Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802 PDF
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Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802- PDF DOWNLOAD
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Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802- PDF DOWNLOAD
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Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802- PDF DOWNLOAD
Language : English
Pages :406
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802- PDF DOWNLOAD
FOREWORD
GENERAL
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 Problems to Causes 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
This section gives the judgement standards when inspecting disassembled parts
Komatsu WB140-2N WB150-2N BACKHOE LOADER Shop Manual CEBM009802- PDF DOWNLOAD
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 VALVE101
FUNCTION101
OPERATION101
INTRODUCTION OF THE LS PRESSURE104
OPERATION104
DELIVERY COMPENSATION105
INTRODUCTION105
FUNCTION105
OPERATION105
LIFD CONTROL SYSTEM108
FUNCTION108
OPERATION108
LS DECOMPRESSION VALVE109
DESCRIPTION109
OPERATION109
PRESSURE CUT-OFF VALVE110
DESCRIPTION110
OPERATION110
PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)111
FUNCTION111
SOLENOID VALVE112
SOLENOID VALVE BLOCK ST1 – DIFFERENTIAL LOCKING – BACKHOE BOOM LOCKING112
SAFETY VALVE113
BRAKE PUMP115
SHOVEL CYLINDERS117
RAISE CYLINDER117
DUMP CYLINDER117
BACKHOE CYLINDERS119
BOOM119
ARM119
BUCKET120
OUTRIGGERS120
BOOM SWING121
TELESCOPIC ARM121
CHARACTERISTICS122
FRONT WORKING EQUIPMENT124
SWING BRACKET126
BACKHOE WORKING EQUIPMENT127
AIR CONDITIONING UNIT129
FUNCTION130
20 TESTING, ADJUSTING AND TROUBLESHOOTING131
STANDARD VALUE TABLES FOR ENGINE133
STANDARD VALUE TABLE FOR CHASSIS135
SPECIAL TOOLS161
ENGINE SPEED162
VALVE CLEARANCE163
COMPRESSION PRESSURE164
FUEL INJECTION TIMING165
FAN AND ALTERNATOR DRIVE BELT167
TENSION CHECK167
TENSION ADJUSTMENT167
COMPRESSOR DRIVE BELT168
CHECKING TENSION168
TENSION ADJUSTMENT168
ACCELERATOR PEDAL AND LEVER TRAVEL169
ACCELERATOR PEDAL TRAVEL ADJUSTMENT169
ACCELERATOR LEVER TRAVEL ADJUSTMENT170
BRAKE PEDAL TRAVEL AND MICROSWITCHES171
MASTER CYLINDER ROD ADJUSTMENT171
MICROSWITCHES ADJUSTMENT171
CHECKING ADJUSTMENT171
BLEEDING AIR172
BLEEDING AIR FROM PUMP172
BLEEDING AIR FROM CYLINDERS172
BLEEDING AIR FROM OIL TANK173
HYDRAULIC OIL TANK PRESSURIZATION173
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS173
BLEEDING AIR FROM THE BRAKING CIRCUIT173
CHECKING AIR BLEEDING FROM BRAKING CIRCUIT174
ATTACHMENTS HYDRAULIC CIRCUIT175
INTRODUCTION175
TESTING AND SETTING GENERAL VALVES178
FRONT SHOVEL CONTROL VALVE (2-3 SPOOLS)178
BACKHOE CONTROL VALVE (6-7-8 SPOOLS)178
TESTING SECONDARY VALVES178
SETTING MAIN AND SECONDARY VALVES180
MAIN RELIEF VALVES180
