CEBM012700
Shop Manual
WB140-2N WB150-2N BACKHOE LOADER SERIAL NUMBERS
WB140-2N WB150-2N
A20637 A60029
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
August 2005 Printed in USA WB140-2N WB150-2N
Copyright 2005 Komatsu DataKom Publishing Division 00-1
FOREWORD
CONTENTS
12
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . .Will be issued at a later date
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WB140-2N WB150-2N
FOREWORD
SAFETY
12
SAFETY SAFETY NOTICE
00
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
00
PREPARATIONS FOR WORK
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
● ●
3.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
5.
6.
Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
WB140-2N WB150-2N
PRECAUTIONS DURING WORK
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
00-3
FOREWORD
SAFETY
12 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
●
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine.
00-4
WB140-2N WB150-2N
FOREWORD
GENERAL
12
GENERAL
00
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.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WB140-2N WB150-2N
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL VOLUMES
00
00
REVISIONS
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Chassis volume: Engine volume:
SYMBOLS
Issued for every machine model Issued for each engine series
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
DISTRIBUTION AND UPDATING
1. 2.
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
FILING METHOD
00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3
★
Item number (10. Structure and Function) Consecutive page number for each item 3.
00
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
10-4 10-4-1 Added pages 10-4-2 10-5
REVISED EDITION MARK
00
When a manual is revised, an edition mark (bcd…) is recorded on the bottom outside corner of the pages.
00-6
WB140-2N WB150-2N
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
can result. Hooks have maximum strength at the middle portion.
00
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol.
●
1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
WIRE ROPES 1.
3.
WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
00
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
WB140-2N WB150-2N
00-7
FOREWORD
PUSH PULL COUPLER
12
PUSH PULL COUPLER
00
WARNING! Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
TYPE 1 DISCONNECTION 1.
2.
3.
4.
2.
00
Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold the rubber cap portion (4). After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks. Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 1.
00
00
Hold the hose adapter (1) or hose (5) and insert it in the mating adapter (3), aligning them with each other. Do not hold the rubber cap portion (4). After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality.
00-8
WB140-2N WB150-2N
FOREWORD
TYPE 2 DISCONNECTION
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and turn the lever (4) to the right clockwise.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1.
00
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-9
WB140-2N WB150-2N
FOREWORD 12 TYPE
3
DISCONNECTION
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1.
00
Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-10
WB140-2N WB150-2N
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
★ The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Adhesives
LT-1A
Part No. 790-129-9030
Quantity
Container
150 g
Tube
LT-1B
790-129-9050
20 g (2 pes.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
179-129-9140
2g
Polyethylene container
Main applications, features ●
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
●
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and nonmetal.
●
● ●
●
Used as adhesive or sealant for metal, glass or plastic.
●
Used as sealant for machined holes.
●
Used as heat-resisting sealant for repairing engine.
●
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
● ● ●
Aronalpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
50 g
Polyethylene container
● ● ● ●
LG-3
790-129-9070
1 kg
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature. Used as adhesive or sealant for gaskets and packing of power train case, etc.
●
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Can ●
00-11
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals.
●
●
Gasket sealant
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
WB140-2N WB150-2N
FOREWORD Category
Code
COATING MATERIALS Part No.
Quantity
Container
Main applications, features ● ●
LG-4
790-129-9020
200 g
Tube
● ● ●
LG-5
790-129-9080
1 kg
Polyethylene container
Gasket sealant
● ●
LG-6
09940-00011
250 g
Tube
● ●
Molybdenum disulphide lubricant
●
LG-7
09920-00150
150 g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2160CNCA
Various
Various
400 g (10 per case)
Belows type
Molybdenum disulphide lubricant
Grease
00-12
SYG2-400M
●
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
●
Used as heat-resisting sealant for repairing engines.
●
Used as lubricant for sliding parts (to prevent squeaking).
● ●
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
●
General purpose type
●
Used for normal temperature, light load bearing at places in contact with water or steam.
●
Used for places with heavy load.
WB140-2N WB150-2N
FOREWORD
STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE
00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
11.8 - 14.7
8.70 - 10.84
8
13
27 - 34
19.91 - 25.07
10
17
59 - 74
43.51 - 54.57
12
19
98 - 123
72.28 - 90.72
14
22
153 - 190
112.84 - 140.13
16
24
235 - 285
173.32 - 210.20
18
27
320 - 400
236.02 - 295.02
20
30
455 - 565
335.59 - 416.72
22
32
610 - 765
449.91 - 564.23
24
36
785 - 980
578.98 - 722.81
27
41
1150 - 1440
848.19 - 1062.09
30
46
1520 - 1910
1121.09 - 1408.74
33
50
1960 - 2450
1445.62 - 1807.02
36
55
2450 - 3040
1807.02 - 2242.19
39
60
2890 - 3630
2131.55 - 2677.35
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
5.9 - 9.8
4.35 - 7.22
8
13
13.7 - 23.5
10.10 - 17.33
10
14
34.3 - 46.1
25.29 - 34.00
12
27
74.5 - 90.2
54.94 - 66.52
00-13
WB140-2N WB150-2N
FOREWORD 12 TIGHTENING
STANDARD TIGHTENING TORQUE
TORQUE OF HOSE NUTS
00
Use these torques for hose nuts. Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
lbf ft
02
14
19
19.6 - 29.4
14.5 - 21.7
03
18
24
29.4 - 68.6
21.7 - 50.6
04
22
27
58.9 - 98.1
44.4 - 72.4
05
24
32
107.9 - 166.7
79.6 - 123.0
06
30
36
147.1 - 205.9
108.5 - 151.9
10
33
41
147.1 - 245.1
108.5 - 180.8
12
36
46
196.2 - 294.2
144.7 - 217.0
14
42
55
245.2 - 343.2
180.9 - 253.1
Nominal No.
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
00
Use these torques for split flange bolts. Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
14
59 - 74
43.51 - 54.57
12
17
98 - 123
72.28 - 90.72
16
22
235 - 285
173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS
00
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
lbf ft
14
19
24.5 ± 4.9
18.0 ± 3.6
18
24
49 ± 19.6
36.1 ± 14.4
22
27
78.5 ± 19.6
57.8 ± 14.4
24
32
137.3 ± 29.4
101.2 ± 21.6
30
36
176.5 ± 29.4
130.1 ± 21.6
33
41
196.1 ± 49
144.6 ± 36.1
36
46
245.2 ± 49
180.8 ± 36.1
42
55
294.2 ± 49
216.9 ± 36.1
00-14
Tightening torque
WB140-2N WB150-2N
FOREWORD 12 TABLE
STANDARD TIGHTENING TORQUE
OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42
Norminal No. 02 03, 04 05, 06 10, 12 14
Width across flat mm Varies depending on type of connector.
Tightening torque (Nm {lbf ft}) Range Target 35 - 63 {25.81 - 46.46} 44 {32.45} 84 - 132 {61.95 - 97.35} 103 {75.96} 128 - 186 {94.40 - 137.18} 157 {115.79} 363 - 480 {267.73 - 354.02} 422 {311.25} 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Thread diameter mm 08 10 12 14 16 18 20 24 30 33 36 42 52
Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 _ 36 _ _
Tightening torque (Nm {lbf lb}) Range Target 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42} 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31} 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01} 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62} 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68} 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91} 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14} 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59} 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50} 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75} 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03} 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40} 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {lbf ft}) Nominal Width size of hose across flats
02 03 04 05 06 (10) (12) (14)
00-15
19 22 24 27 32 36 41 46 55
Range
Target
34 - 54 {25.0 - 39.8} 34 - 63 {25.0 - 46.4} 54 - 93 {39.8 - 68.5} 59 - 98 {43.5 - 72.2} 84 - 132 {61.9 - 97.3} 128 - 186 {94.4 - 137.1} 177 - 245 {130.5 - 180.7} 177 - 245 {130.5 - 180.7} 197 - 294 {145.3 - 216.8} 246 - 343 {181.4 - 252.9}
44 {32.4} 44 {32.4} 74 {54.5} 78 57.5} 103 {75.9} 157 {115.7} 216 {159.3} 216 {159.3} 245 {180.7} 294 {216.8}
Taper seal type
Face seal type
Nominal thread Thread size Root diameter (mm) size - Threads per (mm) (Reference) inch, Thread series 9/16 - 18UN 14.3 14 11/16 -16UN 17.5 18 22 13/16 - 16UN 20.6 24 1 - 14UNS 25.4 30 1 3/16 - 12UN 30.2 33 36 42 -
WB140-2N WB150-2N
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire Nominal numNumber of Dia. Of strand Cross section ber strands (mm) (mm)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
CLASSIFICATION BY COLOR AND CODE
1
Circuits Classification Primary
Priority
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
Black & White
Red & White
Yellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Yellow & Black
Green & Red
Blue & Red
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
2
Auxiliary
3
4
00
5
Black & YelRed & Black low
6
00-16
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
CONVERSION TABLES
00
METHOD OF USING THE CONVERSION TABLE
00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ● Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b. B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c. C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2.
Convert 550 mm into inches. A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. c
Millimeters to inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
d b
00-17
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
00-18
1 kg = 2.2046 lb 0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
1 L = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
WB140-2N WB150-2N
00-19
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
00-20
1 kgm = 7.233 ft. lb. 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63 1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1439.4
1432.1
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
WB140-2N WB150-2N
00-21
FOREWORD
CONVERSION TABLES
12 Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C °F °C °F °C °F °C °F -40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8 -37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6 -34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4 -31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2 -28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0 -28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-22
WB140-2N WB150-2N
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
WB140-2N WB150-2N
01-1
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS Weight
Description
Minimum
Operating weight
Maximum Loader
Bucket capacity
Performance
Unit
Backhoe
kg m³
Travel speeds
Forward 1st Forward 2nd Forward 3rd Forward 4th Reverse 1st Reverse 2nd Reverse 3rd Reverse 4th
km/h
Max rimpull
Forward Reverse
kg
Gradeability
Dimensions
Min. Turning Radius
01-2
WB140-2N - A20637 and UP
WB150-2N - A60029 and UP
7400
7400
8800
8800
1.03
1.03
0.2
0.2
6 11 21 39 6 11 21 39
6 11 21 39 6 11 21 39
Degrees Outside Wheel Tip of BOCE
mm
mm
WB140-2N WB150-2N
GENERAL 12
SPECIFICATIONS Description
Unit
Engine Power Train Wheels and Axle
WB150-2N - A60029 and UP
Komatsu S4D106-1FH diesel en- Komatsu S4D106-1FA diesel engine four cycle, water cooled, four gine four cycle, water cooled, four cylinder, direct injection with turbo-cylinder, direct injection with turbocharger charger
Model Type
Steering Brakes
WB140-2N - A20637 and UP
No. of cylinders - bore x stroke Piston displacement
mm L
Flywheel horsepower @ 2000 rpm Maximum torque @ 1400 rpm Min fuel consumption High idle Low idle
kW N•m g/kWh rpm rpm
Starting motor Alternator Battery
V kW VA V Ah
64 330
72 375
24, 7.5 24, 35 24, 112x2
Torque converter Transmission Reduction gear Differential Final drive Drive type Front axle Rear axle Tire Wheel rim Inflation pressure
Front tire Rear tire
kg/cm²
Main brake Parking brake Type Structure
WB140-2N WB150-2N
01-3
GENERAL 12
SPECIFICATIONS
Hydraulic system Cylinders Pumps
Torque converter Steering Hydraulic
Work
Description
Link type Bucket edge type
Unit
WB140-2N - A20637 and UP
WB150-2N - A60029 and UP
L/min L/min L/min mm
Work equipment valveType Set pressure Travel control valveType Set pressure Cooling fan motorType
01-4
kg/cm² kg/cm²
Simple link Flat edge with BOCE and bolt on teeth
WB140-2N WB150-2N
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE ★ This table is a guide for use when transporting or handling components. Unit : kg Machine Model
WB140-2N WB150-2N
WB140-2N A20637 and UP
WB150-2N A60029 and UP
01-5
GENERAL
FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recommended for this machine. Reservoir
Kind of fluid
Ambient Temperature -30
-20
-10
0
10
20
30
Capacity 40
50°C
Specified
Refill
7.9 L
7.9 L
150 L
92 L
150 L
92 L
6.5 L
6.5 L
1 L each
1 L each
Rear axle diff
14.5 L
14.5 L
Final gear
1.5 L each
1.5 L each
20 L
17 L
0.8 L
0.8 L
130 L
-
14 L
-
SAE 5W-30
Engine oil pan
Oil API CI-4 or JASO SH-1
SAE 10W SAE 20W-20 SAE 30 SAE 40 SAE 10W-30 SAE 15W-40 SAE 5W* SAE 10W
Hydraulic system
SAE 30 SAE 10W-30
Hydraulic system with biodegrad-
See page 3-12
Front axle diff Final gear
See Note 1
Transmission GM DEXRON® II D
ATF Brakes
Fuel tank
Engine cooling system
Diesel fuel
Coolant
ASTM D975 No. 1
ASTM D975 No. 2 AF-NAC
OPTION FOR VERY COLD AREAS:If the temperature is below 10°C, contact your distributor for advise on the type of oil to be used.
01-6
WB140-2N WB150-2N
GENERAL
FUEL COOLANT AND LUBRICANTS
12 API American Petroleum Institute ASTMAmerican Society of Testing and Materials NLGINational Lubricating Grease Institute SAESociety of Automotive Engineers Specified CapacityTotal amount of oil including oil for components and piping. Refill CapacityAmount of oil needed to refill system during normal maintenance. Other equipment may be necessary when operating the machine at temperatures below -20°C. Consult your Komatsu distributor for your specific needs. NOTE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high pressure fuel injection device to obtain good fuel consumption and good exhaust characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a significant drop in durability.
WB140-2N WB150-2N
01-7
GENERAL
FUEL COOLANT AND LUBRICANTS
12
MEMORANDA
01-8
WB140-2N WB150-2N
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
12 ENGINE
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 2WD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 POWER FLOW - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 FORWARD REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 1ST THROUGH 4TH SPEED SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 4WD SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 CENTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 WB140-2N WB150-2N
10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC VALVE, LS VALVE, SERVO PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LS VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WORKING MODE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MECHANICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEFT OUTRIGGER SECTION VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXCAVATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEFT OUTRIGGER SECTION ˜ VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION OF THE LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DELIVERY COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10-45 10-45 10-46 10-46 10-47 10-52 10-57 10-59 10-59 10-59 10-60 10-60 10-62 10-64 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-80 10-81 10-81 10-82 10-83 10-84 10-84 10-84 10-85 10-87 10-87 10-87 10-90 10-90 10-91 10-91 10-91 10-94
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 LS DECOMPRESSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 PRESSURE CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97 PPC JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98 LEFT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98 RIGHT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100 DIFFERENTIAL LOCK - BACKHOE BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . 10-100 PPC SUPPLY VALVE - ST2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101 PPC TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 PPC HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103 PPC ARM AND HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104 LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 BOOM ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107 BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113 BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114 FRONT WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115 REAR WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
WB140-2N WB150-2N
10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE MOUNTING
1212
ENGINE MOUNTING TIER I ENGINE 4WD MACHINES
10-4
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
ENGINE MOUNTING
MACHINES
B Tier I Engine C Transmission D Engine Mount WB140-2N WB150-2N
e Transmission Mount F Rear Axle Input G Front Axle Input - 4WD 10-5
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS 12 TIER
ENGINE MOUNTING
II ENGINE
4WD MACHINES
10-6
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
ENGINE MOUNTING
MACHINE
B Tier II Engine C Transmission D Engine Mount WB140-2N WB150-2N
e Transmission Mount F Rear Axle Input G Front Axle Input - 4WD 10-7
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS
POWER TRAIN
12
POWER TRAIN 4WD MACHINES
B C D E
Engine Torque Converter Transmission Hydraulic Pump
F G H I
Front Axle Rear Axle Front Drive Shaft Rear Drive Shaft
DESCRIPTION ●
● ●
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydraulic oil to convert the torque transmitted by the engine b into driving power. The converter transmits motion to the drive shaft of the transmission d and to the drive shaft of the hydraulic pump e. The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector. It also has manual gear selection (four forward gears and four reverse gears). The driving power is transmitted from the transmission flanges to the front f and rear g axles through the drive shafts h and i. The driving power transmitted to the front and rear axles is reduced by the differentials and then transmitted to the planetary gear through the differential shafts.
10-8
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 POWER Gears
POWER TRAIN
FLOW - 4WD Front Axle Trans
1st
4.28
2nd
2.372
3rd
1.239
4th
0.662
Diff
2.385
b Engine c Convert Transmission d Hydraulic Pump WB140-2N WB150-2N
Rear Axle Planet
6.000
Total
Trans
61.238
5.350
33.939
2.965
17.685
1.544
9.472
0.827
E Rear Drive Shaft F Rear Axle G Rear Tires
Diff
Planet
Total 91.362
2.846
6.000
50.633 26.367 14.123
H Front Drive Shaft I Front Axle J Front Tires 10-9
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS 12 2WD
POWER TRAIN
MACHINES
B Engine C Torque Converter D Transmission
e Hydraulic Pump F Rear Drive Shaft G Rear Axle
DESCRIPTION ●
● ●
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydraulic oil to convert the torque transmitted by the engine b into driving power. The converter transmits motion to the drive shaft of the transmission d and to the drive shaft of the hydraulic pump e. The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector. It also has manual gear selection (four forward gears and four reverse gears). The driving power is transmitted from the transmission flange to the rear g axle through the drive shaft h. The driving power transmitted to rear axle is reduced by the differential and then transmitted to the planetary gear through the differential shafts.
10-10
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
POWER TRAIN
Rear Axle Trans
Diff
Planet
5.350 2.965 1.544
Total 91.362
2.846
0.827
b Engine c Convert Transmission d Hydraulic Pump
WB140-2N WB150-2N
6.000
50.633 26.367 14.123
E Rear Drive Shaft F Rear Axle G Rear Tires
10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
TRANSMISSION DIAGRAM 4WD MACHINES
b Engine c Torque Converter d Forward Clutch
10-12
E Transmission F Reverse Clutch G Hydraulic Pump
H Rear Axle Flange I 4WD Clutch J Front Axle Flange
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
B C D E F
Converter Valve Converter Engine Oil Cooler Forward Clutch
WB140-2N WB150-2N
G H I J 1)
Reverse Clutch Max Pressure Valve Spin On Filter Pump Suction Strainer
1! 1@ 1# 1$ 1%
Control Valve Check Valve Check Valve 4WD Solenoid 4WD Clutch
10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
MACHINES
b Engine c Torque Converter d Forward Clutch
10-14
TRANSMISSION DIAGRAM
E Transmission F Reverse Clutch G Hydraulic Pump
H Rear Axle Flange
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
B C D E
Converter Valve Converter Engine Oil Cooler
WB140-2N WB150-2N
F G H I
Forward Clutch Reverse Clutch Max Pressure Valve Spin On Filter
J 1) 1! 1@
Pump Suction Strainer Control Valve Check Valve
10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
TRANSMISSION COMPLETE ASSEMBLY
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
10-16
F G H I
Suction Strainer
a From Oil Cooler
Reverse Solenoid
b To Oil Cooler
Forward Solenoid
c To Solenoid Valves
4WD Solenoid
d From Solenoid Valves
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
WB140-2N WB150-2N
F G H I
Suction Strainer
a From Oil Cooler
Reverse Solenoid
b To Oil Cooler
Forward Solenoid
c To Solenoid Valves
4WD Solenoid
d From Solenoid Valves
10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
10-18
F Suction Strainer G Reverse Solenoid H Forward Solenoid
a From Oil Cooler b To Oil Cooler c To Solenoid Valves d From Solenoid Valves
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
WB140-2N WB150-2N
F Suction Strainer G Reverse Solenoid H Forward Solenoid
a From Oil Cooler b To Oil Cooler c To Solenoid Valves d From Solenoid Valves
10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft Drive Gears and Shaft
10-20
H I J 1) 1! 1@
Rear Axle Flange 3rd Driven Gear 4th Driven Gear 4WD Drive Gear 1st Driven Gear
1# 1$ 1% 1^ 1&
4WD Clutch 4WD Clutch Shaft Front Axle Flange 2nd Driven Gear Rear Output Shaft
4WD Driven Gear
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft Drive Gears and Shaft
WB140-2N WB150-2N
H I J 1) 1! 1@
Rear Axle Flange 3rd Driven Gear 4th Driven Gear 4WD Drive Gear 1st Driven Gear
1# 1$ 1% 1^ 1&
4WD Clutch 4WD Clutch Shaft Front Axle Flange 2nd Driven Gear Rear Output Shaft
4WD Driven Gear
10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft
10-22
G H I J 1)
Drive Gears and Shaft Rear Axle Flange 3rd Driven Gear
1! 1st Driven Gear 1@ 2nd Driven Gear 1# Rear Output Shaft
4th Driven Gear Gear Spacer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft
WB140-2N WB150-2N
G H I J 1)
Drive Gears and Shaft Rear Axle Flange 3rd Driven Gear
1! 1st Driven Gear 1@ 2nd Driven Gear 1# Rear Output Shaft
4th Driven Gear Gear Spacer
10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Gear Shift Lever Centering Spring Return Spring Check Ball 3rd And 4th Selecting Fork 1st And 2nd Selecting Rod
10-24
H I J 1) 1! 1@
3rd And 4th Selecting Rod 1st And 2nd Selecting Fork 4th Selecting Sensor 3rd And 4th Selector 1st And 2nd Selector
1# 1$ 1% 1^ 1&
Spin On Filter Cold Oil Relief Valve Return Spring Return Spring Return Spring
Suction Strainer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Check Ball Return Spring Piston Return Spring Return Spring
WB140-2N WB150-2N
G H I J 1)
Spring Guide Pin Valve Return Spring Valve Rod
1! 1@ 1# 1$ 1%
Return Spring Spool Return Spring Spool Forward Solenoid Reverse Solenoid
10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 FORWARD
TRANSMISSION
REVERSE CLUTCH
B Reverse Gear C Forward Gear D Forward Clutch Piston
E Reverse Clutch Piston F Thrust Ring G Shaft
a Reverse Clutch Port b Forward Clutch Port c Lubrication Port
1ST THROUGH 4TH SPEED SHAFT
B 2nd Driver Gear C 1st Driven Gear D 4WD Gear
10-26
E 4th Driven Gear F 3rd Driven Gear g Rear Output Shaft
H Thrust Ring I Synchronizer J Gear Spacer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 4WD
TRANSMISSION
SHAFT
B Front Output Shaft C 4WD Driven Gear D Thrust Ring
WB140-2N WB150-2N
E Cylinder F Spring G Disc
a 4WD Pressure Port
10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12
FRONT AXLE 4WD COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut
h Mounting Pin Bushing a Left Cylinder Port b Right Cylinder Port
Unit:mm Check Item i Pin and Bushing Clearance
Standard Size 50
Criteria Tolerance Shaft Bushing 0 +0.04 50 50.19 -0.039 0
Standard Clearance
Clearance Limit
Remedy
---
---
Replace
DIFFERENTIAL 10-28
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
B C D E F G
Side Gear Ring Gear Driven Gear Adjustment Lock Nut Axle Shaft Dowel Pin
H I J 1) 1! 1@
FRONT AXLE
Differential Housing Bearing Spacer Outboard Pinion Bearing Lip Seal Ring Input Flange
1# 1$ 1% 1^ 1&
Pinion Bearing Lock Nut Inboard Pinion Bearing Pinion Gear Dowel Pin Oil Drain Plug
Lip Seal Ring Cover
Unit : mm Check Item 1* 1( 2) 2!
Axle Clearance Ring and Pinion Gear Backlash Pinion Preload * Ring and Pinion Gear Preload *
Criteria Standard Clearance Clearance Limit ----0.17 to 0.23 0.23 92 to 137 N•m 95.9 to 142.9 N•m
Remedy
Adjust
* - Without lip seal ring.
WB140-2N WB150-2N
10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 PLANETARY
B C D E F G H I
Planetary Carrier Planetary Gear Ring Gear Carrier Gear Wheel Hub Lip Ring Seal Upper King Pin Adjustment Shim
Check Item 2% Hub Rotation Torque 2^ Axle Shaft Clearance
10-30
J 1) 1! 1@ 1# 1$ 1% 1^
Belleville Washer Upper King Pin Bushing Lip Ring Seal Axle Housing Spherical Bearing Lower King Pin Bushing Lower King Pin Belleville Washer Criteria -----
1& 1* 1( 2) 2! 2@ 2# 2$
Lip Ring Seal Tapered Roller Bearing Retaining Ring Bolt Bushing Stud Bolt Oil Drain Plug Sun Gear Retaining Ring Remedy Adjust
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 2WD
COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut
h Mounting Pin Bushing a Left Cylinder Port b Right Cylinder Port
Unit : mm Check Item i Pin and Bushing Clearance
WB140-2N WB150-2N
Standard Size 50
Criteria Tolerance Shaft Bushing 0 +0.04 50 50.19 -0.039 0
Standard Clearance
Clearance Limit
Remedy
---
---
Replace
10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 CENTER
HOUSING
B Flange Plug
10-32
FRONT AXLE
c Flange Housing
d Axle Housing
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 STEERING
B C D E F G H I
2@
FRONT AXLE
KNUCKLE
Housing Cover Shaft Plug Screw Bearing Retainer Wheel Hub Lip Ring Seal Upper King Pin Adjustment Shim Check Item Hub Rotation Torque
WB140-2N WB150-2N
J 1) 1! 1@ 1# 1$ 1% 1^
Belleville Washer Upper King Pin Bushing Housing Plug Axle Housing Spherical Bearing
1& 1* 1( 2) 2!
Housing Plug Tapered Roller Bearing Oil Drain Plug Bolt Bushing Stud Bolt
Lower King Pin Bushing Lower King Pin Belleville Washer Criteria ---
Remedy Adjust
10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12
REAR AXLE COMPLETE ASSEMBLY
B C D E
Input Flange Differential Portion Brake Portion Axle Housing
10-34
F G H I
Parking Brake Levers
J Oil Drain Plug 1) Axle Housing Breather
Brake Bleeder Screws
a Brake Port ................. 40.8 kg/cm²
Oil Fill And Level Plugs
b Diff Lock Port ......... 1295.4 kg/cm²
Planetary Portion
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 DIFFERENTIAL
B C D E F
Tapered Roller Bearing Side Gear Rotating Gear Ring Gear Differential Housing
G H I J 1)
1! 1@ 1# 1$ 1%
Bearing Lock Nut Axle Shaft Dowel Pin Tapered Roller Bearing Bearing Lock Nut
Lip Oil Seal Input Flange Bearing Spacer Pinion Gear Differential Housing
Unit : mm Check Item
1^ 1& 1* 1(
Axle Clearance Ring And Pinion Gear Backlash Pinion Gear Preload * Pinion Ring Gear Preload *
Criteria Standard Clearance
Clearance Limit
---
---
0.17 to 0.23
0.23 92 to 138 N•m
Remedy
Adjust
95.23 to 141.84 N•m
* - Without lip seal ring.
