Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual CEBM012701 PDF

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Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual CEBM012701 – PDF DOWNLOAD

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Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual CEBM012701 – PDF DOWNLOAD 

Language : English
Pages : 660
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WB140-2N WB150-2N Backhoe Loader Shop Manual CEBM012701 – PDF DOWNLOAD 

SERIAL NUMBERS

WB140-2N A20637 and up
WB150-2N A60029 and up

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. Forease 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 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 CEBM012701 – PDF DOWNLOAD 

SERIAL NUMBERS

WB140-2N A20637 and up
WB150-2N A60029 and up
ENGINE S4D106-1

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

S.V 15/12/24