SECONDARY VALVES181
LOAD SENSING SIGNAL (LS VALVE)182
LOAD SENSING VALVE ADJUSTMENT182
UNLOADING VALVE183
UNLOADING VALVE ADJUSTMENT183
UNLOADING VALVE FUNCTION184
PRIORITY VALVE185
TESTING PRIORITY VALVE OPERATION185
CLEANING PRIORITY VALVE185
STEERING CONTROL SYSTEM PRESSURE186
TESTING186
SETTING186
BRAKE SYSTEM187
TESTING CIRCUIT AND BRAKE PUMP TIGHTNESS187
TESTING BRAKING GROUP LEAK TIGHTNESS187
ENGINE SPEED UNDER LOAD189
PREPARING THE MACHINE189
TESTING WITH THE TORQUE CONVERTER UNDER STRESS190
TESTING THE TORQUE CONVERTER AND HYDRAULIC SYSTEM UNDER STRESS190
POWER TRAIN GROUP191
PREPARING THE MACHINE191
CONVERTER OIL PRESSURE191
CLUTCH ENGAGEMENT PRESSURE192
POWER TRAIN CLUTCHES193
PREPARATION OF THE MACHINE193
TESTING193
SENSOR FOR RETURN TO DIG DEVICE194
CAUSES OF HYDRAULIC DRIFT195
FRONT EQUIPMENT195
TESTING OF FRONT BUCKET LIFTING195
TESTING OF FRONT BUCKET DUMPING196
BACKHOE197
BOOM TESTING197
ARM TESTING197
BUCKET TESTING198
OUTRIGGER TESTING199
AIR CONDITIONING UNIT200
TESTING THE WORKING TEMPERATURE200
CHECKING THE UNIT201
EMPTYING THE AIR CONDITIONING UNIT201
FRONT AXLE203
REAR AXLE208
TRANSMISSION213
30 DISASSEMBLY AND ASSEMBLY217
METHOD OF USING THIS MANUAL222
REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES222
PRECAUTIONS DURING SERVICE OR REPAIR OPERATIONS222
REMOVAL PRECAUTIONS223
INSTALLATION PRECAUTIONS223
SPECIAL TOOLS224
ENGINE COMPONENTS227
CYLINDER HEAD ASSEMBLY227
CRANKSHAFT DAMPER AND PULLEY ASSEMBLY227
ENGINE OIL COOLER ASSEMBLY227
ENGINE OIL PUMP ASSEMBLY227
FUEL INJECTION PUMP ASSEMBLY227
FUEL INJECTOR ASSEMBLY227
FRONT AND REAR ENGINE OIL SEAL ASSEMBLY227
GOVERNOR ASSEMBLY227
THERMOSTAT ASSEMBLY227
TURBOCHARGER ASSEMBLY227
WATER PUMP ASSEMBLY227
FRONT END LOADER CYLINDER LOCK228
LOCKING PROCEDURES228
STARTER, ALTERNATOR AND COMPRESSOR229
STARTER MOTOR229
REMOVAL229
INSTALLATION229
ALTERNATOR230
REMOVAL230
INSTALLATION231
REFRIGERANT COMPRESSOR232
REMOVAL232
INSTALLATION233
BATTERY DISCONNECT SWITCH234
REMOVAL234
INSTALLATION234
FRONT COUNTERWEIGHT235
REMOVAL235
INSTALLATION235
RADIATOR, CONDENSER AND OIL COOLERS236
RADIATOR236
REMOVAL236
INSTALLATION238
REFRIGERANT CONDENSER239
REMOVAL239
INSTALLATION239
HYDRAULIC OIL COOLER240
REMOVAL240
INSTALLATION240
TRANSMISSION OIL COOLER241
REMOVAL241
INSTALLATION241
MUFFLER AND EXHAUST STACK242
MUFFLER242
REMOVAL242
INSTALLATION242
EXHAUST STACK243
REMOVAL243
INSTALLATION243
ENGINE HOOD AND OPERATORS CAB244
ENGINE HOOD244
REMOVAL244
INSTALLATION245
OPERATORS CAB246
REMOVAL246
INSTALLATION250
AIR CONDITIONING AND HEATER252
REMOVAL252
INSTALLATION253
FUEL AND HYDRAULIC OIL TANKS254
FUEL TANK254
REMOVAL254
INSTALLATION255
HYDRAULIC TANK256
REMOVAL256
INSTALLATION257
ENGINE AND TRANSMISSION258
REMOVAL258
INSTALLATION263
PISTON PUMP264
REMOVAL264
INSTALLATION265
TRANSMISSION266
REMOVAL266
