Komatsu Backhoe Loader WB140N, WB150N Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB140-2N, WB150-2N, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB140-2N, WB150-2N workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM009802 - Backhoe Loader WB140-2N, WB150-2N Shop Manual.pdf
CEBM012701 - Backhoe Loader WB140-2N, WB150-2N Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEBM009802 - Backhoe Loader WB140-2N, WB150-2N Shop Manual....1
COVER....1
CONTENTS....2
FOREWORD....11
SAFETY....11
SAFETY NOTICE....11
IMPORTANT SAFETY NOTICE....11
GENERAL PRECAUTIONS....11
PREPARATIONS FOR WORK....11
PRECAUTIONS DURING WORK....11
GENERAL....13
HOW TO READ THE SHOP MANUAL....14
VOLUMES....14
DISTRIBUTION AND UPDATING....14
FILING METHOD....14
REVISED EDITION MARK....14
REVISIONS....14
SYMBOLS....14
HOISTING INSTRUCTIONS....15
HOISTING....15
WIRE ROPES....15
COATING MATERIALS....16
STANDARD TIGHTENING TORQUE....18
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....18
TIGHTENING TORQUE OF HOSE NUTS....19
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....19
TIGHTENING TORQUE FOR FLARED NUTS....19
ELECTRIC WIRE CODE....20
CLASSIFICATION BY THICKNESS....20
CLASSIFICATION BY COLOR AND CODE....20
CONVERSION TABLES....21
METHOD OF USING THE CONVERSION TABLE....21
10 STRUCTURE AND FUNCTION....27
POWER TRAIN....29
DESCRIPTION....29
TRANSMISSION....31
DIAGRAM OF THE POWER TRAIN....31
HYDRAULIC CONVERTOR-TRANSMISSION CIRCUIT DIAGRAM....32
DRIVE SHAFTS....41
FORWARD AND REVERSE....41
DRIVEN GEAR....41
4WD DRIVEN....42
CONTROL VALVE BLOCK....43
FRONT AXLE....44
DIFFERENTIAL....44
FINAL REDUCTION - JOINT....46
STEERING CYLINDER....48
REAR AXLE....50
DIFFERENTIAL....50
FINAL REDUCTION....52
BRAKES....54
HYDRAULIC PUMP....57
FUNCTION....62
STRUCTURE....62
OPERATION....63
PUMP OPERATION....63
CONTROL OF DELIVERY....64
PC VALVE, LS VALVE, SERVO PISTON....65
LS VALVE....66
PC VALVE....72
WORKING MODE SOLENOID VALVE....77
FUNCTION....77
OPERATION....77
STEERING UNIT....79
TECHNICAL DATA....79
OPERATION....79
HYDRAULIC CIRCUIT....80
SHOVEL CONTROL VALVE....81
2 SPOOL....81
3 SPOOL....85
BACKHOE CONTROL VALVE....89
6 SPOOL....89
7 SPOOL....94
FOR TELESCOPIC ARM....94
FOR HAMMER....94
8 SPOOL....97
FOR HAMMER AND TELESCOPE ARM....97
CLSS (CLOSED CENTER LOAD SENSING SYSTEM....98
CHARACTERISTICS....98
STRUCTURE....98
OPERATION....99
UNLOADING VALVE....101
FUNCTION....101
OPERATION....101
INTRODUCTION OF THE LS PRESSURE....104
OPERATION....104
DELIVERY COMPENSATION....105
INTRODUCTION....105
FUNCTION....105
OPERATION....105
LIFD CONTROL SYSTEM....108
FUNCTION....108
OPERATION....108
LS DECOMPRESSION VALVE....109
DESCRIPTION....109
OPERATION....109
PRESSURE CUT-OFF VALVE....110
DESCRIPTION....110
OPERATION....110
PRIORITY VALVE (ONLY FOR THE 2-3 SPOOL CONTROL VALVE)....111
FUNCTION....111
SOLENOID VALVE....112
SOLENOID VALVE BLOCK ST1 - DIFFERENTIAL LOCKING - BACKHOE BOOM LOCKING...112
SAFETY VALVE....113
