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Komatsu WB150AAWS-2N Backhoe Loader Shop Manual CEBM011300 – PDF DOWNLOAD
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Komatsu WB150AAWS-2N Backhoe Loader Shop Manual
SERIAL NUMBERS : WB150AWS-2N A90001 and UP
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Description
Komatsu WB150AAWS-2N Backhoe Loader Shop Manual
FILE DETAILS:
Komatsu WB150AAWS-2N Backhoe Loader Shop Manual
Brands: Komatsu
Equipment Type: Backhoe Loader
Manuals Type: Shop Manual
Machine Model: WB150AAWS-2N
Serial Number: A90001 and up
Book Code: CEBM011300
Language: English
Pages: 490
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WB150AAWS-2N Backhoe Loader Shop Manual
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 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.
TABLE OF CONTENTS:
Komatsu WB150AAWS-2N Backhoe Loader Shop Manual
MAIN MENU......................................................................... 0 COVER............................................................................. 1 CONTENTS.......................................................................... 2 FOREWORD.......................................................................... 5 SAFETY........................................................................ 5 SAFETY NOTICE............................................................. 5 IMPORTANT SAFETY NOTICE............................................... 5 GENERAL PRECAUTIONS................................................... 5 PREPARATIONS FOR WORK................................................. 5 PRECAUTIONS DURING WORK............................................... 5 GENERAL....................................................................... 7 HOW TO READ THE SHOP MANUAL................................................... 8 VOLUMES................................................................... 8 DISTRIBUTION AND UPDATING................................................. 8 FILING METHOD............................................................. 8 REVISED EDITION MARK...................................................... 8 REVISIONS................................................................. 8 SYMBOLS................................................................... 8 HOISTING INSTRUCTIONS......................................................... 9 HOISTING.................................................................. 9 WIRE ROPES................................................................ 9 COATING MATERIALS............................................................. 10 STANDARD TIGHTENING TORQUE.................................................... 12 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.............................. 12 TIGHTENING TORQUE OF HOSE NUTS............................................ 13 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................... 13 TIGHTENING TORQUE FOR FLARED NUTS......................................... 13 ELECTRIC WIRE CODE............................................................ 14 CLASSIFICATION BY THICKNESS............................................... 14 CLASSIFICATION BY COLOR AND CODE.......................................... 14 CONVERSION TABLES............................................................. 15 METHOD OF USING THE CONVERSION TABLE...................................... 15 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.................................................................. 32 DRIVE SHAFT FOR FORWARD AND REVERSE MOVEMENT.............................. 32 DRIVE SHAFT............................................................... 33 DRIVEN GEAR SHAFT......................................................... 34 DRIVEN SHAFT 4WD.......................................................... 35 FRONT AXLE.................................................................... 38 DIFFERENTIAL.............................................................. 38 FINAL REDUCTION JOINT................................................. 39 STEERING CYLINDER......................................................... 42 REAR AXLE..................................................................... 44 DIFFERENTIAL.............................................................. 44 FINAL REDUCTION........................................................... 46 BRAKES.................................................................... 48 STEERING CYLINDER......................................................... 50 DIFFERENTIAL LOCKING...................................................... 51 HYDRAULIC PUMP................................................................ 52 FUNCTION.................................................................. 57 STRUCTURE................................................................. 57 OPERATION................................................................. 58 PUMP OPERATION........................................................ 58 CONTROL OF DELIVERY................................................... 59 PC VALVE, LS VALVE, SERVO PISTON.......................................... 60 LS VALVE.................................................................. 61 FUNCTION.............................................................. 61 OPERATION............................................................. 62 PC VALVE.................................................................. 67 FUNCTION.............................................................. 67 OPERATION............................................................. 68 WORKING MODE SOLENOID VALVE............................................... 72 FUNCTION.............................................................. 72 OPERATION............................................................. 72 STEERING UNIT................................................................. 74 TECHNICAL DATA............................................................ 74 OPERATION................................................................. 74 HYDRAULIC CIRCUIT............................................................. 76 SHOVEL CONTROL VALVE.......................................................... 77 2-SPOOL................................................................... 77 3-SPOOL................................................................... 81 BACKHOE CONTROL VALVE......................................................... 85 6-SPOOL................................................................... 