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KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBERS
WB140-2N A20001 and UP WB150-2N A60001 - PUBLICATION NUMBER:CEBM009802
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Description
KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL
Screenshot of the Manual:
KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating ยProblemsย to ยCausesย are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
his section gives the judgement standards when inspecting disassembled parts.
Table of Contents:
KOMATSU WB140-2N WB150-2N BACKHOE LOADER SERVICE REPAIR MANUAL
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 CONTENTS.................................................................................. 2 FOREWORD.................................................................................. 11 SAFETY................................................................................ 11 SAFETY NOTICE..................................................................... 11 IMPORTANT SAFETY NOTICE....................................................... 11 GENERAL PRECAUTIONS........................................................... 11 PREPARATIONS FOR WORK......................................................... 11 PRECAUTIONS DURING WORK....................................................... 11 GENERAL............................................................................... 13 HOW TO READ THE SHOP MANUAL........................................................... 14 VOLUMES........................................................................... 14 DISTRIBUTION AND UPDATING......................................................... 14 FILING METHOD..................................................................... 14 REVISED EDITION MARK.............................................................. 14 REVISIONS......................................................................... 14 SYMBOLS........................................................................... 14 HOISTING INSTRUCTIONS................................................................. 15 HOISTING.......................................................................... 15 WIRE ROPES........................................................................ 15 COATING MATERIALS..................................................................... 16 STANDARD TIGHTENING TORQUE............................................................ 18 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...................................... 18 TIGHTENING TORQUE OF HOSE NUTS.................................................... 19 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS........................................... 19 TIGHTENING TORQUE FOR FLARED NUTS................................................. 19 ELECTRIC WIRE CODE.................................................................... 20 CLASSIFICATION BY THICKNESS....................................................... 20 CLASSIFICATION BY COLOR AND CODE.................................................. 20 CONVERSION TABLES..................................................................... 21 METHOD OF USING THE CONVERSION TABLE.............................................. 21 10 STRUCTURE AND FUNCTION................................................................. 27 POWER TRAIN........................................................................... 29 DESCRIPTION....................................................................... 29 TRANSMISSION.......................................................................... 31 DIAGRAM OF THE POWER TRAIN........................................................ 31 HYDRAULIC CONVERTOR-TRANSMISSION CIRCUIT DIAGRAM.................................. 32 DRIVE SHAFTS...................................................................... 41 FORWARD AND REVERSE........................................................... 41 DRIVEN GEAR................................................................... 41 4WD DRIVEN.................................................................... 42 CONTROL VALVE BLOCK............................................................... 43 FRONT AXLE............................................................................ 44 DIFFERENTIAL...................................................................... 44 FINAL REDUCTION - JOINT........................................................... 46 STEERING CYLINDER................................................................. 48 REAR AXLE............................................................................. 50 DIFFERENTIAL...................................................................... 50 FINAL REDUCTION................................................................... 52 BRAKES............................................................................ 54 HYDRAULIC PUMP........................................................................ 57 FUNCTION.......................................................................... 62 STRUCTURE......................................................................... 62 OPERATION......................................................................... 63 PUMP OPERATION................................................................ 63 CONTROL OF DELIVERY........................................................... 64 PC VALVE, LS VALVE, SERVO PISTON.................................................. 65 LS VALVE...................................................................... 66 PC VALVE...................................................................... 72 WORKING MODE SOLENOID VALVE....................................................... 77 FUNCTION...................................................................... 77 OPERATION..................................................................... 77 STEERING UNIT......................................................................... 79 TECHNICAL DATA.................................................................... 79 OPERATION......................................................................... 79 HYDRAULIC CIRCUIT..................................................................... 80 SHOVEL CONTROL VALVE.................................................................. 81 2 SPOOL........................................................................... 81 3 SPOOL........................................................................... 85 BACKHOE CONTROL VALVE................................................................. 89 6 SPOOL........................................................................... 89 7 SPOOL........................................................................... 94 FOR TELESCOPIC ARM............................................................ 94 FOR HAMMER.................................................................... 94 8 SPOOL........................................................................... 97 FOR HAMMER AND TELESCOPE ARM.................................................. 97 CLSS (CLOSED CENTER LOAD SENSING SYSTEM............................................... 98 CHARACTERISTICS................................................................... 98 STRUCTURE......................................................................... 98 OPERATION......................................................................... 