q

Carry out installation in the reverse order to removal.

q

Refilling with oil Add oil to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

WA600-3

30-241 (01)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE SOLENOID VALVE

REMOVAL OF PARKING BRAKE SOLENOID VALVE

k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake acccumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (–) terminal of the battery.

1. Disconnect upper connector (1) (F14).

2. Remove 4 mounting bolts (2), then remove parking brake solenoid valve (3).

INSTALLATION OF PARKING BRAKE SOLENOID VALVE q

Carry out installation in the reverse order to removal.

q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-242 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE

REMOVAL OF PARKING BRAKE k Stop the machine on level ground and lower

the work equipment completely to the ground, then put blocks under the wheels to prevent the machine from moving. k Loosen the oil filler cap of the hydraulic tank gradually to release the pressure in the hydraulic tank. k Release remaining pressure in brake accumulator circuit. For detail, see TESTING AND ADJUSTING "Releasing remaining pressure in hydraulic circuit". k Disconnect the cable from the negative (–) terminal of the battery.

1. Remove disc plate cover (1).

2. Disconnect drive shaft (2).

4 Drive shaft: 57kg

※1

3. Turn adjustment bolt (3) clockwise to increase the ※2 clearance between the pad and disc.

4. Pull out connecting pin (4).

5. Disconnect hose (5).

6. Remove spring cylinder (6). ※3 7. Disconnect plate (7). a Secure the calipers. a Since 2 dowel pins are installed, raise the calipers a little, then remove the plate.

8. Remove pad (8).

9. Remove calipers (9).

4 Calipers: 32kg

10. Remove mounting bolts (10), then remove disc ※4 (11).

4 Disc: 31kg

WA600-3

30-245 (01)

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE

INSTALLATION OF PARKING BRAKE Carry out installation in the reverse order to removal. ※1 3 Mounting bolt: 157.0 - 196.0Nm {16.0 - 20.0kgm} ※2 a Adjust the parking brake. For details, see TESTING AND ADJUSTING PARKING BRAKE of TESTING AND ADJUSTING. ※3 2 Mounting bolt: Adhesive (LT-2) q

3 Mounting bolt:

824.0 - 1030.0Nm {84.0 - 105.0kgm} ※4

2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt:

490.0 - 608.0Nm {50.0 - 62.0kgm} q

Bleeding air Bleed air from the brake circuit. For details, see TESTING AND ADJUSTING, "Bleeding air".

30-245-1 (01)

WA600-3

DISASSEMBLY AND ASSEMBLY

PARKING BRAKE CALIPERS

DISASSEMBLY OF PARKING BRAKE CALIPERS Remove the parking brake calipers. For details, see REMOVAL OF PARKING BRAKE. 1. Remove snap ring (1), then pull out slack adjuster (2).

2. Remove washers (3) and (4), and seal (5).

3. Remove bolts, then remove cap (6) and gasket (7).

4. Remove piston shaft (8) and thrust bearing (9).

5. Remove piston (11) and piston seal (12) from calipers (10).

30-246 2

WA600-3

MAINTENANCE STANDARD

TRANSMISSION CONTROL VALVE

TRANSMISSION SOLENOID VALVE

Unit: mm No.

Check item Tightening torque of solenoid valve

1 mounting screw

Tightening torque of solenoid valve

2 terminal screw

Criteria 1.47 - 1.77 Nm {0.15 - 0.18 kgm} 1.47 - 1.77 Nm {0.15 - 0.18 kgm}

3

Tightening torque of solenoid valve terminal screw

0.441 - 0.50 Nm {0.045 - 0.051 kgm}

4

Tightening torque of solenoid valve connector mounting screw

0.588 - 0.785 Nm {0.06 - 0.08 kgm}

5

Tightening torque of terminal mounting screw

0.588 - 0.785 Nm {0.06 - 0.08 kgm}

Tightening torque of solenoid valve

6 mounting bolt

40-16 (01)

Remedy

Retighten

44.1 - 49.0 Nm {4.5 - 5.0 kgm}

WA600-3