Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual CEBM012801 PDF

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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 CEBM012801 – PDF DOWNLOAD 

Language : English
Pages : 596
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WB140PS-2N WB150PS-2N Backhoe Loader Shop Manual CEBM012801 – PDF DOWNLOAD 

SERIAL NUMBERS WB140PS-2N A40034 and up
WB150PS-2N A70010 and up
ENGINE S4D106-1

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 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 CEBM012801 – PDF DOWNLOAD 

SERIAL NUMBERS WB140PS-2N A40034 and up
WB150PS-2N A70010 and up
ENGINE S4D106-1

COVER 1
FOREWORD 2
CONTENTS 2
SAFETY 9
SAFETY NOTICE 9
IMPORTANT SAFETY NOTICE 9
GENERAL PRECAUTIONS 9
PREPARATIONS FOR WORK 9
PRECAUTIONS DURING WORK 9
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
VOLUMES 12
DISTRIBUTION AND UPDATING 12
FILING METHOD 12
REVISED EDITION MARK 12
REVISIONS 12
SYMBOLS 12
HOISTING INSTRUCTIONS 13
HOISTING 13
WIRE ROPES 13
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

S.V 15/12/24