99 UNLOADING VALVE...................................................................101 FUNCTION......................................................................101 OPERATION.....................................................................101 INTRODUCTION OF THE LS PRESSURE...................................................104 OPERATION.....................................................................104 DELIVERY COMPENSATION.............................................................105 INTRODUCTION..................................................................105 FUNCTION......................................................................105 OPERATION.....................................................................105 LIFD CONTROL SYSTEM...............................................................108 FUNCTION......................................................................108 OPERATION.....................................................................108 LS DECOMPRESSION VALVE............................................................109 DESCRIPTION...................................................................109 OPERATION.....................................................................109 PRESSURE CUT-OFF VALVE............................................................110 DESCRIPTION...................................................................110 OPERATION.....................................................................110 PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE).............................111 FUNCTION......................................................................111 SOLENOID VALVE........................................................................112 SOLENOID VALVE BLOCK ST1 - DIFFERENTIAL LOCKING - BACKHOE BOOM LOCKING............112 SAFETY VALVE..........................................................................113 BRAKE PUMP............................................................................115 SHOVEL CYLINDERS......................................................................117 RAISE CYLINDER....................................................................117 DUMP CYLINDER.....................................................................117 BACKHOE CYLINDERS.....................................................................119 BOOM..............................................................................119 ARM...............................................................................119 BUCKET............................................................................120 OUTRIGGERS........................................................................120 BOOM SWING........................................................................121 TELESCOPIC ARM....................................................................121 CHARACTERISTICS...............................................................122 FRONT WORKING EQUIPMENT...............................................................124 SWING BRACKET.........................................................................126 BACKHOE WORKING EQUIPMENT.............................................................127 AIR CONDITIONING UNIT.................................................................129 FUNCTION..........................................................................130 20 TESTING, ADJUSTING AND TROUBLESHOOTING.................................................131 STANDARD VALUE TABLES FOR ENGINE......................................................133 STANDARD VALUE TABLE FOR CHASSIS......................................................135 SPECIAL TOOLS.........................................................................161 ENGINE SPEED..........................................................................162 VALVE CLEARANCE.......................................................................163 COMPRESSION PRESSURE..................................................................164 FUEL INJECTION TIMING.................................................................165 FAN AND ALTERNATOR DRIVE BELT.........................................................167 TENSION CHECK.....................................................................167 TENSION ADJUSTMENT................................................................167 COMPRESSOR DRIVE BELT.................................................................168 CHECKING TENSION..................................................................168 TENSION ADJUSTMENT................................................................168 ACCELERATOR PEDAL AND LEVER TRAVEL....................................................169 ACCELERATOR PEDAL TRAVEL ADJUSTMENT...............................................169 ACCELERATOR LEVER TRAVEL ADJUSTMENT...............................................170 BRAKE PEDAL TRAVEL AND MICROSWITCHES..................................................171 MASTER CYLINDER ROD ADJUSTMENT....................................................171 MICROSWITCHES ADJUSTMENT..........................................................171 CHECKING ADJUSTMENT...............................................................171 BLEEDING AIR..........................................................................172 BLEEDING AIR FROM PUMP............................................................172 BLEEDING AIR FROM CYLINDERS.......................................................172 BLEEDING AIR FROM OIL TANK........................................................173 HYDRAULIC OIL TANK PRESSURIZATION.................................................173 RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS.....................................173 BLEEDING AIR FROM THE BRAKING CIRCUIT.............................................173 CHECKING AIR BLEEDING FROM BRAKING CIRCUIT........................................174 ATTACHMENTS HYDRAULIC CIRCUIT.........................................................175 INTRODUCTION......................................................................175 TESTING AND SETTING GENERAL VALVES................................................178 FRONT SHOVEL CONTROL VALVE (2-3 SPOOLS).......................................178 BACKHOE CONTROL VALVE (6-7-8 SPOOLS)..........................................178 TESTING SECONDARY VALVES..........................................................178 SETTING MAIN AND SECONDARY VALVES.................................................180 MAIN RELIEF VALVES............................................................180 SECONDARY VALVES..............................................................181 LOAD SENSING SIGNAL (LS VALVE)........................................................182 LOAD SENSING VALVE ADJUSTMENT.....................................................182 UNLOADING VALVE.......................................................................183 UNLOADING VALVE ADJUSTMENT........................................................183 UNLOADING VALVE FUNCTION..............................................................184 PRIORITY VALVE........................................................................185 TESTING PRIORITY VALVE OPERATION..................................................185 CLEANING PRIORITY VALVE...........................................................185 STEERING CONTROL SYSTEM PRESSURE......................................................186 