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Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual CEBM012801 – PDF DOWNLOAD
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Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual
SERIAL NUMBERS:
WB140PS-2N A40034 and up
WB150PS-2N A70010 and up
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Description
Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual
FILE DETAILS:
Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual
Brands: Komatsu
Equipment Type: Backhoe Loader
Manuals Type: Shop Manual
Machine Model: WB140PS-2N, WB150PS-2N
Serial Number: A40034 and up, A70010 and up
Book Code: CEBM012801
Language: English
Pages: 596
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WB140PS-2N WB150PS-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 WB140PS-2N WB150PS-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 QUICK DISCONNECT 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.................................................................. 31 FUEL COOLANT AND LUBRICANTS................................................... 32 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................... 35 ENGINE MOUNTING............................................................... 37 TIER I ENGINE............................................................. 37 TIER II ENGINE............................................................ 38 POWER TRAIN................................................................... 39 DESCRIPTION............................................................... 39 POWER FLOW................................................................ 39 TRANSMISSION DIAGRAM.......................................................... 41 TRANSMISSION.................................................................. 43 COMPLETE ASSEMBLY......................................................... 43 FORWARD REVERSE CLUTCH.................................................... 46 2ND GEAR CLUTCH........................................................... 46 1ST, 3RD AND 4TH GEAR CLUTCH.............................................. 47 4WD SHAFT................................................................. 47 CONTROL VALVE............................................................. 48 FRONT AXLE.................................................................... 49 COMPLETE ASSEMBLY......................................................... 49 DIFFERENTIAL.............................................................. 50 PLANETARY................................................................. 51 REAR AXLE..................................................................... 52 COMPLETE ASSEMBLY......................................................... 52 DIFFERENTIAL.............................................................. 53 PLANETARY................................................................. 54 BRAKES.................................................................... 55 DIFFERENTIAL LOCK......................................................... 56 HYDRAULIC PUMP................................................................ 57 FUNCTION.................................................................. 61 STRUCTURE................................................................. 61 OPERATION................................................................. 62 PUMP OPERATION........................................................ 62 CONTROL OF DELIVERY................................................... 62 PC VALVE, LS VALVE, SERVO PISTON.......................................... 63 LS VALVE FUNCTION..................................................... 63 OPERATION............................................................. 64 PC VALVE FUNCTION..................................................... 69 WORKING MODE SOLENOID VALVE........................................... 74 STEERING UNIT................................................................. 76 TECHNICAL DATA............................................................ 76 OPERATION................................................................. 76 LOADER VALVE.................................................................. 77 2 SPOOL................................................................... 77 3 SPOOL VALVE............................................................. 79 BACKHOE CONTROL VALVE......................................................... 81 MECHANICAL CONTROL........................................................ 81 INLET SECTION VIEWS A-A AND B-B....................................... 82 ARM SECTION VIEW C-C.................................................. 83 SWING SECTION VIEW D-D................................................ 84 LEFT OUTRIGGER SECTION VIEW E-E....................................... 85 RIGHT OUTRIGGER SECTION VIEW F-F...................................... 86 BUCKET SECTION VIEW G-G............................................... 87 BOOM SECTION VIEW H-H................................................. 88 OUTLET SECTION VIEW J-J............................................... 88 TELESCOPIC ARM SECTION VIEW K-K....................................... 89 HAMMER SECTION VIEW L-L............................................... 90 EXCAVATOR CONTROL......................................................... 91 INLET SECTION VIEWS A-A AND B-B....................................... 92 ARM SECTION VIEW C-C.................................................. 93 SWING SECTION VIEW D-D................................................ 94 LEFT OUTRIGGER SECTION VIEW E-E....................................... 95 RIGHT OUTRIGGER SECTION VIEW F-F...................................... 96 BUCKET SECTION VIEW G-G............................................... 97 BOOM SECTION VIEW H-H................................................. 98 OUTLET SECTION VIEW J-J............................................... 98 TELESCOPIC ARM SECTION VIEW K-K....................................... 99 HAMMER SECTION VIEW L-L...............................................100 CLSS..........................................................................101 CHARACTERISTICS...........................................................101 STRUCTURE.................................................................101 OPERATING PRINCIPLES......................................................102 UNLOADING VALVE...........................................................104 FUNCTION..............................................................104 