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Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual CEBM012701 – PDF DOWNLOAD
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Description
Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual
FILE DETAILS:
Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual
Brands: Komatsu
Equipment Type: Backhoe Loader
Manuals Type: Shop Manual
Machine Model: WB140-2N, WB150-2N
Serial Number: A20637 and up, A60029 and up
Book Code: CEBM012701
Language: English
Pages: 660
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual
1 GENERAL :
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, FUNCTION AND MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts. It 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.
TABLE OF CONTENTS:
Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual
COVER............................................................................. 1 FOREWORD.......................................................................... 2 CONTENTS...................................................................... 2 SAFETY........................................................................ 9 SAFETY NOTICE............................................................. 9 IMPORTANT SAFETY NOTICE............................................... 9 GENERAL PRECAUTIONS................................................... 9 PREPARATIONS FOR WORK................................................. 9 PRECAUTIONS DURING WORK............................................... 9 GENERAL....................................................................... 11 HOW TO READ THE SHOP MANUAL................................................... 12 VOLUMES................................................................... 12 DISTRIBUTION AND UPDATING................................................. 12 FILING METHOD............................................................. 12 REVISED EDITION MARK...................................................... 12 REVISIONS................................................................. 12 SYMBOLS................................................................... 12 HOISTING INSTRUCTIONS......................................................... 13 HOISTING.................................................................. 13 WIRE ROPES................................................................ 13 PUSH PULL COUPLER............................................................. 14 TYPE 1.................................................................... 14 DISCONNECTION......................................................... 14 CONNECTION............................................................ 14 TYPE 2.................................................................... 15 DISCONNECTION......................................................... 15 CONNECTION............................................................ 15 TYPE 3.................................................................... 16 DISCONNECTION......................................................... 16 CONNECTION............................................................ 16 COATING MATERIALS............................................................. 17 STANDARD TIGHTENING TORQUE.................................................... 19 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.............................. 19 TIGHTENING TORQUE OF HOSE NUTS............................................ 20 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................... 20 TIGHTENING TORQUE FOR FLARED NUTS......................................... 20 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS................. 21 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS......................... 21 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).... 21 ELECTRIC WIRE CODE............................................................ 22 CLASSIFICATION BY THICKNESS............................................... 22 CLASSIFICATION BY COLOR AND CODE.......................................... 22 CONVERSION TABLES............................................................. 23 METHOD OF USING THE CONVERSION TABLE...................................... 23 01 GENERAL........................................................................ 29 SPECIFICATIONS................................................................ 30 WEIGHT TABLE.................................................................. 33 FUEL COOLANT AND LUBRICANTS................................................... 34 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................... 37 ENGINE MOUNTING............................................................... 40 TIER I ENGINE............................................................. 40 4WD MACHINES.......................................................... 40 2WD MACHINES.......................................................... 41 TIER II ENGINE............................................................ 42 4WD MACHINES.......................................................... 42 2WD MACHINE........................................................... 43 POWER TRAIN................................................................... 44 4WD MACHINES.............................................................. 44 DESCRIPTION........................................................... 44 POWER FLOW - 4WD...................................................... 45 2WD MACHINES.............................................................. 46 DESCRIPTION........................................................... 46 TRANSMISSION DIAGRAM.......................................................... 48 4WD MACHINES.............................................................. 48 2WD MACHINES.............................................................. 50 TRANSMISSION.................................................................. 52 COMPLETE ASSEMBLY......................................................... 52 FORWARD REVERSE CLUTCH.................................................... 62 1ST THROUGH 4TH SPEED SHAFT............................................... 62 4WD SHAFT................................................................. 63 FRONT AXLE.................................................................... 64 4WD....................................................................... 64 COMPLETE ASSEMBLY..................................................... 64 DIFFERENTIAL.......................................................... 64 PLANETARY............................................................. 66 2WD....................................................................... 67 COMPLETE ASSEMBLY..................................................... 67 CENTER HOUSING........................................................ 68 STEERING KNUCKLE...................................................... 69 REAR AXLE..................................................................... 70 COMPLETE ASSEMBLY......................................................... 70 DIFFERENTIAL.............................................................. 71 PLANETARY................................................................. 72 BRAKES.................................................................... 73 DIFFERENTIAL LOCK......................................................... 74 HYDRAULIC PUMP................................................................ 75 FUNCTION.................................................................. 80 STRUCTURE................................................................. 