Komatsu WB142-5 Backhoe Loader Repair Manual CEBM018903 PDF

Description

Komatsu WB142-5 Backhoe Loader Shop Manual CEBM018903 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WB142-5 Backhoe Loader Shop Manual CEBM018903 – PDF DOWNLOAD

Language : English
Pages : 506
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WB142-5 Backhoe Loader Shop Manual CEBM018903 – PDF DOWNLOAD 

SERIAL NUMBERS WB142-5 A13001 and UP
ENGINE 4D102LE-2

COVER 1
CONTENTS 2
FOREWORD 3
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
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 18
TIGHTENING TORQUE OF HOSE NUTS 19
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 19
TIGHTENING TORQUE FOR FLARED NUTS 19
CONNECTING PUSH-PULL TYPE COUPLER 22
CONVERSION TABLES 25
METHOD OF USING THE CONVERSION TABLE 25
01 GENERAL 31
SPECIFICATION DRAWING 32
SPECIFICATIONS 0
MACHINE DIMENSIONS AND WEIGHTS 0
BACKHOE ARM 0
MACHINE SYSTEMS SPECIFICATIONS 32
BACKHOE ARM 33
ENGINE 34
ELECTRICAL SYSTEM 34
SERVICE REFILL CAPACITIES 34
TRANSMISSION 35
TOTAL MASS 35
STANDARD BUCKET CAPACITY 35
LOADER 35
TIRE PRESSURE 35
WEIGHT TABLE 36
FUEL, COOLANT, AND LUBRICANTS 37
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE 37
GREASE 38
FUEL AND ENGINE OIL REMARKS 38
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS 39
LUBRICATION DIAGRAMS 40
GENERAL VIEW 40
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 41
POWER TRAIN 43
SYSTEM OVERVIEW 43
DESCRIPTION 43
4 WHEEL DRIVE SYSTEM 44
TRANSMISSION COMPONENTS 45
CONVERTER AND TRANSMISSION CIRCUIT DIAGRAM 46
TRANSMISSION 47
CASE 47
TRANSMISSION INTERNAL VIEW 48
GEAR SHIFTER AND FILTERING SYSTEM 49
CLUTCH PACKS AND DRIVEN GEAR SET 50
CLUTCH PACK 50
DRIVEN GEAR SET 50
4 WHEEL DRIVE SHAFT 51
CONTROL VALVE BLOCK 53
TRANSMISSION CASE SPECIFICATIONS 54
TORQUE VALUES 54
INTERNAL SPECIFICATIONS 55
GEAR SHIFTER AND COMPONENTS SPECIFICATIONS 56
TORQUE VALUES 57
FRONT AXLE ASSEMBLY 58
DIFFERENTIAL 58
FINAL DRIVE END 59
STEERING CYLINDER 60
AXLE CARRIER SPECIFICATIONS 61
TORQUE VALUES 61
TORQUE VALUES 62
AXLE END SPECIFICATIONS 63
TORQUE VALUES 63
STEERING UNIT CYLINDER SPECIFICATIONS 64
TORQUE VALUES 64
REAR AXLE ASSEMBLY 65
DIFFERENTIAL 65
AXLE END 66
AXLE CARRIER SPECIFICATIONS 68
TORQUE VALUES 69
AXLE END SPECIFICATIONS 70
TORQUE VALUES 70
REAR BRAKES 71
BRAKE SPECIFICATIONS 72
TORQUE VALUES 72
DIFFERENTIAL LOCK 73
LOCK SPECIFICATIONS 74
TORQUE VALUES 74
HYDRAULIC SYSTEM 75
HYDRAULIC CIRCUIT DIAGRAM 75
HYDRAULIC PUMP 76
DESCRIPTION 77
OPERATION 77
LOADER 3 – SPOOL VALVE 78
(WITH FLOAT AND RETURN TO DIG) 78
LOADER SPOOL VIEW 79
BACKHOE CONTROL VALVE 80
(8 – SPOOL VALVE) 80
BACKHOE SPOOL VIEW 81
SOLENOID VALVE 84
(ST1 VALVE LOCK – DIFFERENTIAL LOCK – BACKHOE BOOM LOCK) 84
