Komatsu Backhoe Loader WB140, WB150 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB140-2, WB150-2, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB140-2, WB150-2 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.
WEAM000902 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual.pdf
WEAM000903 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual.pdf
WEAM000904 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual.pdf
WEBM001102 - Backhoe Loader WB140-2, WB150-2 Shop Manual.pdf
WEBM004200 - Backhoe Loader WB140-2, WB150-2 Shop Manual.pdf
WEBM004601 - Backhoe Loader WB140-2, WB150-2 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,613 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM000902 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual....1
COVER....1
TABLE OF CONTENTS....2
FOREWORD....10
INFORMATION ON SAFETY....11
INTRODUCTION....13
INTENDED USES....13
IMPROPER OR UNAUTHORIZED USES....13
MAIN CHARACTERISTICS....14
RUNNING-IN ....14
PRODUCT IDENTIFICATION....15
MACHINE SERIAL NUMBER....15
MACHINE IDENTIFICATION PLATE....15
ENGINE SERIAL NUMBER AND EMISSION LABEL....16
FRONT AXLE SERIAL NUMBER....16
REAR AXLE SERIAL NUMBER....16
TRANSMISSION SERIAL NUMBER....17
CAB SERIAL NUMBER....17
CANOPY SERIAL NUMBER....17
SERIAL NUMBERS AND DEALER'S ADDRESS....18
SAFETY AND ACCIDENT PREVENTION....20
1. GENERAL PRECAUTIONS....21
1.1 GENERAL SAFETY RULES....21
1.2 SAFETY DEVICES AND GUARDS....21
1.3 CLOTHING AND PERSONAL PROTECTION ITEMS....21
1.4 UNAUTHORIZED MODIFICATIONS....21
1.5 LEAVING THE OPERATOR'S SEAT....22
1.6 GETTING ON AND OFF THE MACHINE....22
1.7 CHECKING THE REAR-VIEW MIRROR....23
1.8 PREVENTING FIRES DUE TO FUEL AND OIL....23
1.9 PREVENTING BURNS....23
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER ....24
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....24
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT....24
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....25
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT....25
PRECAUTIONS....26
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....27
2.1 SAFETY ON THE WORK SITE....27
2.2 FIRE PREVENTION....27
2.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....27
2.4 ROOM VENTILATION....28
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS-CHECKING THE WINDSHIELD WIPER BLADES AND THE LIGHT BULBS....28
3. PRECAUTIONS TO BE TAKEN WHEN WORKING....29
3.1 STARTING THE ENGINE....29
3.2 RULES FOR ROAD TRAVEL....29
3.3 CHECKS FOR TRAVELING IN REVERSE....30
3.4 MOVING THE MACHINE....31
3.5 WORKING ON SLOPES....31
3.6 PREVENTING ELECTROCUTION....32
3.7 VISIBILITY....33
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES....33
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....33
3.10 WORKING ON LOOSE GROUND....33
3.11 PARKING THE MACHINE....34
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES....35
4.1 LOADING AND UNLOADING....35
4.2 THE ROUTE....35
5. THE BATTERY....36
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....36
5.2 STARTING THE ENGINE WITH JUMP LEADS....37
6. PRECAUTIONS FOR EMERGENCY RECOVERY....38
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....39
7.1 WARNING PLATES....39
7.2 TOOLS....39
7.3 PERSONAL PRECAUTIONS....39
7.4 EQUIPMENT....40
7.5 WORKING UNDER THE MACHINE....40
7.6 KEEPING THE MACHINE CLEAN....40
7.7 RUNNING THE ENGINE DURING MAINTENANCE....40
7.8 RULES FOR REFUELING AND ADDING OIL....41
7.9 LEVEL OF COOLANT IN THE RADIATOR....41
7.10 USING LAMPS....41
7.11 BATTERY AND ALTERNATOR PRECAUTIONS....42
7.12 PRECAUTIONS CONCERNING THE STARTER....42