OPERATION.............................................................104 INTRODUCTION OF THE LS PRESSURE...........................................107 OPERATION.............................................................107 DELIVERY COMPENSATION.....................................................108 INTRODUCTION..........................................................108 OPERATION.............................................................108 LIFD CONTROL SYSTEM.......................................................111 FUNCTION..............................................................111 OPERATION.............................................................111 LS DECOMPRESSION VALVE....................................................112 DESCRIPTION...........................................................112 OPERATION.............................................................112 PRESSURE CUT OFF VALVE....................................................113 DESCRIPTION...........................................................113 OPERATION.............................................................113 PRIORITY VALVE............................................................114 FUNCTION..............................................................114 PPC JOYSTICK..................................................................115 LEFT VALVE................................................................115 RIGHT VALVE...............................................................116 SOLENOID VALVE................................................................117 DIFFERENTIAL LOCK - BACKHOE BOOM LOCK.....................................117 PPC SUPPLY VALVE - ST2....................................................118 PPC TELESCOPIC ARM........................................................119 PPC HAMMER................................................................120 PPC ARM AND HAMMER........................................................121 LOADER CYLINDERS..............................................................122 BOOM ARM..................................................................122 CHARACTERISTICS.......................................................122 BUCKET....................................................................123 CHARACTERISTICS.......................................................123 MP BUCKET.................................................................124 CHARACTERISTICS.......................................................124 BACKHOE CYLINDERS.............................................................125 BOOM......................................................................125 CHARACTERISTICS.......................................................125 ARM.......................................................................126 CHARACTERISTICS.......................................................126 BUCKET....................................................................127 CHARACTERISTICS.......................................................127 TELESCOPIC ARM CYLINDER...................................................128 CHARACTERISTICS.......................................................128 SWING.....................................................................129 CHARACTERISTICS.......................................................129 OUTRIGGER.................................................................130 CHARACTERISTICS.......................................................130 BOOM LOCK CYLINDER........................................................131 FRONT WORK EQUIPMENT..........................................................132 REAR WORK EQUIPMENT...........................................................134 AIR CONDITIONING..............................................................136 20 TESTING, ADJUSTING AND TROUBLESHOOTING.........................................139 STANDARD VALUE TABLES FOR ENGINE..............................................141 STANDARD VALUE TABLES FOR CHASSIS.............................................142 WB140PS-2N................................................................142 WB150PS-2N................................................................152 SPECIAL TOOLS.................................................................162 ENGINE SPEED..................................................................163 TIER I ENGINE.............................................................163 TIER II ENGINE............................................................163 VALVE CLEARANCE...............................................................164 TIER I ENGINE.............................................................164 ADJUSTING PROCEDURE...................................................164 VALVE COVER INSTALLATION..............................................164 TIER II ENGINE............................................................165 ADJUSTING PROCEDURE...................................................165 COMPRESSION PRESSURE..........................................................169 TIER I ENGINE.............................................................169 TIER II ENGINE............................................................170 FUEL INJECTION TIMING.........................................................172 TIER I ENGINE.............................................................172 TIER II ENGINE............................................................173 FAN BELT......................................................................176 TENSION CHECK.............................................................176 TENSION ADJUSTMENT........................................................176 COMPRESSOR DRIVE BELT.........................................................177 CHECKING TENSION..........................................................177 TENSION ADJUSTMENT........................................................177 ACCELERATOR PEDAL AND LEVER...................................................178 ACCELERATOR PEDAL TRAVEL..................................................178 ACCELERATOR LEVER TRAVEL..................................................179 BRAKE PEDAL TRAVEL............................................................180 TIER I ENGINE.............................................................180 MASTER CYLINDER ROD ADJUSTMENT........................................180 MICROSWITCHES ADJUSTMENT..............................................180 CHECKING ADJUSTMENT...................................................180 TIER II