WB140-2N WB150-2N
10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 PLANETARY
B C D E F G
Planetary Gear Carrier Wheel Stud Wheel Hub Planet Gear Gear Carrier Tapered Roller Bearings Check Item
1& 1*
10-36
H I J 1) 1! 1@
1# 1$ 1% 1^
Lip Ring Seal Shaft Coupler Inner Axle Shaft Sun Gear Shaft
Outer Ring Gear Oil Fill And Drain Plug Bolt Bushing Planet Gear Shaft
Shaft Bushing Retaining Ring Criteria
Hub Rotation Torque
---
Axle Shaft Clearance
---
Remedy Adjust
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 BRAKES
B C D E
Disc Plate Bushing Parking Brake Control Rod Brake Bleeder Valve Parking Brake Lever
f g h i
Parking Brake Control Cam Brake Disc Plate
j Inner Disc Separator Plate 1) Outer Disc Separator Plate
Actuator Piston Brake Disc Plate Return Spring
Unit : mm
Check Item
1! Brake Disc Return Spring 1@ Disc Return Spring 1# Disc Thickness
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
27
13
127 N•m
21
10 N•m
35
19
369 N•m
21
10 N•m
4.85 to 5
Remedy
Replace
3.3
10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 DIFFERENTIAL
B Engagement Sleeve C Locking Pin D Control Rod
10-38
REAR AXLE
LOCK
e Fork Spacer f Shift Fork g Piston
h Piston Cover i Retaining Ring a Diff Lock Port ......... 1295.4 kg/cm²
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
HYDRAULIC PUMP
b Delivery Variation Valve c Valve Working Mode Solenoid d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line b Case Drain To Suction Line c LS Pressure From Loader Control Valve d Output To Loader Control Valve
WB140-2N WB150-2N
10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
b Delivery Variation Valve c Valve Working Mode Solenoid d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line b Case Drain To Suction Line c LS Pressure From Loader Control Valve d Output To Loader Control Valve
10-40
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
b c d e f g
Lip Seal Ring Tapered Roller Bearing Centering Spring Tapered Roller Bearing Drive Shaft Swash Plate
WB140-2N WB150-2N
H I J 1) 1! 1@
Positioning Piston Swash Plate Positioning Spring Cylinder Block Swash Plate Positioning Piston Pump Piston Guide Shoe
10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 Unit : mm Check Item 1# Bearing Preload
Criteria 0 to 0.05 Standard Size
1$ 1% 1^
1&
Piston To Cylinder Backlash Piston To Shoe Backlash Drive Shaft Diameter
Swash Plate Positioning Spring
10-42
20
Tolerance Shaft Hole ---
Remedy Adjust Standard Clearance
Clearance Limit
Remedy
0.065 0.15
34.91
Free Length ---
Standard Size Installed Installed Length Load 88.7 276 ±12 N
Repair Limit Free Installed Length Load
Remedy Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
Piston Rod
f g h
Bushing
PC VALVE
Initial Adjust Spring
i
POWER GOVERNOR
b c d e
Spring
Pressure Cut Off Screw
j 1)
Initial Adjust Screw
LS VALVE
Pressure Cut Off Spring
Spool
1! 1@
Internal Spring External Spring
1# 1$ 1%
Throttles Throttles Spool
External Spring Internal Spring
Unit : mm
Check Item 1^ 1& 1* 1( 2)
Piston Rod Return Spring Internal Power Reg Spring External Power Reg Spring External LS/PC Spring Internal LS/PC Spring
WB140-2N WB150-2N
Spring Criteria Standard Size Repair Limit Installed Install Installed Free Length Free Length Length Load Load ----------125.4 ±10 N 180.2 ±12 N 40.2 ±3 N 81.7 ±14 N
Remedy
Replace
10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 FUNCTION The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered according to the load requirements. The amount of oil delivered can be modified by changing the angle of the swash plate.
STRUCTURE The cylinder block g is supported and connected to the shaft b by the spline a and the shaft is supported by the front and rear tapered roller bearings. The tip of the piston g is ball shaped. The shoe e is caulked to it to form one unit in such a way that the piston f and the shoe together form a spherical bearing. The swash plate d has a flat surface A and the shoe e remains pressed against this surface while sliding in a circular movement. The swash plate brings highly pressurized oil onto the cylindrical surface B fashioned in the pump body c, which means that the swash plate slides on a hydrostatically supported bearing. The pistons f perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the cylinder block g. The oil is brought up to pressure in the chambers of the cylinder block g by the rotatory movement of the block itself. The areas of pressure and suction are determined by the swash plate f. The surface of the swash plate is so designed that the oil pressure always remains within acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate h.
10-44
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 OPERATION
PUMP OPERATION 1.
The cylinder block g rotates together with the shaft b and the shoe e slides on the flat surface A. The swash plate d moves along the cylindrical surface B. The angle α formed between the center line of the shaft and the center line X of the swash plate changes, thus modifying the axial position of the pistons in relation to the cylinder block. Angle α is known as the swash plate angle.
2.
When the center line X of the swash plate d maintains the angle α in relation to the center line of the shaft b, and hence also of the cylinder block g, the flat surface A acts as a cam for the shoe e. As the piston f rotates and slides inside the cylinder block, it creates a difference between the volumes C and D which provokes intake and discharge of the oil in quantities equal to the difference between the volumes (D - C = delivery). As the cylinder block rotates, chamber D loses volume while the volume of chamber C is increased, thus provoking an intake of oil. The figure indicates the state of the pump when the intake of chamber D and the delivery of chamber C have been completed.
3.
When the center line X of the swash plate d and the center line of the cylinder block g are perfectly aligned (the swash plate angle α = 0), the difference between the volumes C and D within the cylinder block becomes 0 and the pump does not take in or deliver any oil. In practice the swash plate angle α never becomes = 0. Pump delivery is directly proportional to the swash plate angle α.
CONTROL OF DELIVERY 1.
As the swash plate angle α grows larger, the difference between volumes C and D increases, and the delivery Q also increases. The swash plate angle is modified by servo pistons I and J.
2.
The servo piston I moves in a reciprocating linear motion caused by pressure signals from the PC and LS valves. The linear movement is transmitted to the swash plate D, which is supported by the cylindrical surface of the cradle C. The swash plate therefore has a semi-circular reciprocating movement.
3.
The surfaces of the servo pistons receiving the pressures PP and LS are dissimilar. The delivery pressure PP of the main pump is always passed into the smaller (upper) pressure chamber, whereas the pressure PEN coming from the LS valve is passed into the larger (lower) pressure chamber. The movement of the servo piston is governed by the relationship between pressures PP and PEN, as well by the proportions between the surfaces (larger and smaller) of the servo piston.
WB140-2N WB150-2N
10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PC
VALVE, LS VALVE, SERVO PISTON
POWER GOVERNOR
b c
HYDRAULIC PUMP
Spring Servo Piston
D
Servo Piston
LS VALVE
PC VALVE
E F
G H
Piston Spring
Servo Piston Spring
LS VALVE FUNCTION ●
●
The LS valve controls the pump delivery according to the stroke of the control valve level, i.e., in function of the delivery demands made by the actuators. The LS valve detects the actuators delivery needs by means of the differential pressure PLS existing between the pump delivery pressure PP and the pressure PLS coming from the control valve. This reading permits control of the main pump delivery Q. PP, PLS and PLS are, respectively, the pump pressure, the Load Sensing pressure, and the difference in pressure between these two values. The LS valve detects the pressure difference PLS generated by the passage of the oil flow through the surface freed by the control valve spool, and controls the pump delivery Q so as to keep the pressure drop constant. Pump delivery is proportional to the demands made known by the control valve.
10-46
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 OPERATION 1.
When the control valve is in a NEUTRAL position.
●
The pressure PLS of the LS coming from the control valve outlet passes into chamber a of the spring of the LS valve. The pressure PP of the pump passes into chamber b of the opposite side. The piston rod movement e is determined by the combination of the force generated by the pressure PLS, the force of the spring g and the force generated on the side opposite the piston rod by the pressure PP. Before the engine is started the servo piston d is pushed to the right by the spring b, corresponding to the maximum angle of the swash plate. If all the control valve spools are in their NEUTRAL position when the engine is started, the pressure PLS of the LS will remain at 4.1 to 8.16 kg/cm² because no oil is flowing through the control valve. At the same time the pump pressure PP increases and is maintained at a value of about 27.54 kg/cm². For this reason the piston e is thrust to the right ( ) and a passage is formed between the delivery lines c and d. This opening enables the pump pressure PP to enter chamber X of the servo piston d. Although the pump pressure PP is always passed into chamber Y of the servo piston c, since the force exerted by that pressure on piston d exceeds the force exerted on piston, the servo piston b moves to the right ( ), i.e. towards the side of the minimum angle of the swash plate.
● ● ●
● ●
WB140-2N WB150-2N
10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 2. When a control valve lever is activated
● ● ●
●
When the control valve lever is moved out of its NEUTRAL position, the opening f is determined, allowing an LS signal to be generated. Until the PLS generates a force less than the force exerted by the spring g on the spool e, the system will remain stable. When the opening f is such as to provoke a reduction in PLS, the spool moves to the left ( ) to form a passage between delivery lines d and e. The chamber X loses pressure and the servo piston causes the swash plate to move towards maximum displacement. Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force exerted by the spring g, and the passage between delivery lines c and d is reopened.
10-48
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 3. When the control valve opening is at its maximum, lever at the end of its stroke.
● ●
● ●
When the control lever is moved to full stroke, the spool opening reaches its maximum, the difference between the pump pressure PP and the LS pressure PLS becomes smaller, differential pressure PLS. The LS pressure PLS introduced into the chamber a of the LS valve becomes about the same as the pump pressure PP and the piston e is moved to the left ( ) by the combined forces generated by the pressure PLS and the spring g. The piston movement closes the delivery line c and forms a passage between lines d and e. The pressurized oil present in the chamber X of the servo cylinder D flows through the lines d and e and reaches the pump drainage chamber, so that the pressure in chamber X of the servo cylinder B becomes equal to the drainage pressure. The servo piston D is thus moved to the right ( ) by swash plate movement due to the pressure PP in the chamber Y of the servo cylinder C. It is drawn in the direction of the increase in angle of the swash plate.
WB140-2N WB150-2N
10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 4. When the spool makes very small movements, fine control.
● ●
● ●
●
When the control valve lever moves in very small increments towards the NEUTRAL position, when the control valve opening f diminishes, the differential pressure PLS between the pump pressure PP and the LS pressure PLS increases. If the differential pressure PLS generates on the spool e a difference in force that exceeds the force exerted by the spring g, the spool moves to the right ( ) and a passage is formed between the delivery lines c and d. The pressure PP is introduced into the chamber X and the swash plate moves towards its minimum angle. When the control valve lever performs small movements towards the position of maximum opening, when the opening f of the control valve increases, the differential pressure PLS diminishes. If the differential pressure PLS generates on the spool e a force difference that does not exceed the force exerted by the spring g, the spool moves to the left ( ) and a passage is formed between the delivery lines d and e. The chamber X loses pressure and the servo piston provokes a movement of the swash plate towards maximum displacement. Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force exerted by the spring g, and hence the passage between delivery lines c and d is also reopened.
10-50
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 5. When pump flow matches the demands of the control valve
● ●
●
● ●
A1 will be the surface of the servo piston d, A2 the surface of the servo piston (2), PEN the pressure acting on the piston b and PP the pressure acting on the piston side c. When pump delivery reaches the quantity demanded by the control valve, the pump pressure PP in chamber b of the LS valve is in equilibrium with the combined forces of the LS pressure PLS in chamber a, and the force exerted by the spring g. Once equilibrium has been reached the piston e stops in the central position. In this condition the passage from chamber c to chamber d remains only slightly open in order to maintain pressure in chamber d. A flow of oil is introduced into the servo cylinder d at a pressure that balances the force generated by the pump pressure PP in the cylinder c. PEN x A1 = PP x A2. The stability of the equilibrium is guaranteed by a flow stabilized by the throttle g. The force of the spring g is regulated so that the piston e is in equilibrium when PP - PLS = PLS = 18.36 kg/cm². The pump flow is made proportional to the section of the opening of the control valve, which maintains the differential pressure. PLS = 18.36 kg/cm².
WB140-2N WB150-2N
10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PC
VALVE FUNCTION
●
The PC valve performs an approximate power check, and ensures that the hydraulic horse power absorbed by the pump does not exceed the horse power delivered by the endothermal engine. This is achieved by limiting the pump delivery Q in function of the delivery pressure PP, even if the LS valve requests an increase in delivery Q due to the larger section freed by the control valve spool, in the presence of high pressure pump delivery. During operation the delivery Q increases and the delivery pressure PP also increases simultaneously, the PC valve reduces the pump delivery Q. When the delivery pressure PP decreases, the PC valve increases the pump flow. The relationships between the pump delivery pressure PP and the delivery Q are shown in the diagram.
●
●
●
10-52
HYDRAULIC PUMP
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 Operation 1.
When the load on the actuators is heavy, high pump delivery pressure
●
When a higher delivery is required, the LS valve receives a signal from the control valve to bring the pump up to maximum displacement. When the swash plate moves it also moves the bushing c joined to it by the pin b, which releases the spring d. As the pressure of the actuators increases, pressure also increases in the delivery line c. When the calibrated setting of the spring d is reached, the piston rod e is thrust to the left ( ) and the passage between chamber b and the pump drainage chamber a is opened. The opening of the passage between the chambers b and a generates a flow of oil and hence, due to the calibrated hole g, a P is generated between chambers f and g at the sides opposite the spool f. P = PP - PPC When the value of PP exceeds the value of the spring loading h the spool f moves to the right ( ) opening the passage between the delivery lines d and e and sending the pump pressure PP towards the servo cylinder i. The pressure PP introduced into chamber X of the cylinder pushes it towards the minimum angle of the swash plate ( ).
●
● ●
WB140-2N WB150-2N
10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 2. When equilibrium has been reached
●
● ●
●
When the piston i is pushed to the left ( ) the bushing c is also moved. The oil flow between the chambers b and a is reduced and the PPC pressure tends to approach the PP pressure value. The P decreases and the spool f is pushed to the left ( ) by the force of the spring h. Equilibrium is reached when the force generated by the PP pressure, the force generated by the PPC pressure, and the force of the spring h are all balanced. The force generated by PP = the force generated by the PPC + the spring force. In this condition the passage from chamber d to chamber e remains only slightly open in order to maintain pressure in chamber e. A flow of oil is introduced into the cylinder i at a pressure that balances the force generated by the pump pressure PP acting on the cylinder j. PEN x A1 = PP x A2 The stability of this equilibrium is generated by a continuous stabilized flow from the throttle 1).
10-54
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 3. When the load on the actuators decreases, pump delivery pressure drops
● ●
● ●
When the load on the actuators diminishes and the pump delivery pressure PP drops, the PPC. pressure also drops. The reduction in the PPC causes the spool e to move and the passage between chambers b, d and a is closed. The PPC pressure and the PP pressure of the pump are equalized due to the interruption of the oil flow through the calibrated hole g and the P becomes zero P = PP - PPC = 0. The spring h pushes the spool f to the left ( ) closing the passage between the chambers d and e and opening the passage between chambers e and g. The pressurized oil present in chamber X of the servo cylinder i passes through chambers e and g and reaches the pump drainage chamber, so that the pressure in chamber X of the servo cylinder becomes equal to the drainage pressure. The servo piston j is caused to move by the PP pressure in chamber Y of the servo cylinder, in the direction of the increase in the angle of the swash plate.
WB140-2N WB150-2N
10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 4. The function of the spring
●
●
●
The loading on the springs d and 1! of the PC valve changes in proportion to the angle of inclination of the pump swash plate. The compression of the spring varies with the movements of the servo piston i. When the piston moves to the left ( ), the spring is compressed. If the piston moves even further to the left ( ), the spring 1! comes into action to increase the loading. The overall loading of the springs is varied by the piston, which either compresses or releases them. The pump absorption torque curve, which indicates the relationship between the pump delivery pressure PP and the delivery Q, is a broken line. The position in which the piston i stops, the pump absorption torque, is determined by the position in which the PPC pressure applied to the spool e is balanced by the force exerted by the springs d and 1!. As pump delivery pressure PP increases, delivery Q decreases, and as pressure PP diminishes, pump delivery Q increases.
10-56
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 WORKING
HYDRAULIC PUMP
MODE SOLENOID VALVE
Function ●
Calibration of the pump absorption torque is normally performed for the working mode E. When the solenoid valve of the working mode is commutated the absorbed power of the pump is increased, as indicated by the working mode curve.
Operation WORKING MODE E
● ●
During normal operation, working mode E, the PC valve intervenes when a P1 is generated equal to the loading on the spring e. The P1 is generated by the calibrated hole d in the spool of the PC valve c when, at a determined pump delivery pressure P1, the valve b puts the delivery line a into discharge, thus generating a flow F1 in the delivery line a.
WB140-2N WB150-2N
10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 WORKING MODE P
● ●
● ●
When the solenoid valve g is commutated, working Mode P, the pressurized oil coming from the pump changes its route and passes through the throttle f, which has a larger diameter than the calibrated hole d. Because the throttle f has a larger diameter, the P2 generated is less than is needed to overcome the force generated by the spring e. The spool of the PC valve c is therefore pushed to the left ( ) by the force of the spring. This shift obliges the pump to increase displacement and hence the delivery. The increase in flow causes an increment of the P2 which, when the loading value of the spring is reached, allows the spool to shift to the right ( ). The pump starts to work in normal fashion once again, and all the valves recommence normal functioning.
10-58
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING UNIT
12
STEERING UNIT
a. b. c. d. e.
Port LS Port T Port L Port D Port P
From the loader control valve To the hydraulic oil tank To the steering cylinder To the steering cylinder From the loader control valve
TECHNICAL DATA Steering unit type .................................................LAGCSDS160P Displacement ............................................................... 160 cc/rev.
OPERATION ●
●
The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering wheel is turned, the control valve sends oil from the pump P2, by means of the rotating oil dispenser, to one side of the steering cylinder. The rotating dispenser ensures that the volume of oil supplied to the cylinder is proportionate to the angle of rotation of the steering wheel. In the event of malfunction, the rotating oil dispenser will function automatically as a hand pump, thus guaranteeing auxiliary steering.
WB140-2N WB150-2N
10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
LOADER VALVE 2 SPOOL
a b c d e f g h j
b c d e f g
Port D - To the Hydraulic Steering Unit Port A2 - To the Bucket Cylinders Port A1 - To the Boom Cylinders Port LS - To the Pump Port T - To the Hydraulic Oil Tank Port P - From the Pump
Loader Relief Valve Plug Ball Check Valve Spring Priority Valve Piston Rod Priority Valve Spring
Port B1 - To the Boom Cylinders Port B2 - To the Bucket Cylinders Port DLS - To the Hydraulic Steering Unit
Unit : mm
Check Item h i
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Check Valve Spring Priority Valve Spring
10-60
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
b c d e f
Port Plug Boom Raise Spool Spool Return Spring Spool Locking Spring
Detent Ball
G H I J 1)
Detent Lock Ball Compensator Anti Cavitation Valve
1! Holding Coil 1@ Check Valve Spring 1# Check Valve
Bucket Dump Spool Spool Return Spring
Unit : mm
Check Item 1$ 1% 1^ 1&
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Spool Return Spring Spool Locking Spring Spool Return Spring Check Valve Spring
WB140-2N WB150-2N
10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 3 SPOOL
a b c d e f g h j
LOADER VALVE
VALVE
k m b c d e f g
Port D - To the Hydraulic Steering Unit Port A3 - To the Auxiliary Cylinders Port A2 - To the Bucket Cylinders Port A1 - To the Boom Cylinders Port LS - To the Pump Port T - To the Hydraulic Oil Tank Port P - From the Pump Port B1 - To the Boom Cylinders
Port B3 - To the Auxiliary Cylinders Port DLS - To the Hydraulic Steering Unit Loader Relief Valve Plug Ball Check Valve Spring Priority Valve Piston Rod Priority Valve Spring
Port B2 - To the Bucket Cylinders
Unit : mm
Check Item h i
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Check Valve Spring Priority Valve Spring
10-62
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
b c d e f
Port Plug Boom Raise Spool Spool Return Spring Spool Locking Spring
Detent Ball
G H I J 1)
Detent Lock Ball Compensator Anti Cavitation Valve Bucket Dump Spool
1! 1@ 1# 1$
Holding Coil Check Valve Spring Check Valve Auxiliary Spool
Spool Return Spring
Unit : mm
Check Item 1% 1^ 1& 1*
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Spool Locking Spring Spool Return Spring Check Valve Spring Spool Return Spring
WB140-2N WB150-2N
10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CONTROL VALVE
12
BACKHOE CONTROL VALVE MECHANICAL CONTROL
10-64
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
A B C D E F G H I
J Arm Cylinder Section A1 Swing Cylinder Section A2 Right Outrigger Cylinder Section A3 Left Outrigger Cylinder Section A4 Bucket Cylinder Section A5 Boom Cylinder Section A6 Telescopic Arm Cylinder Section A7 Hammer Cylinder Section A8 Inlet Section
BACKHOE CONTROL VALVE Outlet Section Arm Cylinder Barrel Right Swing Cylinder Barrel Right Outrigger Cylinder Barrel Left Outrigger Cylinder Barrel Bucket Cylinder Barrel Boom Cylinder Barrel Telescopic Arm Cylinder Barrel
B1 B2 B3 B4 B5 B6 B7 B8
Arm Cylinder Rod Right Swing Cylinder Rod Right Outrigger Cylinder Rod Left Outrigger Cylinder Rod Bucket Cylinder Rod Boom Cylinder Rod Telescopic Arm Cylinder Rod Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve b Return Spring
C Retainer Plug D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item f
Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-65
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 ARM
BACKHOE CONTROL VALVE
SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-66
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 SWING
BACKHOE CONTROL VALVE
SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LEFT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW E-E
a Port Plug D Left Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-68
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 RIGHT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BUCKET
BACKHOE CONTROL VALVE
SECTION VIEW G-G
a Circuit Relief Valve D Bucket Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-70
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BOOM
BACKHOE CONTROL VALVE
SECTION VIEW H-H
a Adjustable Circuit Relief Valve D Boom Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball WB140-2N WB150-2N
10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 TELESCOPIC
BACKHOE CONTROL VALVE
ARM SECTION VIEW K-K
a Port Plug D Telescopic Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Anti Cavitation Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-72
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 HAMMER
BACKHOE CONTROL VALVE
SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 EXCAVATOR
10-74
BACKHOE CONTROL VALVE
CONTROL
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
A B C D E F G H I
J Arm Cylinder Section A1 Swing Cylinder Section A2 Right Outrigger Cylinder Section A3 Left Outrigger Cylinder Section A4 Bucket Cylinder Section A5 Boom Cylinder Section A6 Telescopic Arm Cylinder Section A7 Hammer Cylinder Section A8 Inlet Section
BACKHOE CONTROL VALVE Outlet Section Arm Cylinder Barrel Right Swing Cylinder Barrel Right Outrigger Cylinder Barrel Left Outrigger Cylinder Barrel Bucket Cylinder Barrel Boom Cylinder Barrel Telescopic Arm Cylinder Barrel
B1 B2 B3 B4 B5 B6 B7 B8
Arm Cylinder Rod Right Swing Cylinder Rod Right Outrigger Cylinder Rod Left Outrigger Cylinder Rod Bucket Cylinder Rod Boom Cylinder Rod Telescopic Arm Cylinder Rod Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve b Return Spring
C Retainer Plug D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item f
Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 ARM
BACKHOE CONTROL VALVE
SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-76
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 SWING
BACKHOE CONTROL VALVE
SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LEFT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION Ù VIEW E-E
a Port Plug b LIFD - Load Independent Flow Divider C Port Plug
D Left Outrigger Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-78
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 RIGHT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BUCKET
BACKHOE CONTROL VALVE
SECTION VIEW G-G
a Adjustable Circuit Relief Valve D Bucket Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-80
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BOOM
BACKHOE CONTROL VALVE
SECTION VIEW H-H
a Adjustable Circuit Relief Valve b LIFD - Load Independent Flow Divider C Adjustable Circuit Relief Valve
D Boom Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball WB140-2N WB150-2N
10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 TELESCOPIC
BACKHOE CONTROL VALVE
ARM SECTION VIEW K-K
a Port Plug b LIFD - Load Independent Flow Divider C Anti Cavitation Valve
D Telescopic Arm Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-82
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 HAMMER
BACKHOE CONTROL VALVE
SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
CLSS CHARACTERISTICS The term CLSS means Closed Center Load Sensing System, which has the following characteristics: ● High precision control that is independent of the load applied to the movement; ● High precision control of digging action even during delicate manoeuvres. ● Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the shuttles. ● Energy savings guaranteed by control of pump delivery.
STRUCTURE ● ●
The CLSS system includes the variable flow pump, the control valve and the working equipment. The pump includes the main pump, the PC valve and the LS valve.
10-84
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
OPERATING PRINCIPLES 1.
Control of the angle of the pumping plate. ● The angle of the swash plate and the pump delivery, is controlled in such a way that the differential pressure PLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards the actuator is maintained at a constant value. PLS = pump delivery pressure PP minus pressure PLS of delivery to the actuator. ● If the differential pressure PLS becomes lower than the set pressure of the LS valve, the angle of the swash plate increases, delivery increasing. ● If the differential pressure PLS increases, the angle of the swash plate decreases.
WB140-2N WB150-2N
10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 2. Pressure compensation control. ● The pressure compensation valves are installed downstream from the control valve in order to balance the differential pressure between the loads. ● When two or more movements (cylinders) are activated simultaneously, the pressure differences P between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
10-86
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 UNLOADING
CLSS
VALVE
FUNCTION 1.
When the control valve is in the NEUTRAL position, the flow of the pump, due to the swash plate being in the minimum angle position, is sent to the control valve. In these conditions, the pump delivery pressure PP is regulated to 27.5 kg/cm² by the spring a inside the valve. PP = PLS + spring load with PLS = 6.1 kg/cm²
OPERATION When the control valve is in the NEUTRAL position ● On the two surfaces of the shuttle b, the pump pressure PP acts on the right side, while the LS signal with pressure PLS acts on the left side. ● Because a LS signal is generated with a pressure PLS 6.1 ± 2 kg/cm², when the control valve is in the NEUTRAL position, the pump delivery pressure PP is regulated by the combination of the pressure provided by the spring and by the LS pressure PLS. ● While the pump delivery pressure PP increases until it compensates for the loading on the spring a and for the LS pressure 27.5 kg/cm², the shuttle b moves to the left ( ) and the PP circuit is put into communication with the tank circuit T. ● This system ensures that the pump delivery pressure PP stays regulated at 27.5 kg/cm².
WB140-2N WB150-2N
10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 1. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by the pressure PLS + 21.5 kg/cm². Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and the PLS LS pressure becomes equivalent to the loading of the spring a (21.5 kg/cm²), the differential LS pressure PLS LS becomes 21.5 kg/cm².
Final control of control valve ● When final control are performed with the control valve, a pressure PLS is generated that pressurizes the spring chamber, acts on the left extremity of the valve b. The actuator pressure is introduced into the LS circuit and then into the spring chamber. As a result, the pump pressure PP tends to increase. ● When the differential pressure between the pump delivery pressure PP and the LS pressure PLS has the same value as the loading on the spring a (21.5 kg/cm²), the shuttle b moves to the left ( ) and the pump circuit PP puts itself into communication with the tank circuit T. The exceeding pump delivery, relative to the actuator request, is sent to the tank circuit. ● The pump delivery pressure PP is regulated by the combination of the pressure provided by the spring (21.5 kg/cm²) and by the LS pressure PLS, i.e. when the pressure differential PLS reaches the value of 21.5 kg/cm².
10-88
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 2. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control valve, the connection to the tank circuit is eliminated and all the pump delivery is sent to the actuators.
When the control valve is in use ● When the control valve shuttle is operated to execute a bigger stroke, the opening section of spool becomes bigger and consequently the controlled delivery. Because the control valve passage is large, the difference between the LS pressure PLS and the pump delivery pressure PP is reduced to 18.4 kg/cm², LS pump valve setting. ● Because the differential pressure between the pump delivery pressure PP and the LS pressure PLS is not equal to the pressure given by the spring loading a (21.5 kg/cm²), the shuttle b is pushed to the right ( ) of the spring. ● The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the entire pump delivery is sent to the actuators.
WB140-2N WB150-2N
10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
INTRODUCTION OF THE LS PRESSURE ●
The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control valve.
OPERATION ● ●
● ●
When the spool b is activated, pump pressure PP starts to flow into the actuator circuit A through chamber b. At the same time the compensator c moves upwards ( ) so that the flow controlled by spool b can flow towards the actuator A. Check valve a do not allow any flow up to when pressure in chamber c is higher than pressure in chamber b. Pressure downstream of the spool flows in the PLS circuit downstream the compensator valve through the orifice d. The PLS circuit of the LS is thus in communication with the tank circuit T by means of the LS decompression valve d. The system stabilizes when a pressure difference of 18.4 kg/cm² is generated across the spool b between pump pressure PP and PLS pressure.
10-90
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 DELIVERY
CLSS
COMPENSATION
INTRODUCTION The flow sent to each actuator is controlled by the opening area of each spool. While performing complex control, in traditional control valves the difference between actuators pressure might cause sudden and unexpected movements acceleration in those actuators operated at lower pressure. The adoption of the pressure compensation valve allow to control those situation guarantying the proportionality between each actuator. Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements, the pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to be supplied the actuator operating at lower. In the diagram the actuator on the left is requesting higher pressure.
