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KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL (WEBM004300) – PDF DOWNLOAD
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- KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:WEBM004300
- SERIAL NUMBER:
WB140PS-2 140F50092 and up
WB150PS-2 150F50020 and up
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Description
KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL (WEBM004300)
KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL (WEBM004300) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL (WEBM004300)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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. Themanual is divided into chapters on eachmain group of components; these chapters are further divided into the following sections.
- 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 AND ADJUSTING
This sections 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
TABLE OF CONTENTS:
KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHEO LOADER SERVICE REPAIR MANUAL (WEBM004300)
MAIN MENU........................................................................................................ 0 COVER............................................................................................................ 1 CONTENTS......................................................................................................... 3 SAFETY........................................................................................................... 7 FOREWORD......................................................................................................... 9 HOW TO READ THE SHOP MANUAL.................................................................................. 10 HOISTING INSTRUCTIONS........................................................................................ 11 STANDARD TIGHTENING TORQUE................................................................................... 12 COATING MATERIALS............................................................................................ 14 WEIGHT TABLE................................................................................................. 16 TABLE OF OIL AND COOLANT QUANTITIES.......................................................................... 17 CONVERSION TABLE............................................................................................. 19 10 STRUCTURE AND FUNCTION........................................................................................ 29 POWER TRAIN.................................................................................................. 30 TRANSMISSION................................................................................................. 32 DRIVE SHAFTS................................................................................................. 36 CONTROL VALVE BLOCK.......................................................................................... 38 FRONT AXLE................................................................................................... 40 REAR AXLE.................................................................................................... 43 HYDRAULIC PUMP............................................................................................... 48 STEERING UNIT................................................................................................ 69 HYDRAULIC CIRCUIT (WB140PS-2)................................................................................ 71 HYDRAULIC CIRCUIT (WB150PS-2)................................................................................ 72 SHOVEL CONTROL VALVE......................................................................................... 74 BACKHOE CONTROL VALVE........................................................................................ 78 CLSS......................................................................................................... 85 SOLENOID VALVE............................................................................................... 99 SAFETY VALVE.................................................................................................100 BRAKE PUMP...................................................................................................102 SHOVEL CYLINDERS.............................................................................................103 BACKHOE CYLINDERS............................................................................................104 AIR CONDITIONING UNIT........................................................................................107 HOW THE AIR CONDITIONING UNIT FUNCTIONS......................................................................108 ELECTRICAL DIAGRAM...........................................................................................109 ELECTRICAL DIAGRAM (AIR CONDITIONING)........................................................................111 20 TESTING AND ADJUSTMENTS.......................................................................................115 NORMAL OR STANDARD TECHNICAL DATA............................................................................116 SPECIAL TOOLS................................................................................................140 MEASURING ENGINE SPEED.......................................................................................141 ADJUSTING VALVE CLEARANCE....................................................................................142 MEASURING COMPRESSION PRESSURE...............................................................................143 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................144 CHECKING AND TIGHTENING THE FAN-BELT.........................................................................146 CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT..............................................................147 MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER...........................................148 ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES.................................................150 AIR BLEEDING - RELEASING RESIDUAL PRESSURE...................................................................151 CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...........................................154 TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)......................................................160 TESTING AND ADJUSTING OF UNLOADING VALVE.....................................................................161 CHECKING UNLOADING VALVE FUNCTIONALITY.......................................................................162 TESTING PRIORITY VALVE OPERATION.............................................................................163 TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE.........................................................164 TESTING BRAKE SYSTEM.........................................................................................165 CONTROL OF ENGINE SPEED UNDER LOAD...........................................................................167 TESTING PRESSURES IN THE POWER TRAIN GROUP...................................................................169 TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES..................................................171 ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE................................................................172 ANALYSIS OF CAUSES HYDRAULIC DRIFT...........................................................................173 TESTING THE AIR-CONDITIONING UNIT............................................................................178 EMPTYING THE AIR-CONDITIONING UNIT...........................................................................180 TROUBLESHOOTING..............................................................................................181 FRONT AXLE TROUBLESHOOTING...............................................................................182 REAR AXLE TROUBLESHOOTING................................................................................187 TRANSMISSION TROUBLESHOOTING.............................................................................192 CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT...................................................195 30 REMOVAL AND INSTALLATION......................................................................................199 HOW TO READ THE MANUAL.......................................................................................201 PRECAUTIONS TO BE TAKEN WHILE WORKING........................................................................202 SPECIAL TOOLS................................................................................................203 STARTING MOTOR...............................................................................................207 REMOVAL OF STARTING MOTOR................................................................................207 INSTALLATION OF STARTING MOTOR...........................................................................207 ALTERNATOR...................................................................................................208 REMOVAL OF THE ALTERNATOR................................................................................208 INSTALLATION OF THE ALTERNATOR...........................................................................209 AIR-CONDITIONING UNIT COMPRESSOR.............................................................................210 REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR..........................................................210 INSTALLATION OF THE AIR-CONDITIONING UNIT COMPRESSOR.....................................................211 INJECTION PUMP...............................................................................................212 REMOVAL OF THE INJECTION PUMP............................................................................212 INSTALLATION OF THE INJECTION PUMP.......................................................................215 INJECTION NOZZLES............................................................................................216 REMOVAL OF THE INJECTION NOZZLES.........................................................................216 INSTALLATION OF THE INJECTION NOZZLES....................................................................216 THERMOSTAT...................................................................................................217 REMOVAL OF THE THERMOSTAT................................................................................217 INSTALLATION OF THE THERMOSTAT...........................................................................217 COOLING LIQUID PUMP..........................................................................................218 REMOVAL OF THE COOLING LIQUID PUMP.......................................................................218 INSTALLATION OF THE COOLING LIQUID PUMP..................................................................219 TURBOCOMPRESSOR..............................................................................................220 REMOVAL OF THE TURBOCOMPRESSOR...........................................................................220 INSTALLATION OF THE TURBOCOMPRESSOR......................................................................221 CYLINDER HEAD................................................................................................222 REMOVAL OF THE CYLINDER HEAD.............................................................................222 INSTALLATION OF THE CYLINDER HEAD........................................................................224 ACCUMULATOR DISCONNECTING SWITCH.............................................................................226 REMOVAL OF THE ACCUMULATOR DISCONNECTING SWITCH..........................................................226 INSTALLATION OF THE ACCUMULATOR DISCONNECTING SWITCH.....................................................226 FRONT COUNTERWEIGHT..........................................................................................227 REMOVAL OF THE FRONT COUNTERWEIGHT.......................................................................227 INSTALLATION OF THE FRONT COUNTERWEIGHT..................................................................227 RADIATOR-OIL COOLER UNIT.....................................................................................228 REMOVAL OF THE RADIATOR-OIL COOLER UNIT..................................................................228 INSTALLATION OF THE RADIATOR-OIL COOLER GROUP............................................................230 CONDENSER....................................................................................................231 REMOVAL OF CONDENSER.....................................................................................231 INSTALLATION OF THE CONDENSER............................................................................231 HYDRAULIC OIL COOLER.........................................................................................232 REMOVAL OF HYDRAULIC OIL COOLER..........................................................................232 INSTALLATION OF THE HYDRAULIC OIL COOLER.................................................................233 TRANSMISSION OIL COOLER......................................................................................234 REMOVAL OF THE TRANSMISSION OIL COOLER...................................................................234 INSTALLATION OF THE TRANSMISSION OIL COOLER..............................................................234 MUFFLER......................................................................................................235 REMOVAL OF THE MUFFLER...................................................................................235 INSTALLATION OF THE MUFFLER..............................................................................235 EXHAUST PIPE.................................................................................................236 REMOVAL OF THE EXHAUST PIPE..............................................................................236 INSTALLATION OF THE EXHAUST PIPE.........................................................................236 ENGINE HOOD..................................................................................................237 REMOVAL OF THE ENGINE