TESTING...........................................................................186 SETTING...........................................................................186 BRAKE SYSTEM..........................................................................187 TESTING CIRCUIT AND BRAKE PUMP TIGHTNESS..........................................187 TESTING BRAKING GROUP LEAK TIGHTNESS..............................................187 ENGINE SPEED UNDER LOAD...............................................................189 PREPARING THE MACHINE.............................................................189 TESTING WITH THE TORQUE CONVERTER UNDER STRESS....................................190 TESTING THE TORQUE CONVERTER AND HYDRAULIC SYSTEM UNDER STRESS....................190 POWER TRAIN GROUP.....................................................................191 PREPARING THE MACHINE.............................................................191 CONVERTER OIL PRESSURE............................................................191 CLUTCH ENGAGEMENT PRESSURE........................................................192 POWER TRAIN CLUTCHES..................................................................193 PREPARATION OF THE MACHINE........................................................193 TESTING...........................................................................193 SENSOR FOR RETURN TO DIG DEVICE.......................................................194 CAUSES OF HYDRAULIC DRIFT.............................................................195 FRONT EQUIPMENT...................................................................195 TESTING OF FRONT BUCKET LIFTING...............................................195 TESTING OF FRONT BUCKET DUMPING...............................................196 BACKHOE...........................................................................197 BOOM TESTING..................................................................197 ARM TESTING...................................................................197 BUCKET TESTING................................................................198 OUTRIGGER TESTING.............................................................199 AIR CONDITIONING UNIT.................................................................200 TESTING THE WORKING TEMPERATURE...................................................200 CHECKING THE UNIT.................................................................201 EMPTYING THE AIR CONDITIONING UNIT................................................201 FRONT AXLE............................................................................203 REAR AXLE.............................................................................208 TRANSMISSION..........................................................................213 30 DISASSEMBLY AND ASSEMBLY...............................................................217 METHOD OF USING THIS MANUAL...........................................................222 REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES....................................222 PRECAUTIONS DURING SERVICE OR REPAIR OPERATIONS.......................................222 REMOVAL PRECAUTIONS...............................................................223 INSTALLATION PRECAUTIONS..........................................................223 SPECIAL TOOLS.....................................................................224 ENGINE COMPONENTS.....................................................................227 CYLINDER HEAD ASSEMBLY............................................................227 CRANKSHAFT DAMPER AND PULLEY ASSEMBLY.............................................227 ENGINE OIL COOLER ASSEMBLY........................................................227 ENGINE OIL PUMP ASSEMBLY..........................................................227 FUEL INJECTION PUMP ASSEMBLY......................................................227 FUEL INJECTOR ASSEMBLY............................................................227 FRONT AND REAR ENGINE OIL SEAL ASSEMBLY...........................................227 GOVERNOR ASSEMBLY.................................................................227 THERMOSTAT ASSEMBLY...............................................................227 TURBOCHARGER ASSEMBLY.............................................................227 WATER PUMP ASSEMBLY...............................................................227 FRONT END LOADER CYLINDER LOCK........................................................228 LOCKING PROCEDURES................................................................228 STARTER, ALTERNATOR AND COMPRESSOR....................................................229 STARTER MOTOR.....................................................................229 REMOVAL.......................................................................229 INSTALLATION..................................................................229 ALTERNATOR........................................................................230 REMOVAL.......................................................................230 INSTALLATION..................................................................231 REFRIGERANT COMPRESSOR............................................................232 REMOVAL.......................................................................232 INSTALLATION..................................................................233 BATTERY DISCONNECT SWITCH.............................................................234 REMOVAL...........................................................................234 INSTALLATION......................................................................234 FRONT COUNTERWEIGHT...................................................................235 REMOVAL...........................................................................235 INSTALLATION......................................................................235 RADIATOR, CONDENSER AND OIL COOLERS...................................................236 RADIATOR..........................................................................236 REMOVAL.......................................................................236 INSTALLATION..................................................................238 REFRIGERANT CONDENSER.............................................................239 REMOVAL.......................................................................239 INSTALLATION..................................................................239 HYDRAULIC OIL COOLER..............................................................240 REMOVAL.......................................................................240 INSTALLATION..................................................................240 TRANSMISSION OIL COOLER...........................................................241 REMOVAL.......................................................................241 INSTALLATION..................................................................241 MUFFLER AND EXHAUST STACK.............................................................242 MUFFLER...........................................................................242 REMOVAL.......................................................................242 INSTALLATION..................................................................242 EXHAUST STACK.....................................................................243 