OPERATION 1. ●
●
●
When activating an actuator at a pressure lower than the one already working. While operating actuator A starts operating actuator B. Until the pressure PBV downstream from the shuttle b reaches the same value requested by actuator B, no oil passes. When the pressure requested by actuator B is exceeded, movement can commence. This creates a flow that adding to the one controlled by spool d reduces the pressure upstream of spool b and d and therefore the P between PLS and PP. The pump compares the delivery pressures PP and PLS and senses that the difference P<18.4 kg/cm². This variation in P causes an increase in oil flow increasing the swash plate angle. Until the pump realizes a P of 18.4 kg/cm², i.e. until the increase in oil flow compensates the requirements of the two actuators, the pump will continue to increase delivery. P of 18.4 kg/cm², will stabilize as soon as it is restored to. The compensator C is moved upwards by the oil flow and stops when the aperture between the chambers a and b reduces the passage sufficiently to reduce the pressure in chamber b to be sent to the actuator.
WB140-2N WB150-2N
10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 2. When a low pressure actuator needs to work at a higher pressure than the other
● ● ● ● ● ● ●
If the actuator B needs to work at a higher pressure, PB>PA, the pressure PB will start to increase. Since pressure PB is increasing, the compensator c moves upwards to restore the P between the chambers a and b, and therefore the P does not vary upstream or downstream from the shuttle b. When pressure PB exceeds pressure PA the compensator c is fully open and the pressure PB is introduced into the LS circuit. The increased pressure in the LS circuit obliges the pump to increase delivery until the P is restored to 18.4 kg/cm². Simultaneously the increase in pressure upstream from the shuttle d generates an increase in P upstream and downstream from the shuttle. (PAV
10-92
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 3. When an increase in delivery is required by an actuator
● ● ●
When an increased delivery is required by actuator A, i.e. when the shuttle d is asked to execute a bigger movement, the section of the aperture increases. The increase in aperture provokes a drop in P between the two sides of the shuttles b and d, because the flow, which has remained unchanged until now, is divided between both the actuators. At the same time the pump senses the variation in P and increases the oil flow until the P is restored to P of 18.4 kg/cm² between the two sides of the shuttle d and the compensator a changes position in order to restore the P upstream and downstream from the shuttle d.
WB140-2N WB150-2N
10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LIFD
CLSS
CONTROL SYSTEM
FUNCTION ●
The Load Independence Flow Divider, LIFD, intervenes automatically when the oil flow requested by the actuators exceeds the maximum delivery guaranteed by the pump. In this case, the oil flow is divided between the various actuators in proportion to their requirements.
OPERATION ●
●
●
●
When, during the simultaneous operation of more than one actuator, one of them needs a higher pressure and the characteristics of the pump are exceeded, the pump guarantees a delivery limited by its calibration curve. At this point less oil than requested is distributed to all the actuators. Because the sections of the apertures remain unchanged, the pressure upstream and downstream from the shuttles drops. Since the position of the compensator e is determined by the pressure of the LS signal, by the pressure PBV downstream from the shuttle d and by the flow of oil needed for the movement, the compensator is pushed downwards by the higher pressure in the upper chamber until the pressure PBV downstream from the shuttle becomes equal to the pressure PAV downstream from the shuttle b. This equalizes the pressure P of the shuttle. Thus the flow of each actuator is reduced by a percentage equal to the reduction or absence of pump delivery. When the request for performance is excessive, the system can nevertheless guarantee proportionality and gradually for the movements in any load conditions. If an increase in delivery is requested, rather than an increase in pressure, and the characteristics of the pump are exceeded, the system will function in the same way as described for the above case.
10-94
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LS
CLSS
DECOMPRESSION VALVE
DESCRIPTION The LS decompression valve is a throttle that continuously releases a small quantity of oil from the LS circuit and that, when the shuttles are brought back to a neutral position, releases the residual LS pressure. This continued flow renders the PLS pressure increment more gentle and gradual, and increases stability and control during the phases of reducing the LS pressure.
OPERATION ●
When the LS pressure reaches chamber a of the valve, it generates a force that opposes the force of the spring a. ● Until the force generated by the LS pressure exceeds the force of the spring a (LS pressure low) the shuttle b remains at rest and oil flows through the calibrated orifice b in the tank circuit. ● When the force generated by the LS pressure exceeds the force of the spring a, the shuttle is pushed upwards ( ) and the passages c are closed. Oil continues to flow into the chamber d until the force generated by the pressure contained in chamber d, together with the force of the spring, exceeds the force generated by the LS pressure. ● The shuttle is pushed downwards ( ) and passage c is opened. The system is in equilibrium, i.e. the shuttle is at rest, when the quantity of oil allowed to flow into the tank circuit is equivalent to the quantity that generates a pressure difference P such that PLS x S = [PLS1 x S + F] where: PLS = LS pressure PLS1 = LS pressure contained in chamber d S = Section of the shuttle F = Force of the spring
WB140-2N WB150-2N
10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PRESSURE
CLSS
CUT OFF VALVE
DESCRIPTION The function of the pressure cut off valve is to regulate the maximum pressure of the LS signal and hence also the pressure of the pump.
OPERATION ● ●
The pressurized oil of the LS reaches the chamber a of the valve. When the force generated by the LS pressure on the valve b exceeds the force of the spring a, the valve is pushed upwards ( ) opening the passage between the chamber a and the tank circuit.
10-96
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PRIORITY
CLSS
VALVE
FUNCTION The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Distribution is determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from the pump, the pressure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such as to guarantee that delivery to the steering unit will always correspond to the actual need.
WB140-2N WB150-2N
10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC JOYSTICK
12
PPC JOYSTICK LEFT VALVE
a b c d e f
Port 1 Port T Port 4 Port 3 Port P Port 2
10-98
To Backhoe Arm Control Valve - Crowd In .................................... Port PA1 To Hydraulic Tank To Backhoe Swing Control Valve - Right ....................................... Port PB2 To Backhoe Arm Control Valve - Crowd Out.................................. Port PB1 To Solenoid Valve Group - ST2 ..................................................... Port S1 To Backhoe Swing Control Valve - Left.......................................... Port PA2
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 RIGHT
a b c d e f
Port 1 Port T Port 4 Port 3 Port P Port 2
PPC JOYSTICK
VALVE
To Backhoe Boom Control Valve - Lower ...................................... Port PA6 To Hydraulic Tank To Backhoe Bucket Control Valve - Dump..................................... Port PA5 To Backhoe Boom Control Valve - Raise....................................... Port PB6 To Solenoid Valve Group - ST2 ..................................................... Port S1 To Backhoe Bucket Control Valve - Curl........................................ Port PB5
WB140-2N WB150-2N
10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
12
SOLENOID VALVE DIFFERENTIAL LOCK - BACKHOE BOOM LOCK
A EV4 B EV3
Backhoe Boom Lock Differential Lock
a
Port T To the Transmission
b
Port 1 Boom Lock Cylinder
c
Port 2 To the Rear Axle
d
Port P From the Transmission
10-100
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PPC
A B c d e
SOLENOID VALVE
SUPPLY VALVE - ST2
Y14
PPC Valve
a
ACC
Accumulator
Y23
Right Outrigger Lower
b
P
To Backhoe Control Valve Port M
Y16
Right Outrigger Raise
c
S1
To PPC Valve Port P
Y24
Left Outrigger Raise
d
A1
To Backhoe Right Outrigger Valve Port PA4
Y15
Left Outrigger Lower
e
A2
To Backhoe Left Outrigger Valve Port PA3
f
B2
To Backhoe Left Outrigger Valve Port PB3
g
B1
To Backhoe Right Outrigger Valve Port PB4
h
T
To Hydraulic Tank
WB140-2N WB150-2N
10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PPC
SOLENOID VALVE
TELESCOPIC ARM
A Y22 B Y21
10-102
Telescopic Arm Retract
a
A
To Backhoe Control Valve Port PA7
Telescopic Arm Extend
b
B
To Backhoe Control Valve Port PB7
c
P
To PPC Supply Valve ST2 Port S1
d
T
To Hydraulic Tank
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PPC
SOLENOID VALVE
HAMMER
A Y20
Hammer
a
A
To Backhoe Control Valve Port PA8
b
P
To PPC Supply Valve ST2 Port S1
T
To Hydraulic Tank and Backhoe Control Valve Port PB8
c
WB140-2N WB150-2N
10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PPC
SOLENOID VALVE
ARM AND HAMMER
A B Y22 c Y21
10-104
Hammer
a
T
To Hyd. Tank and Control Valve Port PB7
Telescopic Arm Retract
b
B
To PPC Supply Valve ST2 Port S1
Telescopic Arm Extend
c
A1
To Backhoe Control Valve Port PB7
d
B1
To Backhoe Control Valve Port PA7
e
A
To Backhoe Control Valve Port PA8
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER CYLINDERS
12
LOADER CYLINDERS BOOM ARM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Head
Unit : mm Check Item
Standard Size
i
Piston Rod to Head
50
j
Piston Rod Bushing and Pin
45
1)
Barrel Bushing and Pin
50
Criteria Tolerance Shaft Hole 49.975 50.15 49.950 50.25 44.950 45.08 44.911 45.24 49.950 50.08 49.911 50.24
Standard Clearance 0.175 0.300 0.13 0.33 0.13 0.33
Clearance Limit
Remedy
Replace Replace pin and bushing
CHARACTERISTICS Unit : mm Piston Rod Diameter
50
Max Cylinder Length
1880
Cylinder Barrel Bore
85
Min Cylinder Length
1150
Piston Stroke
730
Rod Thread for Piston Nut
55
WB140-2N WB150-2N
10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER CYLINDERS
12 BUCKET
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four Piece Piston Seal F Cylinder Piston
Unit : mm Check Item Standard Size
i
Piston Rod to Head
50
j
Piston Rod Bushing and Pin
45
1)
Barrel Bushing and Pin
50
Criteria Tolerance Shaft Hole 49.975 50.15 49.950 50.25 44.950 45.08 44.911 45.24 49.950 50.08 49.911 50.24
G Cylinder Rod H Cylinder Head
Remedy Standard Clearance 0.175 0.300 0.13 0.33 0.13 0.33
Clearance Limit Replace Replace pin and bushing
CHARACTERISTICS Unit: mm Piston Rod Diameter
50
Max Cylinder Length
2145
Cylinder Barrel Bore
85
Min Cylinder Length
1390
Piston Stroke
755
Rod Thread for Piston Nut
55
10-106
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 MP
LOADER CYLINDERS
BUCKET
A Piston Rod Bushing B Cylinder Rod C Cylinder Head
D Cylinder Piston E Four Piece Piston Seal F Piston Retaining Pin
G Cylinder Barrel
CHARACTERISTICS Unit : mm Piston Rod Diameter
45
Max Cylinder Length
705
Cylinder Barrel Bore
80
Min Cylinder Length
450
Piston Stroke
230
WB140-2N WB150-2N
10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12
BACKHOE CYLINDERS BOOM
A B C D
E F G H
Piston Rod Bushing Barrel Bushing Cylinder Barrel Stop Ball
Four Piece Piston Seal Cylinder Piston Cylinder Rod Cylinder Head
i j 1) 1!
Set Screw Stop Pin Check Valve Check Valve Spring
Unit : mm Check Item
Standard Size
1@
Piston Rod to Head
60
1#
Piston Rod Bushing and Pin
50
1$
Barrel Bushing and Pin
50
Check Item 1%
Free Length 35
Check Valve Spring
Criteria Tolerance Shaft Hole 59.970 60.030 59.924 60.076 49.950 50.08 49.911 50.24 49.950 50.08 49.911 50.24 Spring Criteria Standard Size Installed Installed Length Load
Standard Clearance
Clearance Limit
0.060 0.152 0.13 0.33 0.13 0.33
Remedy
Replace Replace pin and bushing
Repair Limit Free Installed Length Load
Remedy
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter
60
Max Cylinder Length
2050
Cylinder Barrel Bore
120
Min Cylinder Length
1200
Piston Stroke
850
Rod Thread for Piston
41
10-108
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 ARM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Head i Piston Spacer
Unit : mm Check Item
Standard Size
j
Piston Rod Bushing and Pin
45
1)
Barrel Bushing and Pin
50
1!
Piston Rod to Head
60
Criteria Tolerance Shaft Hole 44.950 45.08 44.911 45.24 49.950 50.08 49.911 50.24 59.970 60.030 59.924 60.076
Standard Clearance 0.13 0.33 0.13 0.33 0.060 0.152
Clearance Limit
Remedy
Replace pin and bushing Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter
60
Max Cylinder Length
2175
Cylinder Barrel Bore
110
Min Cylinder Length
1255
Piston Stroke
920
Rod Thread for Piston Nut
36
WB140-2N WB150-2N
10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 BUCKET
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Head
Unit : mm Check Item
Standard Size
i
Piston Rod to Head
60
j
Piston Rod Bushing and Pin
45
1)
Barrel Bushing and Pin
50
Criteria Tolerance Shaft Hole 59.970 60.030 59.924 60.076 44.950 45.08 44.911 45.24 49.950 50.08 49.911 50.24
Remedy Standard Clearance 0.060 0.152 0.13 0.33 0.13 0.33
Clearance Limit Replace Replace pin and bushing
CHARACTERISTICS Unit: mm Piston Rod Diameter
60
Max Cylinder Length
1850
Cylinder Barrel Bore
95
Min Cylinder Length
1085
Piston Stroke
765
10-110
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 TELESCOPIC
BACKHOE CYLINDERS
ARM CYLINDER
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Wear Rings E Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Head
Unit : mm Check Item
Standard Size
i
Piston Rod to Head
40
j
Piston Rod Bushing and Pin
40
1)
Barrel Bushing and Pin
40
Criteria Tolerance Shaft Hole 39.975 40.025 39.936 40.064 39.950 40.08 39.911 40.24 39.950 40.08 39.911 40.24
Standard Clearance 0.050 0.128 0.13 0.33 0.13 0.33
Clearance Limit
Remedy
Replace Replace pin and bushing
CHARACTERISTICS Unit: mm Piston Rod Diameter
40
Max Cylinder Length
2590
Cylinder Barrel Bore
70
Min Cylinder Length
1450
Piston Stroke
1140
WB140-2N WB150-2N
10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 SWING
A Piston Rod Bushing B Cylinder Rod C Cylinder Barrel
D Cushion Valve E Piston Seal F Cylinder Piston
G Retaining Screw H Cylinder Head
Unit : mm Check Item
Standard Size
i
Piston Rod to Head
50
j
Piston Rod Bushing and Pin
50
1)
Inner Bushing and Cylinder
45
1!
Inner Bushing and Outer Bushing
55
1@
Outer Bushing and Frame
65
Criteria Tolerance Shaft Hole 49.970 50.025 49.924 50.064 49.950 49.881 49.911 49.950 45.050 44.975 45.034 45.000 54.950 55.000 54.911 55.046 65.060 65.000 65.041 65.046
Standard Clearance 0.055 0.140 - 0.069 - 0.039 - 0.075 - 0.034 0.050 0.135 - 0.060 - 0.005
Clearance Limit
Remedy
Replace Replace pin and bushing
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter
50
Max Cylinder Length
678
Cylinder Barrel Bore
115
Min Cylinder Length
446.5
Piston Stroke
231.5
10-112
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 OUTRIGGER
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Retarder Pin E Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Head
Unit : mm Check Item
Standard Size
i
Piston Rod to Head
55
j
Piston Rod Bushing and Pin
45
1)
Barrel Bushing and Pin
45
Criteria Tolerance Shaft Hole 54.97 55.030 54.94 55.076 44.950 45.08 44.911 45.24 44.950 45.08 44.911 45.24
Standard Clearance 0.060 0.136 0.13 0.33 0.13 0.33
Clearance Limit
Remedy
Replace Replace pin and bushing
CHARACTERISTICS Unit: mm Piston Rod Diameter
55
Max Cylinder Length
1365
Cylinder Barrel Bore
110
Min Cylinder Length
850
Piston Stroke
515
WB140-2N WB150-2N
10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BOOM
LOCK CYLINDER
A Cylinder Rod B Cylinder Head and Seal
10-114
BACKHOE CYLINDERS
c Piston and Seal
d Cylinder Barrel
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT WORK EQUIPMENT
12
FRONT WORK EQUIPMENT
WB140-2N WB150-2N
10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT WORK EQUIPMENT
12 Unit : mm Check Item
Standard Size
a
Bucket/Arm Bushing and Pin
45
b
Lever/Arm Bushing and Pin
45
c
Lever/Cylinder Bushing and Pin
45
d
Cylinder/Arm Bushing and Pin
45
e
Arm/Frame Bushing and Pin
50
10-116
Criteria Tolerance Shaft Hole 44.950 45.08 44.911 45.24 44.950 45.08 44.911 45.24 44.950 45.080 44.911 45.119 44.950 45.080 44.911 45.119 49.962 50.08 49.917 50.24
Standard Clearance 0.130 0.329 0.130 0.329 0.130 0.208 0.130 0.208 0.118 0.323
Clearance Limit
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR WORK EQUIPMENT
12
REAR WORK EQUIPMENT
Unit : mm Check Item
Standard Size
a
Top Swing Pin and Bushing
65
b
Bottom Swing Pin and Bushing
65
c
Bucket/Arm Pin and Bushing
40
d
Bucket/Link Pin and Bushing
40
e
Link/Arm Pin and Bushing
45
f
Link/Cylinder Pin and Bushing
45
g
Boom/Arm Pin and Bushing
50
h
Swing/Boom Pin and Bushing
50
i
Outrigger/Frame Pin and Bushing
45
j
Outrigger/Pad Pin and Bushing
45
WB140-2N WB150-2N
Criteria Tolerance Shaft Hole 64.940 65.190 64.894 65.264 64.940 65.190 64.894 65.264 39.950 40.08 39.911 40.24 39.950 40.08 39.911 40.24 44.950 45.08 44.911 45.24 44.950 45.08 44.911 45.24 49.950 50.000 49.911 50.062 49.950 50.000 49.911 50.062 44.950 45.08 44.911 45.24 44.950 45.2 44.911 45.3
Standard Clearance 0.25 0.37 0.25 0.37 0.130 0.329 0.130 0.329 0.130 0.329 0.130 0.329 0.050 0.151 0.050 0.151 0.130 0.329 0.250 0.389
Clearance Limit
Remedy
Replace
10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR WORK EQUIPMENT
12
10-118
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONING
12
AIR CONDITIONING
A B C D
Magnetic Clutch Compressor Condenser Dryer Filter Tank
WB140-2N WB150-2N
E F G H
Safety Pressure Switch Expansion Valve
I Cab Air Circulation Fan J Air Conveyor
Evaporator Clutch Control Sensor
10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONING
12 The compressor b is driven directly by the engine shaft by means of a belt, and made to rotate by a pulley fitted with an electromagnetically engaged clutch a. A thermostatic sensor h controls the engagement and disengagement of the clutch. It disengages the clutch when the evaporator reaches the lower temperature limit and engages when the evaporator reaches the upper temperature limit. The coolant fluid, in gaseous phase is drawn into the compressor where it is subjected to compression and an intense heating process. In these conditions the fluid is then sent into the condenser c where, due to the heat extracted by ambient temperature air flowing over fins, it reaches condensation temperature, and passes into a high pressure liquid state. Subsequently the coolant passes into the dryer filter group d which performs three functions: it filters out impurities, absorbs any moisture present in the circuit and, finally, also functions as a reserve tank. The coolant in its liquid state is then transferred to the evaporator G, first passing through an expansion valve F. The task of this valve is the constant metering of the quantity of fluid in order to maintain optimum evaporation. In the evaporator the coolant fluid is subjected to expansion, bringing it up to the critical evaporation point at a temperature of approximately -8°C. The air flow generated by the centrifugal fan I which passes through the evaporator G at ambient temperature is considerably warmer than 8°C. For this reason it yields heat to the coolant fluid, bringing it up to boiling point and complete evaporation. On leaving the evaporator G the coolant is drawn once more into the compressor d and a new cycle commences. The yielding of heat from the atmosphere in which the evaporator is positioned leads to the condensation of the water suspended in the air, and hence to dehumidification. The condensate is deposited on the evaporator fins where, if a temperature higher than 0°C is not maintained, it freezes and inhibits the functioning of the evaporator. The task of keeping the temperature of the evaporator above 0°C, and thus within the optimum limits for heat exchange, is entrusted to a thermostatic sensor H. The condensate that forms on the evaporator fins G also contains dust, pollens and particles suspended in the air. Continual condensation therefore effectively purifies the air, and the droplets of condensate are discharged to the exterior. A fixed quantity of anti freeze oil is also introduced into the circuit, with the function of lubricating all the mechanical parts of the unit. A percentage of this oil circulates constantly throughout the unit in nebulized form, lubricating the compressor, pistons and bearings and the expansion valve. A pressure switch E has been inserted in the electrical control circuit to protect the unit in the case of a lack of coolant fluid or if the quantity becomes insufficient due to leakages. This switch will inhibit the engagement of the electromagnetic clutch and hence the functioning of the air conditioning unit.
10-120
WB140-2N WB150-2N
20
TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLES FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 STANDARD VALUE TABLES FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 ADJUSTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29 ADJUSTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29 COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 TENSION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 COMPRESSOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41 CHECKING TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41 TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41 ACCELERATOR PEDAL AND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42 ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42 ACCELERATOR LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43 BRAKE PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 MASTER CYLINDER ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 MICROSWITCHES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 CHECKING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 MASTER CYLINDER ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 CHECKING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46 HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 HYDRAULIC OIL TANK PRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47 WB140-2N WB150-2N
20-1
TESTING AND ADJUSTING
TABLE OF CONTENTS
WORK CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXCAVATOR CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER CONTROL VALVE (2 OR 3 SPOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS) . . . . . . . . . . . . . . . . . . . . . . SETTING RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOAD SENSING (LS) VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT AND BRAKE PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKING GROUP LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SPEED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER STALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER AND HYDRAULIC STALL . . . . . . . . . . . . . . . . . . . . . . . . . POWER TRAIN GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDITIONAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIRECTIONAL CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETURN TO DIG DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
20-47 20-47 20-48 20-49 20-49 20-50 20-51 20-53 20-55 20-55 20-55 20-55 20-55 20-57 20-57 20-58 20-59 20-59 20-60 20-61 20-61 20-61 20-62 20-62 20-62 20-63 20-64 20-64 20-64 20-65 20-65 20-65 20-66 20-66 20-67 20-68 20-68 20-68 20-69 20-70 20-70 20-70 20-71 20-71 20-72 20-72 20-72 20-73 20-74
WB140-2N WB150-2N
TESTING AND ADJUSTING
TABLE OF CONTENTS
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTRIGGER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TESTING THE WORKING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EMPTYING THE AC UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-74 20-74 20-75 20-76 20-76 20-76 20-77 20-78 20-79 20-79 20-79 20-80 20-82 20-82 20-87 20-92
WARNING! When working with others, use agreed upon signals and do not let unauthorized persons near the machine. WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is removed when the coolant is hot, the coolant will spurt our and cause burns. Be careful when working close to moving parts, fan, fan belt, etc. Entanglement with moving parts can cause serious injury. WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked on firm, level ground. Check that all machine safety devices are applied and that blocks are in place to prevent the machine from moving.
WB140-2N WB150-2N
20-3
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR ENGINE
12
STANDARD VALUE TABLES FOR ENGINE Machine Model Engine Check Item Engine Speed Exhaust Gas Color Valve Clearance Compression Pressure Blow By Pressure Oil Pressure Oil Temperature Fuel Injection Timing Fan Belt Tension
20-4
Test Conditions High Idle Low Idle Set Idle Sudden Acceleration @ High Idle Speed Intake Valve @ 20°C Exhaust Valve @ 20°C Oil Temperature @ 69 to 72°C @ Engine Speed Using Starter Motor Coolant Temperature within Operating Range @ High Idle Speed @ Set Idle @ Low Idle
Unit RPM Bosch Index mm
WB140-2N S4D106-1FH - TIER I Standard Permissible Value Value 2375 ± 50 2325 to 2425 1050 ± 50 1000 to 1100 2200 ••• 0.9 1.5 0.5 1.0 0.30 ± 0.05 Max 0.35 0.30 ± 0.05 Max 0.35
WB140-2N S4D106-2XFH - TIER II Standard Permissible Value Value 2375 ± 50 2325 to 2425 1050 ± 50 1000 to 1100 2200 ••• 4.0 4.0 3.5 3.5 0.25 ± 0.1 Max 0.35 0.25 ± 0.1 Max 0.35
kg/cm²
34.9 ± 1
27.5 ± 1
34.9 ± 1
27.5 ± 1
RPM
250
250
250
250
mm
•••
•••
kg/cm²
4.48 1.02
3.97 to 4.99 Min 1.02
4.48 1.02
3.97 to 4.99 Min 1.02
°C
120
Max 120
120
Max 120
Before Top Dead Center
Degrees
12.5
11.5 to 13.5
12.5
11.5 to 13.5
Deflection when pressed with finger force of 10 kg
mm
10
10 to 15
10
10 to 15
Entire Speed Range
WB140-2N WB150-2N
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR ENGINE
12 Machine Model Engine Check Item Engine Speed Exhaust Gas Color Valve Clearance Compression Pressure Blow By Pressure Oil Pressure Oil Temperature Fuel Injection Timing Fan Belt Tension
Test Conditions High Idle Low Idle Set Idle Sudden Acceleration @ High Idle Speed Intake Valve @ 20°C Exhaust Valve @ 20°C Oil Temperature @ 69 to 72°C @ Engine Speed Using Starter Motor Coolant Temperature within Operating Range @ High Idle Speed @ Set Idle @ Low Idle
Unit RPM Bosch Index mm
WB150-2N S4D106-1FA - TIER I Standard Permissible Value Value 2375 ± 50 2325 to 2425 1050 ± 50 1000 to 1100 2200 ••• 0.9 1.5 0.5 1.0 0.30 ± 0.05 Max 0.35 0.30 ± 0.05 Max 0.35
WB150-2N S4D106-2SFA - TIER II Standard Permissible Value Value 2375 ± 50 2325 to 2425 1050 ± 50 1000 to 1100 2050 ± 100 ••• 4.0 4.0 3.5 3.5 0.25 ± 0.1 Max 0.35 0.25 ± 0.1 Max 0.35
kg/cm²
34.9 ± 1
27.5 ± 1
34.9 ± 1
27.5 ± 1
RPM
250
250
250
250
mm
•••
•••
kg/cm²
4.48 1.02
3.97 to 4.99 Min 1.02
4.48 1.02
3.97 to 4.99 Min 1.02
°C
120
Max 120
120
Max 120
Before Top Dead Center
Degrees
12.5
11.5 to 13.5
12.5
11.5 to 13.5
Deflection when pressed with finger force of 10 kg
mm
10
10 to 15
10
10 to 15
Entire Speed Range
WB140-2N WB150-2N
20-5
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12
STANDARD VALUE TABLES FOR CHASSIS Machine Model Engine
WB140-2N S4D106-1FH - TIER I
Travel of Levers and Pedals
Control Valve
Engine Speed
Component Test Conditions
Unit
Max Accelerator Hydraulic oil temperapedal ture: 50°C Min Converter oil temperature: 80°C Max Accelerator Engine oil temp cooling circuit: in the limits fuel Min All Controls less loader arm
RPM
8 8
8
8
8
8
8
8
8 8
8
8
8
8
8
8
PPC
BHC
PPC
90 to 140
85
100
70 to 100
90 to 100
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
50
35 to 65
50
•••
40 to 60
•••
Out
15
10 to 20
15
•••
In
30
20 to 40
30
•••
Right
15
10 to 20
15
•••
Left
30
20 to 40
30
•••
Min
Max
70
50 to 90
70
70
55 to 85
55 to 85
Min
Max
80
60 to 100
70
70
55 to 85
55 to 85
Right Left
Left Right
Max 2.5
2.2 to 2.5
Max 2.5
2.2 to 2.5
Max 2.5
2.2 to 2.5
Neutral Engine stopped At the center of the knob lever Valve reading at the end of working stroke Attachments on the ground
Raise Lower Dump Curl Raise Lower Extend Retract Dump Curl Right Left mm Up Down
BHC
115
Backhoe Arm
20-6
b
90 to 100
Neutral
Steering Wheel
a
60 to 90
Backhoe Boom
Fuel Control Lever Accelerator Pedal
a b c
100
Neutral
Hammer Pedal
2350 to 2425 1000 to 1100 1850 to 1950 1000 to 1100 b c
75
Loader Boom
Telescopic Arm
2300 to 2400 1000 to 1100 1850 to 1950 1000 to 1100 a
60 to 110
Neutral
Backhoe Outriggers
2375 ±50 1050 ±50 1900 ±50 1050 ±50 b c
85
Loader Arm
Backhoe Swing
c
2350 ±50 1050 ±50 1900 ±50 1050 ±50 a
mm
Loader Arm
Backhoe Bucket
Standard Permissible Value Value
WB140-2N S4D106-2XFH - TIER II Standard Permissible Value Value BHC PPC BHC PPC
Neutral Neutral Neutral
Neutral
Neutral
Rev
10 to 20 20 to 40 10 to 20 20 to 40
••• ••• ••• •••
WB140-2N WB150-2N
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
Machine Model Engine
WB150-2N S4D106-1FA - TIER I
Travel of Levers and Pedals
Control Valve
Engine Speed
Component Test Conditions
Unit
Max Accelerator Hydraulic oil temperapedal ture: 50°C Min Converter oil temperature: 80°C Max Accelerator Engine oil temp cooling circuit: in the limits fuel Min All Controls less loader arm
RPM
Loader Arm
Neutral
Loader Boom
Neutral
Backhoe Boom
Neutral
Backhoe Bucket Backhoe Swing Backhoe Outriggers Telescopic Arm Hammer Pedal
c
2350 ±50 1050 ±50 1900 ±50 1050 ±50 a
2375 ±50 1050 ±50 1900 ±50 1050 ±50 b c
2300 to 2400 1000 to 1100 1850 to 1950 1000 to 1100 a
2350 to 2425 1000 to 1100 1850 to 1950 1000 to 1100 b c
a b c
a
b
8 8
8
8
8
8
8
8
8 8
8
8
8
8
8
8
mm
Loader Arm
Backhoe Arm
Standard Permissible Value Value
WB150-2N S4D106-2SFA - TIER II Standard Permissible Value Value BHC PPC BHC PPC
Engine stopped At the center of the knob lever Valve reading at the end of working stroke Attachments on the ground
Fuel Control Lever Accelerator Pedal Steering Wheel
WB140-2N WB150-2N
Neutral Neutral Neutral Neutral Neutral Neutral
Raise Lower Dump Curl Raise Lower Extend Retract Dump Curl Right mm Left Up Down Out In Right Left
BHC
PPC
BHC
PPC
85
60 to 110
75
100
60 to 90
90 to 100
115
90 to 140
85
100
70 to 100
90 to 100
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
100
80 to 120
100
55
90 to 110
49 to 60
50
35 to 65
50
•••
40 to 60
•••
15
10 to 20
15
•••
10 to 20
•••
30
20 to 40
30
•••
20 to 40
•••
15
10 to 20
15
•••
10 to 20
•••
30
20 to 40
30
•••
20 to 40
•••
Min
Max
70
50 to 90
70
70
55 to 85 55 to 85
Min
Max
80
60 to 100
70
70
55 to 85 55 to 85
Right Left
Left Right
Max 2.5
2.2 to 2.5
Max 2.5
Rev
2.2 to Max 2.5 2.5
2.2 to 2.5
20-7
TESTING AND ADJUSTING 12 Machine Model Engine
Force for lever or pedal operation
Component
Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB140-2N S4D106-1FH Standard Permissible Value Value Unit
Loader Arm ● Tool connection at knob Lever center and at 90° from lever. ● Value at the 10 mm beLoader fore end of working Bucket stroke. Lever ● Distance between knob and casing: 95 mm Backhoe Boom Lever Backhoe Arm Lever Backhoe ● Engine speed: Bucket min. Lever ● Oil temperature: kg 45 to 55°C Backhoe Swing Lever ● Tool connection at knob center and Outrigger at 90° from the leLever ver. In Telescopic ● Tool connection Arm Lever on edge, for ped- Out Hammer als Pedal ● Value at 10 mm before end of Fuel Control work stroke. Lever Accelerator Pedal Brake Pedals
20-8
WB140-2N S4D106-2XFH Standard Permissible Value Value BHC PPC BHC PPC
2.5
2 to 3
2.5
2.5
1.5 to 3.5
1.5 to 3.5
2.5
2 to 3
1.7
1.7
1.2 to 2.2
1.2 to 2.2
1.5
1 to 2
1.6
2.0
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
2.0
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
3
2.5 to 3.5
3.8
•••
2.3 to 5.3
•••
4
3 to 4
4
•••
3.0 to 4.0
•••
8
6 to 10
8
•••
6.0 to 10
•••
8
6 to 10
8
•••
6.0 to 10
•••
12
10 to 14
4
4
3 to 5
3 to 5
3
2 to 4
4
4
2.5 to 5.5
2.5 to 5.5
30
Max 60
WB140-2N WB150-2N
Loader Con● Engine speed: min trol Valve ● Oil temperature: 45 to Backhoe 55°C Control ● Pump: economy mode. Valve Engine speed: 1500 ±50 Steering Unit RPM Loader Bucket Curl Loader Bucket Dump Loader 3rd Spool Backhoe Boom Raise ● Engine speed: min Backhoe ● Oil temperature: 45 to Boom Lower 55°C ● Check one at a time Backhoe Arm Retract ● Pump: economy mode.