HOOD...............................................................................237 INSTALLATION OF THE ENGINE HOOD..........................................................................238 CAB..........................................................................................................239 REMOVAL OF THE CAB.......................................................................................239 INSTALLATION OF THE CAB..................................................................................242 HEAT AND AIR-CONDITIONING GROUP..............................................................................243 REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP...........................................................243 INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP...................................................244 FUEL TANK....................................................................................................245 REMOVAL OF THE FUEL TANK.................................................................................245 INSTALLATION OF THE FUEL TANK............................................................................245 HYDRAULIC OIL TANK...........................................................................................246 REMOVAL OF HYDRAULIC OIL TANK............................................................................246 INSTALLATION OF THE HYDRAULIC OIL TANK...................................................................246 ENGINE-GEARBOX-PUMP GROUP....................................................................................247 REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP.................................................................247 INSTALLATION OF THE ENGINE-GEARBOX-PUMP GROUP............................................................252 PISTON PUMP..................................................................................................253 REMOVAL OF THE PISTON PUMP...............................................................................253 INSTALLATION OF THE PISTON PUMP..........................................................................254 TRANSMISSION.................................................................................................255 REMOVAL OF THE TRANSMISSION..............................................................................255 INSTALLATION OF THE TRANSMISSION.........................................................................258 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION.................................................................259 CONVERTOR....................................................................................................357 REMOVAL OF THE CONVERTOR.................................................................................357 INSTALLATION OF THE CONVERTOR............................................................................357 TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP............................358 REMOVALL OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP........358 INSTALLATION OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....358 STEERING UNIT................................................................................................359 REMOVAL OF THE STEERING UNIT.............................................................................359 INSTALLATION OF THE STEERING UNIT........................................................................359 WORKING BRAKE PUMP GROUP.....................................................................................360 REMOVAL OF THE WORKING BRAKE PUMP GROUP..................................................................360 INSTALLATION OF THE WORKING BRAKE PUMP GROUP.............................................................360 FRONT WORKING EQUIPMENT CONTROL VALVE........................................................................361 REMOVAL OF THE FRONT WORKING EQUIPMENT CONTROL VALVE.....................................................361 INSTALLATION OF THE FRONT WORKING EQUIPMENT CONTROL VALVE................................................361 FRONT AXLE...................................................................................................362 REMOVAL OF THE FRONT AXLE................................................................................362 INSTALLATION OF THE FRONT AXLE...........................................................................363 DISASSEMBLY OF FRONT AXLE................................................................................364 ASSEMBLY OF FRONT AXLE...................................................................................373 REAR AXLE....................................................................................................389 REMOVAL OF THE REAR AXLE.................................................................................389 INSTALLATION OF THE REAR AXLE............................................................................390 DISASSEMBLY OF REAR AXLE.................................................................................391 ASSEMBLY OF REAR AXLE....................................................................................406 FRONT BUCKET BOOM-RAISING CYLINDER...........................................................................425 REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER........................................................425 INSTALLATION OF FRONT BUCKET BOOM-RAISING CYLINDER.......................................................425 FRONT BUCKET TILT CYLINDERS..................................................................................426 REMOVAL OF THE FRONT BUCKET TILT CYLINDERS...............................................................426 INSTALLATION OF THE FRONT BUCKET TILT CYLINDERS..........................................................426 FRONT BUCKET.................................................................................................427 REMOVAL OF THE FRONT BUCKET..............................................................................427 INSTALLATION OF THE FRONT BUCKET.........................................................................427 FRONT WORKING EQUIPMENT......................................................................................428 REMOVAL OF THE FRONT WORKING EQUIPMENT...................................................................428 INSTALLATION OF THE FRONT WORKING EQUIPMENT..............................................................429 BACKHOE CONTROL VALVE........................................................................................430 REMOVAL OF THE BACKHOE CONTROL VALVE.....................................................................430 INSTALLATION OF THE BACKHOE CONTROL VALVE................................................................431 BACKHOE BOOM CYLINDER........................................................................................432 REMOVAL OF BACKHOE BOOM CYLINDER.........................................................................432 INSTALLATION OF THE BACKHOE BOOM CYLINDER................................................................432 BACKHOE ARM CYLINDER.........................................................................................433 