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KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM011100
- SERIAL NUMBERS
WB140PS-2N A40001
and UP WB150PS-2N A70001
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Description
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL
Screenshot of the Manual:
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating 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-2N WB150PS-2N BACKHOE LOADER SERVICE REPAIR MANUAL
MAIN MENU.................................................................................... 0 COVER........................................................................................ 1 CONTENTS..................................................................................... 2 FOREWORD..................................................................................... 4 SAFETY................................................................................... 3 SAFETY NOTICE........................................................................ 3 IMPORTANT SAFETY NOTICE.......................................................... 3 GENERAL PRECAUTIONS.............................................................. 3 PREPARATIONS FOR WORK............................................................ 3 PRECAUTIONS DURING WORK.......................................................... 3 GENERAL.................................................................................. 5 HOW TO READ THE SHOP MANUAL.............................................................. 6 VOLUMES.............................................................................. 6 DISTRIBUTION AND UPDATING............................................................ 6 FILING METHOD........................................................................ 6 REVISED EDITION MARK................................................................. 6 REVISIONS............................................................................ 6 SYMBOLS.............................................................................. 6 HOISTING INSTRUCTIONS.................................................................... 7 HOISTING............................................................................. 7 WIRE ROPES........................................................................... 7 COATING MATERIALS........................................................................ 8 STANDARD TIGHTENING TORQUE............................................................... 10 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS......................................... 10 TIGHTENING TORQUE OF HOSE NUTS....................................................... 11 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.............................................. 11 TIGHTENING TORQUE FOR FLARED NUTS.................................................... 11 ELECTRIC WIRE CODE....................................................................... 12 CLASSIFICATION BY THICKNESS.......................................................... 12 CLASSIFICATION BY COLOR AND CODE..................................................... 12 CONVERSION TABLES........................................................................ 13 METHOD OF USING THE CONVERSION TABLE................................................. 13 10 STRUCTURE AND FUNCTION.................................................................... 21 POWER TRAIN.............................................................................. 24 TRANSMISSION............................................................................. 26 DIAGRAM OF THE POWER TRAIN........................................................... 26 HYDRAULIC CONVERTER-TRANSMISSION CIRCUIT DIAGRAM..................................... 27 TRANSMISSION............................................................................. 28 DRIVE SHAFTS............................................................................. 33 DRIVE SHAFT FOR FORWARD AND REVERSE MOVEMENT......................................... 33 DRIVE SHAFT.......................................................................... 33 DRIVEN GEAR SHAFT.................................................................... 34 DRIVEN SHAFT 4WD..................................................................... 34 CONTROL VALVE BLOCK...................................................................... 35 FRONT AXLE........................................................................... 37 DIFFERENTIAL..................................................................... 37 FINAL-REDUCTION-JOINT................................................................ 39 STEERING CYLINDER.................................................................... 41 REAR AXLE................................................................................ 43 DIFFERENTIAL......................................................................... 43 FINAL REDUCTION...................................................................... 45 BRAKES............................................................................... 47 DIFFERENTIAL LOCKING................................................................. 49 HYDRAULIC PUMP........................................................................... 51 FUNCTION............................................................................. 56 STRUCTURE............................................................................ 56 OPERATION............................................................................ 57 PUMP OPERATION................................................................... 57 CONTROL OF DELIVERY.............................................................. 58 PC VALVE, LS VALVE, SERVO PISTON..................................................... 59 LS VALVE............................................................................. 60 FUNCTION......................................................................... 60 OPERATION........................................................................ 61 PC VALVE............................................................................. 66 FUNCTION......................................................................... 66 OPERATION........................................................................ 67 WORKING MODE SOLENOID VALVE.......................................................... 71 FUNCTION......................................................................... 71 OPERATION........................................................................ 71 STEERING UNIT............................................................................ 73 TECHNICAL DATA....................................................................... 73 OPERATION............................................................................ 73 HYDRAULIC CIRCUIT........................................................................ 74 SHOVEL CONTROL VALVE..................................................................... 76 2-SPOOL.............................................................................. 76 3-SPOOL.............................................................................. 80 BACKHOE CONTROL VALVE.................................................................... 84 6-SPOOL.............................................................................. 84 7-SPOOL.............................................................................. 91 FOR TELESCOPIC ARM............................................................... 91 FOR HAMMER....................................................................... 91 8-SPOOL.............................................................................. 