80 OPERATION................................................................. 81 PUMP OPERATION........................................................ 81 CONTROL OF DELIVERY................................................... 81 PC VALVE, LS VALVE, SERVO PISTON.......................................... 82 LS VALVE FUNCTION..................................................... 82 OPERATION............................................................. 83 PC VALVE FUNCTION..................................................... 88 WORKING MODE SOLENOID VALVE........................................... 93 STEERING UNIT................................................................. 95 TECHNICAL DATA............................................................ 95 OPERATION................................................................. 95 LOADER VALVE.................................................................. 96 2 SPOOL................................................................... 96 3 SPOOL VALVE............................................................. 98 BACKHOE CONTROL VALVE.........................................................100 MECHANICAL CONTROL........................................................100 INLET SECTION VIEWS A-A AND B-B.......................................101 ARM SECTION VIEW C-C..................................................102 SWING SECTION VIEW D-D................................................103 LEFT OUTRIGGER SECTION VIEW E-E.......................................104 RIGHT OUTRIGGER SECTION VIEW F-F......................................105 BUCKET SECTION VIEW G-G...............................................106 BOOM SECTION VIEW H-H.................................................107 OUTLET SECTION VIEW J-J...............................................107 TELESCOPIC ARM SECTION VIEW K-K.......................................108 HAMMER SECTION VIEW L-L...............................................109 EXCAVATOR CONTROL.........................................................110 INLET SECTION VIEWS A-A AND B-B.......................................111 ARM SECTION VIEW C-C..................................................112 SWING SECTION VIEW D-D................................................113 LEFT OUTRIGGER SECTION VIEW E-E.....................................114 RIGHT OUTRIGGER SECTION VIEW F-F......................................115 BUCKET SECTION VIEW G-G...............................................116 BOOM SECTION VIEW H-H.................................................117 OUTLET SECTION VIEW J-J...............................................117 TELESCOPIC ARM SECTION VIEW K-K.......................................118 HAMMER SECTION VIEW L-L...............................................119 CLSS..........................................................................120 CHARACTERISTICS...........................................................120 STRUCTURE.................................................................120 OPERATING PRINCIPLES......................................................121 UNLOADING VALVE...........................................................123 FUNCTION..............................................................123 OPERATION.............................................................123 INTRODUCTION OF THE LS PRESSURE...........................................126 OPERATION.............................................................126 DELIVERY COMPENSATION.....................................................127 INTRODUCTION..........................................................127 OPERATION.............................................................127 LIFD CONTROL SYSTEM.......................................................130 FUNCTION..............................................................130 OPERATION.............................................................130 LS DECOMPRESSION VALVE....................................................131 DESCRIPTION...........................................................131 OPERATION.............................................................131 PRESSURE CUT OFF VALVE....................................................132 DESCRIPTION...........................................................132 OPERATION.............................................................132 PRIORITY VALVE............................................................133 FUNCTION..............................................................133 PPC JOYSTICK..................................................................134 LEFT VALVE................................................................134 RIGHT VALVE...............................................................135 SOLENOID VALVE................................................................136 DIFFERENTIAL LOCK - BACKHOE BOOM LOCK.....................................136 PPC SUPPLY VALVE - ST2....................................................137 PPC TELESCOPIC ARM........................................................138 PPC HAMMER................................................................139 PPC ARM AND HAMMER........................................................140 LOADER CYLINDERS..............................................................141 BOOM ARM..................................................................141 CHARACTERISTICS.......................................................141 BUCKET....................................................................142 CHARACTERISTICS.......................................................142 MP BUCKET.................................................................143 CHARACTERISTICS.......................................................143 BACKHOE CYLINDERS.............................................................144 BOOM......................................................................144 CHARACTERISTICS.......................................................144 ARM.......................................................................145 CHARACTERISTICS.......................................................145 BUCKET....................................................................146 CHARACTERISTICS.......................................................146 TELESCOPIC ARM CYLINDER...................................................147 CHARACTERISTICS.......................................................147 SWING.....................................................................148 CHARACTERISTICS.......................................................148 OUTRIGGER.................................................................149 CHARACTERISTICS.......................................................149 BOOM LOCK CYLINDER........................................................150 FRONT WORK EQUIPMENT..........................................................151 REAR WORK EQUIPMENT...........................................................153 AIR CONDITIONING..............................................................155 20 TESTING, ADJUSTING AND TROUBLESHOOTING.........................................157 STANDARD VALUE TABLES FOR ENGINE..............................................160 STANDARD VALUE TABLES FOR CHASSIS.............................................162 SPECIAL TOOLS.................................................................181 ENGINE SPEED..................................................................183 TIER I ENGINE.............................................................183 TIER II ENGINE............................................................183 VALVE CLEARANCE...............................................................184 TIER I