INSTALLATION269
TORQUE CONVERTER270
REMOVAL270
INSTALLATION270
STEERING COLUMN AND COLUMN CONTROLS271
STEERING COLUMN271
REMOVAL271
INSTALLATION271
COLUMN CONTROL SWITCHES272
REMOVAL272
INSTALLATION272
MASTER BRAKE CYLINDER273
REMOVAL273
INSTALLATION273
FRONT END LOADER CONTROL VALVE274
REMOVAL274
INSTALLATION274
FRONT AXLE ASSEMBLY276
REMOVAL276
INSTALLATION277
STEERING CYLINDER278
DISASSEMBLY278
ASSEMBLY278
TOE ADJUSTMENT280
STEERING ANGLE ADJUSTMENT282
WHEEL HUB283
OUTER PLANETARY DISASSEMBLY283
PLANETARY GEARS REPLACEMENT (IF NECESSARY)283
OUTER PLANETARY ASSEMBLY283
INNER WHEEL HUB284
DISASSEMBLY284
ASSEMBLY286
STEERING KNUCKLE AND AXLE SHAFT288
REMOVAL288
ASSEMBLY289
AXLE HOUSING ENDS290
DISASSEMBLY290
ASSEMBLY291
DIFFERENTIAL CARRIER (CARRIER SET UP)292
REMOVAL292
INSTALLATION293
RING AND PINION294
DISASSEMBLY294
PINION DISASSEMBLY295
RING GEAR DISASSEMBLY297
ASSEMBLY297
PINION SET UP298
ASSEMBLY298
CHECKING GEAR BACK LASH AND INSTALLING CARRIER301
CHECKING BACK LASH301
REAR AXLE304
REMOVAL304
INSTALLATION305
OUTER PLANETARY REDUCTION GEAR306
DISASSEMBLY306
ASSEMBLY307
INNER WHEEL HUB308
DISASSEMBLY308
ASSEMBLY309
AXLE HOUSING AND BRAKES312
DISASSEMBLY312
BRAKE CONTROL315
DISASSEMBLY315
ASSEMBLY321
BRAKE AND AXLE HOUSING323
ASSEMBLY323
RING GEAR AND CARRIER328
DISASSEMBLY328
PINION DISASSEMBLY328
PINION ASSEMBLY331
DIFFERENTIAL CARRIER334
ASSEMBLY334
RING AND PINION SET UP335
ASSEMBLY335
FRONT BUCKET BOOM CYLINDERS342
REMOVAL342
INSTALLATION343
FRONT BUCKET TILT CYLINDER344
REMOVAL344
INSTALLATION345
FRONT BUCKET346
REMOVAL346
INSTALLATION347
FRONT WORKING EQUIPMENT348
REMOVAL348
INSTALLATION349
BACKHOE CONTROL VALVE350
REMOVAL350
INSTALLATION351
BACKHOE BOOM CYLINDER352
REMOVAL352
INSTALLATION352
BACKHOE ARM CYLINDER354
REMOVAL354
INSTALLATION355
TELESCOPIC ARM CYLINDER356
REMOVAL356
INSTALLATION357
BACKHOE BUCKET CYLINDER358
REMOVAL358
INSTALLATION359
OUTRIGGER CYLINDERS360
REMOVAL360
INSTALLATION361
BACKHOE SWING CYLINDERS362
REMOVAL362
INSTALLATION363
CYLINDERS (FRONT BUCKET RAISE AND TILT, BOOM, ARM, OUTRIGGERS, AND TELESCOPIC ARM)364
DISASSEMBLY364
ASSEMBLY366
CYLINDER (BOOM SWING)370
DISASSEMBLY370
ASSEMBLY371
BOOM SAFETY CYLINDER374
REMOVAL374
INSTALLATION375
BACKHOE WORK EQUIPMENT376
REMOVAL376
INSTALLATION377
BACKHOE BUCKET378
REMOVAL378
INSTALLATION378
BACKHOE ARM380
REMOVAL380
INSTALLATION381
TELESCOPIC ARM (COMPLETE)382
REMOVAL382
INSTALLATION383
INNER ARM384
REMOVAL384
INSTALLATION385
INNER ARM GUIDES386
REMOVAL386
INSTALLATION386
BACKHOE BOOM388
REMOVAL388
INSTALLATION389
BACKHOE SWING BRACKET390
REMOVAL390
INSTALLATION391
BACKHOE OUTRIGGERS392
REMOVAL392
INSTALLATION393
90 OTHERS395
HYDRAULIC CIRCUIT (WB150-2N)397
HYDRAULIC CIRCUIT (WB140-2N)399
ELECTRICAL SCHEMATIC401
AIR CONDITIONER CIRCUIT403
IMAGES PREVIEW OF THE MANUAL:
S.M 15/12/24