STANDARD VALUE TABLES FOR CHASSIS
kg/cm²
Individual Circuits
Main
TESTING AND ADJUSTING
Backhoe Swing Backhoe Bucket Curl Hammer Delivery Steering Unit Safety
188.65
188.65 ±7.14 209.1
209.1 ±10.2
204
204 ±7.14
211.08
211.08 ±7.14 209.1
209.1 ±10.2
204
204 ±7.14
178.45
178.45 ±7.14 178.5
178.5 ±10.2
178.5
178.5 ±7.14
239.63
239.63 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
178.45
178.45 ±7.14 188.7
188.7 ±10.2
188.7
178.5 ±7.14
239.63
239.63 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
362
362.00 ±7.14 306.0
306.0 ±10.2
311.1
311.1 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
193.75
193.75 ±7.14 249.9
249.9 ±10.2
249.9
249.9 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
173.35
173.35 ±7.14 173.4
173.4 ±10.2
173.4
173.4 ±7.14
244.73
244.73 ±7.14 244.8
244.8 ±10.2
244.8
244.8 ±7.14
●
Converter/ Hydraulic Stall
WB140-2N WB150-2N
2100 ±50
2050 to 2150
2200 ±50
2275 ±50
2150 to 2250
2225 to 2325
2000 ±50
1950 to 2050
2050 ±100
2250 ±50
2225 to 2325
2200 to 2300
RPM
Converter
Converter Stall
Engine speed (w/o load): 2350 ±50 ● Hydraulic oil temperature: 45 to 55°C ● Converter oil temperature: 80°C ● Machine in 4th gear ● Working brakes applied ● Engine speed (w/o load): 2350 ±50 ● Hydraulic oil temperature: 45 to 55°C ● Converter oil temperature: 80°C ● Machine in 4th gear with brakes applied ● Front bucket curled stop ● Steering at the end of stroke
20-9
TESTING AND ADJUSTING 12 Machine Model Engine
Force for lever or pedal operation
Component
Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB150-2N S4D106-1FA Standard Permissible Value Value Unit
Loader Arm ● Tool connection at knob Lever center and at 90° from lever. ● Value at the 10 mm beLoader fore end of working Bucket stroke. Lever ● Distance between knob and casing: 95 mm Backhoe Boom Lever Backhoe Arm Lever Backhoe ● Engine speed: Bucket min. Lever ● Oil temperature: kg 45 to 55°C Backhoe Swing Lever ● Tool connection at knob center and Outrigger at 90° from the leLever ver. In Telescopic ● Tool connection Arm Lever on edge, for ped- Out Hammer als Pedal ● Value at 10 mm before end of Fuel Control work stroke. Lever Accelerator Pedal Brake Pedals
20-10
WB150-2N S4D106-2SFA Standard Permissible Value Value BHC PPC BHC PPC
2.5
2 to 3
2.5
2.5
1.5 to 3.5
1.5 to 3.5
2.5
2 to 3
1.7
1.7
1.2 to 2.2
1.2 to 2.2
1.5
1 to 2
1.6
2
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
2
1.0 to 2.2
1.8 to 2.2
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
1.5
1 to 2
1.6
1.4
1.0 to 2.2
1.3 to 1.5
3
2.5 to 3.5
3.8
•••
2.3 to 5.3
•••
4
3 to 4
4
•••
3.0 to 4.0
•••
8
6 to 10
8
•••
6.0 to 10
•••
8
6 to 10
8
•••
6.0 to 10
•••
12
10 to 14
4
4
3 to 5
3 to 5
3
2 to 4
4
4
2.5 to 5.5
2.5 to 5.5
30
Max 60
WB140-2N WB150-2N
Loader Con● Engine speed: min trol Valve ● Oil temperature: 45 to Backhoe 55°C Control ● Pump: economy mode. Valve Engine speed: 1500 ±50 Steering Unit RPM Loader Bucket Curl Loader Bucket Dump Loader 3rd Spool Backhoe Boom Raise ● Engine speed: min Backhoe ● Oil temperature: 45 to Boom Lower 55°C ● Check one at a time Backhoe Arm Retract ● Pump: economy mode.
STANDARD VALUE TABLES FOR CHASSIS
kg/cm²
Individual Circuits
Main
TESTING AND ADJUSTING
Backhoe Swing Backhoe Bucket Curl Hammer Delivery Steering Unit Safety
188.65
188.65 ±7.14 209.1
209.1 ±10.2
204
204 ±7.14
211.08
211.08 ±7.14 209.1
209.1 ±10.2
204
204 ±7.14
178.45
178.45 ±7.14 178.5
178.5 ±10.2
178.5
178.5 ±7.14
239.63
239.63 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
178.45
178.45 ±7.14 188.7
188.7 ±10.2
188.7
178.5 ±7.14
239.63
239.63 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
362
362.00 ±7.14 306.0
306.0 ±10.2
311.1
311.1 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
193.75
193.75 ±7.14 249.9
249.9 ±10.2
249.9
249.9 ±7.14
249.83
249.83 ±7.14 239.7
239.7 ±10.2
239.7
239.7 ±7.14
173.35
173.35 ±7.14 173.4
173.4 ±10.2
173.4
173.4 ±7.14
244.73
244.73 ±7.14 244.8
244.8 ±10.2
244.8
244.8 ±7.14
●
Converter/ Hydraulic Stall
WB140-2N WB150-2N
2275 ±50
2225 to 2325
2200 ±50
2275 ±50
2150 to 2250
2225 to 2325
2000 ±50
1950 to 2050
2050 ±100
2250 ±50
2225 to 2325
2200 to 2300
RPM
Converter
Converter Stall
Engine speed (w/o load): 2350 ±50 ● Hydraulic oil temperature: 45 to 55°C ● Converter oil temperature: 80°C ● Machine in 4th gear ● Working brakes applied ● Engine speed (w/o load): 2350 ±50 ● Hydraulic oil temperature: 45 to 55°C ● Converter oil temperature: 80°C ● Machine in 4th gear with brakes applied ● Front bucket curled stop ● Steering at the end of stroke
20-11
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12 ★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with the standard arm or telescopic arm closed. Machine Model WB140-2N WB140-2N Engine S4D106-1FH S4D106-2XFH Standard Permissible Standard Permissible Value Value Value Value Component Test Conditions Unit BHC PPC BHC PPC
Hydraulic Drift of Working Equipment
Loader
Complete Working Equipment
250
400
250
250
250
250
30
45
24
24
24
24
15
25
10
10
10
10
Complete Measuring position Working Equipment
300
450
Max Max Max Max 325 325 300 300
Boom Cylinder
35
50
Max Max Max Max 24 24 24 24
15
25
Max Max Max Max 13 13 13 13
10
15
Max Max Max Max 10 10 10 10
Boom Cylinder
Backhoe
Bucket Cylinder
Arm Cylinder
Bucket Cylinder
20-12
Measuring position
In this position, check the feedback of each cylinder and the leakage with a load applied to the tip of the cutting mm edge. Ground level ● Bucket: normal load (1500 kg) ● Engine stopped ● Oil temperature: 45 to 55°C Make measurements as soon as the engine is stopped. Measure the changes every 5 min. and the total change after 15 min.
In this position, check the extension of each cylinder and the leakage with mm a normal load on the bucket. On level ground. ● Bucket: normal load (450 kg) ● Engine stopped ● Oil temperature: 45 to 55°C Make measurements as soon as the engine is stopped. Measure the changes every 5 min. and the total change after 15 min.
WB140-2N WB150-2N
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12 Machine Model Engine Component Test Conditions
Hydraulic Drift of Working Equipment
Loader
Complete Working Equipment
Unit
WB150-2N S4D106-1FA Standard Permissible Value Value
WB150-2N S4D106-2SFA Standard Permissible Value Value BHC PPC BHC PPC
Measuring position 250
400
250
250
250
250
30
45
24
24
24
24
15
25
10
10
10
10
Complete Measuring position Working Equipment
300
450
Max Max Max 325 325 300
Max 300
Boom Cylinder
35
50
Max Max Max 24 24 24
Max 24
15
25
Max Max Max 13 13 13
Max 13
10
15
Max Max Max 10 10 10
Max 10
Boom Cylinder
Backhoe
Bucket Cylinder
Arm Cylinder
Bucket Cylinder
In this position, check the feedback of each cylinder and the leakage with a load applied to the tip of the cutting mm edge. Ground level ● Bucket: normal load (1500 kg) ● Engine stopped ● Oil temperature: 45 to 55°C Make measurements as soon as the engine is stopped. Measure the changes every 5 min. and the total change after 15 min.
In this position, check the extension of each cylinder and the leakage with mm a normal load on the bucket. On level ground. ● Bucket: normal load (450 kg) ● Engine stopped ● Oil temperature: 45 to 55°C Make measurements as soon as the engine is stopped. Measure the changes every 5 min. and the total change after 15 min.
WB140-2N WB150-2N
20-13
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12 ★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with the standard arm or telescopic arm closed. Machine Model WB140-2N WB140-2N Engine S4D106-1FH - TIER I S4D106-2XFH - TIER II Standard Permissible Standard Permissible Value Value Value Component Test Conditions Unit Value BHC PPC BHC PPC Measuring position
Backhoe
Hydraulic Drift of Working Equipment
Swing Cylinders
Oil temperature: 45 to 55°C Backhoe balanced on the guides, mm bucket in transport position. Arm and bucket cylinder in. Put the bucket link pin one meter from the ground and swing at the end of boom stroke in one of two directions. Move the machine onto an incline of 15° and apply the parking brake. Stop the machine. After one min. check the cylinder feedback opposite the boom every 5 min. for a total of 15 min. Measuring position
mm
Outriggers
15
25
Max Max Max 20 Max 30 20 30
20
30
Max Max Max 5 5 5
Max 5
Oil temperature: 45 to 55°C Backhoe balanced. Boom and arm cylinders in, bucket cylinder out. Outriggers at max extension. Engine stopped. Check the frame lowering for each side every 5 min. for a total of 15 min.
20-14
WB140-2N WB150-2N
TESTING AND ADJUSTING 12
Machine Model Engine Component Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB150-2N S4D106-1FA - TIER I Standard Permissible Value Unit Value
WB150-2N S4D106-2SFA - TIER II Standard Permissible Value Value BHC PPC BHC PPC
Measuring position
Backhoe
Hydraulic Drift of Working Equipment
Swing Cylinders
Oil temperature: 45 to 55°C Backhoe balanced on the guides, mm bucket in transport position. Arm and bucket cylinder in. Put the bucket link pin one meter from the ground and swing at the end of boom stroke in one of two directions. Move the machine onto an incline of 15° and apply the parking brake. Stop the machine. After one min. check the cylinder feedback opposite the boom every 5 min. for a total of 15 min. Measuring position
mm
Outriggers
15
25
Max Max Max 20 Max 30 20 30
20
30
Max Max 5 5
Max 5
Max 5
Oil temperature: 45 to 55°C Backhoe balanced. Boom and arm cylinders in, bucket cylinder out. Outriggers at max extension. Engine stopped. Check the frame lowering for each side every 5 min. for a total of 15 min.
WB140-2N WB150-2N
20-15
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
Boom
2
Max 8
2
2
Max Max 8 8
Bucket
1.6
Max 6
1.6
1.6
Max Max 6 6
3.3
Max 13.5
3.3
3.3
Max Max 13.5 13.5
3
Max 12
3
3
Max Max 12 12
2.4
Max 9.5
2.4
2.4
Max Max 9.5 9.5
3.2
Max 13
3.2
3.2
Max Max 13 13
Outrigger
3.3
Max 13.5
3.3
3.3
Max Max 13.5 13.5
Telescopic Arm
1.6
Max 6
1.6
1.6
Max Max 6 6
3.5
3.1 to 3.9
3.6
3.5
2.9 to 4.3
3.1 to 3.9
3.5
3.1 to 3.9
3.6
3.5
2.9 to 4.3
3.1 to 3.9
Arm Backhoe
Cylinder Leakage
Boom
Bucket Swing
Engine: Max. speed Oil temperature: 45 to 55°C Leak check: check the low pressure side of the cylinder. Check one cylinder at a time. For loader bucket and arm or backhoe swing, check the two cylinders separately.
cm³/mm
Loader
12 ★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with the standard arm or telescopic arm closed. Machine Model WB140-2N WB140-2N S4D106-2XFH - TIER Engine S4D106-1FH - TIER I II Standard Permissible Standard Permissible Value Value Component Test Conditions Unit Value Value BHC PPC BHC PPC
Right
Backhoe
Work Equipment Speed
Measuring position
20-16
Boom swing Right End Travel to Left End Travel
Sec Engine speed 1700 to 1750 RPM Oil temperature: 45 to 55°C Arm horizontal Left Power mode The time referenced is for the cylinder stroke without the brake phase
WB140-2N WB150-2N
TESTING AND ADJUSTING Machine Model Engine
WB150-2N WB150-2N S4D106-1FA - TIER I S4D106-2SFA - TIER II Standard Permissible Standard Permissible Value Value Unit Value Value BHC PPC BHC PPC
Loader
Component Test Conditions
Boom
2
Max 8
2
2
Max 8
Max 8
Bucket
1.6
Max 6
1.6
1.6
Max 6
Max 6
3.3
Max 13.5
3.3
3.3
Max Max 13.5 13.5
3
Max 12
3
3
Max 12
Max 12
2.4
Max 9.5
2.4
2.4
Max 9.5
Max 9.5
3.2
Max 13
3.2
3.2
Max 13
Max 13
Outrigger
3.3
Max 13.5
3.3
3.3
Max Max 13.5 13.5
Telescopic Arm
1.6
Max 6
1.6
1.6
Max 6
3.5
3.1 to 3.9
3.6
3.5
2.9 to 3.1 to 4.3 3.9
3.5
3.1 to 3.9
3.6
3.5
2.9 to 3.1 to 4.3 3.9
Arm Backhoe
Cylinder Leakage
Boom
Bucket Swing
Engine: Max. speed Oil temperature: 45 to 55°C Leak check: check the low pressure side of the cylinder. Check one cylinder at a time. For loader bucket and arm or backhoe swing, check the two cylinders separately.
cm³/mm
12
STANDARD VALUE TABLES FOR CHASSIS
Max 6
Right
Backhoe
Work Equipment Speed
Measuring position
Boom swing Right End Travel to Left End Travel
Sec Engine speed 1700 to 1750 RPM Oil temperature: 45 to 55°C Arm horizontal Left Power mode The time referenced is for the cylinder stroke without the brake phase
WB140-2N WB150-2N
20-17
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12 ★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with the standard arm or telescopic arm closed. Machine Model WB140-2N WB140-2N Engine S4D106-1FH - TIER I S4D106-2XFH - TIER II Standard Permissible Standard Permissible Value Value Value Component Test Conditions Unit Value BHC PPC BHC PPC Measuring position 3.2 3.2 to Low3.6 3.1 to 4.1 3.5 3.5 to 3.8 ered 3.8 Arm Cylinders Out ↕ To level ground
2.5
2.1 to 2.9
2.6
2.6
2.3 2.3 to to 2.9 2.9
Curl
2.5
2.1 to 2.9
2.5
1.9
2.1 1.6 to to 2.2 2.9
Dump
3.2
2.7 to 3.7
3.2
2.8
2.8 2.6 to to 3.1 3.6
2.3
1.9 to 2.7
2.6
2.6
2.3 2.3 to to 2.9 2.9
1.6
1.2 to 2.0
2.2
1.9
1.8 1.6 to to 2.2 2.6
●
Engine speed: Max Oil temperature: 45 to 55°C ● Speed up Measuring position
Loader
●
Bucket Cylinders Out ↕ Cylinders In
Work Equipment Speed
Raised
●
Engine speed: Max Oil temperature: 45 to 55°C ● Speed up Measuring position
Backhoe
●
20-18
Boom Cylinder in ↕ Bucket teeth on level ground
Sec Raise ★
●
Engine speed 1700 to 1750 RPM The engine speed, 1700 to 1750 rpm, is to be checked using the procedure described in ENGINE Lower SPEED in this section of the manual. ● Oil temperature: 45 to 55°C ● Backhoe balanced ● Power mode ★ The time referenced is for the cylinder stroke without the brake phase
WB140-2N WB150-2N
TESTING AND ADJUSTING 12
STANDARD VALUE TABLES FOR CHASSIS
Machine Model Engine Component Test Conditions Measuring position Arm Cylinders Out ↕ To level ground
Raised
2.5
2.1 to 2.9
2.6
2.6
2.3 to 2.3 to 2.9 2.9
Curl
2.5
2.1 to 2.9
2.5
1.9
2.1 to 1.6 to 2.9 2.2
Dump
3.2
2.7 to 3.7
3.2
2.8
2.8 to 2.6 to 3.6 3.1
2.3
1.9 to 2.7
2.6
2.6
2.3 to 2.3 to 2.9 2.9
1.6
1.2 to 2.0
2.2
1.9
1.8 to 1.6 to 2.6 2.2
●
Engine speed: Max Oil temperature: 45 to 55°C ● Speed up Measuring position
Loader
●
Bucket Cylinders Out ↕ Cylinders In
Work Equipment Speed
Lowered
WB150-2N WB150-2N S4D106-1FA - TIER I S4D106-2SFA - TIER II StanPermissible Standard Permissible dard Value Value Value Unit Value BHC PPC BHC PPC 3.2 to 3.2 to 3.6 3.1 to 4.1 3.5 3.5 3.8 3.8
●
Engine speed: Max Oil temperature: 45 to 55°C ● Speed up Measuring position
Backhoe
●
Boom Cylinder in ↕ Bucket teeth on level ground
Sec Raise ★
●
Engine speed 1700 to 1750 RPM The engine speed, 1700 to 1750 rpm, is to be checked using the procedure described in ENGINE Lower SPEED in this section of the manual. ● Oil temperature: 45 to 55°C ● Backhoe balanced ● Power mode ★ The time referenced is for the cylinder stroke without the brake phase
WB140-2N WB150-2N
20-19
TESTING AND ADJUSTING
STANDARD VALUE TABLES FOR CHASSIS
12 ★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with the standard arm or telescopic arm closed. Machine Model WB140-2N WB140-2N Engine S4D106-1FH - TIER I S4D106-2XFH - TIER II Standard Permissible Standard Permissible Value Value Component Test Conditions Unit Value Value BHC PPC BHC PPC Measuring position
Open
Backhoe
Work Equipment Speed
Arm Cylinder In ↕ Cylinder Out
2.9 to 3.9
3.4
3.6
3.0 3.2 to to 4.0 3.8
4.3
3.8 to 4.8
4.4
4.5
4.0 4.1 to to 4.9 4.8
2.1
1.7 to 2.5
2.2
2.6
1.8 2.4 to to 2.8 2.6
2.9
2.5 to 3.3
3.0
3.1
2.6 2.6 to to 3.4 3.4
●
Engine speed 1700 to 1750 RPM The engine speed, 1700 to 1750 rpm, is to be checked using the procedure described in ENGINE SPEED in this section of the manual. Close ● Oil temperature: 45 to 55°C ★ ● Backhoe balanced ● Power mode ★ The time referenced is for the cylinder stroke without Sec the brake phase Measuring position
Dump Bucket Cylinder In ● Engine speed 1700 to 1750 ↕ RPM Cylinder The engine speed, 1700 to 1750 Out rpm, is to be checked using the procedure described in ENGINE SPEED in this section of the Curl manual. ● Oil temperature: 45 to 55°C ● Backhoe balanced ● Power mode
20-20
3.4
WB140-2N WB150-2N
TESTING AND ADJUSTING 12
STANDARD VALUE TABLES FOR CHASSIS
Machine Model Engine
WB150-2N WB150-2N S4D106-1FA - TIER I S4D106-2SFA - TIER II Standard Permissible StanPermissible Value Value Unit dard Value Value BHC PPC BHC PPC
Component Test Conditions Measuring position
Open
Backhoe
Work Equipment Speed
Arm Cylinder In ↕ Cylinder Out
3.4
2.9 to 3.9
3.4
3.6
3.0 to 3.2 to 3.8 4.0
4.3
3.8 to 4.8
4.4
4.5
4.0 to 4.1 to 4.8 4.9
2.1
1.7 to 2.5
2.2
2.6
1.8 to 2.4 to 2.6 2.8
2.9
2.5 to 3.3
3.0
3.1
2.6 to 2.6 to 3.4 3.4
●
Engine speed 1700 to 1750 RPM The engine speed, 1700 to 1750 rpm, is to be checked using the procedure described in ENGINE SPEED in this section of the manual. Close ● Oil temperature: 45 to 55°C ★ ● Backhoe balanced ● Power mode ★ The time referenced is for the cylinder stroke without Sec the brake phase Measuring position
Dump Bucket Cylinder In ● Engine speed 1700 to 1750 ↕ RPM Cylinder The engine speed, 1700 to 1750 Out rpm, is to be checked using the procedure described in ENGINE SPEED in this section of the Curl manual. ● Oil temperature: 45 to 55°C ● Backhoe balanced ● Power mode
WB140-2N WB150-2N
20-21
TESTING AND ADJUSTING 12
Machine Model Engine Component Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB140-2N S4D106-1FH - TIER I Standard Permissible Value Unit Value
WB140-2N S4D106-2XFH - TIER II Standard Permissible Value Value BHC PPC BHC PPC
Loader
Measuring position
Lift Arm
0
Max 2
0
Max 2
0
Max 2
0
0
Max 2
Max 2
Max Max 2 2
Max 2
Max 2
Max Max 2 2
Max 2
Max 2
●
Engine speed: Min. Oil temperature: 45 to 55°C Check the time needed to lift the bucket from level ground. Measuring position
Work Equipment Speed Time Lag Backhoe
●
Boom
Arm
20-22
●
Engine speed: Min. ● Oil temperature: 45 to 55°C With attachments fully extended, Sec lower the boom and check the elapsed time from the beginning of the machine lifting until the bucket is on level ground. Measuring position
●
Engine speed: Min. ● Oil temperature: 45 to 55°C Put the boom at 45° and open the arm completely with the bucket curled. Extend the arm cylinder and check the elapsed time between arm stop at dead center and restart movement.
WB140-2N WB150-2N
TESTING AND ADJUSTING 12
Machine Model Engine Component Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB150-2N S4D106-1FA - TIER I Standard Permissible Value Unit Value
WB150-2N S4D106-2SFA - TIER II Standard Permissible Value Value BHC PPC BHC PPC
Loader
Measuring position
Lift Arm
0
Max 2
0
0
Max 2 Max 2
0
Max 2
Max Max Max 2 Max 2 2 2
0
Max 2
Max Max Max 2 Max 2 2 2
●
Engine speed: Min. Oil temperature: 45 to 55°C Check the time needed to lift the bucket from level ground. Measuring position
Work Equipment Speed Time Lag Backhoe
●
Boom
Arm
●
Engine speed: Min. ● Oil temperature: 45 to 55°C With attachments fully extended, lower the boom and check the elapsed time from the beginning of the machine lifting until the bucket is on level ground. Measuring position
●
Engine speed: Min. Oil temperature: 45 to 55°C Put the boom at 45° and open the arm completely with the bucket curled. Extend the arm cylinder and check the elapsed time between arm stop at dead center and restart movement.