REMOVAL OF THE BACKHOE ARM CYLINDER......................................................................433 INSTALLATION OF THE BACKHOE ARM CYLINDER.................................................................433 TELESCOPIC ARM CYLINDER......................................................................................434 REMOVAL OF THE TELESCOPIC ARM CYLINDER...................................................................434 INSTALLATION OF THE TELESCOPIC ARM CYLINDER..............................................................434 BACKHOE BUCKET CYLINDER......................................................................................435 REMOVAL OF THE BACKHOE BUCKET CYLINDER...................................................................435 INSTALLATION OF THE BACKHOE BUCKET CYLINDER..............................................................435 OUTRIGGER CYLINDERS..........................................................................................436 REMOVAL OF THE OUTRIGGER CYLINDERS.......................................................................436 INSTALLATION OF THE OUTRIGGER CYLINDERS..................................................................436 BACKHOE SWING CYLINDERS......................................................................................437 REMOVAL OF THE BACKHOE SWING CYLINDERS...................................................................437 INSTALLATION OF THE BACKHOE SWING CYLINDERS..............................................................437 CYLINDERS....................................................................................................438 DISASSEMBLY OF CYLINDERS.................................................................................438 ASSEMBLY OF CYLINDERS....................................................................................440 BOOM SWING CYLINDER..........................................................................................443 DISASSEMBLY OF BOOM SWING CYLINDER.......................................................................443 ASSEMBLY OF BOOM SWING CYLINDER..........................................................................444 BOOM SAFETY CYLINDER.........................................................................................446 REMOVAL OF THE BOOM SAFETY CYLINDER......................................................................446 INSTALLATION OF THE BOOM SAFETY CYLINDER.................................................................446 BACKHOE WORKING EQUIPMENT....................................................................................447 REMOVAL OF THE BACKHOE WORKING EQUIPMENT.................................................................447 INSTALLATION OF THE BACKHOE WORKING EQUIPMENT............................................................447 BACKHOE BUCKET...............................................................................................448 REMOVAL OF THE BACKHOE BUCKET............................................................................448 INSTALLATION OF THE BACKHOE BUCKET.......................................................................448 THE ARM......................................................................................................449 REMOVAL OF THE ARM.......................................................................................449 INSTALLATION OF THE ARM..................................................................................449 COMPLETE TELESCOPIC ARM......................................................................................450 REMOVAL OF COMPLETE TELESCOPIC ARM.......................................................................450 INSTALLATION OF THE COMPLETE TELESCOPIC ARM..............................................................450 2ND ARM......................................................................................................451 REMOVAL OF 2ND ARM.......................................................................................451 INSTALLATION OF 2ND ARM..................................................................................451 2ND ARM GUIDES...............................................................................................452 REMOVAL OF 2ND ARM GUIDES................................................................................452 INSTALLATION OF 2ND ARM GUIDE............................................................................452 BACKHOE BOOM.................................................................................................453 REMOVAL OF THE BACKHOE BOOM..............................................................................453 INSTALLATION OF THE BACKHOE BOOM.........................................................................453 BACKHOE SWING BRACKET........................................................................................454 REMOVAL OF THE BACKHOE SWING BRACKET.....................................................................454 INSTALLATION OF THE BACKHOE SWING BRACKET................................................................454 BACKHOE OUTRIGGERS...........................................................................................455 REMOVAL OF THE BACKHOE OUTRIGGERS........................................................................455 INSTALLATION OF THE BACKHOE OUTRIGGERS...................................................................456 40 STANDARD MAINTENANCE..........................................................................................459 TRANSMISSION.................................................................................................460 FRONT AXLE...................................................................................................463 REAR AXLE....................................................................................................466 HYDRAULIC PUMP...............................................................................................470 2-SPOOL CONTROL VALVE........................................................................................472 3-SPOOL CONTROL VALVE........................................................................................474 6-SPOOL CONTROL VALVE........................................................................................476 7-SPOOL CONTROL VALVE........................................................................................479 8-SPOOL CONTROL VALVE........................................................................................481 BRAKE PUMP...................................................................................................482 SHOVEL CYLINDERS.............................................................................................483 BACKHOE CYLINDERS............................................................................................484 FRONT WORKING EQUIPMENT......................................................................................488 SWING BRACKET................................................................................................490 BACKHOE WORKING EQUIPMENT....................................................................................492
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