85 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 SOLENOID VALVE GROUP ST2 - STEERING.......................................113 SAFETY VALVE..................................................................114 BRAKE PUMP....................................................................116 SHOVEL CYLINDERS..............................................................118 RAISING CYLINDER..........................................................118 DUMPING CYLINDER..........................................................118 DUMP CYLINDER.............................................................119 RAISE CYLINDER............................................................119 BACKHOE CYLINDERS.............................................................120 BOOM......................................................................120 ARM.......................................................................120 BUCKET....................................................................121 OUTRIGGERS................................................................121 BOOM SWING................................................................122 TELESCOPIC ARM............................................................122 BACKHOE CYLINDERS.............................................................124 BOOM......................................................................124 ARM.......................................................................124 BUCKET....................................................................124 BOOM SWING................................................................124 OUTRIGGER.................................................................126 TELESCOPIC ARM............................................................126 FRONT WORKING EQUIPMENT.......................................................128 SWING BRACKET.................................................................130 BACKHOE WORK EQUIPMENT........................................................132 AIR-CONDITIONING UNIT.........................................................134 AIR-CONDITIONING UNIT FUNCTION............................................135 FOUR-WHEEL STEERING SYSTEM (4WS)..............................................136 DESCRIPTION...............................................................136 OPERATION.................................................................137 FRONT-WHEEL STEERING ONLY.............................................137 FRONT WHEELS TURN OPPOSITE DIRECTION OF REAR WHEELS...................138 ALL FOUR WHEELS TURN IN SAME DIRECTION................................139 20 TESTING, ADJUSTING AND TROUBLESHOOTING.........................................141 NORMAL OR STANDARD TECHNICAL DATA.............................................144 SPECIAL TOOLS.............................................................156 MEASURING ENGINE SPEED........................................................157 ADJUSTING VALVE CLEARANCE.....................................................158 MEASURING COMPRESSION PRES SURE...............................................159 FUEL INJECTION TIMING.........................................................160 FAN BELT......................................................................162 TENSION CHECK.............................................................162 FAN BELT TENSION..........................................................162 COMPRESSOR BELT...............................................................163 CHECKING TENSION..........................................................163 FAN BELT TENSION..........................................................163 ACCELERATOR PEDAL AND LEVER...................................................164 OPERATING TRAVEL..........................................................164 ACCELERATOR PEDAL TRAVEL ADJUSTING....................................164 ACCELERATOR LEVER TRAVEL ADJUSTING....................................165 BRAKE PEDAL AND ALIGNMENT.....................................................166 TRAVEL AND MICRO SWITCHES.................................................166 MASTER CYLINDER ROD ADJUSTMENT........................................166 MICROSWITCHES ADJUSTMENT..............................................166 AIR BLEEDING..................................................................167 RELEASING RESIDUAL PRESSURE...............................................167 AIR BLEEDING FROM PUMP................................................167 AIR BLEEDING FROM CYLINDERS...........................................167 AIR BLEEDING FROM OIL TANK............................................168 HYDRAULIC OIL TANK PRESSURIZATION.....................................168 RELEASING RESIDUAL PRESSURE FROM CIRCUITS.............................168 AIR BLEEDING FROM BRAKING CIRCUIT.....................................168 CHECKING AIR BLEEDING FROM BRAKING CIR CUIT...........................169 ATTACHMENTS HYDRAULIC CIRCUIT.................................................170 CHECKING AND SETTING PRESSURE.............................................170 INTRODUCTION..........................................................170 TESTING AND SETTING GENERAL VALVES....................................172 TESTING AND SETTING SECONDARY VALVES..................................173 MAIN AND SECONDARY VALVES SETTING.....................................175 SENSING SIGNAL (LS VALVE).....................................................177 UNLOADING VALVE...............................................................178 ADJUSTING THE UNLOADING VALVE.............................................178 UNLOADING VALVE FUNCTIONALITY.............................................179 PRIORITY VALVE................................................................180 TESTING PRIORITY VALVE OPERATION..........................................180 PRIORITY VALVE CLEANING...................................................180 STEERING CONTROL SYSTEM PRESSURE..............................................181 TESTING...................................................................181 SETTING...................................................................181 BRAKE SYSTEM..................................................................182 TESTING CIRCUIT AND BRAKE TIGHTNESS.......................................182 TESTING BRAKING GROUP LEAK TIGHTNESS......................................183 ENGINE SPEED CONTROL..........................................................184 UNDER LOAD................................................................184 PREPARING THE MACHINE.....................................................184 TESTING WITH THE TORQUE CONVERTER UNDER STRESS............................185 TESTING THE TORQUE CONVERTER AND HYDRAULIC SYSTEM UNDER STRESS............185 POWER TRAIN PRESSURES.........................................................186 PREPARING THE MACHINE.....................................................186 CONVERTER OIL PRESSURE....................................................186 CLUTCH ENGAGEMENT PRESSURE................................................187 POWER TRAIN CLUTCHES FUNCTION.................................................188 PREPARATION OF THE MACHINE................................................188 TESTING...................................................................188 RETURN TO DIG DEVICE SENSOR...............................................189 ANALYSIS OF HYDRAULIC DRIFT...................................................190 FRONT EQUIPMENT...........................................................190 TESTING FRONT BUCKET LIFTING..........................................190 TESTING FRONT BUCKET DUMPING..............................................191 BACKHOE...................................................................192 BOOM TESTING..........................................................192 ARM TESTING...........................................................192 BUCKET TESTING........................................................193 OUTRIGGERS TESTING....................................................194 AIR-CONDITIONING UNIT.........................................................195 TESTING THE WORKING TEMPERATURE...........................................195 CHECKING THE UNIT.........................................................196 EMPTYING THE AIR CONDITIONING UNIT........................................197 TROUBLESHOOTING...............................................................198 FRONT AXLE................................................................198 REAR AXLES................................................................204 TRANSMISSION..............................................................211 ELECTRONIC