ENGINE.............................................................184 ADJUSTING PROCEDURE...................................................184 VALVE COVER INSTALLATION..............................................184 TIER II ENGINE............................................................185 ADJUSTING PROCEDURE...................................................185 COMPRESSION PRESSURE..........................................................189 TIER I ENGINE.............................................................189 TIER II ENGINE............................................................190 FUEL INJECTION TIMING.........................................................192 TIER I ENGINE.............................................................192 TIER II ENGINE............................................................193 FAN BELT......................................................................196 TENSION CHECK.............................................................196 TENSION ADJUSTMENT........................................................196 COMPRESSOR DRIVE BELT.........................................................197 CHECKING TENSION..........................................................197 TENSION ADJUSTMENT........................................................197 ACCELERATOR PEDAL AND LEVER...................................................198 ACCELERATOR PEDAL TRAVEL..................................................198 ACCELERATOR LEVER TRAVEL..................................................199 BRAKE PEDAL TRAVEL............................................................200 TIER I ENGINE.............................................................200 MASTER CYLINDER ROD ADJUSTMENT........................................200 MICROSWITCHES ADJUSTMENT..............................................200 CHECKING ADJUSTMENT...................................................200 TIER II ENGINE............................................................201 MASTER CYLINDER ROD...................................................201 CHECKING ADJUSTMENT...................................................201 BLEEDING AIR..................................................................202 HYDRAULIC PUMP............................................................202 CYLINDERS.................................................................202 HYDRAULIC OIL TANK........................................................203 HYDRAULIC OIL TANK PRESSURIZATION.........................................203 WORK CIRCUITS.............................................................203 BRAKE CIRCUIT.............................................................203 CHECK BRAKE CIRCUIT.......................................................204 HYDRAULIC CIRCUIT.............................................................205 INTRODUCTION..............................................................205 LOADER CONTROL VALVES.....................................................206 BACKHOE CONTROLS STYLE VALVE..............................................207 EXCAVATOR CONTROLS STYLE VALVE............................................209 MAIN RELIEF VALVES............................................................211 TESTING...................................................................211 LOADER CONTROL VALVE (2 OR 3 SPOOL)...................................211 BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)..............................211 SETTING RELIEF PRESSURE...................................................211 LOADER CIRCUIT RELIEF VALVES..................................................213 TESTING PRESSURE..........................................................213 SETTING PRESSURE..........................................................214 BACKHOE CIRCUIT RELIEF VALVES.................................................215 TESTING PRESSURE..........................................................215 SETTING PRESSURE..........................................................216 UNLOADING VALVE...............................................................217 TESTING...................................................................217 ADJUSTMENT................................................................217 LOAD SENSING (LS) VALVE.......................................................218 TESTING...................................................................218 ADJUSTMENT................................................................218 FLOW VALVE....................................................................219 PRIORITY VALVE................................................................220 TESTING...................................................................220 CLEANING PRIORITY VALVE...................................................220 STEERING SYSTEM...............................................................221 TESTING...................................................................221 SETTING...................................................................221 BRAKE SYSTEM..................................................................222 CIRCUIT AND BRAKE PUMP TEST...............................................222 BRAKING GROUP LEAK TEST...................................................223 ENGINE SPEED UNDER LOAD.......................................................224 PREPARING THE MACHINE.....................................................224 TORQUE CONVERTER STALL....................................................224 TORQUE CONVERTER AND HYDRAULIC STALL......................................225 POWER TRAIN GROUP.............................................................226 PREPARING THE MACHINE.....................................................226 CONVERTER OIL PRESSURE....................................................226 CLUTCH PRESSURE...........................................................227 ADDITIONAL PRESSURES......................................................227 DIRECTIONAL CLUTCHES..........................................................228 PREPARATION OF THE MACHINE................................................228 TESTING...................................................................228 RETURN TO DIG DEVICE..........................................................229 HYDRAULIC DRIFT...............................................................230 LOADER....................................................................230 LIFT CYLINDER.........................................................230 BUCKET CYLINDER.......................................................231 BACKHOE...................................................................232 BOOM CYLINDER.........................................................232 ARM CYLINDER..........................................................232 BUCKET CYLINDER.......................................................233 OUTRIGGER TESTING.....................................................234 AIR CONDITIONING UNIT.........................................................235 TESTING THE WORKING TEMPERATURE...........................................235 CHECKING THE UNIT.........................................................235 EMPTYING THE AC UNIT......................................................236 TROUBLESHOOTING GUIDE.........................................................238 FRONT AXLE................................................................238 REAR AXLE.................................................................243 TRANSMISSION..............................................................248 30 REMOVAL AND INSTALLATION.......................................................251 