BRAKE PUMP....115
SHOVEL CYLINDERS....117
RAISE CYLINDER....117
DUMP CYLINDER....117
BACKHOE CYLINDERS....119
BOOM....119
ARM....119
BUCKET....120
OUTRIGGERS....120
BOOM SWING....121
TELESCOPIC ARM....121
CHARACTERISTICS....122
FRONT WORKING EQUIPMENT....124
SWING BRACKET....126
BACKHOE WORKING EQUIPMENT....127
AIR CONDITIONING UNIT....129
FUNCTION....130
20 TESTING, ADJUSTING AND TROUBLESHOOTING....131
STANDARD VALUE TABLES FOR ENGINE....133
STANDARD VALUE TABLE FOR CHASSIS....135
SPECIAL TOOLS....161
ENGINE SPEED....162
VALVE CLEARANCE....163
COMPRESSION PRESSURE....164
FUEL INJECTION TIMING....165
FAN AND ALTERNATOR DRIVE BELT....167
TENSION CHECK....167
TENSION ADJUSTMENT....167
COMPRESSOR DRIVE BELT....168
CHECKING TENSION....168
TENSION ADJUSTMENT....168
ACCELERATOR PEDAL AND LEVER TRAVEL....169
ACCELERATOR PEDAL TRAVEL ADJUSTMENT....169
ACCELERATOR LEVER TRAVEL ADJUSTMENT....170
BRAKE PEDAL TRAVEL AND MICROSWITCHES....171
MASTER CYLINDER ROD ADJUSTMENT....171
MICROSWITCHES ADJUSTMENT....171
CHECKING ADJUSTMENT....171
BLEEDING AIR....172
BLEEDING AIR FROM PUMP....172
BLEEDING AIR FROM CYLINDERS....172
BLEEDING AIR FROM OIL TANK....173
HYDRAULIC OIL TANK PRESSURIZATION....173
RELEASING RESIDUAL PRESSURE FROM THE CIRCUITS....173
BLEEDING AIR FROM THE BRAKING CIRCUIT....173
CHECKING AIR BLEEDING FROM BRAKING CIRCUIT....174
ATTACHMENTS HYDRAULIC CIRCUIT....175
INTRODUCTION....175
TESTING AND SETTING GENERAL VALVES....178
FRONT SHOVEL CONTROL VALVE (2-3 SPOOLS)....178
BACKHOE CONTROL VALVE (6-7-8 SPOOLS)....178
TESTING SECONDARY VALVES....178
SETTING MAIN AND SECONDARY VALVES....180
MAIN RELIEF VALVES....180
SECONDARY VALVES....181
LOAD SENSING SIGNAL (LS VALVE)....182
LOAD SENSING VALVE ADJUSTMENT....182
UNLOADING VALVE....183
UNLOADING VALVE ADJUSTMENT....183
UNLOADING VALVE FUNCTION....184
PRIORITY VALVE....185
TESTING PRIORITY VALVE OPERATION....185
CLEANING PRIORITY VALVE....185
STEERING CONTROL SYSTEM PRESSURE....186
TESTING....186
SETTING....186
BRAKE SYSTEM....187
TESTING CIRCUIT AND BRAKE PUMP TIGHTNESS....187
TESTING BRAKING GROUP LEAK TIGHTNESS....187
ENGINE SPEED UNDER LOAD....189
PREPARING THE MACHINE....189
TESTING WITH THE TORQUE CONVERTER UNDER STRESS....190
TESTING THE TORQUE CONVERTER AND HYDRAULIC SYSTEM UNDER STRESS....190
POWER TRAIN GROUP....191
PREPARING THE MACHINE....191
CONVERTER OIL PRESSURE....191
CLUTCH ENGAGEMENT PRESSURE....192
POWER TRAIN CLUTCHES....193
PREPARATION OF THE MACHINE....193
TESTING....193
SENSOR FOR RETURN TO DIG DEVICE....194
CAUSES OF HYDRAULIC DRIFT....195
FRONT EQUIPMENT....195
TESTING OF FRONT BUCKET LIFTING....195
TESTING OF FRONT BUCKET DUMPING....196
BACKHOE....197
BOOM TESTING....197
ARM TESTING....197
BUCKET TESTING....198
OUTRIGGER TESTING....199
AIR CONDITIONING UNIT....200
TESTING THE WORKING TEMPERATURE....200
CHECKING THE UNIT....201
EMPTYING THE AIR CONDITIONING UNIT....201
FRONT AXLE....203
REAR AXLE....208
TRANSMISSION....213