CONTROL UNIT INSPECTION............................................215 FAILURE...................................................................215 NUMERICAL ERROR.......................................................215 ANOMALY...............................................................215 30 DISASSEMBLY AND ASSEMBLY.......................................................217 METHOD OF USING MANUAL........................................................220 PRECAUTIONS DURING OPERATION..................................................221 SPECIAL TOOLS.................................................................224 STARTING MOTOR................................................................227 REMOVAL...................................................................227 INSTALLATION..............................................................227 ALTERNATOR....................................................................228 REMOVAL...................................................................228 INSTALLATION..............................................................228 AIR CONDITIONING COMPRESSOR...................................................229 REMOVAL...................................................................229 INSTALLATION..............................................................230 INJECTION PUMP................................................................231 REMOVAL...................................................................231 INSTALLATION..............................................................234 INJECTION NOZZLES.............................................................235 REMOVAL...................................................................235 INSTALLATION..............................................................236 THERMOSTAT....................................................................237 REMOVAL...................................................................237 INSTALLATION..............................................................238 COOLING LIQUID PUMP...........................................................239 REMOVAL...................................................................239 INSTALLATION..............................................................241 TURBOCHARGER..................................................................242 REMOVAL...................................................................242 INSTALLATION..............................................................243 CYLINDER HEAD.................................................................244 REMOVAL...................................................................244 INSTALLATION..............................................................246 ACCUMULATOR DISCONNECT SWITCH.................................................249 REMOVAL...................................................................249 INSTALLATION..............................................................249 FRONT COUNTERWEIGHT.......................................................250 REMOVAL...............................................................250 INSTALLATION..........................................................250 RADIATOR OIL COOLER UNIT......................................................251 REMOVAL...................................................................251 INSTALLATION..............................................................253 CONDENSER.....................................................................254 REMOVAL...................................................................254 INSTALLATION..............................................................254 MUFFLER.......................................................................255 REMOVAL...................................................................255 INSTALLATION..............................................................255 EXHAUST PIPE..................................................................256 REMOVAL...................................................................256 INSTALLATION..............................................................256 ENGINE HOOD...................................................................257 REMOVAL...................................................................257 INSTALLATION..............................................................258 CAB...........................................................................259 REMOVAL...................................................................259 INSTALLATION..............................................................263 HEAT AND AIR CONDITIONING GROUP...............................................264 REMOVAL...................................................................264 INSTALLATION..............................................................265 FUEL TANK.....................................................................266 REMOVAL...................................................................266 INSTALLATION..............................................................267 HYDRAULIC OIL TANK............................................................268 REMOVAL...................................................................268 INSTALLATION..............................................................269 ENGINE-GEARBOX-PUMP GROUP.....................................................270 REMOVAL...................................................................270 INSTALLATION..............................................................274 PISTON PUMP...................................................................277 REMOVAL...................................................................277 INSTALLATION..............................................................278 TRANSMISSION..................................................................279 REMOVAL...................................................................279 INSTALLATION..............................................................282 TRANSMISSION..................................................................284 DISASSEMBLY CONVERTER.....................................................284 ASSEMBLY CONVERTER........................................................285 DISASSEMBLY PLUGS AND FILTERS.............................................287 ASSEMBLY PLUGS AND FILTERS................................................288 DISASSEMBLY OIL PUMP......................................................290 ASSEMBLY OIL PUMP.........................................................291 DISASSEMBLY PIPES AND SENSORS.............................................293 ASSEMBLY PIPES AND SENSORS................................................299 DISASSEMBLY HYDRAULIC CONTROL VALVE.......................................304 ASSEMBLY HYDRAULIC CONTROL VALVE..........................................306 DISASSEMBLY TRANSMISSION HOUSING..........................................308 ASSEMBLY TRANSMISSION HOUSING.............................................315 DISASSEMBLY SHAFT A.......................................................323 ASSEMBLY SHAFT A..........................................................332 DISASSEMBLY SHAFT B.......................................................340 ASSEMBLY SHAFT B..........................................................346 DISASSEMBLY SHAFT C.......................................................351 ASSEMBLY SHAFT C..........................................................360 DISASSEMBLY SHAFT E.......................................................371 ASSEMBLY SHAFT E..........................................................376 