Sec
●
WB140-2N WB150-2N
20-23
TESTING AND ADJUSTING 12
Machine Model Engine Component Test Conditions
STANDARD VALUE TABLES FOR CHASSIS WB140-2N S4D106-1FH - TIER I
WB140-2N S4D106-2XFH - TIER II Standard Permissible Standard Permissible Value Value Unit Value Value BHC PPC BHC PPC
Measuring position
Bucket
●
Engine speed: Min. Oil temperature: 45 to 55°C Put arm in horizontal position. Tilt back the bucket cylinder and then extend it. Check the elapsed time between bucket stop at dead center and the restart movement. Measuring position
0
Max 2
Max 2 Max 2 Max 2 Max 2
0
Max 2
Max 2 Max 2 Max 2 Max 2
Work Equipment Speed Time Lag Backhoe
●
Sec
Outriggers ●
Engine speed: Min. Oil temperature: 45 to 55°C Boom, arm, and bucket fully retracted and placed in machine centre position. Check the time needed for outriggers to raise the machine from when they lean on level ground. Check each outrigger separately.
●
20-24
WB140-2N WB150-2N
TESTING AND ADJUSTING 12
SPECIAL TOOLS
Machine Model Engine
WB150-2N S4D106-1FA - TIER I
WB150-2N S4D106-2SFA - TIER II Standard Permissible Standard Permissible Value Value Unit Value Value BHC PPC BHC PPC
Component Test Conditions Measuring position
Bucket
●
Engine speed: Min. Oil temperature: 45 to 55°C Put arm in horizontal position. Tilt back the bucket cylinder and then extend it. Check the elapsed time between bucket stop at dead center and the restart movement. Measuring position
0
Max 2
Max 2 Max 2 Max 2
Max 2
0
Max 2
Max 2 Max 2 Max 2
Max 2
Work Equipment Speed Time Lag Backhoe
●
Sec
Outriggers ●
Engine speed: Min. Oil temperature: 45 to 55°C Boom, arm, and bucket fully retracted and placed in machine centre position. Check the time needed for outriggers to raise the machine from when they lean on level ground. Check each outrigger separately.
●
SPECIAL TOOLS Measurement Point
Symbol
Code
Name
Qty
Note
Valve clearance
A
Available Locally
Feeler gauge
1
–
Compression gauge
B
Compression gauge
1
Adapter
1
Kit Yanmar TOL-97190080
Engine speed
C
Available Locally
Multi scale tachometer
1
20 to 4000 rpm
Oil and coolant temp
D
Available Locally
Digital thermometer
1
-50 to 1200°C
WB140-2N WB150-2N
1 2
1
ATR800208
20-25
TESTING AND ADJUSTING
E Hydraulic pressure
SPECIAL TOOLS 1
Available Locally
Pressure gauge
2
Full scale 61 kg/cm²
2
Available Locally
Pressure gauge
1
Full scale 255 kg/cm²
3
Available Locally
Pressure gauge
1
Full scale 408 kg/cm²
4
Available Locally
Pressure gauge
1
Full scale 612 kg/cm²
Servo control kit
1
0 to1020 kg/cm²
Flow meter
1
Delivery 0 to 300 l/ min.
Pipe fitting kit
1
–
5 6 F
1
ATR800200
2 Air bleeding
G
ATR201490
Tank cap
1
Pump air bleeding
Hand brake
L
Available Locally
Spring dynamometer
1
Full scale 20 kg
1
Available Locally
Maintenance station
1
For coolant R134a
2
Available Locally
Thermometer hygrometer 1
Sampling every 15 sec
3
Available Locally
Leak detector
For coolant R134a
Air Conditioning unit
20-26
M
1
WB140-2N WB150-2N
TESTING AND ADJUSTING
ENGINE SPEED
12
ENGINE SPEED WARNING! When checking the engine speed be careful. Do not touch high temperature parts or get caught in rotating parts.
★ Check the engine speed under the following conditions: ● Engine coolant temperature: 68 to 80 °C. ● Hydraulic oil temperature: 45 to 55 °C.
TIER I ENGINE 1.
Install and connect tachometer C.
2.
Start the engine and check: Low idle speed without load, accelerator pedal released in minimum position. High idle speed without load, accelerator pedal at the travel end. ● Low idle speed: 1050 ± 50 RPM ● High idle speed: 2375 ± 50 RPM ★ If the idle speeds are not within limits, without a load on the engine, check the accelerator pedal stoppers and wiring insulation before going on with other operations. See “ACCELERATOR PEDAL AND LEVER” on page 20-42. ●
TIER II ENGINE 1.
Remove the air filter a.
2.
Start the engine and check: ● Low idle speed without load, accelerator pedal released in minimum position. High idle speed without load, accelerator pedal at the travel end. ● Low idle speed: 1050 ± 50 RPM ● High idle speed: 2375 ± 50 RPM ★ If the idle speeds are not within limits, without a load on the engine, check the accelerator pedal stoppers and wiring insulation before going on with other operations. See “ACCELERATOR PEDAL AND LEVER” on page 20-42.
WB140-2N WB150-2N
20-27
TESTING AND ADJUSTING
VALVE CLEARANCE
12
VALVE CLEARANCE TIER I ENGINE ★ Measurement conditions: ● Engine: Cold ★ Adjust the clearance between the valves and rocker levers as follows: Unit: mm With cold engine
Engine
Intake – Exhaust
S4D106-1FH
0.30 ±0.05
S4D106-1FA
0.30 ±0.05
★ Firing order: 1-3-4-2-1 at 180° steps ★ Normal rotation: Counterclockwise from flywheel ★ Cylinder No. 1: Opposite the fan side
ADJUSTING PROCEDURE 1.
Remove the air cleaner A, muffler B, and valve cover C.
2.
Rotate the crankshaft in its normal direction until the piston to be checked is at full compression, Top Dead Center (TDC). In this position the intake and exhaust valves are closed.
3.
Loosen the lock nut d and unscrew the tappet e one turn. Check that valve insert f is laying flat on the valve stem and that it is not worn. If the valve inserts are damaged, replace them with new ones. Make sure that the inserts fit and lay flat on the valve stem.
4.
Place feeler gauge A between the insert and the rocker lever to be adjusted. Rotate the tappet e until the rocker lever touches the gauge. Secure the tappet with lock nut d. Lock Nut:
14.7 to 19.6 N•m
★ After tightening the lock nut, check the clearance again. 5.
Adjust the next cylinder valve using this same procedure. Repeat the procedure for the other cylinders, according to their firing order.
VALVE COVER INSTALLATION 1.
Check condition of valve cover c, gasket g, o-rings h and lock nuts i; carefully clean the contact surface of the cylinder head. Install the gasket, valve cover, fit o-rings and lock nuts. Cover lock nut:
20-28
25 ±3 N•m
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 TIER
VALVE CLEARANCE
II ENGINE
★ Measurement conditions: ● Engine: Cold ★ Adjust the clearance between the valves and rocker levers as follows: Unit: mm With cold engine
Engine
Intake – Exhaust
S4D106-2XFH
0.25 ±0.01
S4D106-2SFA
0.25 ±0.01
★ Firing order: 1-3-4-2-1 at 180° steps ★ Normal rotation: Counterclockwise from flywheel ★ Cylinder No. 1: Opposite the fan side
ADJUSTING PROCEDURE 1.
Remove the air filter a and the muffler b.
2.
Loosen the muffler support screws d and remove the air intake duct e.
3.
Disconnect the fuel feed pipes f. Remove clamp g and loosen clamp h.
WB140-2N WB150-2N
20-29
TESTING AND ADJUSTING
VALVE CLEARANCE
12 4. Loosen the fittings i connecting to the pump j on the fuel feed pipes f.
5.
Rotate the pipes f until they become disengaged from the valve cover 1).
6.
Remove the feed-through fittings 1! and their seals.
7.
Loosen and remove the screws 1@ retaining the valve cover c. ★ Inspect the grommets.
8.
Remove the valve cover c. ★ Inspect the seal. Replace the seal if damaged or cracked.
20-30
WB140-2N WB150-2N
TESTING AND ADJUSTING
VALVE CLEARANCE
12 9. Rotate the crankshaft in the normal direction until the piston of the cylinder you want to check reaches the compression position at Top Dead Center (TDC). ★ In this position, the intake and exhaust valves are closed.
10. Loosen the lock nut 1# and unscrew the tappet by about one half turn 1$.
11. Introduce the A feeler gauge between the valve link 1% and the rocker arm 1^; tighten the tappet 1$ until rubbing against the A feeler gauge. Lock the tappet using the lock nut 1#. Lock Nut:
22 to 28 N•m
12. Loosen the nut 1& and, while applying pressure to the valve link 1%, tighten the tappet 1* until it bottoms on the valve 1( and zeroes the clearances. Lock the tappet using the nut. Lock Nut:
22 to 28 N•m
★ If the nut 1& is very tight, use pliers to hold the valve link in position 1%.
WB140-2N WB150-2N
20-31
TESTING AND ADJUSTING
VALVE CLEARANCE
12 13. Reinstall all previously removed parts.
20-32
Valve cover screws
16.7 to 22.5 N•m
Injectors pump fittings
19.6 to 24.5 N•m
Clamp screws
7.8 to 9.8 N•m
WB140-2N WB150-2N
TESTING AND ADJUSTING
COMPRESSION PRESSURE
12
COMPRESSION PRESSURE WARNING! When measuring the compression pressure be careful not to get caught in the cooling fan, alternator belt or in any other rotating parts. For this measurement the engine should be at operating temperature. Take every precaution against burns.
★ Measurement conditions: ● Engine: Operating temperature ● Hydraulic oil: 55 to 60°C. ● Battery: Full charge ● Valve clearance: Adjusted
TIER I ENGINE 1.
Disconnect the high pressure pipe a.
2.
Remove the nozzle holder b of the cylinder to be checked.
3.
Disconnect the connector c of the fuel cut off the solenoid valve d.
4.
Crank the engine with the starting motor.
5.
Install B2 adapter and connect B1 pressure gauge. Check that the seal is installed in the adapter and that it is not damaged.
6.
Crank the engine with the starting motor and measure the compression pressure. ★ Measure the compression pressure at the point where the pressure gauge indicator remains steady. ★ While measuring the compression pressure, monitor the engine speed with a tachometer; if speed is not within the specified range, refer to the diagram. ★ Compression value: 35 ±1 kg/cm² @ 250 RPM ★ Minimum permissible: 27.5 ±1 kg/cm² @ 250 RPM ★ Difference between cylinders: 2 to 3 kg/cm²
7.
After measuring, reinstall the nozzle holder b, reconnect the high pressure pipe, feedback pipe and connector c. Nozzle holder collar bolts: 10 to 12 N•m High pressure union:
20 to 25 N•m
NOTE: Check compression in all cylinders.
WB140-2N WB150-2N
20-33
TESTING AND ADJUSTING 12 TIER
II ENGINE
1.
Access the valves using the same procedure as in “VALVE CLEARANCE” on page 20-28.
2.
Loosen and remove the fittings a retaining the fuel recovery piping b and the seals.
3.
Loosen the fitting c and rotate the piping b outward.
4.
Loosen and remove the screw d retaining the bracket e retaining the injector f.
5.
Turn the bracket e over and pull out the injector f. ★ Use care not to allow dirt inside the injector and/or its seat.
6.
Disconnect the engine shutdown connector g and ensure that the accelerator is fully released, no fuel flow.
20-34
COMPRESSION PRESSURE
WB140-2N WB150-2N
TESTING AND ADJUSTING
COMPRESSION PRESSURE
12 7. Using the starter motor, crank the engine complete a few revs. 8.
Apply the adaptor B2 and gauge B1 and follow the instructions provided with the equipment. ★ Check for a seal inside the adaptor and verify that the seal is not damaged.
9.
Crank the engine with the starting motor and measure the compression pressure. ★ Measure the compression pressure at the point where the pressure gauge indicator remains steady. ★ When measuring the compression pressure, check also engine speed with a tachometer; if the speed is not within the specified range, refer to diagram. ★ Compression value: 35 ±1 kg/cm² @ 250 RPM ★ Minimum permissible: 28 ±1 kg/cm² @ 250 RPM ★ Difference between cylinders: 2 to 3 kg/cm²
10. After completing the procedure, reinstall the injector f, reconnect the fuel return pipe and complete the assembly procedure. Nozzle holder collar bolts: 8 to 10 N•m High pressure union:
20 to 25 N•m
NOTE: Check compression in all cylinders.
WB140-2N WB150-2N
20-35
TESTING AND ADJUSTING
FUEL INJECTION TIMING
12
FUEL INJECTION TIMING TIER I ENGINE ★ Check the fuel injection timing of the No. 1 cylinder by means of the No. 1 delivery valve of the injection pump. ★ The cylinders are numbered 1 2 3 4 starting from the flywheel side. 1.
Rotate the crankshaft using the engine pulley a and put the No. 1 cylinder piston at top dead center (TDC).
★ Top dead center (TDC) is shown by the notch d on the pulley a positioned on zero of the scale e and by the closing of both cylinder No. 1 valves. ★ If the notch d of the pulley a is in the zero position on the scale e but the cylinder No. 1 valves are not closed, rotate the crankshaft one full turn. ★ After recognition of TDC, rotate the crankshaft counterclockwise, as viewed from the pulley side, 20°.
2.
Disconnect the cylinder No. 1 high pressure tube C from the injection pump.
3.
Rotate the crankshaft slowly in the clockwise direction (as viewed from the pulley side), checking the fuel level in the No. 1 delivery holder of the injection pump.
4.
Stop the pulley B rotation as soon as the fuel level starts to increase.
20-36
WB140-2N WB150-2N
TESTING AND ADJUSTING
FUEL INJECTION TIMING
12 5. Check the notch d position on the crankshaft pulley a compared with the scale e; the indicated value should correspond to the angle of the fuel injection timing. ★ Standard fuel injection timing: S4D106-1FA ............................................. 12.5° ±1° S4D106-1FH:............................................ 12.5° ±1° NOTE: Repeat this procedure several times.
6.
If the injection timing does not meet the standard value, rotate the injection pump f away from or toward the cylinder block after loosening the pump nuts g (quantity 4) and lock nuts h which attach the bracket i to the injection pump. ● To RETARD the injection timing, rotate the pump f away from the cylinder block. ● To ADVANCE the injection timing, rotate the pump f toward the cylinder block.
7.
Tighten the pump lock nuts g at the cylinder block and lock nuts h at bracket i.
8.
Nuts:
34 to 44 N•m
Bracket lock nut:
44 to 54 N•m
Reconnect the cylinder No. 1 high pressure pipe b to the injection pump. Delivery pipe union:
20 to 25 N•m
TIER II ENGINE WARNING! Remove the ignition key.
★ Check the fuel injection timing of No. 1 cylinder by means of the No.1 delivery valve of the injection pump. ★ The cylinders are numbered 1 2 3 4 starting from the flywheel side. 1.
Rotate the crankshaft using the engine pulley and put the No. 1 cylinder piston at top dead center (TDC). ★ Top dead center (TDC) is shown by the notch d on the pulley a positioned on zero of the scale e and by the closing of all cylinder No. 1 valves.
WB140-2N WB150-2N
20-37
TESTING AND ADJUSTING
FUEL INJECTION TIMING
12 ★ If the notch d of the pulley a is in the zero position on the scale e but cylinder No. 1 valves are not closed, rotate the crankshaft one turn. ★ After recognition of TDC, rotate the crankshaft in the counterclockwise direction, from the pulley side view, 20°. 2.
Disconnect the cylinder No.1 high pressure pipe b from the injection pump.
3.
Rotate the crankshaft slowly in the clockwise direction from the pulley side, checking the fuel level into the No. 1 delivery valve of the injection pump.
4.
Stop the pulley a rotation as soon as the fuel level starts to increase.
5.
Check the notch d position on the crankshaft pulley a compared with the scale e; the reading value corresponds to angle of the fuel injection timing. Standard fuel injection timing.................................. 12.5° ±1°
NOTE:Repeat checking more than once.
6.
If the injection timing is not on the standard value, rotate the injection pump f inwards or outwards of the engine block after loosening the pump nuts g. ● To RETARD the injection timing, rotate the pump f outward from the engine block. ● To ADVANCE the injection timing, rotate the pump f inward to the engine block.
20-38
WB140-2N WB150-2N
TESTING AND ADJUSTING
FUEL INJECTION TIMING
12 7. Tight the pump nuts g at the cylinder block. Nuts:
8.
34 to 44 N•m
Reconnect the cylinder No. 1 high pressure pipe b to the injection pump. Delivery pipe union:
WB140-2N WB150-2N
20 to 25 N•m
20-39
TESTING AND ADJUSTING
FAN BELT
12
FAN BELT TENSION CHECK 1.
Push the fan belt B at the midway point between the alternator C and the water pump pulley A. Check the deflection with a pressure of 10 kg. ● New belt tension: 7 to 9 mm ● In use belt tension: 10 to 15 mm
TENSION ADJUSTMENT 1.
Loosen the alternator mounting bolt d and the mounting bolt e of the adjustment plate.
2.
Rotate the alternator c to tension the fan belt b and tighten the mounting bolts d and e.
3. Check the fan belt b tension. ★ If the belt has been replaced, check the tension again after the first 20 hours of operation.
20-40
Bolt d:
44 to 54 N•m
Bolt e:
23 to 29 N•m
WB140-2N WB150-2N
TESTING AND ADJUSTING
COMPRESSOR DRIVE BELT
12
COMPRESSOR DRIVE BELT CHECKING TENSION 1.
Push fan belt b at midway point between compressor c and pulley d. Check the deflection with a pressure of 10 kg. ● New belt tension: 4 to 6 mm ● In use belt tension: 7 to 10 mm
TENSION ADJUSTMENT 1.
Loosen the mounting bolt e of the eccentric d.
2.
Use a lever on the eccentric d to correctly tension the belt and secure the adjustment with bolt e.
3. Recheck the belt b tension. ★ If the belt has been replaced, recheck the tension again after 20 hours of operation. Bolt:
WB140-2N WB150-2N
123 N•m
20-41
TESTING AND ADJUSTING
ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR PEDAL AND LEVER ★ Measurement conditions: ● Machine: Shut down with safety features engaged ● Engine: Stopped and at operating temperature ● Idle speeds: Within standard value. ★ In order to check high speed engine idle, push the accelerator pedal a manually.
ACCELERATOR PEDAL TRAVEL 1.
Make sure that the accelerator pedal a is fully raised and the accelerator lever b is at its minimum stroke.
2.
Check that the accelerator lever c is in contact with low idle speed adjusting screw d.
3.
Adjust the nut e and locknut f of the accelerator pedal cable, and the hand accelerator at a distance of 0.2 to 0.3 mm from the lever g.
20-42
WB140-2N WB150-2N
TESTING AND ADJUSTING
ACCELERATOR PEDAL AND LEVER
12 4. Push the accelerator pedal until the accelerator lever c contacts the high idle adjusting screw h. 5.
Adjust the end travel stopper i of the accelerator pedal a in this position and secure it with the nut j.
6.
Release the accelerator pedal a.
ACCELERATOR LEVER TRAVEL 1.
Remove the mat and lateral cover a.
2.
Loosen the nut b and tighten the end lever travel bolt c a few turns.
3.
Start the engine.
4.
With the lever d, set the hand accelerator idle speeds. ★ High idle TIER I Engine: 2000 ±50 RPM ★ High idle TIER II Engine: 1900 ±50 RPM ★ Low idle: 1050 ±50 RPM
5.
Loosen the end lever travel bolt c so that it is in contact with the lever d and then secure the nut.
6.
Bring the engine to low idle and check the accelerator lever idle speed adjustment by pushing the lever to the end of its stroke.
WB140-2N WB150-2N
20-43
TESTING AND ADJUSTING
BRAKE PEDAL TRAVEL
12
BRAKE PEDAL TRAVEL ★ Measurement conditions: ● EngineStopped ● MachineAttachments on ground 1.
Check that the pedal A is at the stopper B and the pedals height matches side view A measurement. If necessary, correct the height by adjusting the stopper. ★ A measurement: 313 ± 3 mm
2.
Check that pin C can freely run and lock the pedals A.
TIER I ENGINE MASTER CYLINDER ROD ADJUSTMENT 1.
Loosen the nut d which locks the adjusting rod e. Loosen the adjusting rod until it touches the brake pump piston seat.
2.
Tighten the adjusting rod e one turn and lock it with nut d.
3. Repeat Steps 1 and 2 for the other pedal. ★ After tightening the nuts d, check that the adjusting rod e touches the brake pump piston seat.
MICROSWITCHES ADJUSTMENT 1.
Loosen the microswitch locking nuts f.
2.
Adjust the microswitches g and make sure there is a minimum clearance, 1 mm with the pedals in the neutral position, between the microswitches body and the pedal.
CHECKING ADJUSTMENT 1.
Verify the below measurements as shown in the figure. A measurement......................With pedal in neutral position B measurement.................With cylinder rod touching pump C measurement.................With pedal touching microswitch
20-44
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 TIER
BRAKE PEDAL TRAVEL
II ENGINE
MASTER CYLINDER ROD 1.
Loosen the nut d locking the adjusting rod e and loosen until it touches the brake pump piston seat.
2.
Tighten the adjusting rod e one turn and lock it with the nut d.
3.
Repeat operations 1 and 2 for the other pedal. ★ After tightened the nuts d, check that the adjusting rod e touch the brake pump piston seat simultaneously.
CHECKING ADJUSTMENT 1.
Verify measurements shown in figure. A measurement ..............................Pedal in neutral position B measurement............ Master cylinder rod touching the pump
WB140-2N WB150-2N
20-45
TESTING AND ADJUSTING
BLEEDING AIR
12
BLEEDING AIR HYDRAULIC PUMP ★ Bleeding of air from the pump is necessary: make sure the pump is full of oil 1.
When installing the pump.
2.
When replacing connecting hoses between the pump and hydraulic tank.
3.
When replacing the hydraulic oil and hydraulic tank overhaul. Bleeding air is accomplished as follows:
4.
Fill the hydraulic tank with oil and install plug G. Remove plug b on top side of pump c. Connect plug G to low pressure compressed air connection.
5.
Slowly and intermittently introduce compressed air into the hydraulic tank until oil flows out without air bubbles. ★ Maximum pressure in tank: 0.51 kg/cm²
6.
Install plug b and lock it. While slowly depressurizing the hydraulic tank, check the oil level. Add oil as necessary to maintain the proper level.
7.
Start the engine and run it for few minutes before bleeding air from the whole system.
CYLINDERS ★ When the hydraulic cylinders or pipe fittings have been replaced, it is necessary to bleed air before using the machine again. ★ Operate one movement at a time starting from the lift cylinders. 1.
Start the engine and run it at high idle speed for about 5 min. to warm up the oil and pressurize the hydraulic system.
2.
Return the engine to low idle speed, extend and retract the piston 4 to 5 times. ★ Extend and retract pistons to within 100 mm of end of stroke.
3.
Bring the engine to high idle speed and repeat Step 2. above. Return the engine to low idle speed and make a complete travel of the piston until the hydraulic pump reaches its maximum pressure.
4.
Repeat above operation, starting with Step 2. for all cylinders.
20-46
WB140-2N WB150-2N
TESTING AND ADJUSTING
BLEEDING AIR
12REPEAT ABOVE OPERATION FROM POINT 2) FOR ALL CYLIN.HE AIR BLEEDING IS OBTAINED HYDRAULIC OIL TANK (STARTING 1.
Put the machine in oil level check position and remove the tank plug. If necessary add oil to reach the correct level.
2.
After stopping the engine wait for a few minutes until the air bubbles disappear on oil surface.
3.
Install the tank plug.
HYDRAULIC OIL TANK PRESSURIZATION 1.
With engine at low idle speed, slowly extend all cylinders to their end of stroke.
2.
Stop the engine and remove tank plug.
3. Check the condition of gasket and reassemble plug. ★ Avoid increasing the engine speed until after completing all air bleeding procedures and after the pressurization of oil tank. ★ After air bleeding procedures, operate the engine at low idle speed for about 10 minutes before starting to work.
WORK CIRCUITS 1.
Put all work attachments on level ground, stop the engine.
2.
Move all control levers in all directions to completely release remain pressure in the cylinders and the main circuit.
3.
Slowly loosen the oil filler from the tank to remove any residual pressure.
BRAKE CIRCUIT ★ You must bleed air from the braking circuit every time maintenance is performed on the braking circuit, a component is replaced, or when air has entered the circuit. Machine must be stopped with all attachments on level ground. 1.
Make sure that oil in the brake system tank a is at maximum level. Remove the pedal lock pin.
2.
Remove the safety plugs and connect a plastic hose to the bleed screws b to catch the oil.
3.
Push the brake pedals to the bottom. Keeping them pushed, loosen the bleed screw b of the left brake until the pedals reach the end of their stroke.
4.
Keeping the pedal at the end of its stroke, tighten the bleed screw b.
WB140-2N WB150-2N
20-47
TESTING AND ADJUSTING
BLEEDING AIR
12 5. Release the brake pedals, wait for few seconds and repeat above operations two or three times until oil without air bubbles flows out from the bleed screw. 6.
Repeat same operations for the right brake unit.
7.
Disconnect the pedal lock pin.
8.
Push one brake pedal to bottom and, keeping it pushed, loosen the bleed screw b of one of the two braking units until the pedal reaches the end of its stroke. ★ Check that oil without air bubbles flows out from the bleed screw b.
9.
Repeat same operations for the other brake unit. ★ Frequently check the oil level in the tank and refill it when the level approaches minimum. ★ After bleeding the air, reinstall the safety plugs on the screws b.
CHECK BRAKE CIRCUIT 1.
Start the engine and lower the backhoe outrigger and force them downwards in order to raise the rear wheels.
2.
Engage forward gear in order to move the wheels.
3.
Return the machine to neutral and lower it. Stop the engine.
4.
Apply 50 kg on the pedal and verify measure D.
5.
Insert the pedal lock pin and applying the same mass, verify the measurement D. ★ D measurement, one pedal: Not < 165 mm ★ D measurement with both pedals: Not < 170 mm
20-48
WB140-2N WB150-2N
TESTING AND ADJUSTING
HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT INTRODUCTION
A Engine B Transmission C Hydraulic Pump ● ● ● ● ●
D Loader Control Valve E Backhoe Control Valve F Loader Relief Valve
G Backhoe Relief Valve H Steering Valve I Filtered Return To Tank
The machine is equipped with two control valves having the following functions: Loader Control Valve, 2 or 3 spools: For front work attachments control. Backhoe Control Valve, 6, 7 or 8-spools: For rear work attachments control. The two control valves are each protected against overpressure by a main relief valve with adjustable setting. Control valves are fed by hydraulic pump P1 which is controlled by a priority valve when the steering unit is used.
WB140-2N WB150-2N
20-49
TESTING AND ADJUSTING 12 LOADER
HYDRAULIC CIRCUIT
CONTROL VALVES
2 SPOOL LOADER CONTROL VALVE
a
Arm
b
Bucket
Cylinder Control
Port
Lift
A1
Lower
B1
Curl
A2
Dump
B2
3 SPOOL LOADER CONTROL VALVE
a
Arm
b
Bucket
Cylinder Control
Port
Lift
A1
Lower
B1
Curl
A2
Dump
B2
MP Bucket Or Retract
A3
Extend
B3
C Attachment
20-50
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 BACKHOE
HYDRAULIC CIRCUIT
CONTROLS STYLE VALVE
6 SPOOL BACKHOE CONTROL VALVE Bottom Port
Top Port
a Arm b Swing
Close A1
Open B1
Left A2
Right B2
C d e f
Up A3
Down B3
Right Outrigger Up A4
Down B4
Left Outrigger
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
7 SPOOL BACKHOE CONTROL VALVE
a b C d e f g
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
Telescope Arm
In
A7
Out B7
7 SPOOL BACKHOE CONTROL VALVE
a b C d e
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
f Boom h Hammer
Dump A5
Curl B5
Lift A6
Lower B6
Run A8
Blank B8
WB140-2N WB150-2N
20-51
TESTING AND ADJUSTING
HYDRAULIC CIRCUIT
8 SPOOL BACKHOE CONTROL VALVE
a b C d e f g h
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
Telescope Arm
In
Hammer
Run A8
20-52
A7
Out B7 Blank B7
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 EXCAVATOR
HYDRAULIC CIRCUIT
CONTROLS STYLE VALVE
6 SPOOL BACKHOE CONTROL VALVE Bottom Port
Top Port
a Arm b Swing
Close A1
Open B1
Left A2
Right B2
C d e f
Up A3
Down B3
Right Outrigger Up A4
Down B4
Left Outrigger
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
7 SPOOL BACKHOE CONTROL VALVE
a b C d e f g
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
Telescope Arm
In
A7
Out B7
7 SPOOL BACKHOE CONTROL VALVE
a b C d e
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
f Boom h Hammer
Dump A5
Curl B5
Lift A6
Lower B6
Run A8
Blank B8
WB140-2N WB150-2N
20-53
TESTING AND ADJUSTING
HYDRAULIC CIRCUIT
8 SPOOL BACKHOE CONTROL VALVE
a b C d e f g h
Bottom Port
Top Port
Arm
Close A1
Open B1
Swing
Left A2
Right B2
Left Outrigger
Up A3
Down B3
Right Outrigger Up A4
Down B4
Bucket
Dump A5
Curl B5
Boom
Lift A6
Lower B6
Telescope Arm
In
Hammer
Run A8
20-54
A7
Out B7 Blank B7
WB140-2N WB150-2N
TESTING AND ADJUSTING
MAIN RELIEF VALVES
12
MAIN RELIEF VALVES ★ The pressure readings are to be taken from check points on both control valves. Measurement conditions: ● EngineStopped at operating temperature ● Hydraulic oil55 to 60°C ● Parking brakeApplied
TESTING LOADER CONTROL VALVE (2 OR 3 SPOOL) 1.