30 DISASSEMBLY AND ASSEMBLY....217
METHOD OF USING THIS MANUAL....222
REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES....222
PRECAUTIONS DURING SERVICE OR REPAIR OPERATIONS....222
REMOVAL PRECAUTIONS....223
INSTALLATION PRECAUTIONS....223
SPECIAL TOOLS....224
ENGINE COMPONENTS....227
CYLINDER HEAD ASSEMBLY....227
CRANKSHAFT DAMPER AND PULLEY ASSEMBLY....227
ENGINE OIL COOLER ASSEMBLY....227
ENGINE OIL PUMP ASSEMBLY....227
FUEL INJECTION PUMP ASSEMBLY....227
FUEL INJECTOR ASSEMBLY....227
FRONT AND REAR ENGINE OIL SEAL ASSEMBLY....227
GOVERNOR ASSEMBLY....227
THERMOSTAT ASSEMBLY....227
TURBOCHARGER ASSEMBLY....227
WATER PUMP ASSEMBLY....227
FRONT END LOADER CYLINDER LOCK....228
LOCKING PROCEDURES....228
STARTER, ALTERNATOR AND COMPRESSOR....229
STARTER MOTOR....229
REMOVAL....229
INSTALLATION....229
ALTERNATOR....230
REMOVAL....230
INSTALLATION....231
REFRIGERANT COMPRESSOR....232
REMOVAL....232
INSTALLATION....233
BATTERY DISCONNECT SWITCH....234
REMOVAL....234
INSTALLATION....234
FRONT COUNTERWEIGHT....235
REMOVAL....235
INSTALLATION....235
RADIATOR, CONDENSER AND OIL COOLERS....236
RADIATOR....236
REMOVAL....236
INSTALLATION....238
REFRIGERANT CONDENSER....239
REMOVAL....239
INSTALLATION....239
HYDRAULIC OIL COOLER....240
REMOVAL....240
INSTALLATION....240
TRANSMISSION OIL COOLER....241
REMOVAL....241
INSTALLATION....241
MUFFLER AND EXHAUST STACK....242
MUFFLER....242
REMOVAL....242
INSTALLATION....242
EXHAUST STACK....243
REMOVAL....243
INSTALLATION....243
ENGINE HOOD AND OPERATORS CAB....244
ENGINE HOOD....244
REMOVAL....244
INSTALLATION....245
OPERATORS CAB....246
REMOVAL....246
INSTALLATION....250
AIR CONDITIONING AND HEATER....252
REMOVAL....252
INSTALLATION....253
FUEL AND HYDRAULIC OIL TANKS....254
FUEL TANK....254
REMOVAL....254
INSTALLATION....255
HYDRAULIC TANK....256
REMOVAL....256
INSTALLATION....257
ENGINE AND TRANSMISSION....258
REMOVAL....258
INSTALLATION....263
PISTON PUMP....264
REMOVAL....264
INSTALLATION....265
TRANSMISSION....266
REMOVAL....266
INSTALLATION....269
TORQUE CONVERTER....270
REMOVAL....270
INSTALLATION....270
STEERING COLUMN AND COLUMN CONTROLS....271
STEERING COLUMN....271
REMOVAL....271
INSTALLATION....271
COLUMN CONTROL SWITCHES....272
REMOVAL....272
INSTALLATION....272
MASTER BRAKE CYLINDER....273
REMOVAL....273
INSTALLATION....273
FRONT END LOADER CONTROL VALVE....274
REMOVAL....274
INSTALLATION....274
FRONT AXLE ASSEMBLY....276
REMOVAL....276
INSTALLATION....277
STEERING CYLINDER....278
DISASSEMBLY....278
ASSEMBLY....278
TOE ADJUSTMENT....280
STEERING ANGLE ADJUSTMENT....282
WHEEL HUB....283
OUTER PLANETARY DISASSEMBLY....283
PLANETARY GEARS REPLACEMENT (IF NECESSARY)....283
OUTER PLANETARY ASSEMBLY....283
INNER WHEEL HUB....284
DISASSEMBLY....284
ASSEMBLY....286
STEERING KNUCKLE AND AXLE SHAFT....288
REMOVAL....288
ASSEMBLY....289
AXLE HOUSING ENDS....290
DISASSEMBLY....290
ASSEMBLY....291
DIFFERENTIAL CARRIER (CARRIER SET UP)....292
REMOVAL....292