CONVERTER.....................................................................381 REMOVAL...................................................................381 INSTALLATION..............................................................382 HEADLIGHT CONTROL GROUP.......................................................383 REMOVAL OF THE TRANSMISSION INDICA TOR AND HEADLIGHT DIMMER...............383 INSTALLATION OF THE TRANSMISSION INDICATOR AND HEADLIGHT DIMMER...........383 STEERING UNIT.................................................................384 REMOVAL...................................................................384 INSTALLATION..............................................................384 WORKING BRAKE PUMP GROUP......................................................385 REMOVAL...................................................................385 INSTALLATION..............................................................385 FRONT WORK EQUIPMENT CONTROL VALVE............................................386 REMOVAL...................................................................386 INSTALLATION..............................................................386 FRONT AXLE....................................................................387 REMOVAL...................................................................387 INSTALLATION..............................................................388 FRONT AXLE....................................................................389 DISASSEMBLY...............................................................389 FRONT AXLE....................................................................398 ASSEMBLY..................................................................398 REAR AXLE.....................................................................414 REMOVAL...................................................................414 INSTALLATION..............................................................415 DISASSEMBLY...............................................................416 ASSEMBLY..................................................................430 PINION GROUP ASSEMBLY.....................................................430 WORK EQUIPMENT................................................................449 FRONT BUCKET BOOM-RAISING CYLINDER........................................449 REMOVAL...............................................................449 INSTALLATION..........................................................450 FRONT BUCKET TILT CYLINDERS...............................................451 REMOVAL...............................................................451 INSTALLATION..........................................................452 FRONT BUCKET..............................................................453 REMOVAL...............................................................453 INSTALLATION..........................................................453 FRONT WORK EQUIPMENT......................................................454 REMOVAL...............................................................454 INSTALLATION..........................................................455 BACKHOE CONTROL VALVE.....................................................456 REMOVAL...............................................................456 INSTALLATION..........................................................457 BACKHOE BOOM CYLINDER.....................................................458 REMOVAL...............................................................458 INSTALLATION..........................................................459 BACKHOE ARM CYLINDER......................................................460 REMOVAL...............................................................460 INSTALLATION..........................................................460 TELESCOPIC ARM CYLINDER...................................................461 REMOVAL...............................................................461 INSTALLATION..........................................................461 BACKHOE BUCKET CYLINDER...................................................462 REMOVAL...............................................................462 INSTALLATION..........................................................463 OUTRIGGER CYLINDERS.......................................................464 REMOVAL...............................................................464 INSTALLATION..........................................................464 BACKHOE SWING CYLINDERS...................................................465 REMOVAL...............................................................465 INSTALLATION..........................................................465 CYLINDERS.....................................................................467 DISASSEMBLY...............................................................467 ASSEMBLY..................................................................469 BOOM SWING CYLINDER...........................................................473 DISASSEMBLY...............................................................473 ASSEMBLY..................................................................474 BOOM SAFETY CYLINDER..........................................................476 REMOVAL...................................................................476 INSTALLATION..............................................................477 BACKHOE WORKING EQUIPMENT.....................................................478 INSTALLATION..............................................................479 BACKHOE BUCKET................................................................479 REMOVAL...................................................................479 INSTALLATION..............................................................479 BACKHOE ARM...................................................................480 REMOVAL...................................................................480 INSTALLATION..............................................................480 TELESCOPIC ARM, COMPLETE......................................................481 REMOVAL...................................................................481 INSTALLATION..............................................................481 2nd ARM.......................................................................482 REMOVAL...................................................................482 INSTALLATION..............................................................482 2nd ARM GUIDES................................................................483 REMOVAL...................................................................483 INSTALLATION..............................................................483 BACKHOE BOOM..................................................................484 REMOVAL...................................................................484 INSTALLATION..............................................................484 BACKHOE SWING BRACKET.........................................................485 REMOVAL...................................................................485 INSTALLATION..............................................................485 BACKHOE OUTRIGGERS............................................................486 REMOVAL...................................................................486 INSTALLATION..............................................................487
KOMATSU WB150AAWS-2N BACKHOE LOADER SHOP MANUAL CEBM011300 – PDF DOWNLOAD:
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