Connect the pressure gauge E3 to the pressure adapter B of the front shovel control valve A.
2.
Start the engine and bring up to max speed and check the nominal pressure of the main relief valve E by rolling the front bucket to the end of its stroke. Nominal pressure: WB140-2N: .................................................... 189 ±7 kg/cm² WB150-2N: .................................................... 204 ±7 kg/cm²
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS) 1.
Connect the pressure gauge E3 to the pressure adapter D of the backhoe control valve c.
2.
Start the engine and bring up to max speed and check the nominal pressure of the main relief valve F while forcing the bucket into maximum curl position. Nominal pressure: WB140-2N: .................................................... 211 ±7 kg/cm² WB150-2N: .................................................... 224 ±7 kg/cm²
★ If the main relief valve pressures do not correspond to the nominal values, they must be reset.
SETTING RELIEF PRESSURE WARNING! For adjustments, prepare the machine as for pressure testing. 1.
Remove safety plug.
2.
Loosen lock nut g.
3.
Force the specific control lever to the end of its stroke. ● Loader: Force the bucket into the maximum curl position. ● Backhoe: Force the bucket into the maximum curl position.
WB140-2N WB150-2N
20-55
TESTING AND ADJUSTING
MAIN RELIEF VALVES
12 4. Adjust the pressure with the adjusting screw h. ● To INCREASE the pressure, rotate the adjusting screw in the CLOCKWISE direction. ● To DECREASE the pressure, rotate the adjusting screw in the COUNTERCLOCKWISE direction.
5.
Tighten the locknut g to secure the adjustment.
6.
Reinstall safety plug.
20-56
WB140-2N WB150-2N
TESTING AND ADJUSTING
LOADER CIRCUIT RELIEF VALVES
12
LOADER CIRCUIT RELIEF VALVES ★ Measurement conditions: ● Engine: Stopped at operating temperature ● Hydraulic oil: 55 to 60°C ● Parking brake: Applied
TESTING PRESSURE 1.
Connect the pressure gauge E3 to the pressure adapter B of the loader control valve.
2.
Start the engine and bring the hand accelerator lever up to 1050 rpm.
3.
Set the main relief valve c to a value 30 kg/cm² higher than the maximum pressure to be tested.
4.
Check the circuit relief valve d, e, f and g single movement pressure. Refer to the following tables for the cylinder and its movement. d
Raise the loader arm so that the bucket will clear the ground. Fully curl the bucket and read and record the pressure on the gauge.
e
Raise the loader arm so that the bucket will clear the ground. Fully dump the bucket and read and record the pressure on the gauge.
f
Raise the loader arm so that the bucket will clear the ground. Fully extend the cylinder and read and record the pressure on the gauge.
g
Raise the loader arm so that the bucket will clear the ground. Fully retract the cylinder and read and record the pressure on the gauge.
Unit: kg/cm² Port
Description
Pressure
d
A2
Bucket Dump
235
e
B2
Bucket Curl
166
f
A3
Cylinder Retract
235
g
B3
Cylinder Extend
235
WB140-2N WB150-2N
20-57
TESTING AND ADJUSTING 12 SETTING
LOADER CIRCUIT RELIEF VALVES
PRESSURE
★ The pressure must be set while the control lever, for the cylinder being tested, is forced to the end of its stroke. 1.
Remove the safety plug h.
2.
Loosen the locknut i.
3.
Adjust the pressure with the adjusting screw j. ● To INCREASE the pressure, rotate CLOCKWISE. ● To DECREASE the pressure, rotate COUNTERCLOCKWISE.
4.
Tighten locknut i to secure the adjustment. Locknut:
10 ±1 N•m
WARNING! After the pressure is adjusted, install the safety plug h to avoid unauthorized tampering. 5.
Reset the main relief valve pressure to the standard value after all of the secondary valves have been checked and set.
20-58
WB140-2N WB150-2N
TESTING AND ADJUSTING
BACKHOE CIRCUIT RELIEF VALVES
12
BACKHOE CIRCUIT RELIEF VALVES ★ Measurement conditions: ● Engine: Stopped at operating temperature ● Hydraulic oil: 55 to 60°C ● Parking brake: Applied
TESTING PRESSURE 1.
Connect the pressure gauge E3 to the pressure adapter B of the backhoe control valve a.
2.
Start the engine and bring the hand accelerator lever up to 1050 rpm.
3.
Set the main relief valve c to a value 40 kg/cm² higher than the maximum pressure to be tested.
4.
Check the circuit relief valve d, e, f, g, h and i single movement pressure. Refer to the following tables for the cylinder and its movement. d
Spread the backhoe along the ground. Curl the bucket and fully retract the arm cylinder. Read and record the pressure on the gauge.
e
Place the backhoe in the transport position and lock the boom. Swing the backhoe to the full right. Read and record the pressure on the gauge.
f
With the backhoe in the transport position and the boom lock in place, swing the backhoe to the full left. Read and record the pressure on the gauge.
g
With the backhoe centered raise the boom and extend the arm the bucket will clear when curled. Fully curl the bucket and read and record the pressure on the gauge.
h
Place the backhoe in the transport position and lock the boom. Lower the boom and read and record the pressure on the gauge.
i
The backhoe boom raise circuit valve pressure can only be checked and set during a bench test.
WB140-2N WB150-2N
20-59
TESTING AND ADJUSTING
BACKHOE CIRCUIT RELIEF VALVES
12 Unit: kg/cm² Port
Description
Pressure
d A1
Arm Retract
245
e B2
Swing Right
184
F A2
Swing Left
184
G B5
Bucket Curl
245
H B6
Boom Lower
245
I A6
Boom Raise
357 ★
J A8
Not Used
163
★ The backhoe boom raise circuit valve pressure can only be checked and set during a bench test.
SETTING PRESSURE ★ The pressure must be set while the control lever, for the cylinder being tested, is forced to the end of its stroke. 1.
Remove the safety plug 1).
2.
Loosen the locknut 1!.
3.
Adjust the pressure with the adjusting screw 1@. ● To INCREASE the pressure, rotate CLOCKWISE. ● To DECREASE the pressure, rotate COUNTERCLOCKWISE.
4.
Tighten locknut 1! to secure the adjustment. Locknut:
10 ±1 N•m
WARNING! After the pressure is adjusted, install the safety plug 1) to avoid unauthorized tampering.
5.
Reset the main relief valve pressure to the standard value after all of the secondary valves have been checked and set.
20-60
WB140-2N WB150-2N
TESTING AND ADJUSTING
UNLOADING VALVE
12
UNLOADING VALVE ★ Measurement conditions: ● Engine: Stopped and at working temperature. ● Hydraulic oil: 45 to 55°C. ● Machine: front equipment on the ground, parking brake applied and boom and arm fully extended. ● Working mode: Power
TESTING 1.
Disconnect the hose b from the load sensing line. Install a tee and reconnect the hose.
2.
Remove the plug c and install pressure adapter.
3.
Connect pressure gauge E5 to the adapter.
4.
Start the engine and set it at 1050 ±50 rpm. Without any machine movement, all the control levers in the neutral position, read the ρP pressure. ρP - Unloading Valve ......................................... 24.5 kg/cm² ★ If the ρP value is not within the limits, adjust the unloading valve a.
ADJUSTMENT 1.
Remove plug e, spring f, washers g, and valve body h.
2.
Place a shim d under the spring f and install the valve. ● One shim, 1 mm thick, increases the ρP by 3 kg/cm². Plug:
WB140-2N WB150-2N
100 N•m
20-61
TESTING AND ADJUSTING
LOAD SENSING (LS) VALVE
12
LOAD SENSING (LS) VALVE ★ Measurement conditions: ● Engine: Stopped and at working temperature. ● Hydraulic oil: 45 to 55°C. ● Machine: front equipment on the ground, parking brake applied and boom and arm fully extended. ● Working mode: Power
TESTING 1.
Disconnect the hose b from the load sensing line. Install a tee and reconnect the hose.
2.
Remove the plug c and install a pressure adapter.
3.
Connect the pressure gauge E5 to the adapter.
4.
Start the engine and set at 1050 ±50 RPM. Without any machine movement, and all levers in the neutral position, read the ρP pressure on the gauge. ρP - Unloading Valve ......................................... 24.5 kg/cm² ★ If the ρP value is not within this limit, adjust the unloading valve.
5.
Raise the boom up to the end of its stroke and read the ρP pressure on the gauge. ρP - Load Sensing Valve ................................... 21.5 kg/cm² ★ If the ρP value is not within limits, adjust the load sensing valve a.
ADJUSTMENT 1.
Remove the cover nut e. Loosen the locknut f.
2.
Adjust the pressure using the adjustment screw g. ● To INCREASE the pressure, rotate CLOCKWISE. ● To DECREASE the pressure, rotate COUNTERCLOCKWISE.
3.
Tighten the locknut f to secure the adjustment. Locknut:
4.
21 N•m
Check the gasket d and install the nut e. Cover Nut:
20-62
21 N•m
WB140-2N WB150-2N
TESTING AND ADJUSTING
FLOW VALVE
12
FLOW VALVE ★ Measurement conditions: ● Engine: Stopped at working temperature ● Hydraulic oil: 45 to 55°C ● Machine: Safe, parking brake applied ● Control valve lever: Neutral position 1.
Disconnect the hose a from the load sensing line. Install the tee b and reconnect the hose.
2.
Connect a pressure port and gauge E1 to the tee b.
3.
Connect a second gauge E1 to the rear control valve pressure port c.
4.
Start the engine and at low idle without any machine movement, check the pressure on both gauges. ★ P pressure at control valve gauge: 30 ±3 kg/cm² ★ Normal pressure PLS: 6 ±2 kg/cm² This value is due to the influence of the counterpressure present in the steering circuit. ★ If any variations are found, they do not represent a problem provided that the difference of 21 ±1 kg/cm² between the two readings is respected.
5.
If the difference between the readings is higher than 24 ±1 kg/cm², stop the engine and release the residual pressures.
6.
Thoroughly clean the valve d and reinstall it. Valve:
7.
20 N•m
If, after cleaning the valve d, the value still does not fall within the tolerance limits of 24 ±1 kg/cm², install a new valve.
WB140-2N WB150-2N
20-63
TESTING AND ADJUSTING
PRIORITY VALVE
12
PRIORITY VALVE ★ Measurement conditions: ● Engine: Stopped at working temperature ● Hydraulic oil: 55 to 60°C ● Parking brake: Applied
TESTING 1.
Connect a pressure gauge E2 to the pressure adapter a of the backhoe control valve.
2.
Start the engine and set it at 1500 ±50 rpm. Check the gauge E2 pressure value with a stopped steering wheel. ● Pressure Value24 kg/cm²
3.
Slightly turn the steering wheel and check that pressure increases. Continue turning the steering wheel to the end of a full turn and check that while forcing the steering wheel, pressure increases to the normal value. ● Backhoe Controls: 178 ±10 kg/cm² ● Excavator Controls: 178 ±7 kg/cm² ★ If the pressure does not reach the normal value, reset the pressure of the steering unit ★ If the pressure indicated by the gauge does not change while turning the steering wheel, and it takes excessive force to turn the wheel, the priority valve b needs to be cleaned.
CLEANING PRIORITY VALVE 1.
Remove the priority valve plug d, spring e and rod f. ★ Carefully check and make notes on the disassembly so that you can reassemble the priority valve.
2.
Remove the plug g and ball h of the inside valve and the spring i. Check that the hole j and nozzle c are completely clean. Replace the spring i, ball h and plug g Plug:
Plug:
Loctite 542
20 N•m
★ Do not allow any Loctite to enter the hole j. Remove all excess Loctite from the rod f. 3.
Lubricate the rod f and install it in its seat. Make sure that it slides freely. Insert the spring e and plug d. Plug:
4.
100 N•m
Start the engine and execute several steering manoeuvres. If the fault is not corrected, replace the complete steering column with a new one.
20-64
WB140-2N WB150-2N
TESTING AND ADJUSTING
STEERING SYSTEM
12
STEERING SYSTEM ★ Measurement condition: ● Engine: Operating temperature ● Hydraulic oil: 55 to 60°C
TESTING 1.
Connect a pressure gauge E2 to the pressure adapter a of the backhoe control valve.
2.
Start the engine and set at 1500 ±50 rpm. Turn the steering wheel from end to end.
3.
Force the steering wheel to the end of its rotation and check the pressure. ● Backhoe Controlled Pressure: 178 ±10 kg/cm² ● Excavator Controlled Pressure: 178 ±7 kg/cm²
4.
Check the pressure at the other end of the steering direction as well.
SETTING ★ If the pressure is not within the permissible limits, reset the pressure on the upper valve b of the steering unit. 1.
Remove the plug c. Insert a wrench and loosen the screw d.
2.
Adjust the pressure with the screw e. ● To INCREASE the pressure, rotate CLOCKWISE. ● To DECREASE the pressure, rotate COUNTERCLOCKWISE.
3.
Stop the engine. Secure the adjustment screw e by tightening screw d.
4.
Install the plug E making sure that the gasket f is properly seated.
WB140-2N WB150-2N
20-65
TESTING AND ADJUSTING
BRAKE SYSTEM
12
BRAKE SYSTEM ★ Measurement condition: ● Engine: Stopped ● Machine: on solid and level ground, with the equipment raised and safety devices engaged. ● Brake pedals: independent, with the fluid container level at maximum. Brake system testing is accomplished in two parts: 1.
Testing the circuit and brake pump tightness.
2.
Leak tightness test of the braking group. WARNING! If both the tests give positive results, check for leaks in the piping of the braking system.
CIRCUIT AND BRAKE PUMP TEST 1.
Disconnect the equalizer connecting pipe a from the brake pumps b of the circuit being tested.
2.
Securely plug the equalizer orifice A when the pipe is disconnected.
3.
Remove clamp d and disconnect delivery lines e from the pumps.
4.
Connect a pressure gauge E2 to the pump b.
5.
Push the brake pedal corresponding to the pump and bring the circuit up to a pressure. ● Brake Pressure: 122 kg/cm². ★ Do not exceed the maximum permissible value of 153 ±5 kg/ cm².
6.
Keep the pedal pushed for at least 2 minutes and check that the pedal pressure and position remain steady. ★ If the position of the pedal changes to maintain the pressure, the pressure loss is due to leaks inside the pump. This can be confirmed by checking the oil. If there are leaks, it will show signs of mixing.
7.
Repeat the test for the other brake pump.
20-66
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 BRAKING
BRAKE SYSTEM
GROUP LEAK TEST
1.
Disconnect the delivery tube e of the braking group being tested.
2.
Connect the tee between delivery line f and the braking group. ★ Make sure to insert pressure adapter between the braking group and the cut off valve g.
3.
Connect pressure gauge E2 to the pressure adapter of the tee and open the valve g.
4.
Operate the brake pump to feed pressure into the circuit to a pressure of about 122 kg/cm². ★ Do not exceed the maximum permissible value of 158 ±5 kg/ cm².
5.
Close valve g to maintain pressure in the braking group being tested.
6.
Release the brake pedal and observe the pressure indicated on gauge E2 for 2 minutes. ★ If the pressure value shows a negative change, it means that the braking piston seals are defective. WARNING! For further confirmation of the leak can be obtained by an increase in the oil level in the axle, which leads to a mixing of the oils. Change all the sealing rings between the axle sections, and carry out a complete lubrication oil change.
7.
Repeat the test for the other braking group, follow the same method.
8.
Reassemble the braking circuit WARNING! After testing and any repairs, bleed air from the brake units, see BLEEDING AIR.
WB140-2N WB150-2N
20-67
TESTING AND ADJUSTING
ENGINE SPEED UNDER LOAD
12
ENGINE SPEED UNDER LOAD ★ Measurement conditions: ● Engine: Stopped at working temperature ● Hydraulic oil: 45 to 55 °C ● Power train oil: Working temperature ● Brake pedals: Connected ● Machine: on solid and level ground with the equipment raised and safety devices engaged. Two tests must be performed: 1.
Stall test with the torque converter under load.
2.
Stall test with the torque converter and the hydraulic system under load. ★ The tests must be performed after a no load test of the engine speed. For details, see ENGINE SPEED. WARNING! During the following tests, while accelerating the engine with the gear engaged, the condition of the brake disks can also be checked. If, while force is being exerted on the brake pedals, the machine moves, even slowly; A. Release the accelerator immediately and stop the engine. B. Check the wear on the brake disks and change them before completing the tests.
PREPARING THE MACHINE 1.
Prepare the tachometer C to measure the engine rpm. ★ When mounting an electronic transducer tachometer on a diesel delivery line to the injection nozzles, make sure that it is placed far away from the clamp. WARNING! Make sure that the brake pedals are fastened together with the cotter pin b.
TORQUE CONVERTER STALL 1.
Start the engine at set at the lowest idle. Engage 4th gear and apply the brake firmly.
2.
While keeping the brake applied, accelerate the engine gradually up to high idle and measure the speed reached. ★ WB140-2N TIER I Engine: 2100 ±50 rpm ★ WB140-2N TIER II Engine BH Controls: 2200 ±50 rpm ★ WB140-2N TIER II Engine EX Controls: 2275 ±50 rpm ★ WB150-2N TIER I Engine: 2275 ±50 rpm ★ WB150-2N TIER II Engine BH Controls: 2200 ±50 rpm ★ WB150-2N TIER II Engine EX Controls2275 ±50 rpm
3.
Release the accelerator pedal and move on to the next test.
20-68
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 TORQUE
ENGINE SPEED UNDER LOAD
CONVERTER AND HYDRAULIC STALL
1.
Start the motor at set at the lowest idle. Engage 4th gear and apply the brake firmly.
2.
While keeping the brake applied, 4th gear engaged, accelerate the engine gradually and at the same time activate the control valve lever to curl the front bucket, and turn the steering wheel and hold it at the end of its stroke.
3.
Once the maximum engine speed and maximum pressure of the bucket circuit have been reached, note the speed reached by the engine. ★ TIER I Engine: 2000 ±50 rpm ★ TIER II Engine BH Controls: 2050 ±50 rpm ★ TIER II Engine EX Controls: 2250 ±50 rpm ● If the engine rpm are higher than the permissible limit in both tests, check the delivery pressure to the converter and the clutch pressures. ● If the engine rpm is lower than the permissible limit, check the condition of the air filter, the engine compression, the timing, the injection pump, and the valve clearances.
WB140-2N WB150-2N
20-69
TESTING AND ADJUSTING
POWER TRAIN GROUP
12
POWER TRAIN GROUP The power train group can be used to perform pressure tests on the internal hydraulic circuit. These are useful for identifying malfunctions. Specifically, the tests involve: 1.
Converter oil pressure.
2. Clutch engagement pressures for both directions of travel. ★ Test conditions: ● Engine: Stopped ● Brake pedals: Connected ● Machine: On solid and level ground with the equipment raised and safety devices engaged.
PREPARING THE MACHINE 1.
Prepare the tachometer C to measure the engine rpm. ★ When mounting an electronic transducer tachometer on a diesel delivery line to the injection nozzles, make sure that it is placed far away from the line clamp. WARNING! Make sure that the brake pedals are fastened together with the cotter pin b.
CONVERTER OIL PRESSURE 1.
Remove the plug P22 and connect pressure gauge E6.
2.
Start and engine and heat all the fluids up to working temperature. Make sure that the power train oil reaches a temperature of 80 ±5°C.
3.
With the engine at low idle, check the pressure on the pressure gauge E6. ★ Normal pressure: Min. 0.5 kg/cm²
4.
Gradually increase the engine speed to high idle. Take a new reading from the pressure gauge E6. ★ Normal pressure: 9.2 kg/cm²
5.
Bring the engine back to low idle and compare the pressure with the normal value. ★ Normal pressure: Min. 0.5 kg/cm² ★ If the maximum pressure value drops to below the permissible lower limit, the power train pump needs an overhaul.
20-70
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 CLUTCH
POWER TRAIN GROUP
PRESSURE
1.
Remove the access plate from the cab floor.
2.
Remove plug P19 and connect pressure gauge E6.
3.
Start and heat the engine and all the fluids up to working temperature. Make sure that the power train oil reaches a temperature of 80 ±5°C.
4.
With the engine at low idle, check the pressure on the gauge E6. ★ Normal pressure: Max. 0.32 kg/cm²
5.
Select the REVERSE gear and gradually increase the engine speed to high idle. Take a new reading from the pressure gauge E6. ★ Normal pressure: 11 to 13 kg/cm²
6.
Bring the engine back to low idle and place the transmission in neutral. Compare the pressure with the normal value. ★ Normal pressure: Max. 0.36 kg/cm²
7.
Remove the pressure adapter and replace the plug P19. Plug
8.
23 N•m
Repeat the same test for the FORWARD gear, reading the pressure from the plug P18. ● If the pressures are different for the travel directions, there is a loss of pressure on the clutch piston with lowest pressure.
ADDITIONAL PRESSURES P17 ★ ★ P21 ★ ★
Oil Cooler Back Pressure FWD/REV clutch in neutral: 0.5 to 5 kg/cm² FWD/REV clutch ENGAGED: 0.5 to 3.5 kg/cm² 4WD Engagement Pressure @ 900 RPM: 13 to 14 kg/cm² @ 2200 RPM: 13 to 15.5 kg/cm²
WB140-2N WB150-2N
20-71
TESTING AND ADJUSTING
DIRECTIONAL CLUTCHES
DIRECTIONAL CLUTCHES ★ Test conditions: ● Engine: Stopped. ● Brake pedals: Connected ● Machine: on solid and level ground with the equipment raised and safety devices engaged. ★ This test must be performed after having checked the pressures of the power train group.
PREPARATION OF THE MACHINE 1.
Prepare tachometer C to measure the engine rpm. ★ When mounting an electronic transducer tachometer on a diesel delivery line to the injection nozzles, make sure that it is placed far away from the line clamp. WARNING! During the following tests, while accelerating the engine with the gear engaged, the condition of the brake disks can also be checked. If, while force is being exerted on the brake pedals, the machine moves, even slowly; A. Release the accelerator immediately and stop the engine. B. Check the wear on the brake disks and change them before completing the tests. WARNING! Make sure that the brake pedals are fastened together by the cotter pin a.
TESTING 1.
Start and heat the engine and all the fluids up to working temperature. Make sure that the power train oil reaches a temperature of 80 ±5°C.
2.
With the engine at low idle, accelerate to high idle. Check that the rpm remain within permissible limits.
3.
Brake hard and bring the engine up to high idle.
4.
Maintaining the braking action and the acceleration, engage the FORWARD gear and check that the engine speed decreases until it is once again within permissible limits.
5. Repeat this test in REVERSE gear. ★ If the rpm are higher than the permissible limits, the clutches are worn, and must be replaced.
20-72
WB140-2N WB150-2N
TESTING AND ADJUSTING
RETURN TO DIG DEVICE
12
RETURN TO DIG DEVICE ★ Adjustment conditions: ● Machine: On solid and level ground ● Engine: Stopped ● Hydraulic oil: 45 to 55°C ● Parking brake: Engaged 1.
Rest the bucket on the ground, making sure that the bottom is parallel to the surface.
2.
Stop the engine and remove the sensor guard a.
3.
Check that there is a distance of 3 to 4 mm between the sensor C and rod D. If necessary, loosen the nuts E and adjust the distance until the indicated measurement is obtained. Tighten the nuts to secure the adjustment.
4.
Loosen screw F and move bracket G towards the rear until the sensor is completely free of rod D.
5.
Start the engine and set at low idle. Adjust the position of the bracket G until the sensor C is engaged. ★ When the rod contacts the sensor, the warning lamp b will be activated.
6.
Secure the bracket G position by tightening the screw.
7.
Perform several tests by raising and dumping the bucket. If the bucket is able to rest flat on the ground, reinstall the sensor guard a.
WB140-2N WB150-2N
20-73
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12
HYDRAULIC DRIFT ★ If working attachments drift, check if the drift is due to the cylinder seals or the control valve. ★ Test conditions: ● Engine: Operating temperature ● Hydraulic oil: 45 to 55°C ● Remove and install pipes only after any residual pressure has been removed.
LOADER LIFT CYLINDER 1.
Position the bucket vertically with the cutting edge or teeth resting on 10 cm blocks a.
2.
Stop the engine and remove any residual hydraulic pressure.
3.
Disconnect the hoses B and C from the lift cylinders D and plug them.
4.
Plug the lift cylinder base side. Apply a temporary hose to the rod side to catch any oil leakage.
5.
Start the engine and retract the bucket until the cutting edge or teeth tilt 15° above horizontal.
6.
Stop the engine and check the bucket link position for 5 minutes. ● If the bucket link has no lowering movement, drift is due to the control valve. To check each cylinder, proceed as follows: 7.
Position the bucket vertically with the teeth resting on 10 cm thick blocks.
8.
Remove the plug (installed earlier in Step 4) from the base side of one cylinder.
9.
Start the engine and retract the bucket until the teeth tilt 15° above horizontal.
10. Stop the engine and check the bucket position for 5 minutes. ● If the bucket link has a lowering movement, drift is due to gasket seals of the plugged cylinder. 11. Repeat Steps 7 through 10 to check the other cylinder.
20-74
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 BUCKET
HYDRAULIC DRIFT
CYLINDER
1.
Position the bucket on level ground and tilt the cutting edge or teeth up 15° a. Put a 1500 kg weight into the bucket. Stop the engine and remove any residual hydraulic pressure.
2.
Disconnect the hoses B and C from the dump cylinders D and plug them.
3.
Plug the dump cylinder base side. Apply a temporary hose to the rod side to catch any oil leakage.
4.
Start the engine and raise the bucket up to horizontal alignment of the bucket hinge and arm hinge.
5.
Stop the engine and check the bucket cutting edge or teeth position for 5 minutes. ● If the bucket has no swing movement, drift is due to the control valve. To test the individual cylinders, proceed as follows: 6.
Lower the bucket to the ground.
7.
Remove the plug from one of the cylinders installed on the base side in Step 3.
8.
Start the engine and raise the bucket as indicated in Step 4.
9.
Stop the engine and check the position of the bucket cutting edge or teeth for 5 minutes. ● If the bucket cutting edge or teeth turn, the drift is due to the gasket seals of the plugged cylinder.
10. Repeat Steps 6 through 10 to test the other cylinder.
WB140-2N WB150-2N
20-75
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 BACKHOE ★ Test condition: ● Backhoe: Aligned ● Outriggers: Raised
BOOM CYLINDER 1.
Position the machine with its arm in vertical position with the bottom of the bucket resting on level ground.
2.
Stop the engine and remove any residual hydraulic pressure.
3.
Disconnect hoses B and C from cylinder D and plug them.
4.
Plug the cylinder head side.
5.
Apply a temporary hose to the base side to catch any oil leakage.
6.
Start the engine and extend the arm completely.
7.
Stop the engine and check the boom position for 5 minutes. ● If the boom has a lowering movement, drift is due to cylinder gaskets. ● If the boom has no lowering movement, drift is due to the control valve.
ARM CYLINDER 1.
Position the machine with its arm a fully extended with the bucket opened and teeth on the ground.