95 FOR HAMMER AND TELESCOPIC ARM.................................................... 95 CLSS (CLOSED CENTER LOAD SENSING SYSTEM)................................................. 98 DESCRIPTION.......................................................................... 98 CHARACTERISTICS.................................................................. 98 STRUCTURE........................................................................ 98 OPERATION........................................................................ 99 UNLOADING VALVE......................................................................101 FUNCTION.........................................................................101 OPERATION........................................................................101 INTRODUCTION OF THE LS PRESSURE......................................................104 OPERATION........................................................................104 DELIVERY COMPENSATION................................................................105 INTRODUCTION.....................................................................105 FUNCTION.........................................................................105 OPERATION........................................................................105 LIFD CONTROL SYSTEM..................................................................108 FUNCTION.........................................................................108 OPERATION........................................................................108 LS DECOMPRESSION VALVE...............................................................109 DESCRIPTION......................................................................109 OPERATION........................................................................109 PRESSURE CUT-OFF VALVE...............................................................110 DESCRIPTION......................................................................110 OPERATION........................................................................110 PRIORITY VALVE (ONLY FOR THE 2-3-SPOOL CONTROL VALVE)................................111 FUNCTION.........................................................................111 SOLENOID VALVE...........................................................................112 SOLENOID VALVE BLOCK ST1 - DIFFERENTIAL LOCKING - BACKHOE BOOM LOCKING...............112 SAFETY VALVE.............................................................................113 BRAKE PUMP...............................................................................115 SHOVEL CYLINDERS.........................................................................117 RAISING CYLINDER.....................................................................117 DUMPING CYLINDER.....................................................................117 DUMP CYLINDER........................................................................118 RAISE CYLINDER.......................................................................118 BACKHOE CYLINDERS........................................................................119 BOOM.................................................................................119 ARM..................................................................................119 BUCKET...............................................................................120 OUTRIGGERS...........................................................................120 BOOM SWING...........................................................................120 TELESCOPIC ARM.......................................................................121 CHARACTERISTICS..................................................................121 BACKHOE CYLINDER MAINTENANCE STANDARD....................................................122 BOOM.................................................................................122 ARM..................................................................................122 BUCKET...............................................................................122 BOOM SWING...........................................................................122 OUTRIGGER............................................................................124 TELESCOPIC ARM.......................................................................124 FRONT WORKING EQUIPMENT..................................................................126 SWING BRACKET............................................................................128 BACKHOE WORK EQUIPMENT...................................................................130 AIR-CONDITIONING UNIT....................................................................132 AIR-CONDITIONING UNIT FUNCTION.......................................................133 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................135 NORMAL OR STANDARD TECHNICAL DATA........................................................138 FOR ENGINE...........................................................................138 FOR MACHINE..........................................................................139 SPECIAL TOOLS............................................................................151 MEASURING ENGINE SPEED...................................................................152 ADJUSTING VALVE CLEARANCE................................................................153 MEASURING COMPRESSION PRESSURE...........................................................154 FUEL INJECTION TIMING....................................................................155 FAN BELT.................................................................................157 TENSION CHECK........................................................................157 FAN BELT TENSION.....................................................................157 COMPRESSOR BELT..........................................................................158 CHECKING TENSION.....................................................................158 FAN BELT TENSION.....................................................................158 ACCELERATOR PEDAL AND LEVER..............................................................159 OPERATING TRAVEL.....................................................................159 ACCELERATOR PEDAL TRAVEL ADJUSTING...............................................159 ACCELERATOR LEVER TRAVEL ADJUSTING...............................................160 BRAKE PEDAL AND ALIGNMENT................................................................161 TRAVEL AND MICRO SWITCHES............................................................161 MASTER CYLINDER ROD ADJUSTMENT...................................................161 MICROSWITCHES ADJUSTMENT.........................................................161 AIR BLEEDING.............................................................................162 RELEASING RESIDUAL PRESSURE..........................................................162 AIR BLEEDING FROM PUMP...........................................................162 AIR BLEEDING FROM CYLINDERS......................................................162 AIR BLEEDING FROM OIL TANK.......................................................163 HYDRAULIC OIL TANK PRESSURIZATION................................................163 RELEASING RESIDUAL PRESSURE FROM CIRCUITS........................................163 AIR BLEEDING FROM BRAKING CIRCUIT................................................163 CHECKING AIR BLEEDING FROM BRAKING CIRCUIT.......................................164 ATTACHMENTS HYDRAULIC CIRCUIT............................................................165 CHECKING AND SETTING PRESSURE........................................................165 INTRODUCTION.....................................................................165 TESTING AND SETTING GENERAL