INSTALLATION....293
RING AND PINION....294
DISASSEMBLY....294
PINION DISASSEMBLY....295
RING GEAR DISASSEMBLY....297
ASSEMBLY....297
PINION SET UP....298
ASSEMBLY....298
CHECKING GEAR BACK LASH AND INSTALLING CARRIER....301
CHECKING BACK LASH....301
REAR AXLE....304
REMOVAL....304
INSTALLATION....305
OUTER PLANETARY REDUCTION GEAR....306
DISASSEMBLY....306
ASSEMBLY....307
INNER WHEEL HUB....308
DISASSEMBLY....308
ASSEMBLY....309
AXLE HOUSING AND BRAKES....312
DISASSEMBLY....312
BRAKE CONTROL....315
DISASSEMBLY....315
ASSEMBLY....321
BRAKE AND AXLE HOUSING....323
ASSEMBLY....323
RING GEAR AND CARRIER....328
DISASSEMBLY....328
PINION DISASSEMBLY....328
PINION ASSEMBLY....331
DIFFERENTIAL CARRIER....334
ASSEMBLY....334
RING AND PINION SET UP....335
ASSEMBLY....335
FRONT BUCKET BOOM CYLINDERS....342
REMOVAL....342
INSTALLATION....343
FRONT BUCKET TILT CYLINDER....344
REMOVAL....344
INSTALLATION....345
FRONT BUCKET....346
REMOVAL....346
INSTALLATION....347
FRONT WORKING EQUIPMENT....348
REMOVAL....348
INSTALLATION....349
BACKHOE CONTROL VALVE....350
REMOVAL....350
INSTALLATION....351
BACKHOE BOOM CYLINDER....352
REMOVAL....352
INSTALLATION....352
BACKHOE ARM CYLINDER....354
REMOVAL....354
INSTALLATION....355
TELESCOPIC ARM CYLINDER....356
REMOVAL....356
INSTALLATION....357
BACKHOE BUCKET CYLINDER....358
REMOVAL....358
INSTALLATION....359
OUTRIGGER CYLINDERS....360
REMOVAL....360
INSTALLATION....361
BACKHOE SWING CYLINDERS....362
REMOVAL....362
INSTALLATION....363
CYLINDERS (FRONT BUCKET RAISE AND TILT, BOOM, ARM, OUTRIGGERS, AND TELESCOPIC ARM)....364
DISASSEMBLY....364
ASSEMBLY....366
CYLINDER (BOOM SWING)....370
DISASSEMBLY....370
ASSEMBLY....371
BOOM SAFETY CYLINDER....374
REMOVAL....374
INSTALLATION....375
BACKHOE WORK EQUIPMENT....376
REMOVAL....376
INSTALLATION....377
BACKHOE BUCKET....378
REMOVAL....378
INSTALLATION....378
BACKHOE ARM....380
REMOVAL....380
INSTALLATION....381
TELESCOPIC ARM (COMPLETE)....382
REMOVAL....382
INSTALLATION....383
INNER ARM....384
REMOVAL....384
INSTALLATION....385
INNER ARM GUIDES....386
REMOVAL....386
INSTALLATION....386
BACKHOE BOOM....388
REMOVAL....388
INSTALLATION....389
BACKHOE SWING BRACKET....390
REMOVAL....390
INSTALLATION....391
BACKHOE OUTRIGGERS....392
REMOVAL....392
INSTALLATION....393
90 OTHERS....395
HYDRAULIC CIRCUIT (WB150-2N)....397
HYDRAULIC CIRCUIT (WB140-2N)....399
ELECTRICAL SCHEMATIC....401
AIR CONDITIONER CIRCUIT....403
CEBM012701 - Backhoe Loader WB140-2N, WB150-2N Shop Manual....407
COVER....407
FOREWORD....408
CONTENTS....408
SAFETY....415
SAFETY NOTICE....415
IMPORTANT SAFETY NOTICE....415
GENERAL PRECAUTIONS....415
PREPARATIONS FOR WORK....415
PRECAUTIONS DURING WORK....415
GENERAL....417
HOW TO READ THE SHOP MANUAL....418
VOLUMES....418
DISTRIBUTION AND UPDATING....418
FILING METHOD....418
REVISED EDITION MARK....418
REVISIONS....418
SYMBOLS....418
HOISTING INSTRUCTIONS....419
HOISTING....419
WIRE ROPES....419
PUSH PULL COUPLER....420