7.13 PRECAUTIONS REGARDING HIGH PRESSURE HOSES....42
7.14 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS....43
7.15 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....43
7.16 THE RADIATOR COOLING FAN AND FAN BELT....43
7.17 WASTE MATERIALS....44
7.18 PRECAUTIONS FOR INFLATING TIRES....44
7.19 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE....44
8. SAFETY PLATES....45
8.1 POSITION OF THE SAFETY PLATES....45
8.2 POSITION OF THE PICTOGRAMS....59
8.3 PICTOGRAMS AND RELEVANT MEANINGS....61
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....64
TECHNICAL SPECIFICATIONS....66
9. TECHNICAL DATA....67
9.1 STANDARD OVERALL DIMENSIONS....67
9.2 TECHNICAL CHARACTERISTICS WB140-2 (ASPIRATED ENGINE)....68
9.3 TECHNICAL CHARACTERISTICS WB140-2 (TURBOCHARGED ENGINE)....69
9.4 TECHNICAL CHARACTERISTICS WB150-2....70
9.5 LIFTING CAPACITIES....71
9.5.1 SYMBOL TABLE....71
9.5.2 LIFTING CAPACITY WB140-2....72
9.5.3 LIFTING CAPACITY WB150-2....74
DESCRIPTION AND USE OF THE MACHINE....76
10. SAFETY LOCKS....77
10.1 FRONT LOADER LOCK....77
10.2 BACKHOE LOCKS....79
11. GENERAL VIEWS....80
11.1 FRONT GENERAL VIEW....80
11.2 BACKHOE GENERAL VIEW....81
11.3 CAB INSIDE GENERAL VIEW....82
12. INSTRUMENTS AND CONTROLS....83
12.1 FRONT INSTRUMENTS....83
12.2 SIDE INSTRUMENTS....86
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER....90
12.4 PUSH BUTTON ON THE GEARSHIFT LEVER....91
12.5 ELECTRICAL ACCESSORIES....91
12.6 MACHINE CONTROLS....92
13. FUSES AND RELAYS....105
13.1 EQUIPMENT FUSES AND RELAYS....105
13.2 ENGINE FUSES AND RELAYS....107
14. GUARDS, CAB AND DRIVER'S SEAT....109
14.1 ENGINE HOOD....109
14.2 CANOPY....109
14.3 CAB....110
14.4 VENTILATION AND HEATING....112
14.5 SEAT....113
14.6 SAFETY BELT....113
14.7 FIRE EXTINGUISHER....114
14.8 FIRST AID KIT....114
14.9 TECHNICAL DOCUMENTATION....114
14.10 ADDITIONAL TOOL CASE (IF PROVIDED)....114
15. USE OF THE MACHINE....116
15.1 CHECKS BEFORE STARTING THE ENGINE....116
15.1.1 VISUAL CHECKS....116
15.1.2 DAILY CHECKS....116
15.1.3 OPERATIONAL CHECKS....117
15.2 STARTING THE ENGINE....118
15.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES (MORE THAN 0°C (32°F))....118
15.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES (UP TO -16°C (3°F))....119
15.2.3 STARTING THE ENGINE IN VERY COLD AREAS (UP TO -30°C (-22°F))....119
15.3 WARMING THE ENGINE....120
15.4 HEATING THE HYDRAULIC OIL....120
15.5 HOW TO MOVE THE MACHINE....121
15.5.1 LOCKING THE DIFFERENTIAL....122
15.5.2 ENGAGING THE FOUR-WHEEL DRIVE....122
15.5.3 WORKING ON SLOPES....123
15.5.4 MAXIMUM IMMERSION DEPTH....124
16. PARKING THE MACHINE....125
16.1 PARKING ON LEVEL GROUND....125
16.2 PARKING ON SLOPES....126
17. STOPPING THE ENGINE....127
18. TRANSPORTING THE MACHINE ON OTHER SURFACES....128
18.1 LOADING AND UNLOADING THE MACHINE....128
18.2 TRANSPORT....129
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....130
19.1 FUEL AND LUBRICANTS....130
19.2 COOLANT....130
19.3 BATTERY....130
19.4 OTHER PRECAUTIONS....131
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....131
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....132
21. USING THE MACHINE AS A LOADER....133
21.1 BUCKET POSITION INDICATOR....133
21.2 ORGANIZING THE WORK AREA....133
21.2.1 LOADING HEAPED AND LEVEL MATERIAL....134
21.2.2 LOADING OPERATIONS ON SLOPES....134
21.3 CHANGING THE STANDARD FRONT BUCKET....135
22. USING THE MACHINE AS AN EXCAVATOR....136
22.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT....136
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....137
22.3 DIGGING METHOD....138
22.4 CHANGING THE BACKHOE BUCKET....139