MASTER CYLINDER (BRAKES) 85
SPECIFICATIONS 85
LOADER CYLINDERS 86
ARM CYLINDERS 86
BUCKET CYLINDER 86
SPECIFICATIONS 86
ARM CYLINDER TOLERANCE 87
BUCKET CYLINDER TOLERANCE 87
TORQUE VALUES 87
BACKHOE CYLINDERS 88
BOOM cylinder 88
ARM cylinder 88
BUCKET SPECIFICATIONS 89
OUTRIGGER SPECIFICATIONS 89
BOOM SWING SPECIFICATIONS 90
SPECIFICATIONS 90
BOOM CYLINDER TOLERANCE 93
ARM CYLINDER TOLERANCE 93
BUCKET CYLINDER TOLERANCE 93
BOOM SWING CYLINDER TOLERANCE 94
TORQUE VALUES 94
OUTRIGGERS TOLERANCE 0
TORQUE VALUES 0
PIN AND BUSHING CLEARANCES 96
LOADER WORK EQUIPMENT 96
BACKHOE WORK EQUIPMENT 99
20 STANDARD VALUE TABLES 105
STANDARD VALUE TABLE FOR ENGINE 106
STANDARD VALUE TABLE FOR CHASSIS 107
30 TESTING AND ADJUSTING 115
BLEED AIR FROM CIRCUITS 117
BLEED AIR FROM BRAKING CIRCUIT 117
RELEASING RESIDUAL PRESSURE 117
ACCELERATOR PEDAL AND THROTTLE LEVER 118
ACCELERATOR PEDAL TRAVEL 118
THROTTLE LEVER TRAVEL 119
BRAKE SYSTEM 120
CONTROL 120
ADJUSTMENT 120
CHECKS 121
LEAKAGE CHECKS 121
INDIVIDUAL PUMP CHECK 122
BRAKE ASSEMBLY LEAKAGE 123
PARKING BRAKE ADJUSTMENT 124
HYDRAULIC CIRCUIT 125
INTRODUCTION 125
3-SPOOL VALVE 126
7-SPOOL VALVE 126
MAIN RELIEF VALVE 127
SETTING (PRESSURE CUT-OFF) 127
PUMP P2 PRESSURE RELIEF VALVE CALIBRATION 127
SECONDARY VALVES SETTING 128
Calibration Values For 3-element Control Valve Secondary Valves 129
Calibration Values For 7 and 8-element Control Valve Secondary Valves 129
SETTING THE MAIN RELIEF AND REDUCING VALVES 130
SECONDARY VALVES AND P2 PUMP RELIEF VALVE 131
CHECKING LOAD SENSING SIGNAL (LS VALVE) 132
UNLOADING VALVE CALIBRATION 132
CHECKING COMPENSATED FLOW VALVE 133
OPERATION OF THE PRIORITY VALVE 134
TESTING AND SETTING STEERING SYSTEM PRESSURE 135
CONTROL 135
SETTING 135
CHECKING FOR LEAKS IN THE STEERING CYLINDERS 136
POWER TRAIN 137
CONVERTER OIL PRESSURE 137
CLUTCH ENGAGEMENT PRESSURE 137
CLUTCH FUNCTION 139
MACHINE PREPARATION 139
CONTROL 139
HYDRAULIC DRIFT 140
LOADER 140
BOOM CIRCUIT 140
BUCKET CIRCUIT 141
BACKHOE 142
BOOM CIRCUIT 142
ARM CIRCUIT 142
BUCKET CIRCUIT 143
OUTRIGGERS TESTING 144
40 TROUBLESHOOTING 145
POINTS TO REMEMBER WHEN TROUBLESHOOTING 146
SEQUENCE OF EVENTS IN TROUBLESHOOTING 148
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 149
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT 149
HANDLING ELECTRONIC CONTROL UNIT 154
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 155
HOW TO READ ELECTRIC WIRE CODE 156
CLASSIFICATION BY COLOR AND CODE 158
POINTS TO REMEMBER WHEN LHANDLING HUYDRAULIC EQUIPMENT 159
CHECKS BEFORE TROUBLESHOOTING 161
TROUBLESHOOTING GUIDE 162
FRONT AXLE 162
REAR AXLE 167
TRANSMISSION 172
50 DISASSEMBLY AND ASSEMBLY 175
HOW TO USE THIS MANUAL 180
REMOVAL AND INSTALLATION OF COMPONENTS 0
REMOVAL 0
INSTALLATION 0