METHOD OF USING THIS MANUAL...................................................253 REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES............................253 PRECAUTIONS DURING SERVICE OPERATIONS.........................................254 REMOVAL PRECAUTIONS.......................................................254 INSTALLATION PRECAUTIONS..................................................254 SPECIAL TOOLS.................................................................255 LISTING...................................................................255 SKETCHES..................................................................257 ENGINE COMPONENTS.............................................................260 LOADER CYLINDER LOCK..........................................................261 LOCKING PROCEDURES........................................................261 STARTER.......................................................................262 REMOVAL...................................................................262 INSTALLATION..............................................................262 ALTERNATOR....................................................................263 REMOVAL...................................................................263 INSTALLATION..............................................................263 AC COMPRESSOR.................................................................264 REMOVAL...................................................................264 INSTALLATION..............................................................265 INJECTION PUMP................................................................266 TIER I ENGINE.............................................................266 TIER II ENGINE............................................................269 VALVE COVER...................................................................272 TIER I ENGINE.............................................................272 TIER II ENGINE............................................................272 INJECTION NOZZLE..............................................................275 TIER I ENGINE.............................................................275 TIER II ENGINE............................................................276 THERMOSTAT....................................................................278 TIER I ENGINE.............................................................278 TIER II ENGINE............................................................279 COOLANT PUMP..................................................................280 TIER I ENGINE.............................................................280 TIER II ENGINE............................................................282 TURBOCHARGER..................................................................285 REMOVAL...................................................................285 INSTALLATION..............................................................287 CYLINDER HEAD.................................................................288 TIER I ENGINE.............................................................288 TIER II ENGINE............................................................292 BATTERY DISCONNECT SWITCH.....................................................297 REMOVAL...................................................................297 INSTALLATION..............................................................297 COUNTERWEIGHT.................................................................298 REMOVAL...................................................................298 INSTALLATION..............................................................298 RADIATOR OIL COOLERS..........................................................299 REMOVAL...................................................................299 INSTALLATION..............................................................301 AC CONDENSOR..................................................................302 REMOVAL...................................................................302 INSTALLATION..............................................................303 MUFFLER.......................................................................304 REMOVAL...................................................................304 INSTALLATION..............................................................304 EXHAUST STACK.................................................................305 REMOVAL...................................................................305 INSTALLATION..............................................................305 ENGINE HOOD...................................................................306 REMOVAL...................................................................306 INSTALLATION..............................................................306 CAB...........................................................................307 TIER I ENGINE.............................................................307 TIER II ENGINE............................................................311 AC AND HEATER.................................................................316 REMOVAL...................................................................316 INSTALLATION..............................................................317 FUEL TANK.....................................................................318 REMOVAL...................................................................318 INSTALLATION..............................................................319 HYDRAULIC TANK................................................................320 REMOVAL...................................................................320 INSTALLATION..............................................................321 ENGINE AND TRANSMISSION.......................................................322 REMOVAL...................................................................322 INSTALLATION..............................................................327 PISTON PUMP...................................................................329 REMOVAL...................................................................329 INSTALLATION..............................................................330 TRANSMISSION..................................................................331 REMOVAL...................................................................331 INSTALLATION..............................................................334 DISASSEMBLY...............................................................335 REASSEMBLY................................................................383 TORQUE CONVERTER..............................................................427 REMOVAL...................................................................427 INSTALLATION..............................................................428 STEERING VALVE................................................................429 REMOVAL...................................................................429 INSTALLATION..............................................................430 COLUMN CONTROL SWITCHES.......................................................431 REMOVAL...................................................................431 INSTALLATION..............................................................432 MASTER BRAKE CYLINDER.........................................................433 REMOVAL...................................................................433 INSTALLATION..............................................................433 LOADER CONTROL