20-76
WB140-2N WB150-2N
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 2. Stop the engine and remove any residual hydraulic pressure. 3.
Disconnect the hoses B and C from the arm cylinder D and plug them. ★ If a safety valve is installed, remove it for this test.
4.
Plug the arm cylinder port on the rod side. Attach a temporary hose to the base side to catch any oil leakage.
5.
Start the engine and raise the boom.
6.
Stop the engine and check the arm position for 5 minutes. If the arm has a lowering movement, the drift is due to the cylinder gaskets. ● If the arm has no movement, the drift is due to the control valve. ●
BUCKET CYLINDER 1.
Position the machine with the bucket arm vertical and the bottom of the bucket resting on level ground.
2.
Put a 450 kg weight a into the bucket
3.
Stop the engine and remove any remaining hydraulic pressure.
4.
Disconnect hoses b and c from bucket cylinder d and plug them.
5.
Plug the bucket cylinder hole on the base side and attach a temporary hose to the rod side to catch any oil leakage.
WB140-2N WB150-2N
20-77
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12R 6. Start the engine and raise the boom. 7.
Stop the engine and check the bucket position for 5 minutes. ● If the bucket has an opening movement, drift is due to cylinder gaskets. ● If the bucket has no movement, drift is due to the control valve.
OUTRIGGER TESTING 1.
Position the machine with its arm in vertical position with the bottom of the bucket resting on level ground.
2.
Place support stands a of a suitable height beneath the outriggers, and bring the cylinder eyes to a horizontal position.
3.
Without forcing them, lower the outriggers onto the support stands.
4.
Stop the engine and release any residual hydraulic pressure.
5.
Remove the hoses b and c from the cylinders d and plug them.
6.
Plug the cylinder base side c. Apply a temporary hose to the rod side to catch any oil leakage.
7.
Start the engine. Use force on the boom to raise the machine and remove the support stands supporting the outriggers.
8.
Lower the machine and stop the engine.
9.
Check the outriggers position for 5 minutes. ● If one or both outriggers have a lowering movement, drift is due to one or both cylinders. ● If there is no lowering, drift is due to the control valve.
20-78
WB140-2N WB150-2N
TESTING AND ADJUSTING
AIR CONDITIONING UNIT
12
AIR CONDITIONING UNIT ★ Test conditions: ● Machine on level ground with the work equipment raised and safety devices engaged ● Parking brake: Engaged
TESTING THE WORKING TEMPERATURE 1.
Connect the maintenance station to the high pressure valve and the low pressure valve.
2.
Start the engine and bring it up to a speed of 1500 rpm.
3.
Switch on the AC unit using the switch in the cab.
4.
Select an intermediate ventilation speed inside the cab.
5.
Use the thermometer M2 to check that the temperature inside the cab is equal to or lower than the ambient temperature. ★ If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab temperature stabilizes at the outside value.
6.
Close the doors and windows and let the AC unit operating these conditions for 5 to 10 minutes.
7.
Use the thermometer M2 to check the temperature of the air at the central outlets. ★ Position the probe as close as possible to the air outlets.
8.
Compare the average value of the measured temperatures using the following table:
Ambient Air Temp °C
20
25
30
35
Outgoing Air Temp °C
6 to 8
8 to 10
8 to 12
9 to 14
9.
If the average value of the temperature measured does not fall within the values given in the table, it will be necessary to thoroughly check the unit.
CHECKING THE UNIT Check the unit after the Steps 1 through 4.and 6. of the preceding paragraph. A diagnosis of faults in the unit is based upon the working pressures. When the pressures do not fall within the values given in the following table, the causes must be found by checking the highpressure and low pressure gauges.
WB140-2N WB150-2N
20-79
TESTING AND ADJUSTING
AIR CONDITIONING UNIT
12 Unit: kg/cm² Outside Air Temperature °C
Unit with R134a. Low Pressure
High Pressure
Min
Max
Min
Max
20
1.2
2.5
6.0
9.0
25
1.0
2.5
7.5
10.5
30
1.1
2.4
9.5
13.0
35
1.3
2.4
12.0
15.5
40
1.5
1.8
18.0
18.8
45 1.8 The following conditions can be found:
1.9
21.5
22.0
CONDITIONS
CAUSES - FAULTS
LP high to HP normal or low
● ● ●
LP low to HP high or normal
● ● ●
LP normal to HP normal
● ● ●
LP high to HP high
● ● ● ● ●
LP normal or low to HP low
● ● ● ●
LP roughly equal to HP
● ● ●
Electromagnetic pulley that slips or does not engage correctly Expansion valve blocked in open position Compressor damaged Expansion valve blocked in closed position or obstructed Filter saturated with moisture Obstruction in the LP line or in the HP line between the filter and the evaporator. Infiltration of hot air into the evaporator group, the pipes or the cab Hot air circulating in the heating group Formation of ice on the evaporator Normal condition with very high ambient temperature, higher than 43°C Excess coolant, 30 to 35% more Overheating of condenser Air present in the unit Obstruction in the HP line between the compressor and the condenser filler tube behind the measurement point of the HP Normal condition with very low temperature, lower than 5°C Lack of coolant, 70 to 75% less, probable leakages Obstruction in the HP line between the compressor and the condenser filler tube before the measurement point of the HP Compressor damaged Compressor belt missing Electromagnetic pulley that slips or does not engage Compressor damaged
EMPTYING THE AC UNIT 1.
Connect the maintenance station M1 to service valves a and b and follow the specific maintenance station instructions relative to the drainage of the unit.
2.
Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station. Plug the removed or disconnected connection tubes tightly and with a minimum of delay.
20-80
WB140-2N WB150-2N
TESTING AND ADJUSTING 3.
AIR CONDITIONING UNIT
Carefully check the quantity of R134A recovered and contained in the disassembled parts, since the same quantity must be replaced when the air conditioning unit is filled.
WB140-2N WB150-2N
20-81
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12
TROUBLESHOOTING GUIDE FRONT AXLE Wheel vibration; front tire resistance; half shaft breakage. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent half shaft
Replace half shaft
No differential action; jamming while steering. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Broken half shaft
Replace half shaft
Bent half shaft
Replace half shaft
Steering is difficult; vehicle goes straight while trying to turn it. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Broken half shaft
Replace half shaft
Excess noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft
Replace half shaft
Incorrect wheel adjustment
Verify group integrity and wheel side bearings
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle.
20-82
WB140-2N WB150-2N
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Uneven wear of tires CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft
Replace half shaft
Blocked half shaft: ● Abnormal functioning of the differential or ● breakage/blockage of control device ● Vehicles with wide steering angle may proceed ● with kicks, have steering difficulty or cause pneumatic wear on sharp turns. Incorrect wheel adjustment
Verify assembly of all components Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
Verify group integrity and wheel side bearings
Friction noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Bent or broken half shaft
Replace half shaft
Damaged or worn out axle parts
Check the condition of the ring gear, pinion gear, bearings, etc. Replace when necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle. Replace or adjust as required. Incorrect adjustment of bevel gear set. Parts of the trans worn out transmission gears, U joint, etc. Vibration during forward drive, intermittent noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Bent half shaft
Replace half shaft
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
WB140-2N WB150-2N
20-83
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Noise while driving CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust
Worn out pinion and ring gear
Replace
Worn out pinion bearings
Replace
Pinion bearings loose
Adjust
Excessive axial pinion backlash
Adjust
Worn out differential bearings
Replace
Differential bearings loose
Adjust
Ring gear out of round
Replace
Low oil level
Oil level
Poor or worn oil
Replace
Bent half shaft
Replace
Noise while driving in neutral CAUSES
REMEDY
Noises coming from axle are usually heard but not Replace or adjust (see above) loud when vehicle moves in neutral gear. Incorrect backlash between pinion and ring, sound Replace heard while decelerating, disappears while increasing speed Pinion or input flange worn out
Adjust
Intermittent noise CAUSES
REMEDY
Ring gear damaged
Replace bevel gear set
Differential box bolts loosened
Tighten to torque
Constant noise CAUSES
REMEDY
Ring gear teeth or pinion damaged
Replace bevel gear set
Worn out bearings
Replace
Pinion spline worn out
Replace
Bent half shaft
Replace
Noise while steering CAUSES
REMEDY
Worn out differential gears
Replace
Worn out differential box or spider
Replace
Differential thrust washers worn out
Replace
Half shaft spline worn out
Replace
20-84
WB140-2N WB150-2N
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Ring gear teeth broken at the outer side CAUSES
REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
Incorrect gear adjustment (excessive backlash) Pinion nut loosened Ring gear tooth broken CAUSES
REMEDY
Load bump
Replace bevel gear set. Adjust bevel gear set free backlash
Incorrect gear adjustment insufficient backlash Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations lubrication for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES
REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Insufficient lubrication; contaminated oil; improper lubrication Pinion teeth pitting CAUSES
REMEDY
Excessive use
Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Insufficient lubrication Axle beam body bent CAUSES
REMEDY
Vehicle overloaded
Replace axle beam body
Vehicle accident Load bump Worn out or pitted bearings CAUSES
REMEDY
Insufficient lubrication; contaminated oil
Replace bearings, use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Excessive use Normal wear out Pinion nut loosened
WB140-2N WB150-2N
20-85
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Oil leakage from gaskets and seals CAUSES
REMEDY
Prolonged operation at high temperature
Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Oil gasket assembled incorrectly Seal lip damaged Contaminated oil Excessive wearing out of input flange spline CAUSES
REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required
Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES
REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload Pinion and ring teeth breakage CAUSES
REMEDY
Crash load of differential components
Check and/or replace other differential components
Side gear spline worn out CAUSES
REMEDY
Excessive use
Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched CAUSES
REMEDY
Insufficient lubrication; contaminated oil, improper Use correct lubricants, fill to proper levels and replace according to the lubrication recommended schedule. Replace all scratched washers and those with 0.1 mm smaller thickness than the new ones Inner diameter of tapered roller bearing worn out CAUSES
REMEDY
Excessive use axial pinion
Replace bearing. Check pinion axial backlash Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Excessive pinion axial backlash Insufficient lubrication; contaminated oil
Bent or broken half shaft or half shaft broken at wheel side CAUSES
REMEDY
Vehicle intensively operated or overloaded
Replace. Check that wheel support is not worn out or incorrectly adjusted.
Wheel support loosened Beam body bent
20-86
WB140-2N WB150-2N
TESTING AND ADJUSTING 12 REAR
TROUBLESHOOTING GUIDE
AXLE
Wheel vibration; front tire resistance; half shaft breakage. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent half shaft
Replace half shaft
Steering is difficult; vehicle goes straight while trying to turn it. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Broken half shaft
Replace half shaft
No differential action; jamming while steering. CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Broken half shaft
Replace half shaft
Bent half shaft
Replace half shaft
Excess noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft
Replace half shaft
Incorrect wheel adjustment
Verify group integrity and wheel side bearings
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle.
WB140-2N WB150-2N
20-87
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Uneven wear of tires CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft
Replace half shaft
Blocked half shaft: ● Abnormal functioning of the differential or ● breakage/blockage of control device. ● Vehicles with wide steering angle may proceed ● with kicks, have steering difficulty or cause pneumatic wear on sharp turns. Incorrect wheel adjustment
Verify assembly of all components Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
Verify group integrity and wheel side bearings
Friction noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Bent or broken half shaft
Replace half shaft
Damaged or worn out axle parts
Check the condition of the ring gear, pinion gear, bearings, etc. Replace when necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle. Replace or adjust as required. Incorrect adjustment of bevel gear set. Parts of the trans worn out transmission gears, U joint, etc. Vibration during forward drive, intermittent noise CAUSES
REMEDY
Incorrect installation
Correct installation
Defective axle
Replace the differential in case it does not survive any of the test phases
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle
Bent half shaft
Replace half shaft
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires
20-88
WB140-2N WB150-2N
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Noise while driving CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust
Worn out pinion and ring gear
Replace
Worn out pinion bearings
Replace
Pinion bearings loose
Adjust
Excessive axial pinion backlash
Adjust
Worn out differential bearings
Replace
Differential bearings loose
Adjust
Ring gear out of round
Replace
Low oil level
Oil level
Poor or worn oil
Replace
Bent half shaft
Replace
Noise while driving in neutral CAUSES
REMEDY
Noises coming from axle are usually heard but not Replace or adjust (see above) loud when vehicle moves in neutral gear. Incorrect backlash between pinion and ring sound Replace heard while decelerating, disappears while increasing speed Pinion or input flange worn out
Adjust
Intermittent noise CAUSES
REMEDY
Ring gear damaged
Replace bevel gear set
Differential box bolts loosened
Tighten to torque
Constant noise CAUSES
REMEDY
Ring gear teeth or pinion damaged
Replace bevel gear set
Worn out bearings
Replace
Pinion spline worn out
Replace
Bent half shaft
Replace
Noise while steering CAUSES
REMEDY
Worn out differential gears
Replace
Worn out differential box or spider
Replace
Differential thrust washers worn out
Replace
Half shaft spline worn out
Replace
WB140-2N WB150-2N
20-89
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Ring gear teeth broken at the outer side CAUSES
REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
Incorrect gear adjustment, excessive backlash Pinion nut loosened Ring gear tooth broken CAUSES
REMEDY
Load bump
Replace bevel gear set. Adjust bevel gear set free backlash.
Incorrect gear adjustment, insufficient backlash Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations lubrication for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES
REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Insufficient lubrication; contaminated oil; improper lubrication Pinion teeth pitting CAUSES
REMEDY
Excessive use
Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Insufficient lubrication Axle beam body bent CAUSES
REMEDY
Vehicle overloaded
Replace axle beam body
Vehicle accident Load bump Worn out or pitted bearings CAUSES
REMEDY
Insufficient lubrication; contaminated oil
Replace bearings. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Excessive use Normal wear out Pinion nut loosened
20-90
WB140-2N WB150-2N
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Oil leakage from gaskets and seals CAUSES
REMEDY
Prolonged operation at high temperature
Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Oil gasket assembled incorrectly Seal lip damaged Contaminated oil Excessive wearing out of input flange spline CAUSES
REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required
Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES
REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload Pinion and ring teeth breakage CAUSES
REMEDY
Crash load of differential components
Check and/or replace other differential components
Side gear spline worn out CAUSES
REMEDY
Excessive use
Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched CAUSES
REMEDY
Lack of lubrication; contaminated oil, improper Use correct lubricants, fill to proper levels and replace according to the lubrication recommended schedule. Replace all scratched washers and those with 0.1 mm smaller thickness than the new ones Inner diameter of tapered roller bearing worn out CAUSES
REMEDY
Excessive use axial pinion
Replace bearing. Check pinion axial backlash. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Excessive pinion axial backlash Insufficient lubrication; contaminated oil
Bent or broken half shaft or half shaft broken at wheel side CAUSES
REMEDY
Vehicle intensively operated or overloaded
Replace. Check that wheel support is not worn out or incorrectly adjusted.
Wheel support loosened Beam body bent
WB140-2N WB150-2N
20-91
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 TRANSMISSION Vehicle does not move CAUSES
REMEDY
Faulty supply to solenoid valves
Check/Replace
Damaged wiring connections between transmission Repair/Replace and vehicle Oxidized contacts in electrical wiring
Clean
Break in electrical cable
Replace
Damaged solenoids
Replace
Damaged sensors
Replace
Short circuits or open connections
Check/replace fuses
Incorrect oil level
Fill oil to proper level
Check for leaks
Repair
Blocked intake filter
Clean
Damaged oil pump
Replace
Damaged oil pump relief valve
Replace oil pump
Blocked/damaged transmission filter
Replace
Damaged/jammed control valve
Replace
Damaged converter
Replace
Oil temperature below 0°C
Wait for oil to reach operating temperature (stall test)
Damaged rotary seals
Replace
Damaged synchronizers
Replace
Blocked reverse lever
Repair
Worn clutch
Replace/repair clutch
No drive transmission, broken gears, shafts, bear- Check/Repair/Replace ings, etc. Vehicle has reduced power transmission CAUSES
REMEDY
Incorrect oil temperature
Wait for oil to reach operating temperature (stall test)
Transmission oil overheating
See “Overheating”
Incorrect operating pressure
Check hydraulic circuit and replace, oil pump, filters, control valve
Damaged converter
Replace
Incorrect oil level
Fill oil to proper level
Worn clutch
Replace/Repair
4WD clutch failure
Repair/Replace 4WD shaft group
Overheating solenoids
Replace
Damaged transmission and vehicle wiring connec- Repair/Replace tions Damaged sensors
20-92
Replace
WB140-2N WB150-2N
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Overheating CAUSES
REMEDY
Damaged hydraulic cooling system
Repair
Dirty heat exchanger
Clean
Parking brake inadvertently activated
Release
Excessive dirt on axle wheel hubs
Clean
Seizing, broken gears, shafts, bearings, etc.
Check/Repair/Replace
Braking force outside transmission: irregular axle Check/Repair axle operation Clutch plate drag
Repair/Replace
Damaged converter
Replace
Damaged oil thermostat
Replace
Incorrect oil level
Add oil
Worn oil pump
Replace
Wheels rotate when vehicle is raised CAUSES
REMEDY
Clutch plate drag
Repair/Replace
Low oil temperature (high oil viscosity)
Wail for oil to reach operating temperature (stall test)
Incorrect oil specifications
Replace oil and filters
Damaged control valve
Replace
Faulty reverser locking
Repair/Replace
Noise CAUSES
REMEDY
Damaged converter
Replace
Damaged oil pump
Replace
Aeration/Cavitation
Check oil level
Seizing (broken gears, shafts, bearings, etc.)
Check/Repair/Replace
Worn clutch plates
Replace
Irregular actuation CAUSES
REMEDY
Damaged control valve
Replace
Electrical system fault
Repair/Replace
Worn clutch plates
Replace
Damaged converter
Replace
Low oil temperature (high oil viscosity)
Wail for oil to reach operating temperature (stall test)
Overheating
See “Overheating”
Damaged hydraulic system
Repair/Replace
WB140-2N WB150-2N
20-93
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Gear remains engaged CAUSES
REMEDY
Damaged/jammed shuttle shaft lever
Repair/Replace
Electrical system fault
Repair/Replace
Damaged control valve
Replace
Damaged hydraulic system
Repair/Replace
Damaged clutch
Repair/Replace
Damaged gear lever rod
Replace
Damaged synchronizer
Replace
No 4WD power transmission CAUSES
REMEDY
Damaged 4WD clutch
Replace
Hydraulic system fault
Repair/Replace
Damaged control valve
Replace
Faulty brake sensor
Check/Replace
Electrical system fault
Repair/Replace
Gear shift will not engage CAUSES
REMEDY
Damaged shifter
Replace
Damaged synchronizer
Replace
20-94
WB140-2N WB150-2N
90
OTHERS
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . 90-3 STANDARD CONTROLS FOR WB140-2N SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . 90-5 STANDARD CONTROLS FOR WB150-2N SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . 90-7 STANDARD CONTROLS FOR WB150-2N SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . 90-9 PPC SYSTEM FOR WB140-2N SHEET 1 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 PPC SYSTEM FOR WB140-2N SHEET 2 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 PPC SYSTEM FOR WB140-2N SHEET 3 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 PPC SYSTEM FOR WB150-2N SHEET 1 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17 PPC SYSTEM FOR WB150-2N SHEET 2 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 PPC SYSTEM FOR WB150-2N SHEET 3 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 CAB WIRING SCHEMATIC SHEET 1 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 CAB WIRING SCHEMATIC SHEET 2 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25 CAB WIRING SCHEMATIC SHEET 3 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27 CAB WIRING SCHEMATIC SHEET 4 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 CAB WIRING SCHEMATIC SHEET 5 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31 LEGEND FOR CAB WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33 CANOPY WIRING SCHEMATIC SHEET 1 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35 CANOPY WIRING SCHEMATIC SHEET 2 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37 CANOPY WIRING SCHEMATIC SHEET 3 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39 CANOPY WIRING SCHEMATIC SHEET 4 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41 CANOPY WIRING SCHEMATIC SHEET 5 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43 LEGEND FOR CANOPY WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45 TIER I ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47 TIER II ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49 LEGEND FOR TIER I AND II ENGINE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . 90-51 FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53 LEGEND FOR FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55 LATERAL HARNESS AND SIDE DASHBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57 TIER I ENGINE SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57 TIER I ENGINE SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59 LEGEND FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61 TIER II ENGINE SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63 TIER II ENGINE SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65 LEGEND FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS . 90-67 PPC FRAME AND SIDE DASH BOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 90-69 FRAME HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-69 SIDE DASH BOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-71 WB140-2N WB150-2N
90-1
OTHERS