REMOVAL.......................................................................243 INSTALLATION..................................................................243 ENGINE HOOD AND OPERATORS CAB.........................................................244 ENGINE HOOD.......................................................................244 REMOVAL.......................................................................244 INSTALLATION..................................................................245 OPERATORS CAB.....................................................................246 REMOVAL.......................................................................246 INSTALLATION..................................................................250 AIR CONDITIONING AND HEATER...........................................................252 REMOVAL...........................................................................252 INSTALLATION......................................................................253 FUEL AND HYDRAULIC OIL TANKS..........................................................254 FUEL TANK.........................................................................254 REMOVAL.......................................................................254 INSTALLATION..................................................................255 HYDRAULIC TANK....................................................................256 REMOVAL.......................................................................256 INSTALLATION..................................................................257 ENGINE AND TRANSMISSION...............................................................258 REMOVAL...........................................................................258 INSTALLATION......................................................................263 PISTON PUMP...........................................................................264 REMOVAL...........................................................................264 INSTALLATION......................................................................265 TRANSMISSION..........................................................................266 REMOVAL...........................................................................266 INSTALLATION......................................................................269 TORQUE CONVERTER......................................................................270 REMOVAL...........................................................................270 INSTALLATION......................................................................270 STEERING COLUMN AND COLUMN CONTROLS...................................................271 STEERING COLUMN...................................................................271 REMOVAL.......................................................................271 INSTALLATION..................................................................271 COLUMN CONTROL SWITCHES...........................................................272 REMOVAL.......................................................................272 INSTALLATION..................................................................272 MASTER BRAKE CYLINDER.................................................................273 REMOVAL...........................................................................273 INSTALLATION......................................................................273 FRONT END LOADER CONTROL VALVE........................................................274 REMOVAL...........................................................................274 INSTALLATION......................................................................274 FRONT AXLE ASSEMBLY...................................................................276 REMOVAL...........................................................................276 INSTALLATION......................................................................277 STEERING CYLINDER.................................................................278 DISASSEMBLY...................................................................278 ASSEMBLY......................................................................278 TOE ADJUSTMENT....................................................................280 STEERING ANGLE ADJUSTMENT.........................................................282 WHEEL HUB.........................................................................283 OUTER PLANETARY DISASSEMBLY...................................................283 PLANETARY GEARS REPLACEMENT (IF NECESSARY)....................................283 OUTER PLANETARY ASSEMBLY......................................................283 INNER WHEEL HUB...................................................................284 DISASSEMBLY...................................................................284 ASSEMBLY......................................................................286 STEERING KNUCKLE AND AXLE SHAFT...................................................288 REMOVAL.......................................................................288 ASSEMBLY......................................................................289 AXLE HOUSING ENDS.................................................................290 DISASSEMBLY...................................................................290 ASSEMBLY......................................................................291 DIFFERENTIAL CARRIER (CARRIER SET UP).............................................292 REMOVAL.......................................................................292 INSTALLATION..................................................................293 RING AND PINION...................................................................294 DISASSEMBLY...................................................................294 PINION DISASSEMBLY............................................................295 RING GEAR DISASSEMBLY.........................................................297 ASSEMBLY......................................................................297 PINION SET UP.....................................................................298 ASSEMBLY......................................................................298 CHECKING GEAR BACK LASH AND INSTALLING CARRIER....................................301 CHECKING BACK LASH............................................................301 REAR AXLE.............................................................................304 REMOVAL...........................................................................304 INSTALLATION......................................................................305 OUTER PLANETARY REDUCTION GEAR....................................................306 DISASSEMBLY...................................................................306 ASSEMBLY......................................................................307 INNER WHEEL HUB...................................................................308 DISASSEMBLY...................................................................308 ASSEMBLY......................................................................309 AXLE HOUSING AND BRAKES...........................................................312 DISASSEMBLY...................................................................312 BRAKE CONTROL.....................................................................315 