ENGINE............................................................181 MASTER CYLINDER ROD...................................................181 CHECKING ADJUSTMENT...................................................181 BLEEDING AIR..................................................................182 HYDRAULIC PUMP............................................................182 CYLINDERS.................................................................182 HYDRAULIC OIL TANK........................................................183 HYDRAULIC OIL TANK PRESSURIZATION.........................................183 WORK CIRCUITS.............................................................183 BRAKE CIRCUIT.............................................................183 CHECK BRAKE CIRCUIT.......................................................184 HYDRAULIC CIRCUIT.............................................................185 INTRODUCTION..............................................................185 LOADER CONTROL VALVES.....................................................186 BACKHOE CONTROLS STYLE VALVE..............................................187 EXCAVATOR CONTROLS STYLE VALVE............................................188 MAIN RELIEF VALVES............................................................189 TESTING...................................................................189 LOADER CONTROL VALVE (2 OR 3 SPOOL)...................................189 BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)..............................189 SETTING RELIEF PRESSURE...................................................189 LOADER CIRCUIT RELIEF VALVES..................................................191 TESTING PRESSURE..........................................................191 SETTING PRESSURE..........................................................192 BACKHOE CIRCUIT RELIEF VALVES.................................................193 TESTING PRESSURE..........................................................193 SETTING PRESSURE..........................................................194 UNLOADING VALVE...............................................................195 TESTING...................................................................195 ADJUSTMENT................................................................195 LOAD SENSING (LS) VALVE.......................................................196 TESTING...................................................................196 ADJUSTMENT................................................................196 FLOW VALVE....................................................................197 PRIORITY VALVE................................................................198 TESTING...................................................................198 CLEANING PRIORITY VALVE...................................................198 STEERING SYSTEM...............................................................199 TESTING...................................................................199 SETTING...................................................................199 BRAKE SYSTEM..................................................................200 CIRCUIT AND BRAKE PUMP TEST...............................................200 BRAKING GROUP LEAK TEST...................................................201 ENGINE SPEED UNDER LOAD.......................................................202 PREPARING THE MACHINE.....................................................202 TORQUE CONVERTER STALL....................................................202 TORQUE CONVERTER AND HYDRAULIC STALL......................................203 POWER TRAIN GROUP.............................................................204 PREPARING THE MACHINE.....................................................204 CONVERTER OIL PRESSURE....................................................204 CLUTCH PRESSURE...........................................................204 TRANSMISSION CLUTCHES.........................................................206 PREPARATION OF THE MACHINE................................................206 TESTING...................................................................206 RETURN TO DIG DEVICE..........................................................207 HYDRAULIC DRIFT...............................................................208 LOADER....................................................................208 LIFT CYLINDER.........................................................208 BUCKET CYLINDER.......................................................209 BACKHOE...................................................................210 BOOM CYLINDER.........................................................210 ARM CYLINDER..........................................................210 BUCKET CYLINDER.......................................................211 OUTRIGGER TESTING.....................................................212 AIR CONDITIONING UNIT.........................................................213 TESTING THE WORKING TEMPERATURE...........................................213 CHECKING THE UNIT.........................................................213 EMPTYING THE AC UNIT......................................................214 TROUBLESHOOTING GUIDE.........................................................215 FRONT AXLE................................................................215 REAR AXLE.................................................................220 TRANSMISSION..............................................................225 30 REMOVAL AND INSTALLATION.......................................................229 METHOD OF USING THIS MANUAL...................................................231 PARTS OR ASSEMBLIES.......................................................231 PRECAUTIONS DURING SERVICE OPERATIONS.........................................232 REMOVAL PRECAUTIONS.......................................................232 INSTALLATION PRECAUTIONS..................................................232 SPECIAL TOOLS.................................................................233 LISTING...................................................................233 SKETCHES..................................................................236 ENGINE COMPONENTS.............................................................239 LOADER CYLINDER LOCK..........................................................240 LOCKING PROCEDURES........................................................240 