23. TROUBLESHOOTING....140
23.1 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....140
23.2 IF THE BATTERY IS DEPLETED....140
23.2.1 STARTING WITH BOOSTER CABLES....141
23.3 OTHER TROUBLES....142
23.3.1 ELECTRICAL CIRCUIT....142
23.3.2 HYDRAULIC SYSTEM....142
23.3.3 BRAKING SYSTEM....143
23.3.4 TORQUE CONVERTER SYSTEM....143
23.3.5 ENGINE....144
MAINTENANCE....146
24. GUIDE TO MAINTENANCE....147
25. MAINTENANCE NOTES....149
25.1 NOTES REGARDING THE ENGINE....149
25.1.1 ENGINE OIL....149
25.1.2 COOLANT....149
25.1.3 FUEL....150
25.2 NOTES REGARDING THE HYDRAULIC SYSTEM....150
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM....151
25.4 NOTES REGARDING LUBRICATION....151
25.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....152
26. FUEL, COOLANT AND LUBRICANTS....153
26.1 LUBRICATION DIAGRAM....157
26.2 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)....158
26.3 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS)....159
26.4 LUBRICATION DIAGRAM (TELESCOPIC ARM)....160
27. NUT AND BOLT TIGHTENING TORQUES....161
27.1 STANDARD TIGHTENING TORQUES....161
27.2 SPECIFIC TIGHTENING TORQUES....161
28. MAINTENANCE PLAN....162
28.1 CHECK BEFORE STARTING....165
28.1.A VARIOUS CHECKS....165
28.1.B CHECKING THE FUEL LEVEL....165
28.1.C CHECKING THE COOLANT LEVEL....166
28.1.D CHECKING THE ENGINE OIL LEVEL....166
28.1.E CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL....167
28.1.F LUBRICATING THE JOINTS....167
28.2 MAINTENANCE EVERY 50 HOURS OF OPERATION....170
28.2.A CHECKING THE RADIATOR FLUID LEVEL....170
28.2.B CHECKING THE BRAKING SYSTEM OIL LEVEL....170
28.2.C LUBRICATING THE PROPELLER SHAFTS....171
28.2.D LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING....172
28.2.E DRAINING THE WATER SEPARATOR....172
28.2.F CHECKING THE TIRE PRESSURE....173
28.2.G CHECKING THE ELECTRICAL SYSTEM....173
28.3 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....174
28.4 MAINTENANCE EVERY 250 HOURS OF OPERATION....174
28.4.A ADJUSTING THE FAN BELT TENSION....174
28.4.B CLEANING THE OUTSIDE OF THE RADIATORS....175
28.4.C CHECKING THE BATTERY ELECTROLYTE LEVEL....175
28.4.D CHECKING THE FRONT AXLE OIL LEVELS....176
28.4.E CHECKING THE REAR AXLE OIL LEVELS....176
28.4.F CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL....177
28.4.G CHECKING THE WHEEL NUT DRIVING TORQUE....177
28.5 MAINTENANCE EVERY 500 HOURS OF OPERATION....178
28.5.A CHANGING THE ENGINE OIL....178
28.5.B CHANGING THE ENGINE OIL FILTER....178
28.5.C CHANGING THE HYDRAULIC SYSTEM OIL FILTER....179
28.5.D CHANGING THE FUEL FILTER....180
28.5.E DRAINING THE FUEL TANK....181
28.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION....182
28.6.A CHANGING THE FRONT AXLE OIL....182
28.6.B CHANGING THE REAR AXLE OIL....183
28.6.C CHANGING THE HYDRAULIC TRANSMISSION OIL....184
28.6.D CHANGING THE HYDRAULIC TRANSMISSION FILTER....185
28.6.E CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....185
28.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION....186
28.7.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....186
28.7.B CHANGING THE COOLANT....188
28.7.C CHANGING THE BRAKING SYSTEM OIL....189
28.7.D CHECKING THE ALTERNATOR AND THE STARTER....189
28.8 WHEN REQUIRED....190
28.8.A CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....190
28.8.B CHECKING AND CLEANING THE CAB AIR FILTER....191
28.8.C BLEEDING THE BRAKING CIRCUIT....192
28.8.D WASHING THE COOLING CIRCUIT....192
28.8.E CLEANING THE WATER SEPARATOR....194
28.8.F CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN....194
28.8.G CHECKING AND ADJUSTING THE PARKING BRAKE....195