TABLE OF CONTENTS LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS . . . . . . . . . WORK LIGHT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE AND RELAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEGEND FOR FUSE AND RELAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90-2
90-73 90-75 90-77 90-77
WB140-2N WB150-2N
OTHERS
HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2
WB140-2N WB150-2N
90-3
OTHERS
HYDRAULIC CIRCUIT
12
90-4
WB140-2N WB150-2N
OTHERS 12 STANDARD
HYDRAULIC CIRCUIT
CONTROLS FOR WB140-2N SHEET 2 OF 2
WB140-2N WB150-2N
90-5
OTHERS
HYDRAULIC CIRCUIT
12
90-6
WB140-2N WB150-2N
OTHERS 12 STANDARD
HYDRAULIC CIRCUIT
CONTROLS FOR WB150-2N SHEET 1 OF 2
WB140-2N WB150-2N
90-7
OTHERS
HYDRAULIC CIRCUIT
12
90-8
WB140-2N WB150-2N
OTHERS 12 STANDARD
HYDRAULIC CIRCUIT
CONTROLS FOR WB150-2N SHEET 2 OF 2
WB140-2N WB150-2N
90-9
OTHERS
HYDRAULIC CIRCUIT
12
90-10
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB140-2N SHEET 1 OF 3
WB140-2N WB150-2N
90-11
OTHERS
HYDRAULIC CIRCUIT
12
90-12
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB140-2N SHEET 2 OF 3
WB140-2N WB150-2N
90-13
OTHERS
HYDRAULIC CIRCUIT
12
90-14
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB140-2N SHEET 3 OF 3
WB140-2N WB150-2N
90-15
OTHERS
HYDRAULIC CIRCUIT
12
90-16
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB150-2N SHEET 1 OF 3
WB140-2N WB150-2N
90-17
OTHERS
HYDRAULIC CIRCUIT
12
90-18
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB150-2N SHEET 2 OF 3
WB140-2N WB150-2N
90-19
OTHERS
HYDRAULIC CIRCUIT
12
90-20
WB140-2N WB150-2N
OTHERS 12 PPC
HYDRAULIC CIRCUIT
SYSTEM FOR WB150-2N SHEET 3 OF 3
WB140-2N WB150-2N
90-21
OTHERS
HYDRAULIC CIRCUIT
12
90-22
WB140-2N WB150-2N
OTHERS
ELECTRICAL
12
ELECTRICAL CAB WIRING SCHEMATIC SHEET 1 OF 5
WB140-2N WB150-2N
90-23
OTHERS
ELECTRICAL
12
90-24
WB140-2N WB150-2N
OTHERS 12 CAB
ELECTRICAL
WIRING SCHEMATIC SHEET 2 OF 5
WB140-2N WB150-2N
90-25
OTHERS
ELECTRICAL
12
90-26
WB140-2N WB150-2N
OTHERS 12 CAB
ELECTRICAL
WIRING SCHEMATIC SHEET 3 OF 5
WB140-2N WB150-2N
90-27
OTHERS
ELECTRICAL
12
90-28
WB140-2N WB150-2N
OTHERS 12 CAB
ELECTRICAL
WIRING SCHEMATIC SHEET 4 OF 5
WB140-2N WB150-2N
90-29
OTHERS
ELECTRICAL
12
90-30
WB140-2N WB150-2N
OTHERS 12 CAB
ELECTRICAL
WIRING SCHEMATIC SHEET 5 OF 5
WB140-2N WB150-2N
90-31
OTHERS
ELECTRICAL
12
90-32
WB140-2N WB150-2N
OTHERS 12 LEGEND ITEM EV1 EV2 EV3 EV4 F1A F1B F1C F2A F2B F2C F3A F3B F3C F4A F4B F4C F5A F5B F5C F6A F6B F6C F7A F7B F7C FUG1 FUG2 FUG3 FUG4 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15
ELECTRICAL
FOR CAB WIRING SCHEMATIC
DESCRIPTION MP Bucket Open Solenoid MP Bucket Close Solenoid Diff Lock Solenoid Boom Lock Solenoid Low Beam Fuse, 15A Right Light Fuse, 3A Left Light Fuse, 3A Fuse, 10A Not Used Cab Fuse, 15A Hazard Fuse, 10A Stp Seat DL Fuse, 7.5A Instr. Warn RTD, 10A MPB Declutch Fuse, 7.5A 4WD Ft Washer Fuse, 7.5A F/R BUA Fuse, 10A High Beam Fuse, 15A Heater Relay Fuse, 10A Rear Work Light, 15A Front Work Light, 15A Rear Wiper Front Horn, 15A Light Sel Horn Relay, 7.5A Direction Lights, 10A Fuse, 7.5A Not Used Front Horn Fuse, 10A Fuel Shut Off Fuse, 7.5 A Key Switch Fuse, 60A Preheat Switch Fuse, 80A FSO Power Fuse, 40A Heater A/C Fuse, 40A Battery Alternator Preheat Warn Light Alternator Warn Light Coolant Warn Light Eng Oil Pressure Warn Light Air Filter Warn Light Hyd Oil Filter Warn Light Opt Warn Light Opt Warn Light Coolant Warn Light Converter Temp Warn Light 4WD Warn Light Low Fuel Warn Light Komatsu Logo Light Komatsu Logo Light Lighter Light
WB140-2N WB150-2N
SHEET 5 of 5 5 of 5 5 of 5 5 of 5 1 of 5 2 of 5 2 of 5 2 of 5 3 of 5 2 of 5 2 of 5 2 of 5 1 of 5 2 of 5 1 of 5 1 of 5 3 of 5 3 of 5 2 of 5 3 of 5 1 of 5 2 of 5 1 of 5 1 of 5 2 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 3 of 5
ITEM H16 H17 H18 H19 H20 H21 H22 H23 H24 H25 H28 H29 H36 H37 H38 HA1 HA2 HA3 HA4 K01 K02 K03 K04 K05 K06 KC K1 K2 K3 K4 K5 K6 K7 K8 K9 K12 K13 KT1 KT2 M1 M2 M3 M4 M5 M8 M9
DESCRIPTION Cab Light Front Work Light Front Work Light Beacon Light Rear Work Light Rear Work Light Indicators Warn Light High Beam Warn Light Brake Oil Warn Light Diff Lock Warn Light Right Front Light Left Front Light Rear Left Side Lights Rear Right Side Lights Courtesy Light Horn Buzzer Fuel Shut Off Relay Back Up Alarm Starter Relay Preheat Relay Fuel Shut Off Relay AC Blower Relay Return to Dig Relay Power ECO Unit Load Fan Heater Relay Forward Direction Relay Reverse Direction Relay 4WD Relay Neutral Position Relay Low Beam Relay Main Beam Relay Gear Relay Front Horn Relay Flasher Unit Seat Unit Stop Light, Diff Lock Unit Fuel Shut Off Timer Preheater Timer Starter Motor Washer Pump Windshield Wiper Motor Blower Motor Transfer Fuel Pump Windshield Wiper Motor Fuel Pump
SHEET 4 of 5 4 of 5 4 of 5 4 of 5 4 of 5 4 of 5 1 of 5 1 of 5 1 of 5 1 of 5 2 of 5 1 of 5 4 of 5 4 of 5 4 of 5 5 of 5 2 of 5 3 of 5 3 of 5 5 of 5 5 of 5 5 of 5 3 of 5 2 of 5 5 of 5 3 of 5 1 of 5 1 of 5 1 of 5 2 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 5 of 5 4 of 5 5 of 5 5 of 5 5 of 5 2 of 5 5 of 5 3 of 5 5 of 5 1 of 5 5 of 5
ITEM P1 P2 P3 P4 R30 R31 R32 R33 S1 S2 S4 S6 S10 S13 S15 S16 S17 S18 S19 S21 S22 S23 S24 S26 S27 S37 S1A S1L S2A S2L S3A S3L S4A S4L S5L SM2 SM3 SM4 SM5 SM6 Y0 Y1 Y2 Y4 Y5 Y6
DESCRIPTION Tachometer Hour Meter Fuel Level Gauge Coolant Temp Gauge Heating Start Fuel Level Sender Coolant Temp Sender Alternator ECO Power Button Boom Unlock Switch Blower Motor Switch Starting Switch Declutch Button Battery Cut Off Switch Hand Brake Switch Brake Oil Level Low Switch Brake Pressure Switch Brake Pressure Switch Seat Sensor Coolant High Temp Switch Air Filter Clogged Switch Lo Eng Oil Pres Switch Fuel Gauge Trans Oil Temp Switch Return to Dig Sensor Rear Door Switch 4WD Switch Rear Work Light Switch Front Wiper/Washer Switch Rear Wiper/Washer Switch Front Work Light Rotary Beacon Switch Warning Switch Horn Switch Optional Switch Power Button MPB Grab Button Converter Declutch Button MPB Open Button Differential Lock Button Fuel Shutoff Solenoid Valve Eco Power Solenoid Valve 4WD Solenoid Forward Solenoid Reverse Solenoid Return to Dig Magnet
SHEET 2 of 5 2 of 5 2 of 5 2 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 4 of 5 3 of 5 2 of 5 5 of 5 5 of 5 3 of 5 1 of 5 1 of 5 1 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 3 of 5 3 of 5 3 of 5 1 of 5 3 of 5 1 of 5 3 of 5 1 of 5 3 of 5 1 of 5 3 of 5 3 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 1 of 5 1 of 5 1 of 5 3 of 5
ITEM C1 XC1 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10 X11 X12 X16 X17 X18 X19 X20 X21 X22 X23 X24 X25 X26 X27 X28 X29 X30 X31 X32 X33 X34 X35 X38 X39 X40 X41 X43 X45 X46 X47 X53 X59 X60 X63
DESCRIPTION A/C Magnetic Clutch Lighter Socket Engine Harness, 11 Pin Lights and Gear Shift, 9 Pin Front Line, 11 Pin Not Used, 11 Pin Cab Controls, 11 Pin Trans Solenoids, 9 Pin Not Used, 9 Pin Side Dashboard, 17 Pins Front Dashboard, 17 Pins To Engine Harness, 13 Pin 2 Way Power, 2 Pin Front Cross Over, 2 Pin AC Clutch, 2 Pin Side Dashboard, 21 Pin Front Cable, 5 Pin Front Dashboard, 9 Pin Blower Motor Fuel Level Indicator, 3 Pin Washer Pump, 2 Pin Optional, 2 Pin Front Wiper, 4 Pin Blower Motor, 2 Pin Rear Line, 8 Pin Valve Lines, 6 Pin Loader Lever, 12 Pin Declutch Button, 2 Pin Transfer Fuel Pump, 2 Pin Cab, 5 Pin Radio, 2 Pin Wiper and Beacon, 7 Pin Right Front Light, 6 Pin Left Front Light, 6 Pin F and R Solenoids, 4 Pin Proximity, 3 Pin Flasher Unit, 13 Pin 4WD Solenoid, 2 Pins Power Relay, 7 Pin Power ECO Unit, 5 Pin Rear Wiper, 4 Pin Beacon Light, 2 Pin AC Interface, 1 Pin Front Line Cross, 6 Pin Optional, 1 Pin Alternator Resistance, 2 Pin
SHEET 5 of 5 3 of 5 2 of 5 1 of 5 1 of 5 1 of 5 3 of 5 1 of 5 3 of 5 2 of 5 1 of 5 4 of 5 4 of 5 4 of 5 5 of 5 2 of 5 2 of 5 2 of 5 3 of 5 5 of 5 2 of 5 1 of 5 1 of 5 3 of 5 4 of 5 5 of 5 5 of 5 5 of 5 5 of 5 4 of 5 3 of 5 3 of 5 2 of 5 1 of 5 1 of 5 3 of 5 1 of 5 1 of 5 3 of 5 5 of 5 5 of 5 4 of 5 3 of 5 4 of 5 1 of 5 5 of 5
ITEM X67 XA XAM XD1 XD2 XM9 XS XT1 XT2 XK12 XK13
DESCRIPTION Seat Sensor, 3 Pin Alternator, 2 Pin Fuel Shutoff Valve, 3 Pin Light Switch, 9 Pin Gear Shift, 5 Pin Fuel Pump, 2 Pin Instrument Panel, 6 Pin Fuel Shutoff Timer, 4 Pin Preheat Timer, 4 Pin Seat Unit, 6 Pin Stop Light Diff Lock, 6 Pin
SHEET 5 of 5 5 of 5 5 of 5 1 of 5 1 of 5 5 of 5 2 of 5 5 of 5 5 of 5 5 of 5 4 of 5
90-33
OTHERS
ELECTRICAL
12
90-34
WB140-2N WB150-2N
OTHERS 12 CANOPY
ELECTRICAL
WIRING SCHEMATIC SHEET 1 OF 5
WB140-2N WB150-2N
90-35
OTHERS
ELECTRICAL
12
90-36
WB140-2N WB150-2N
OTHERS 12 CANOPY
ELECTRICAL
WIRING SCHEMATIC SHEET 2 OF 5
WB140-2N WB150-2N
90-37
OTHERS
ELECTRICAL
12
90-38
WB140-2N WB150-2N
OTHERS 12 CANOPY
ELECTRICAL
WIRING SCHEMATIC SHEET 3 OF 5
WB140-2N WB150-2N
90-39
OTHERS
ELECTRICAL
12
90-40
WB140-2N WB150-2N
OTHERS 12 CANOPY
ELECTRICAL
WIRING SCHEMATIC SHEET 4 OF 5
WB140-2N WB150-2N
90-41
OTHERS
ELECTRICAL
12
90-42
WB140-2N WB150-2N
OTHERS 12 CANOPY
ELECTRICAL
WIRING SCHEMATIC SHEET 5 OF 5
WB140-2N WB150-2N
90-43
OTHERS
ELECTRICAL
12
90-44
WB140-2N WB150-2N
OTHERS
ELECTRICAL
12 LEGEND ITEM EV1 EV2 EV3 EV4 F1A F1B F1C F2A F2B F2C F3A F3B F3C F4A F4B F4C F5A F5B F5C F6A F6B F6C F7A F7B F7C FUG1 FUG2 FUG3 FUG4 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15
FOR CANOPY WIRING SCHEMATIC
DESCRIPTION MP Bucket Open Solenoid MP Bucket Close Solenoid Diff Lock Solenoid Boom Lock Solenoid Low Beam Fuse, 15A Right Light Fuse, 3A Left Light Fuse, 3A Fuse, 10A Not Used Canopy Fuse, 15A Hazard Fuse, 10A Stp Seat DL Fuse, 7.5A Instr. Warn RTD, 10A MPB Declutch Fuse, 7.5A 4WD Fuse, 7.5A F/R BUA Fuse, 10A High Beam Fuse, 15A Fuse, 10A Not Used Rear Work Light, 15A Front Work Light, 15A Rear Wiper Front Horn, 15A Light Sel Horn Relay, 7.5A Direction Lights, 10A Fuse, 7.5A Not Used Front Horn Fuse, 10A Fuel Shut Off Fuse, 7.5 A Key Switch Fuse, 60A Preheat Switch Fuse, 80A FSO Power Fuse, 40A Fuse, 40A Not Used Battery Alternator Preheat Warn Light Alternator Warn Light Coolant Warn Light Eng Oil Pressure Warn Light Air Filter Warn Light Hyd Oil Filter Warn Light Opt Warn Light Opt Warn Light Coolant Warn Light Converter Temp Warn Light 4WD Warn Light Low Fuel Warn Light Komatsu Logo Light Komatsu Logo Light Lighter Light
WB140-2N WB150-2N
SHEET 5 of 5 5 of 5 5 of 5 5 of 5 1 of 5 2 of 5 2 of 5 2 of 5 3 of 5 2 of 5 2 of 5 2 of 5 1 of 5 2 of 5 1 of 5 1 of 5 3 of 5 3 of 5 2 of 5 3 of 5 1 of 5 2 of 5 1 of 5 1 of 5 2 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 2 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 3 of 5
ITEM H17 H18 H19 H20 H21 H22 H23 H24 H25 H28 H29 H36 H37 H38 HA1 HA2 HA3 HA4 K01 K02 K03 K05 K06 K1 K2 K3 K4 K5 K6 K7 K8 K9 K12 K13 KT1 KT2 M1 M5 M9 P1 P2 P3 P4 R30 R31 R32
DESCRIPTION Front Work Light Front Work Light Beacon Light Rear Work Light Rear Work Light Indicators Warn Light High Beam Warn Light Brake Oil Warn Light Diff Lock Warn Light Right Front Light Left Front Light Rear Left Side Lights Rear Right Side Lights Courtesy Light Horn Buzzer Fuel Shut Off Relay Back Up Alarm Starter Relay Preheat Relay Fuel Shut Off Relay Return to Dig Relay Power ECO Unit Forward Direction Relay Reverse Direction Relay 4WD Relay Neutral Position Relay Low Beam Relay Main Beam Relay Gear Relay Front Horn Relay Flasher Unit Seat Unit Stop Light, Diff Lock Unit Fuel Shut Off Timer Preheater Timer Starter Motor Transfer Fuel Pump Fuel Pump Tachometer Hour Meter Fuel Level Gauge Coolant Temp Gauge Heating Start Fuel Level Sender Coolant Temp Sender
SHEET 4 of 5 4 of 5 4 of 5 4 of 5 4 of 5 1 of 5 1 of 5 1 of 5 1 of 5 2 of 5 1 of 5 4 of 5 4 of 5 4 of 5 5 of 5 2 of 5 3 of 5 3 of 5 5 of 5 5 of 5 5 of 5 2 of 5 5 of 5 1 of 5 1 of 5 1 of 5 2 of 5 1 of 5 1 of 5 1 of 5 1 of 5 1 of 5 5 of 5 4 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 2 of 5 2 of 5 2 of 5 2 of 5 5 of 5 5 of 5 5 of 5
ITEM R33 S1 S2 S6 S10 S13 S15 S16 S17 S18 S19 S21 S22 S23 S24 S26 S27 S1A S1L S3A S3L S4A S4L S5L SM2 SM3 SM4 SM5 SM6 Y0 Y1 Y2 Y4 Y5 Y6 XC1 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10
DESCRIPTION Alternator ECO Power Button Boom Unlock Switch Starting Switch Declutch Button Battery Cut Off Switch Hand Brake Switch Brake Oil Level Low Switch Brake Pressure Switch Brake Pressure Switch Seat Sensor Coolant High Temp Switch Air Filter Clogged Switch Lo Eng Oil Pres Switch Fuel Gauge Trans Oil Temp Switch Return to Dig Sensor 4WD Switch Rear Work Light Switch Front Work Light Rotary Beacon Switch Warning Switch Horn Switch Optional Switch Power Button MPB Grab Button Converter Declutch Button MPB Open Button Differential Lock Button Fuel Shutoff Solenoid Valve Eco Power Solenoid Valve 4WD Solenoid Forward Solenoid Reverse Solenoid Return to Dig Magnet Lighter Socket Engine Harness, 11 Pin Lights and Gear Shift, 9 Pin Front Line, 11 Pin Not Used, 11 Pin Canopy Controls, 11 Pin Trans Solenoids, 9 Pin Not Used, 9 Pin Side Dashboard, 17 Pins Front Dashboard, 17 Pins To Engine Harness, 13 Pin
SHEET 5 of 5 5 of 5 4 of 5 2 of 5 5 of 5 5 of 5 3 of 5 1 of 5 1 of 5 1 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 3 of 5 3 of 5 1 of 5 3 of 5 1 of 5 3 of 5 1 of 5 3 of 5 3 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 5 of 5 1 of 5 1 of 5 1 of 5 3 of 5 3 of 5 2 of 5 1 of 5 1 of 5 1 of 5 3 of 5 1 of 5 3 of 5 2 of 5 1 of 5 4 of 5
ITEM X11 X12 X17 X18 X19 X21 X23 X26 X27 X28 X29 X30 X31 X33 X34 X35 X38 X39 X40 X41 X43 X45 X47 X59 X60 X63 X65 X66 X67 XA XAM XD1 XD2 XM9 XS XT1 XT2 XK12 XK13
DESCRIPTION 2 Way Power, 2 Pin Front Cross Over, 2 Pin Side Dashboard, 21 Pin Front Cable, 5 Pin Front Dashboard, 9 Pin Fuel Level Indicator, 3 Pin Optional, 2 Pin Rear Line, 8 Pin Valve Lines, 6 Pin Loader Lever, 12 Pin Declutch Button, 2 Pin Transfer Fuel Pump, 2 Pin Canopy, 5 Pin Beacon, 7 Pin Right Front Light, 6 Pin Left Front Light, 6 Pin F and R Solenoids, 4 Pin Proximity, 3 Pin Flasher Unit, 13 Pin 4WD Solenoid, 2 Pins Power Relay, 7 Pin Power ECO Unit, 5 Pin Beacon Light, 2 Pin Front Line Cross, 6 Pin Optional, 1 Pin Alternator Resistance, 2 Pin Optional Light, 1 Pin Optional Light, 1 Pin Seat Sensor, 3 Pin Alternator, 2 Pin Fuel Shutoff Valve, 3 Pin Light Switch, 9 Pin Gear Shift, 5 Pin Fuel Pump, 2 Pin Instrument Panel, 6 Pin Fuel Shutoff Timer, 4 Pin Preheat Timer, 4 Pin Seat Unit, 6 Pin Stop Light Diff Lock, 6 Pin
SHEET 4 of 5 4 of 5 2 of 5 2 of 5 2 of 5 5 of 5 1 of 5 4 of 5 5 of 5 5 of 5 5 of 5 5 of 5 4 of 5 3 of 5 2 of 5 1 of 5 1 of 5 3 of 5 1 of 5 1 of 5 3 of 5 5 of 5 4 of 5 4 of 5 1 of 5 5 of 5 2 of 5 3 of 5 5 of 5 5 of 5 5 of 5 1 of 5 1 of 5 5 of 5 2 of 5 5 of 5 5 of 5 5 of 5 4 of 5
90-45
OTHERS
ELECTRICAL
12
90-46
WB140-2N WB150-2N
OTHERS 12 TIER
ELECTRICAL
I ENGINE HARNESS
WB140-2N WB150-2N
90-47
OTHERS
ELECTRICAL
12
90-48
WB140-2N WB150-2N
OTHERS 12 TIER
ELECTRICAL
II ENGINE HARNESS
WB140-2N WB150-2N
90-49
OTHERS
ELECTRICAL
12
90-50
WB140-2N WB150-2N
OTHERS 12 LEGEND
ELECTRICAL
FOR TIER I AND II ENGINE HARNESSES
TIER I ENGINE No. Connector Description X10 To Front Line A To Front Line b X13 XAD Coolant Temperature with Diode c Ground d X11 +30 +50 e Ground f Ground g Ground h S23 Oil Temperature i Fuel Shut Off j XAM +30 Starter Motor 1) Starter Motor 1! +50 W RPM (Tachometer) Indicator 1@ Alternator 1# XA B+ 1$ Coolant Temperature 1% S21 S22 Air Filter Clogged Switch 1^ Air Filter Clogged Switch 1& S22 R32 Coolant Temperature 1* AC Magnetic Clutch 1( X16 HA1 Horn 2) Horn 2! HA1 R30 Preheat Grid Block 2@ Preheat Relay 2# K02 K02 Preheat Relay 2$ Preheat Relay 2% K02 XT2 Preheat Timer Excitation 2^ Fuel Shut Off Timer 2& XT1 80A Fuse 2* 30A Fuse 2( 60A Fuse 3) 30A Fuse 3! Fuse Ground 3@ Matcher 3# 12V 70A Relay 3$ Timer 3% Timer 3^ Relay 3& Control Box 3* Fuel Shut Off Relay 3( K03 K01 Starting Relay 4(
WB140-2N WB150-2N
No. Connector A K03 b X61 c X10 d X02 e X63 f X11
g h i j 1) 1! 1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2! 2@ 2# 2$ 2% 2^ 2& 2* 2( 3) 3! 3@ 3# 3$ 3% 3^ 3& 3* 3(
S23 XAM M9
W XA S21 S22 R32 X16 HA1 R30 GND2 KT2 X64 XT2 XT1
TIER II ENGINE Description Fuel Shut Off Relay Safety Relays To Front Line
+30 +50 Ground Ground Ground Oil Temperature Fuel Shut Off Fuel Pump +50 +50 +30 +30 +30 +30 RPM (Tachometer) Indicator Alternator Coolant Temperature Air Filter Clogged Switch Coolant Temperature AC Magnetic Clutch Horn Preheat Grid Block Ground Preheat Relay Preheat Start Relay Preheat Timer Excitation Fuel Shut Off Timer 80A Fuse 30A Fuse 60A Fuse 30A Fuse Fuse Ground Matcher 12V 70A Relay Timer Timer Relay Control Box Power Box
90-51
OTHERS
ELECTRICAL
12
90-52
WB140-2N WB150-2N
OTHERS 12 FRONT
ELECTRICAL
HARNESS
WB140-2N WB150-2N
90-53
OTHERS
ELECTRICAL
12
90-54
WB140-2N WB150-2N
OTHERS 12 LEGEND
ELECTRICAL
FOR FRONT HARNESS
TIER I ENGINE No. Connector Description Power Box A X18
B C D E F G H I J 1) 1! 1@ 1# 1$ 1% 1^
X12
Power +30 +50
X59
To Platform Cable
X23
Optional
X35
Front Left Light
X10
To Engine Harness
X11
Power +30 +50
GND
Ground
S18
Stop Light Switch
S17
Stop Light Switch
S16
Brake Oil Level Switch
X22
Washer Pump
X34
Front Right Light
X1
Electronic Board
X3
Electronic Board
X60
Optional
+30
Electronic Board
WB140-2N WB150-2N
90-55
OTHERS
ELECTRICAL
12
90-56
WB140-2N WB150-2N
OTHERS 12 LATERAL
ELECTRICAL
HARNESS AND SIDE DASHBOARD
TIER I ENGINE SHEET 1 OF 2
WB140-2N WB150-2N
90-57
OTHERS
ELECTRICAL
12
90-58
WB140-2N WB150-2N
OTHERS 12 TIER
ELECTRICAL
I ENGINE SHEET 2 OF 2
WB140-2N WB150-2N
90-59
OTHERS
ELECTRICAL
12
90-60
WB140-2N WB150-2N
OTHERS 12 LEGEND
ELECTRICAL FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD HARNESS
No. Connector A X19 b +15 c X8 d X5 e X27 f X28 g X39
h i j 1) 1! 1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2! 2@ 2# 2$ 2% 2^ 2& 2* 2( 3) 3! 3@ 3# 3$ 3% 3^ 3& 3* 3( 4)
X25 K04 K05 K06 S4 X31 X17 X15 S3 S2 S1 X32 X26
X20 X29 X30 X21 X12 X14 X43
Description To Front Dash Board Electronic Board Electronic Board Electronic Board Solenoid Valves Loader Control Lever Return Sender Return Valve Ground Electric Bridge Heater Motor Relay Return Relay Power EC Relay Heater Cab/Canopy AC Kit Side Dash Board Starting Switch Not Used Relay Valve Switch Economy Power Button Lighter Radio Rear Light Cable Parking Brake Switch Rear Horn Not Used Back Up Alarm Heater Motor Converter Detach - 2nd Button Economy Power with Diode Fuel Pump Fuel Float To Front Cable To Front Cable Wiring Gear Switch To Platform Cable Wiper Switch Optional Switch Connectors Rear Horn Switch
WB140-2N WB150-2N
TIER I ENGINE No. Connector
4! 4@ 4# 4$ 4% 4^ 4& 4* 4( 5) 5! 5@ 5# 5$ S3 5% 5^ S2 5& 5* S1 5( 6)
Description Connectors Battery Warning Light Preheat Warning Light Engine Oil Pressure Warning Light Engine Air Filter Warning Light Tachometer/Hour Meter Fuel Level Gauge Engine Coolant Temperature Gauge Buzzer Optional Warning Light Engine Coolant Temp Warning Light Hydraulic Oil Filter Warning Light Starting Switch Beacon Lamp Switch Connectors Optional Switch Connectors Work Light Switch Connectors To Platform Cable
90-61
OTHERS
ELECTRICAL
12
90-62
WB140-2N WB150-2N
OTHERS 12 TIER
ELECTRICAL
II ENGINE SHEET 1 OF 2
WB140-2N WB150-2N
90-63
OTHERS
ELECTRICAL
12
90-64
WB140-2N WB150-2N
OTHERS 12 TIER
ELECTRICAL
II ENGINE SHEET 2 OF 2
WB140-2N WB150-2N
90-65
OTHERS
ELECTRICAL
12
90-66
WB140-2N WB150-2N
OTHERS 12 LEGEND
ELECTRICAL FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS
No. Connector Description To Front Dash Board A X19
b c d e f g h i j 1) 1! 1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2! 2@ 2# 2$ 2% 2^ 2& 2* 2( 3) 3! 3@ 3# 3$ 3% 3^ 3& 3*
X5
Electronic Board
X8
Electronic Board
X27
Solenoid Valves
X28
Loader Control Lever
X39
Return to Dig Sensor
Y6
RTD Valve Ground
X25
Electronic Bridge
K04
3 Speed Fan Relay - AC
K05
RTD Relay
KC
Load Fan Relay
K12
Not Used
K06
Power Economy Unit
K13
Relay
S4
Heater
X53
AC Kit
X31
Cab/Canopy
X17
Side Dash Board
S6
Starting Switch
S3
Not Used
S2
Boom Unlock Switch
S1
Economy Power Switch
XC1
Lighter
X32
Radio
X26
Rear Work Light
X67
Not Used
S15
Parking Brake Switch
HA3
Rear Horn
Y3
Not Used
HA4
Back Up Alarm
X20
Heater Motor
X29
Converter Detach - 2nd Button
Y1
Economy Power
X30
Fuel Pump
X21
Fuel Float
X43
To 4th Gear Relay
X12
Power Supply
X59
Front Wiring Interface
WB140-2N WB150-2N
TIER II ENGINE No. Connector Description +15 Electronic Board 3( X15
4) 4! 4@ 4# 4$ 4% 4^ 4& 4* 4( 5) 5! 5@ 5# 5$ 5% 5^ 5& 5* 5(
X17
To Platform Harness Light
S3L
Beacon Light Switch
S2L
Front Wiper Switch
S1L
Work Light Switch
HA
Lamp Lamp Lamp Fuel Gauge Battery Warning Light Preheater Warning Light Light Engine Air Filter Warning Light Engine Oil Pressure Warning Light
S4L
Switch
S5L
Switch +15
X33
Cab/Canopy
X65
Rear Work Light
X66
Rear Work Light
90-67
OTHERS
ELECTRICAL
12
90-68
WB140-2N WB150-2N
OTHERS 12 PPC
ELECTRICAL
FRAME AND SIDE DASH BOARD HARNESS
FRAME HARNESS
WB140-2N WB150-2N
90-69
OTHERS
ELECTRICAL
12
90-70
WB140-2N WB150-2N
OTHERS 12 SIDE
ELECTRICAL
DASH BOARD HARNESS
WB140-2N WB150-2N
90-71
OTHERS
ELECTRICAL
12
90-72
WB140-2N WB150-2N
OTHERS 12 LEGEND
ELECTRICAL FOR PPC FRAME AND SIDE DASH BOARD HARNESS
No. Connector Description X55 To Cab/Canopy Wiring A
b c d e f g h i j 1) 1! 1@ 1# 1$ 1% 1^ 1& 1* 1( 2) 2! 2@ 2# 2$ 2% 2^ 2& 2* 2( 3) 3! 3@ 3#
Y25
Arm Block Solenoid Valve
GND
Ground
Y14
PPC Solenoid Valve
Y15
Left Outrigger Down Solenoid Valve
Y16
Right Outrigger Up Solenoid Valve
Y22
Telescopic Extend
Y21
Telescopic Retract
Y20
Hammer Solenoid Valve
S43
Hammer Foot Switch
Y18
Left Turn Solenoid Valve
Y17
Right Turn Solenoid Valve
X57
Left Lever
HA3
Horn
HA4
Horn
Y19
Not Used
X58
Right Lever
Y23
Right Outrigger Down Solenoid Valve
Y24
Left Outrigger Up Solenoid Valve
X55
From Platform Harness
X1
Seat Swivel Switch
X3
Backhoe Lock Out Switch
X2
Boom Lock Switch
X42c
Power Right Outrigger Switch
X42b
Up Right Outrigger Switch
X42a
Down Right Outrigger Switch
X41c
Power Left Outrigger Switch
X41b
Up Left Outrigger Switch
X41a
Down Left Outrigger Switch
X40
Power Economy Switch
X10
Telephone Exchange Relay
X11
Relay
X9
15A Fuse
X4
Power from Key Switch
WB140-2N WB150-2N
90-73
OTHERS
ELECTRICAL
12
90-74
WB140-2N WB150-2N
OTHERS 12 WORK
ELECTRICAL
LIGHT HARNESS No. Connector
A B C D E F G H
WB140-2N WB150-2N
Description Ground Front Work Light Front Work Light Rear Work Light Rear Work Light Rear Relay Front Relay 25A Fuse
90-75
OTHERS
ELECTRICAL
12
90-76
WB140-2N WB150-2N
OTHERS 12 FUSE
ELECTRICAL
AND RELAY PANEL LEGEND FOR FUSE AND RELAY PANEL
WB140-2N WB150-2N
Position F1 A F1 B F1 C F2 A F2 B F2 C F3 A F3 B F3 C F4 A F4 B F4 C F5 A F5 B F5 C F6 A F6 B F6 C F7 A F7 B F7 C
TIER I ENGINE Description 15A Light Blue for Low Beam 3A Violet for Parking Lights 3A Violet for Parking Lights 10A Red for Lighter 7.5A Brown for Dome Light Radio 10A Red for Emergency Power Supply 7.5A Brown for Start Enable 7.5A Brown for Instruments Switch Lights 7.5A Brown for OPT Solenoid 7.5A Brown for Diff Lock Solenoid Valve 10A Red for Direction Selector 15A Light Blue for High Beam 15A Light Blue for Heater 15A Light Blue for Rear Work Light 15A Light Blue for Front Work Light 15A Light Blue for Wiper and Beacon 7.5A Brown for Dimmer Switch Horn Relay 10A Red for Directional Indicators 7.5A Brown for Monitor 10A Red for Horn 7.5A Brown for Alt Excitation Stop Solenoid
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11
Forward Gear Relay Reverse Gear Relay Four Wheel Drive Relay ··· Low Beam Relay High Beam Relay Direction Selector Power Supply Relay Horn Relay Turn Indicator Relay Flasher Relay 4th Gear Signaling Relay
Position F1 A F1 B F1 C F2 A F2 B F2 C F3 A F3 B F3 C F4 A F4 B F4 C F5 A F5 B F5 C F6 A F6 B F6 C F7 A F7 B F7 C
TIER II ENGINE Description 15A Light Blue for Low Beam 3A Violet for Parking Lights 3A Violet for Parking Lights 10A Red 15A Light Blue for Cab Features 10A Red for Emergency Power Supply 7.5A Brown for Stop Lights Differential Lock 7.5A Brown for Instruments Lights RTD 7.5A Brown for Opt Solenoid Trans Disengage 7.5A Brown for 4WD Front Wiper 10A Red for Direction Selector 15A Light Blue for High Beam 10A Red for Heater Motor Power Econ Unit 15A Light Blue for Rear Work Light 15A Light Blue for Front Work Light 15A Light Blue for Rear Horn Rear Wiper 7.5A Brown for Dimmer Switch Horn Relay 10A Red for Directional Indicators 7.5A Brown 10A Red for Front Horn 7.5A Brown for Engine Stop Solenoid
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
Forward Gear Relay Reverse Gear Relay Back Up Alarm Four Wheel Drive Relay Start Relay Low Beam Relay High Beam Relay Direction Selector Power Supply Relay Front Horn Relay Turn Indicator Relay 4th Gear Signaling Relay
90-77
OTHERS
ELECTRICAL
12
90-78
WB140-2N WB150-2N
Komatsu America Corp. DataKom Publications & Training 440 North Fairway Drive Vernon Hills, IL. 60061-8112 U.S.A. Attn: Service Publications Fax No. (847)-970-4186
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