TYPE 1....420
DISCONNECTION....420
CONNECTION....420
TYPE 2....421
DISCONNECTION....421
CONNECTION....421
TYPE 3....422
DISCONNECTION....422
CONNECTION....422
COATING MATERIALS....423
STANDARD TIGHTENING TORQUE....425
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....425
TIGHTENING TORQUE OF HOSE NUTS....426
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....426
TIGHTENING TORQUE FOR FLARED NUTS....426
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS....427
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS....427
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)....427
ELECTRIC WIRE CODE....428
CLASSIFICATION BY THICKNESS....428
CLASSIFICATION BY COLOR AND CODE....428
CONVERSION TABLES....429
METHOD OF USING THE CONVERSION TABLE....429
01 GENERAL....435
SPECIFICATIONS....436
WEIGHT TABLE....439
FUEL COOLANT AND LUBRICANTS....440
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....443
ENGINE MOUNTING....446
TIER I ENGINE....446
4WD MACHINES....446
2WD MACHINES....447
TIER II ENGINE....448
4WD MACHINES....448
2WD MACHINE....449
POWER TRAIN....450
4WD MACHINES....450
DESCRIPTION....450
POWER FLOW - 4WD....451
2WD MACHINES....452
DESCRIPTION....452
TRANSMISSION DIAGRAM....454
4WD MACHINES....454
2WD MACHINES....456
TRANSMISSION....458
COMPLETE ASSEMBLY....458
FORWARD REVERSE CLUTCH....468
1ST THROUGH 4TH SPEED SHAFT....468
4WD SHAFT....469
FRONT AXLE....470
4WD....470
COMPLETE ASSEMBLY....470
DIFFERENTIAL....470
PLANETARY....472
2WD....473
COMPLETE ASSEMBLY....473
CENTER HOUSING....474
STEERING KNUCKLE....475
REAR AXLE....476
COMPLETE ASSEMBLY....476
DIFFERENTIAL....477
PLANETARY....478
BRAKES....479
DIFFERENTIAL LOCK....480
HYDRAULIC PUMP....481
FUNCTION....486
STRUCTURE....486
OPERATION....487
PUMP OPERATION....487
CONTROL OF DELIVERY....487
PC VALVE, LS VALVE, SERVO PISTON....488
LS VALVE FUNCTION....488
OPERATION....489
PC VALVE FUNCTION....494
WORKING MODE SOLENOID VALVE....499
STEERING UNIT....501
TECHNICAL DATA....501
OPERATION....501
LOADER VALVE....502
2 SPOOL....502
3 SPOOL VALVE....504
BACKHOE CONTROL VALVE....506
MECHANICAL CONTROL....506
INLET SECTION VIEWS A-A AND B-B....507
ARM SECTION VIEW C-C....508
SWING SECTION VIEW D-D....509
LEFT OUTRIGGER SECTION VIEW E-E....510
RIGHT OUTRIGGER SECTION VIEW F-F....511
BUCKET SECTION VIEW G-G....512
BOOM SECTION VIEW H-H....513
OUTLET SECTION VIEW J-J....513
TELESCOPIC ARM SECTION VIEW K-K....514
HAMMER SECTION VIEW L-L....515
EXCAVATOR CONTROL....516
INLET SECTION VIEWS A-A AND B-B....517
ARM SECTION VIEW C-C....518
SWING SECTION VIEW D-D....519
LEFT OUTRIGGER SECTION VIEW E-E....520
RIGHT OUTRIGGER SECTION VIEW F-F....521
BUCKET SECTION VIEW G-G....522
BOOM SECTION VIEW H-H....523
OUTLET SECTION VIEW J-J....523
TELESCOPIC ARM SECTION VIEW K-K....524
HAMMER SECTION VIEW L-L....525
CLSS....526
CHARACTERISTICS....526
STRUCTURE....526
OPERATING PRINCIPLES....527
UNLOADING VALVE....529
FUNCTION....529