28.8.H CHECKING THE BRAKING EFFICIENCY....196
28.8.J CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE....197
28.8.K ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSTION....197
29. LONG PERIODS OF INACTIVITY....198
29.1 BEFORE THE PERIOD OF INACTIVITY....198
29.2 AFTER THE PERIOD OF INACTIVITY....198
AUTHORIZED OPTIONAL EQUIPMENT....200
30. AUTHORIZED OPTIONAL EQUIPMENT....201
30.1 PRECAUTIONS REGARDING SAFETY....201
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB140-2....202
30.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB150-2....203
31. FRONT EQUIPMENT RAPID COUPLING DEVICES....204
31.1 MANUAL CONTROL RAPID COUPLING....204
31.2 HYDRAULIC CONTROL RAPID COUPLING FOR STANDARD BUCKET....205
31.3 HYDRAULIC CONTROL RAPID COUPLING FOR MULTIPURPOSE BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....205
32. MULTIPURPOSE BUCKET ....206
32.1 DESCRIPTION AND CONTROLS....206
32.2 SAFETY DEVICES....206
32.3 INSTALLING THE MULTIPURPOSE BUCKET....207
32.4 USING THE MULTIPURPOSE BUCKET....208
32.5 MAINTENANCE....208
33. PALLET FORKS....209
33.1 DESCRIPTION....209
33.2 SAFETY DEVICES....209
33.3 USING THE FORKS....209
33.3.1 PREPARING THE PALLET FORKS FOR USE....210
33.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS....210
33.4 REMOVING THE FORKS....211
33.5 INSTALLING THE FORKS....211
33.6 MAINTENANCE....211
34. BACKHOE TELESCOPIC ARM....212
34.1 DESCRIPTION AND CONTROL....212
34.2 SAFETY DEVICES....212
34.3 USING THE TELESCOPIC ARM....213
34.4 MAINTENANCE....213
34.4.1 ADJUSTING THE GUIDE SLACK....213
35. ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....215
35.1 DESCRIPTION AND CONTROL....215
35.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....216
35.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....220
35.3.1 INSTALLING THE HAMMER....220
35.3.2 REMOVING THE HAMMER....222
35.4 MAINTENANCE....222
36. ARRANGEMENT FOR THE OPERATION OF OPERATIONAL EQUIPMENT WIHT UNIDIRECTIONAL OIL FLOW....223
36.1 DESCRIPTION AND CONTROL....223
36.2 INSTALLING AND CONNECTING THE EQUIPMENT....223
36.3 MAINTENANCE....224
37. ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET....225
37.1 DESCRIPTION AND CONTROL....225
37.2 INSTALLING THE CLAMSHELL BUCKET....226
37.3 USING THE CLAMSHELL BUCKET....227
37.4 MAINTENANCE....227
38. ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER....228
38.1 DESCRIPTION AND CONTROL....228
38.2 CONNECTING AND REMOVING THE HAMMER....229
38.2.1 CONNECTING THE HAMMER....229
38.2.2 REMOVING THE CONNECTIONS....229
38.3 USING THE HAMMER....230
38.4 MAINTENANCE....230
39. LOAD STABILIZER SYSTEM (LSS) (OPTIONAL)....231
39.1 ACCUMULATION OF THE LOAD STABILIZER SYSTEM (LSS)....231
40. AIR CONDITIONER (OPTIONAL)....232
WEAM000903 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual....234
COVER....234
TABLE OF CONTENTS....235
FOREWORD....243
INFORMATION ON SAFETY....244
INTRODUCTION....246
INTENDED USES....246
IMPROPER OR UNAUTHORIZED USES....246
MAIN CHARACTERISTICS....247
RUNNING-IN....247
PRODUCT IDENTIFICATION....248
MACHINE SERIAL NUMBER....248
MACHINE IDENTIFICATION PLATE....248
ENGINE SERIAL NUMBER AND EMISSION LABEL....249
FRONT AXLE SERIAL NUMBER....249
REAR AXLE SERIAL NUMBER....249
TRANSMISSION SERIAL NUMBER....250
CAB SERIAL NUMBER....250
CANOPY SERIAL NUMBER....250
SERIAL NUMBERS AND DEALER'S ADDRESS....251
SAFETY AND ACCIDENT PREVENTION....253
1. GENERAL PRECAUTIONS....254
1.1 GENERAL SAFETY RULES....254
1.2 SAFETY DEVICES AND GUARDS....254
1.3 CLOTHING AND PERSONAL PROTECTION ITEMS....254
1.4 UNAUTHORIZED MODIFICATIONS....254
1.5 LEAVING THE OPERATOR'S SEAT....255