DISASSEMBLY...................................................................315 ASSEMBLY......................................................................321 BRAKE AND AXLE HOUSING............................................................323 ASSEMBLY......................................................................323 RING GEAR AND CARRIER.............................................................328 DISASSEMBLY...................................................................328 PINION DISASSEMBLY............................................................328 PINION ASSEMBLY...............................................................331 DIFFERENTIAL CARRIER..............................................................334 ASSEMBLY......................................................................334 RING AND PINION SET UP............................................................335 ASSEMBLY......................................................................335 FRONT BUCKET BOOM CYLINDERS...........................................................342 REMOVAL...........................................................................342 INSTALLATION......................................................................343 FRONT BUCKET TILT CYLINDER............................................................344 REMOVAL...........................................................................344 INSTALLATION......................................................................345 FRONT BUCKET..........................................................................346 REMOVAL...........................................................................346 INSTALLATION......................................................................347 FRONT WORKING EQUIPMENT...............................................................348 REMOVAL...........................................................................348 INSTALLATION......................................................................349 BACKHOE CONTROL VALVE.................................................................350 REMOVAL...........................................................................350 INSTALLATION......................................................................351 BACKHOE BOOM CYLINDER.................................................................352 REMOVAL...........................................................................352 INSTALLATION......................................................................352 BACKHOE ARM CYLINDER..................................................................354 REMOVAL...........................................................................354 INSTALLATION......................................................................355 TELESCOPIC ARM CYLINDER...............................................................356 REMOVAL...........................................................................356 INSTALLATION......................................................................357 BACKHOE BUCKET CYLINDER...............................................................358 REMOVAL...........................................................................358 INSTALLATION......................................................................359 OUTRIGGER CYLINDERS...................................................................360 REMOVAL...........................................................................360 INSTALLATION......................................................................361 BACKHOE SWING CYLINDERS...............................................................362 REMOVAL...........................................................................362 INSTALLATION......................................................................363 CYLINDERS (FRONT BUCKET RAISE AND TILT, BOOM, ARM, OUTRIGGERS, AND TELESCOPIC ARM)....364 DISASSEMBLY.......................................................................364 ASSEMBLY..........................................................................366 CYLINDER (BOOM SWING).................................................................370 DISASSEMBLY.......................................................................370 ASSEMBLY..........................................................................371 BOOM SAFETY CYLINDER..................................................................374 REMOVAL...........................................................................374 INSTALLATION......................................................................375 BACKHOE WORK EQUIPMENT................................................................376 REMOVAL...........................................................................376 INSTALLATION......................................................................377 BACKHOE BUCKET........................................................................378 REMOVAL...........................................................................378 INSTALLATION......................................................................378 BACKHOE ARM...........................................................................380 REMOVAL...........................................................................380 INSTALLATION......................................................................381 TELESCOPIC ARM (COMPLETE).............................................................382 REMOVAL...........................................................................382 INSTALLATION......................................................................383 INNER ARM.........................................................................384 REMOVAL.......................................................................384 INSTALLATION..................................................................385 INNER ARM GUIDES..................................................................386 REMOVAL.......................................................................386 INSTALLATION..................................................................386 BACKHOE BOOM..........................................................................388 REMOVAL...........................................................................388 INSTALLATION......................................................................389 BACKHOE SWING BRACKET.................................................................390 REMOVAL...........................................................................390 INSTALLATION......................................................................391 BACKHOE OUTRIGGERS....................................................................392 REMOVAL...........................................................................392 INSTALLATION......................................................................393 90 OTHERS.................................................................................395 HYDRAULIC CIRCUIT (WB150-2N)..........................................................397 HYDRAULIC CIRCUIT (WB140-2N)..........................................................399 ELECTRICAL SCHEMATIC..................................................................401 AIR CONDITIONER CIRCUIT...........................................................403
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