OPERATION....529
INTRODUCTION OF THE LS PRESSURE....532
OPERATION....532
DELIVERY COMPENSATION....533
INTRODUCTION....533
OPERATION....533
LIFD CONTROL SYSTEM....536
FUNCTION....536
OPERATION....536
LS DECOMPRESSION VALVE....537
DESCRIPTION....537
OPERATION....537
PRESSURE CUT OFF VALVE....538
DESCRIPTION....538
OPERATION....538
PRIORITY VALVE....539
FUNCTION....539
PPC JOYSTICK....540
LEFT VALVE....540
RIGHT VALVE....541
SOLENOID VALVE....542
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK....542
PPC SUPPLY VALVE - ST2....543
PPC TELESCOPIC ARM....544
PPC HAMMER....545
PPC ARM AND HAMMER....546
LOADER CYLINDERS....547
BOOM ARM....547
CHARACTERISTICS....547
BUCKET....548
CHARACTERISTICS....548
MP BUCKET....549
CHARACTERISTICS....549
BACKHOE CYLINDERS....550
BOOM....550
CHARACTERISTICS....550
ARM....551
CHARACTERISTICS....551
BUCKET....552
CHARACTERISTICS....552
TELESCOPIC ARM CYLINDER....553
CHARACTERISTICS....553
SWING....554
CHARACTERISTICS....554
OUTRIGGER....555
CHARACTERISTICS....555
BOOM LOCK CYLINDER....556
FRONT WORK EQUIPMENT....557
REAR WORK EQUIPMENT....559
AIR CONDITIONING....561
20 TESTING, ADJUSTING AND TROUBLESHOOTING....563
STANDARD VALUE TABLES FOR ENGINE....566
STANDARD VALUE TABLES FOR CHASSIS....568
SPECIAL TOOLS....587
ENGINE SPEED....589
TIER I ENGINE....589
TIER II ENGINE....589
VALVE CLEARANCE....590
TIER I ENGINE....590
ADJUSTING PROCEDURE....590
VALVE COVER INSTALLATION....590
TIER II ENGINE....591
ADJUSTING PROCEDURE....591
COMPRESSION PRESSURE....595
TIER I ENGINE....595
TIER II ENGINE....596
FUEL INJECTION TIMING....598
TIER I ENGINE....598
TIER II ENGINE....599
FAN BELT....602
TENSION CHECK....602
TENSION ADJUSTMENT....602
COMPRESSOR DRIVE BELT....603
CHECKING TENSION....603
TENSION ADJUSTMENT....603
ACCELERATOR PEDAL AND LEVER....604
ACCELERATOR PEDAL TRAVEL....604
ACCELERATOR LEVER TRAVEL....605
BRAKE PEDAL TRAVEL....606
TIER I ENGINE....606
MASTER CYLINDER ROD ADJUSTMENT....606
MICROSWITCHES ADJUSTMENT....606
CHECKING ADJUSTMENT....606
TIER II ENGINE....607
MASTER CYLINDER ROD....607
CHECKING ADJUSTMENT....607
BLEEDING AIR....608
HYDRAULIC PUMP....608
CYLINDERS....608
HYDRAULIC OIL TANK....609
HYDRAULIC OIL TANK PRESSURIZATION....609
WORK CIRCUITS....609
BRAKE CIRCUIT....609
CHECK BRAKE CIRCUIT....610
HYDRAULIC CIRCUIT....611
INTRODUCTION....611
LOADER CONTROL VALVES....612
BACKHOE CONTROLS STYLE VALVE....613
EXCAVATOR CONTROLS STYLE VALVE....615
MAIN RELIEF VALVES....617
TESTING....617
LOADER CONTROL VALVE (2 OR 3 SPOOL)....617
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)....617
SETTING RELIEF PRESSURE....617
LOADER CIRCUIT RELIEF VALVES....619
TESTING PRESSURE....619
SETTING PRESSURE....620
BACKHOE CIRCUIT RELIEF VALVES....621
TESTING PRESSURE....621
SETTING PRESSURE....622
UNLOADING VALVE....623
TESTING....623
ADJUSTMENT....623
LOAD SENSING (LS) VALVE....624
TESTING....624
ADJUSTMENT....624
FLOW VALVE....625
PRIORITY VALVE....626
TESTING....626