VALVES...............................................167 TESTING AND SETTING SECONDARY VALVES.............................................167 MAIN AND SECONDARY VALVES SETTING................................................170 SENSING SIGNAL (LS VALVE)................................................................172 UNLOADING VALVE..........................................................................173 ADJUSTING THE UNLOADING VALVE........................................................173 UNLOADING VALVE FUNCTIONALITY........................................................174 PRIORITY VALVE...........................................................................175 TESTING PRIORITY VALVE OPERATION.....................................................175 CLEANING PRIORITY VALVE..............................................................175 STEERING CONTROL SYSTEM PRESSURE.........................................................176 TESTING..............................................................................176 SETTING..............................................................................176 BRAKE SYSTEM.............................................................................177 TESTING CIRCUIT AND BRAKE TIGHTNESS..................................................177 TESTING BRAKING GROUP LEAK TIGHTNESS.................................................178 ENGINE SPEED CONTROL.....................................................................179 UNDER LOAD...........................................................................179 PREPARING THE MACHINE................................................................179 TESTING WITH THE TORQUE CONVERTER UNDER STRESS.......................................180 TESTING THE TORQUE CONVERTER AND HYDRAULIC SYSTEM UNDER STRESS.......................180 POWER TRAIN PRESSURES....................................................................181 PREPARING THE MACHINE................................................................181 CONVERTER OIL PRESSURE...............................................................181 CLUTCH ENGAGEMENT PRESSURE...........................................................182 POWER TRAIN CLUTCHES FUNCTION............................................................183 PREPARATION OF THE MACHINE...........................................................183 TESTING..............................................................................183 RETURN TO DIG DEVICE SENSOR..........................................................184 ANALYSIS OF HYDRAULIC DRIFT..............................................................185 FRONT EQUIPMENT......................................................................185 TESTING FRONT BUCKET LIFTING.....................................................185 TESTING FRONT BUCKET DUMPING.........................................................186 BACKHOE..............................................................................187 BOOM TESTING.....................................................................187 ARM TESTING......................................................................187 BUCKET TESTING...................................................................188 OUTRIGGERS TESTING...............................................................189 AIR-CONDITIONING UNIT....................................................................190 TESTING THE WORKING TEMPERATURE......................................................190 CHECKING THE UNIT....................................................................191 EMPTYING THE AIR CONDITIONING UNIT...................................................192 FRONT AXLE TROUBLESHOOTING...............................................................193 REAR AXLE TROUBLESHOOTING................................................................198 TRANSMISSION TROUBLESHOOTING.............................................................205 ELECTRONIC CONTROL UNIT INSPECTION.......................................................208 FAILURE..............................................................................208 NUMERICAL ERROR..................................................................208 ANOMALY..........................................................................208 30 DISASSEMBLY AND ASSEMBLY..................................................................211 METHOD OF USING MANUAL...................................................................216 PRECAUTIONS DURING OPERATION.............................................................217 SPECIAL TOOLS............................................................................220 STARTING MOTOR...........................................................................223 REMOVAL..............................................................................223 INSTALLATION.........................................................................223 ALTERNATOR...............................................................................224 REMOVAL..............................................................................224 INSTALLATION.........................................................................224 AIR CONDITIONING COMPRESSOR..............................................................225 REMOVAL..............................................................................225 INSTALLATION.........................................................................226 INJECTION PUMP...........................................................................227 REMOVAL..............................................................................227 INSTALLATION.........................................................................230 INJECTION NOZZLES........................................................................231 REMOVAL..............................................................................231 INSTALLATION.........................................................................232 THERMOSTAT...............................................................................233 REMOVAL..............................................................................233 INSTALLATION.........................................................................234 COOLING LIQUID PUMP......................................................................235 REMOVAL..............................................................................235 INSTALLATION.........................................................................237 TURBOCHARGER.............................................................................238 REMOVAL..............................................................................238 INSTALLATION.........................................................................239 CYLINDER HEAD............................................................................240 REMOVAL..............................................................................240 INSTALLATION.........................................................................242 ACCUMULATOR DISCONNECT SWITCH............................................................245 REMOVAL..............................................................................245 INSTALLATION.........................................................................245 FRONT COUNTERWEIGHT......................................................................246 REMOVAL..............................................................................246 INSTALLATION.........................................................................246 RADIATOR OIL COOLER UNIT.................................................................247 REMOVAL..............................................................................247 