OVERHAUL OF COMPONENTS 0
DISASSEMBLY PROCEDURES 0
ASSEMBLY PROCEDURES 0
PRECAUTIONS WHEN CARRYING OUT AN OPERATION 182
SPECIAL TOOL LIST 184
CONNECTOR REPAIR PROCEDURES 186
CONTACT TERMINAL REMOVAL (HD30 TYPE) 0
CRIMPING CONTACT TERMINAL (HD30 TYPE) 187
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 188
CONTACT TERMINAL REMOVAL (DT TYPE) 189
CRIMPING CONTACT TERMINAL (DT TYPE) 190
INSERTION OF CONTACT TERMINAL (DT TYPE) 191
STRIPPING INSULATION 192
ENGINE HOOD 193
REMOVAL 193
INSTALLATION 194
FRONT GUARD 195
REMOVAL 195
INSTALLATION 195
RADIATOR 196
REMOVAL 196
INSTALLATION 199
MUFFLER 200
REMOVAL 200
INSTALLATION 202
AIR FILTER 203
REMOVAL 203
INSTALLATION 203
EXHAUST STACK 204
REMOVAL 204
INSTALLATION 205
OPERATORS SEAT 206
REMOVAL 206
INSTALLATION 206
SIDE PANEL AND INSTRUMENT GROUP 207
LOWER ELECTRICAL GROUP 207
REMOVAL 207
INSTALLATION 208
DASH BEZEL AND COVER 209
REMOVAL 209
INSTALLATION 211
BATTERY 212
REMOVAL 212
INSTALLATION 213
FUEL TANK 214
REMOVAL 214
INSTALLATION 215
STEERING AND FRONT DASH ASSEMBLY 216
STEERING WHEEL 216
REMOVAL 216
INSTALLATION 217
FRONT DASH ASSEMBLY 218
REMOVAL 218
INSTALLATION 219
STEERING UNIT 220
REMOVAL 220
INSTALLATION 221
BRAKE SYSTEM 222
REMOVAL 222
INSTALLATION 224
BLEED AIR FROM BRAKING CIRCUIT 225
STEERING UNIT 226
REMOVAL 226
INSTALLATION 227
CANOPY 228
REMOVAL 228
INSTALLATION 235
HYDRAULIC OIL TANK 236
REMOVAL 236
INSTALLATION 241
HYDRAULIC PUMP 242
REMOVAL 242
INSTALLATION 243
TRANSMISSION 244
REMOVAL 244
INSTALLATION 248
TRANSMISSION OVERHAUL PROCEDURES 249
TORQUE CONVERTER 249
REMOVAL 249
INSTALLATION 249
PLUGS AND FILTERS 250
DISASSEMBLY 250
ASSEMBLY 254
PUMP 257
DISASSEMBLY 257
ASSEMBLY 259
OIL LINE 261
REMOVAL 261
ASSEMBLY 261
VALVE BODY 262
DISASSEMBLY 262
ASSEMBLY 270
4 WHEEL DRIVE SOLENOID VALVE 278
DISASSEMBLY 278
ASSEMBLY 280
TRANSMISSION HOUSING 282
DISASSEMBLY 282
ASSEMBLY 292
CLUTCH PACK (A) AND GEAR SHAFT (D) 302
DISASSEMBLY 302
Shaft A (Clutch Pack) 303
Gear Shaft D 310
Clutches And Disc Inspections 311
ASSEMBLY 312
Shaft (A) Clutch Pack 312
Gear Shaft D 320
CHECKING CLUTCH FUNCTION 321
GEAR SHAFTS (B) AND (C) 322
DISASSEMBLY 322
Gear Shaft (C) 323
Gear Shaft B 330
ASSEMBLY 331
Gear Shaft C 331
Gear Shaft B 338
GEAR SHAFT (E) 340
DISASSEMBLY 340
ASSEMBLY 344
SHIFTER TOWER AND FORKS 350
DISASSEMBLY 350
ASSEMBLY 353
BACKHOE CONTROL VALVE 356
REMOVAL 356
INSTALLATION 357
FRONT AXLE ASSEMBLY 358
REMOVAL 358
INSTALLATION 359
FRONT AXLE OVERHAUL PROCEDURES 360
STEERING CYLINDER ASSEMBLY 360
DISASSEMBLY 360
ASSEMBLY 361
Checking Toe-in 363
Camber Angle Adjustment 365
FRONT AXLE END PLANETARY ASSEMBLY 366
DISASSEMBLY 366
Removing The Planetary Gears (If Necessary) 367
ASSEMBLY 367
AXLE END HUB ASSEMBLY 376
DISASSEMBLY 376
ASSEMBLY 373
AXLE HOUSING 376