CLEANING PRIORITY VALVE....626
STEERING SYSTEM....627
TESTING....627
SETTING....627
BRAKE SYSTEM....628
CIRCUIT AND BRAKE PUMP TEST....628
BRAKING GROUP LEAK TEST....629
ENGINE SPEED UNDER LOAD....630
PREPARING THE MACHINE....630
TORQUE CONVERTER STALL....630
TORQUE CONVERTER AND HYDRAULIC STALL....631
POWER TRAIN GROUP....632
PREPARING THE MACHINE....632
CONVERTER OIL PRESSURE....632
CLUTCH PRESSURE....633
ADDITIONAL PRESSURES....633
DIRECTIONAL CLUTCHES....634
PREPARATION OF THE MACHINE....634
TESTING....634
RETURN TO DIG DEVICE....635
HYDRAULIC DRIFT....636
LOADER....636
LIFT CYLINDER....636
BUCKET CYLINDER....637
BACKHOE....638
BOOM CYLINDER....638
ARM CYLINDER....638
BUCKET CYLINDER....639
OUTRIGGER TESTING....640
AIR CONDITIONING UNIT....641
TESTING THE WORKING TEMPERATURE....641
CHECKING THE UNIT....641
EMPTYING THE AC UNIT....642
TROUBLESHOOTING GUIDE....644
FRONT AXLE....644
REAR AXLE....649
TRANSMISSION....654
30 REMOVAL AND INSTALLATION....657
METHOD OF USING THIS MANUAL....659
REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES....659
PRECAUTIONS DURING SERVICE OPERATIONS....660
REMOVAL PRECAUTIONS....660
INSTALLATION PRECAUTIONS....660
SPECIAL TOOLS....661
LISTING....661
SKETCHES....663
ENGINE COMPONENTS....666
LOADER CYLINDER LOCK....667
LOCKING PROCEDURES....667
STARTER....668
REMOVAL....668
INSTALLATION....668
ALTERNATOR....669
REMOVAL....669
INSTALLATION....669
AC COMPRESSOR....670
REMOVAL....670
INSTALLATION....671
INJECTION PUMP....672
TIER I ENGINE....672
TIER II ENGINE....675
VALVE COVER....678
TIER I ENGINE....678
TIER II ENGINE....678
INJECTION NOZZLE....681
TIER I ENGINE....681
TIER II ENGINE....682
THERMOSTAT....684
TIER I ENGINE....684
TIER II ENGINE....685
COOLANT PUMP....686
TIER I ENGINE....686
TIER II ENGINE....688
TURBOCHARGER....691
REMOVAL....691
INSTALLATION....693
CYLINDER HEAD....694
TIER I ENGINE....694
TIER II ENGINE....698
BATTERY DISCONNECT SWITCH....703
REMOVAL....703
INSTALLATION....703
COUNTERWEIGHT....704
REMOVAL....704
INSTALLATION....704
RADIATOR OIL COOLERS....705
REMOVAL....705
INSTALLATION....707
AC CONDENSOR....708
REMOVAL....708
INSTALLATION....709
MUFFLER....710
REMOVAL....710
INSTALLATION....710
EXHAUST STACK....711
REMOVAL....711
INSTALLATION....711
ENGINE HOOD....712
REMOVAL....712
INSTALLATION....712
CAB....713
TIER I ENGINE....713
TIER II ENGINE....717
AC AND HEATER....722
REMOVAL....722
INSTALLATION....723
FUEL TANK....724
REMOVAL....724
INSTALLATION....725
HYDRAULIC TANK....726
REMOVAL....726
INSTALLATION....727
ENGINE AND TRANSMISSION....728
REMOVAL....728
INSTALLATION....733
PISTON PUMP....735
REMOVAL....735
INSTALLATION....736
TRANSMISSION....737
REMOVAL....737
INSTALLATION....740
DISASSEMBLY....741
REASSEMBLY....789
TORQUE CONVERTER....833
REMOVAL....833
INSTALLATION....834
STEERING VALVE....835
REMOVAL....835
INSTALLATION....836
COLUMN CONTROL SWITCHES....837
REMOVAL....837
INSTALLATION....838
MASTER BRAKE CYLINDER....839