INSTALLATION.........................................................................249 CONDENSER................................................................................250 REMOVAL..............................................................................250 INSTALLATION.........................................................................250 MUFFLER..................................................................................251 REMOVAL..............................................................................251 INSTALLATION.........................................................................251 EXHAUST PIPE.............................................................................252 REMOVAL..............................................................................252 INSTALLATION.........................................................................252 ENGINE HOOD..............................................................................253 REMOVAL..............................................................................253 INSTALLATION.........................................................................254 CAB......................................................................................255 REMOVAL..............................................................................255 INSTALLATION.........................................................................258 HEAT AND AIR CONDITIONING GROUP..........................................................259 REMOVAL..............................................................................259 INSTALLATION.........................................................................260 FUEL TANK................................................................................261 REMOVAL..............................................................................261 INSTALLATION.........................................................................262 HYDRAULIC OIL TANK.......................................................................263 REMOVAL..............................................................................263 INSTALLATION.........................................................................264 ENGINE-GEARBOX-PUMP GROUP................................................................265 REMOVAL..............................................................................265 INSTALLATION.........................................................................269 PISTON PUMP..............................................................................272 REMOVAL..............................................................................272 INSTALLATION.........................................................................273 TRANSMISSION.............................................................................274 REMOVAL..............................................................................274 INSTALLATION.........................................................................277 TRANSMISSION.............................................................................279 DISASSEMBLY CONVERTER................................................................279 ASSEMBLY CONVERTER...................................................................280 DISASSEMBLY PLUGS AND FILTERS........................................................282 ASSEMBLY PLUGS AND FILTERS...........................................................283 DISASSEMBLY OIL PUMP.................................................................285 ASSEMBLY OIL PUMP....................................................................286 DISASSEMBLY PIPES AND SENSORS........................................................288 ASSEMBLY PIPES AND SENSORS...........................................................294 DISASSEMBLY HYDRAULIC CONTROL VALVE..................................................299 ASSEMBLY HYDRAULIC CONTROL VALVE.....................................................301 DISASSEMBLY TRANSMISSION HOUSING.....................................................303 ASSEMBLY TRANSMISSION HOUSING........................................................310 DISASSEMBLY SHAFT A..................................................................318 ASSEMBLY SHAFT A.....................................................................327 DISASSEMBLY SHAFT B..................................................................335 ASSEMBLY SHAFT B.....................................................................341 DISASSEMBLY SHAFT C..................................................................346 ASSEMBLY SHAFT C.....................................................................355 DISASSEMBLY SHAFT E..................................................................366 ASSEMBLY SHAFT E.....................................................................371 CONVERTER................................................................................376 REMOVAL..............................................................................376 INSTALLATION.........................................................................377 HEADLIGHT CONTROL GROUP..................................................................378 REMOVAL OF THE TRANSMISSION INDICATOR AND HEADLIGHT DIMMER...........................378 INSTALLATION OF THE TRANSMISSION- INDICATOR AND HEADLIGHT DIMMER.....................378 STEERING UNIT............................................................................379 REMOVAL..............................................................................379 INSTALLATION.........................................................................379 WORKING BRAKE PUMP GROUP.................................................................380 REMOVAL..............................................................................380 INSTALLATION.........................................................................380 FRONT WORK EQUIPMENT CONTROL VALVE.......................................................381 REMOVAL..............................................................................381 INSTALLATION.........................................................................381 FRONT AXLE...............................................................................382 REMOVAL..............................................................................382 INSTALLATION.........................................................................383 FRONT AXLE...............................................................................384 DISASSEMBLY..........................................................................384 ASSEMBLY.............................................................................393 PINION GROUP ASSEMBLY............................................................393 DIFFERENTIAL CARRIER GROUP ASSEMBLY..............................................396 AXLE BEAM GROUP ASSEMBLY.........................................................400 WHEEL HUB GROUP ASSEMBLY.........................................................401 EPICYCLIC REDUCTION GEAR ASSEMBLY................................................404 STEERING CYLINDERS GROUP ASSEMBLY................................................404 TOE-IN ADJUSTMENT................................................................406 STEERING ANGLE ADJUSTMENT........................................................407 REAR AXLE................................................................................409 REMOVAL..............................................................................409 INSTALLATION.........................................................................410 DISASSEMBLY..........................................................................411 EPICYCLIC REDUCTION GEAR DISASSEMBLY.............................................411 