VALVE..........................................................435 REMOVAL...................................................................435 INSTALLATION..............................................................436 2WD FRONT AXLE................................................................437 REMOVAL...................................................................437 INSTALLATION..............................................................438 DISASSEMBLY...............................................................438 4WD FRONT AXLE................................................................448 REMOVAL...................................................................448 INSTALLATION..............................................................449 DISASSEMBLY...............................................................449 REASSEMBLY................................................................458 REAR AXLE.....................................................................474 REMOVAL...................................................................474 INSTALLATION..............................................................475 DISASSEMBLY...............................................................475 REASSEMBLY................................................................490 LOADER CYLINDERS..............................................................509 BOOM......................................................................509 BUCKET....................................................................513 INSTALLATION..............................................................514 MP BUCKET CYLINDER........................................................518 FRONT EQUIPMENT...............................................................524 BUCKET....................................................................524 BOOM......................................................................525 BACKHOE CONTROL VALVE.........................................................528 BACKHOE CONTROL...........................................................528 INSTALLATION..............................................................529 EXCAVATOR CONTROLS........................................................529 PPC CONTROLS..................................................................533 PPC VALVE.................................................................533 SUPPORT RELEASE CABLES....................................................534 SUPPORT RETURN GAS SPRING.................................................537 SOLENOID VALVE............................................................539 SERVO CONTROL FEED VALVE..................................................540 BACKHOE CYLINDERS.............................................................541 BOOM......................................................................541 INSTALLATION..............................................................541 ARM.......................................................................547 BUCKET....................................................................551 INSTALLATION..............................................................552 TELESCOPIC ARM............................................................556 OUTRIGGERS................................................................561 SWING.....................................................................567 BOOM LOCK.................................................................571 BACKHOE WORK EQUIPMENT........................................................573 BOOM TO BUCKET............................................................573 BUCKET....................................................................574 STANDARD ARM..............................................................575 TELESCOPIC ARM............................................................576 INNER ARM.................................................................577 INNER ARM GUIDES..........................................................578 BOOM......................................................................579 SWING BRACKET.............................................................580 OUTRIGGERS................................................................581 90 OTHER..........................................................................583 HYDRAULIC CIRCUIT.............................................................585 STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2...............................585 STANDARD CONTROLS FOR WB140-2N SHEET 2 OF 2...............................587 STANDARD CONTROLS FOR WB150-2N SHEET 1 OF 2...............................589 STANDARD CONTROLS FOR WB150-2N SHEET 2 OF 2...............................591 PPC SYSTEM FOR WB140-2N SHEET 1 OF 3......................................593 PPC SYSTEM FOR WB140-2N SHEET 2 OF 3......................................595 PPC SYSTEM FOR WB140-2N SHEET 3 OF 3......................................597 PPC SYSTEM FOR WB150-2N SHEET 1 OF 3......................................599 PPC SYSTEM FOR WB150-2N SHEET 2 OF 3......................................601 PPC SYSTEM FOR WB150-2N SHEET 3 OF 3......................................603 ELECTRICAL....................................................................605 CAB WIRING SCHEMATIC SHEET 1 OF 5.........................................605 CAB WIRING SCHEMATIC SHEET 2 OF 5.........................................607 CAB WIRING SCHEMATIC SHEET 3 OF 5.........................................609 CAB WIRING SCHEMATIC SHEET 4 OF 5.........................................611 CAB WIRING SCHEMATIC SHEET 5 OF 5.........................................613 LEGEND FOR CAB WIRING SCHEMATIC...........................................615 CANOPY WIRING SCHEMATIC SHEET 1 OF 5......................................617 CANOPY WIRING SCHEMATIC SHEET 2 OF 5......................................619 CANOPY WIRING SCHEMATIC SHEET 3 OF 5......................................621 CANOPY WIRING SCHEMATIC SHEET 4 OF 5......................................623 CANOPY WIRING SCHEMATIC SHEET 5 OF 5......................................625 LEGEND FOR CANOPY WIRING SCHEMATIC........................................627 TIER I ENGINE HARNESS.....................................................629 TIER II ENGINE HARNESS....................................................631 LEGEND FOR TIER I AND II ENGINE HARNESSES.................................633 FRONT HARNESS.............................................................635 LEGEND FOR FRONT HARNESS..................................................637 LATERAL HARNESS AND SIDE DASHBOARD........................................639 TIER I ENGINE SHEET 2 OF 2............................................641 LEGEND FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD HARNESS..........643 TIER II ENGINE SHEET 1 OF 2...........................................645 TIER II ENGINE SHEET 2 OF 2...........................................647 LEGEND FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS.............649 PPC FRAME AND SIDE DASH BOARD HARNESS.....................................651 SIDE DASH BOARD HARNESS...............................................653 LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS......................655 WORK LIGHT HARNESS........................................................657 FUSE AND RELAY PANEL......................................................659 LEGEND FOR FUSE AND RELAY PANEL.......................................659
KOMATSU WB140-2N WB150-2N BACKHOE LOADER SHOP MANUAL CEBM012701 – PDF DOWNLOAD:
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