DISASSEMBLY 376
ASSEMBLY 378
DIFFERENTIAL 379
DISASSEMBLY 379
ASSEMBLY 381
Pinion Gear Contact Test 384
PINION 385
DISASSEMBLY 385
ASSEMBLY 388
CARRIER 392
DISASSEMBLY 392
ASSEMBLY 393
REAR AXLE ASSEMBLY 395
REMOVAL 395
INSTALLATION 397
REAR AXLE OVERHAUL PROCEDURES 398
PARKING BRAKE ASSEMBLY 398
DISASSEMBLY 398
ASSEMBLY 400
MAINTENANCE 402
Brake Pad Adjustment Procedure 402
Ball And Cam Replacement 403
Lining Replacement 403
Sleeve Seal Replacement 404
Replacing The Cable Attachment Bracket 404
SERVICE BRAKE ASSEMBLY 405
DISASSEMBLY 405
ASSEMBLY 410
REAR AXLE END PLANETARY ASSEMBLY 416
DISASSEMBLY 416
ASSEMBLY 421
DIFFERENTIAL 425
DISASSEMBLY 425
ASSEMBLY 427
Contact 429
Movements To Correct 430
DIFFERENTIAL LOCK 432
DISASSEMBLY 432
ASSEMBLY 435
CARRIER 438
DISASSEMBLY 438
ASSEMBLY 442
PINION 446
DISASSEMBLY 446
ASSEMBLY 448
FRONT LOADER CONTROL VALVE ASSEMBLY 452
REMOVAL 452
INSTALLATION 452
SOLENOID VALVE ASSEMBLY 453
REMOVAL 453
INSTALLATION 453
FRONT-END LOADER ASSEMBLY 454
LOADER BOOM CYLINDERS 454
REMOVAL 454
INSTALLATION 455
BLEED AIR FROM HYDRAULIC CYLINDERS 456
BUCKET CYLINDER AND MONO-LINK 457
REMOVAL 457
INSTALLATION 459
LOADER BUCKET 460
REMOVAL 460
INSTALLATION 460
LOADER BOOM ASSEMBLY 461
REMOVAL 461
INSTALLATION 463
BACKHOE ASSEMBLY 464
BUCKET CYLINDER 464
REMOVAL 464
INSTALLATION 465
ARM CYLINDER 466
REMOVAL 466
INSTALLATION 467
BOOM CYLINDER 468
REMOVAL 468
INSTALLATION 470
SWING CYLINDERS 471
REMOVAL 471
INSTALLATION 473
BOOM LOCK CYLINDER 474
REMOVAL 474
INSTALLATION 475
BACKHOE BUCKET 476
REMOVAL 476
INSTALLATION 476
BACKHOE ARM 477
REMOVAL 477
INSTALLATION 479
BACKHOE BOOM 480
REMOVAL 480
INSTALLATION 481
BACKHOE SWING FRAME 482
REMOVAL 482
INSTALLATION 482
OUTRIGGER CYLINDERS 483
REMOVAL 483
INSTALLATION 484
OUTRIGGER ARMS 485
REMOVAL 485
INSTALLATION 485
WORK EQUIPMENT CYLINDER OVERHAUL PROCEDURES 486
LOADER AND BACKHOE CYLINDERS 486
DISASSEMBLY 486
Arm Only 487
Boom Cylinder Rod Only 487
All Cylinders 487
Boom Gland Nut 487
ASSEMBLY 488
Boom Gland Only 488
All Cylinders 488
Assemble Piston 488
Boom Cylinder Only 488
Arm Cylinder Only 489
Boom Cylinder Only 489
All Cylinders 490
Final Assembly 490
SWING CYLINDERS 491
DISASSEMBLY 491
ASSEMBLY 0
Head 493
Piston 493
Assembling the complete Piston 494
Assembling the complete piston 494
Final Assembly 495
90 OTHERS 497
ELECTRICAL SCHEMATIC 499
CONNECTOR DESCRIPTION 499
SIDE INSTRUMENT PANEL 500
FRONT INSTRUMENT PANEL 501
FUSES, SWITCHES AND RELAYS 502
WIRE HARNESS 503
SWITCHES (1) 504
SWITCHES (2) 505
TRANSMISSION HARNESS 506

DESCRIPTION:

Komatsu WB142-5 Backhoe Loader Shop Manual CEBM018903 – PDF DOWNLOAD 

SERIAL NUMBERS WB142-5 A13001 and UP
ENGINE 4D102LE-2

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 12/12/24