WHEEL HUB GROUP DISASSEMBLY......................................................412 AXLE BEAM TRUMPETS AND BRAKE GROUPS DISASSEMBLY..................................413 BRAKE CONTROL GROUP DISASSEMBLY..................................................416 DIFFERENTIAL GROUP DISASSEMBLY...................................................422 PINION GROUP DISASSEMBLY.........................................................423 ASSEMBLY.............................................................................425 PINION GROUP ASSEMBLY............................................................425 DIFFERENTIAL GROUP ASSEMBLY......................................................428 BRAKE FLANGE AND DIFFERENTIAL HOUSING ASSEMBLY...................................429 BRAKE CONTROL GROUP ASSEMBLY.....................................................434 WORK EQUIPMENT...........................................................................444 FRONT BUCKET BOOM-RAISING CYLINDER...................................................444 REMOVAL..........................................................................444 INSTALLATION.....................................................................445 FRONT BUCKET TILT CYLINDERS..........................................................446 REMOVAL..........................................................................446 INSTALLATION.....................................................................447 FRONT BUCKET.........................................................................448 REMOVAL..........................................................................448 INSTALLATION.....................................................................448 FRONT WORK EQUIPMENT.................................................................449 REMOVAL..........................................................................449 INSTALLATION.....................................................................450 BACKHOE CONTROL VALVE................................................................451 REMOVAL..........................................................................451 INSTALLATION.....................................................................452 BACKHOE BOOM CYLINDER................................................................453 REMOVAL..........................................................................453 INSTALLATION.....................................................................454 BACKHOE ARM CYLINDER.................................................................455 REMOVAL..........................................................................455 INSTALLATION.....................................................................455 TELESCOPIC ARM CYLINDER..............................................................456 REMOVAL..........................................................................456 INSTALLATION.....................................................................456 BACKHOE BUCKET CYLINDER..............................................................457 REMOVAL..........................................................................457 INSTALLATION.....................................................................458 OUTRIGGER CYLINDERS..................................................................459 REMOVAL..........................................................................459 INSTALLATION.....................................................................459 BACKHOE SWING CYLINDERS..............................................................460 REMOVAL..........................................................................460 INSTALLATION.....................................................................460 CYLINDERS................................................................................462 DISASSEMBLY..........................................................................462 FRONT BUCKET RAISE AND TILT, BOOM, ARM, BUCKET, OUTRIGGERS.......................462 ASSEMBLY.............................................................................464 FRONT BUCKET RAISE AND TILT, BOOM, ARM, BUCKET, OUTRIGGERS AND TELESCOPIC ARM....464 BOOM SWING CYLINDER......................................................................468 DISASSEMBLY..........................................................................468 ASSEMBLY.............................................................................469 BOOM SAFETY CYLINDER.....................................................................471 REMOVAL..............................................................................471 INSTALLATION.........................................................................472 BACKHOE WORKING EQUIPMENT................................................................473 REMOVAL..............................................................................473 INSTALLATION.........................................................................474 BACKHOE BUCKET...........................................................................474 REMOVAL..............................................................................474 INSTALLATION.........................................................................474 BACKHOE ARM..............................................................................475 REMOVAL..............................................................................475 INSTALLATION.........................................................................475 TELESCOPIC ARM, COMPLETE.................................................................476 REMOVAL..............................................................................476 INSTALLATION.........................................................................476 2nd ARM..............................................................................477 REMOVAL..........................................................................477 INSTALLATION.....................................................................477 2nd ARM GUIDES.......................................................................478 REMOVAL..........................................................................478 INSTALLATION.....................................................................478 BACKHOE BOOM.............................................................................479 REMOVAL..............................................................................479 INSTALLATION.........................................................................479 BACKHOE SWING BRACKET....................................................................480 REMOVAL..............................................................................480 INSTALLATION.........................................................................480 BACKHOE OUTRIGGERS.......................................................................481 REMOVAL..............................................................................481 INSTALLATION.........................................................................482 90 OTHERS....................................................................................483 HYDRAULIC CIRCUIT (CONTROL VALVE)........................................................485 HYDRAULIC CIRCUIT (PUMP AND TANK)........................................................487 ELECTRICAL SCHEMATIC (Sheet 1 of 3)......................................................489 ELECTRICAL SCHEMATIC (Sheet 2 of 3)......................................................491 ELECTRICAL SCHEMATIC (Sheet 3 of 3)......................................................493 AIR CONDITIONER CIRCUIT..................................................................495
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