STARTER.......................................................................241 REMOVAL...................................................................241 INSTALLATION..............................................................241 ALTERNATOR....................................................................242 REMOVAL...................................................................242 INSTALLATION..............................................................242 AC COMPRESSOR.................................................................243 REMOVAL...................................................................243 INSTALLATION..............................................................244 INJECTION PUMP................................................................245 TIER I ENGINE.............................................................245 TIER II ENGINE............................................................248 VALVE COVER...................................................................251 TIER I ENGINE.............................................................251 TIER II ENGINE............................................................251 INJECTION NOZZLE..............................................................254 TIER I ENGINE.............................................................254 TIER II ENGINE............................................................255 THERMOSTAT....................................................................257 TIER I ENGINE.............................................................257 TIER II ENGINE............................................................258 COOLANT PUMP..................................................................259 TIER I ENGINE.............................................................259 TIER II ENGINE............................................................261 TURBOCHARGER..................................................................264 REMOVAL...................................................................264 INSTALLATION..............................................................266 CYLINDER HEAD.................................................................267 TIER I ENGINE.............................................................267 TIER II ENGINE............................................................271 BATTERY DISCONNECT SWITCH.....................................................276 REMOVAL...................................................................276 INSTALLATION..............................................................276 COUNTERWEIGHT.................................................................277 REMOVAL...................................................................277 INSTALLATION..............................................................277 90 OTHER..........................................................................555 HYDRAULIC CIRCUIT.............................................................557 BACKHOE STYLE CONTROLS FOR WB140PS-2N (1 OF 2)............................557 BACKHOE STYLE CONTROLS FOR WB140PS-2N (2 OF 2)............................558 BACKHOE STYLE CONTROLS FOR WB150PS-2N (1 OF 2)............................559 BACKHOE STYLE CONTROLS FOR WB150PS-2N (2 OF 2)............................560 EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (1 OF 3)..........................561 EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (2 OF 3)..........................562 EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (3 OF 3)..........................563 EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (1 OF 3)..........................564 EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (2 OF 3)..........................565 EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (3 OF 3)..........................566 ELECTRICAL CIRCUIT............................................................567 CAB WIRING SCHEMATIC (1 OF 5).............................................567 CAB WIRING SCHEMATIC (2 OF 5).............................................568 CAB WIRING SCHEMATIC (3 OF 5).............................................569 CAB WIRING SCHEMATIC (4 OF 5).............................................570 CAB WIRING SCHEMATIC (5 OF 5).............................................571 LEGEND FOR CAB WIRING SCHEMATIC.......................................572 CANOPY WIRING SCHEMATIC (1 OF 5)..........................................573 CANOPY WIRING SCHEMATIC (2 OF 5)..........................................574 CANOPY WIRING SCHEMATIC (3 OF 5)..........................................575 CANOPY WIRING SCHEMATIC (4 OF 5)..........................................576 CANOPY WIRING SCHEMATIC (5 OF 5)..........................................577 LEGEND FOR CANOPY WIRING SCHEMATIC....................................578 TIER I ENGINE HARNESS.....................................................579 TIER II ENGINE HARNESS....................................................580 LEGEND FOR TIER I AND II ENGINE HARNESS...............................581 FRONT HARNESS.............................................................582 LEGEND FOR FRONT HARNESS..............................................583 LATERAL HARNESS AND SIDE DASHBOARD........................................584 TIER I ENGINE (1 OF 2)................................................584 TIER I ENGINE (2 OF 2)................................................585 LEGEND FOR TIER I ENGINE..........................................586 TIER II ENGINE (1 OF 2)...............................................587 TIER II ENGINE (2 OF 2)...............................................588 LEGEND FOR TIER II ENGINE.........................................589 PPC FRAME AND SIDE DASH BOARD HARNESS.................................590 FRAME HARNESS.....................................................590 SIDE DASH BOARD HARNESS...........................................591 LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS..................592 WORK LIGHT HARNESS....................................................593 TRANSMISSION HARNESS..................................................594 LEGEND FOR TRANSMISSION HARNESS...................................595 FUSE AND RELAY PANEL..................................................596 LEGEND FOR FUSE AND RELAY PANEL...................................596
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER SHOP MANUAL CEBM012801 – PDF DOWNLOAD:
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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