REMOVAL....839
INSTALLATION....839
LOADER CONTROL VALVE....841
REMOVAL....841
INSTALLATION....842
2WD FRONT AXLE....843
REMOVAL....843
INSTALLATION....844
DISASSEMBLY....844
4WD FRONT AXLE....854
REMOVAL....854
INSTALLATION....855
DISASSEMBLY....855
REASSEMBLY....864
REAR AXLE....880
REMOVAL....880
INSTALLATION....881
DISASSEMBLY....881
REASSEMBLY....896
LOADER CYLINDERS....915
BOOM....915
BUCKET....919
INSTALLATION....920
MP BUCKET CYLINDER....924
FRONT EQUIPMENT....930
BUCKET....930
BOOM....931
BACKHOE CONTROL VALVE....934
BACKHOE CONTROL....934
INSTALLATION....935
EXCAVATOR CONTROLS....935
PPC CONTROLS....939
PPC VALVE....939
SUPPORT RELEASE CABLES....940
SUPPORT RETURN GAS SPRING....943
SOLENOID VALVE....945
SERVO CONTROL FEED VALVE....946
BACKHOE CYLINDERS....947
BOOM....947
INSTALLATION....947
ARM....953
BUCKET....957
INSTALLATION....958
TELESCOPIC ARM....962
OUTRIGGERS....967
SWING....973
BOOM LOCK....977
BACKHOE WORK EQUIPMENT....979
BOOM TO BUCKET....979
BUCKET....980
STANDARD ARM....981
TELESCOPIC ARM....982
INNER ARM....983
INNER ARM GUIDES....984
BOOM....985
SWING BRACKET....986
OUTRIGGERS....987
90 OTHER....989
HYDRAULIC CIRCUIT....991
STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2....991
STANDARD CONTROLS FOR WB140-2N SHEET 2 OF 2....993
STANDARD CONTROLS FOR WB150-2N SHEET 1 OF 2....995
STANDARD CONTROLS FOR WB150-2N SHEET 2 OF 2....997
PPC SYSTEM FOR WB140-2N SHEET 1 OF 3....999
PPC SYSTEM FOR WB140-2N SHEET 2 OF 3....1001
PPC SYSTEM FOR WB140-2N SHEET 3 OF 3....1003
PPC SYSTEM FOR WB150-2N SHEET 1 OF 3....1005
PPC SYSTEM FOR WB150-2N SHEET 2 OF 3....1007
PPC SYSTEM FOR WB150-2N SHEET 3 OF 3....1009
ELECTRICAL....1011
CAB WIRING SCHEMATIC SHEET 1 OF 5....1011
CAB WIRING SCHEMATIC SHEET 2 OF 5....1013
CAB WIRING SCHEMATIC SHEET 3 OF 5....1015
CAB WIRING SCHEMATIC SHEET 4 OF 5....1017
CAB WIRING SCHEMATIC SHEET 5 OF 5....1019
LEGEND FOR CAB WIRING SCHEMATIC....1021
CANOPY WIRING SCHEMATIC SHEET 1 OF 5....1023
CANOPY WIRING SCHEMATIC SHEET 2 OF 5....1025
CANOPY WIRING SCHEMATIC SHEET 3 OF 5....1027
CANOPY WIRING SCHEMATIC SHEET 4 OF 5....1029
CANOPY WIRING SCHEMATIC SHEET 5 OF 5....1031
LEGEND FOR CANOPY WIRING SCHEMATIC....1033
TIER I ENGINE HARNESS....1035
TIER II ENGINE HARNESS....1037
LEGEND FOR TIER I AND II ENGINE HARNESSES....1039
FRONT HARNESS....1041
LEGEND FOR FRONT HARNESS....1043
LATERAL HARNESS AND SIDE DASHBOARD....1045
TIER I ENGINE SHEET 2 OF 2....1047
LEGEND FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD HARNESS....1049
TIER II ENGINE SHEET 1 OF 2....1051
TIER II ENGINE SHEET 2 OF 2....1053
LEGEND FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS....1055
PPC FRAME AND SIDE DASH BOARD HARNESS....1057
SIDE DASH BOARD HARNESS....1059
LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS....1061
WORK LIGHT HARNESS....1063
FUSE AND RELAY PANEL....1065
LEGEND FOR FUSE AND RELAY PANEL....1065
Komatsu Backhoe Loader WB140N, WB150N Repair Service Manual