1.6 GETTING ON AND OFF THE MACHINE....255
1.7 CHECKING THE REAR VIEW MIRROR....256
1.8 PREVENTING FIRES DUE TO FUEL AND OIL....256
1.9 PREVENTING BURNS....256
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....257
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....257
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT....257
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....258
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT....258
PRECAUTIONS....259
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....260
2.1 SAFETY ON THE WORK SITE....260
2.2 FIRE PREVENTION....260
2.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....260
2.4 ROOM VENTILATION....261
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS-CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS....261
3. PRECAUTIONS TO BE TAKEN WHEN WORKING....262
3.1 STARTING THE ENGINE....262
3.2 RULES FOR ROAD TRAVEL....262
3.3 CHECKS FOR TRAVELING IN REVERSE....263
3.4 MOVING THE MACHINE....264
3.5 WORKING ON SLOPES....264
3.6 PREVENTING ELECTROCUTION....265
3.7 VISIBILITY....266
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES....266
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....266
3.10 WORKING ON LOOSE GROUND....266
3.11 PARKING THE MACHINE....267
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES....268
4.1 LOADING AND UNLOADING....268
4.2 THE ROUTE....268
5. THE BATTERY....269
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....269
5.2 STARTING THE ENGINE WITH JUMP LEADS....270
6. PRECAUTIONS FOR EMERGENCY RECOVERY....271
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....272
7.1 WARNING PLATES....272
7.2 TOOLS....272
7.3 PERSONAL PRECAUTIONS....272
7.4 EQUIPMENT....273
7.5 WORKING UNDER THE MACHINE....273
7.6 KEEPING THE MACHINE CLEAN....273
7.7 RUNNING THE ENGINE DURING MAINTENANCE....274
7.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....274
7.9 RULES FOR REFUELING AND ADDING OIL....275
7.10 LEVEL OF COOLANT IN THE RADIATOR....275
7.11 USING LAMPS....275
7.12 BATTERY AND ALTERNATOR PRECAUTIONS....276
7.13 PRECAUTIONS CONCERNING THE STARTER....276
7.14 PRECAUTIONS REGARDING HIGH PRESSURE HOSES....277
7.15 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS....277
7.16 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....277
7.17 THE RADIATOR COOLING FAN AND FAN BELT....278
7.18 WASTE MATERIALS....278
7.19 PRECAUTIONS FOR INFLATING TIRES....278
7.20 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE....279
7.21 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....279
8. SAFETY PLATES....280
8.1 POSITION OF SAFETY PLATES....280
8.2 POSITION OF PICTOGRAMS....294
8.3 PICTOGRAMS AND RELEVANT MEANINGS....296
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....299
TECHNICAL SPECIFICATIONS....301
9. TECHNICAL DATA....302
9.1 STANDARD OVERALL DIMENSIONS....302
9.2 TECHNICAL CHARACTERISTICS WB140R-2 (ASPIRATED ENGINE)....303
9.3 TECHNICAL CHARACTERISTICS WB140R-2 (TURBOCHARGED ENGINE)....304
9.4 TECHNICAL CHARACTERISTICS WB150R-2....305
9.5 LIFTING CAPACITIES....306
9.5.1 SYMBOL TABLE....306
9.5.2 LIFTING CAPACITY WB140R-2....307
9.5.3 LIFTING CAPACITY WB150R-2....309
THE MACHINE AND ITS OPERATIONS....311
10. SAFETY LOCKS....312
10.1 FRONT LOADER LOCK....312
10.2 BACKHOE LOCKS....314
11. GENERAL VIEWS....315
11.1 FRONT GENERAL VIEW....315
11.2 BACKHOE GENERAL VIEW....316
11.3 CAB INSIDE GENERAL VIEW....317
12. INSTRUMENTS AND CONTROLS....318
12.1 FRONT INSTRUMENTS....318
12.2 SIDE INSTRUMENTS....322
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER....327
12.4 PUSH BUTTON ON THE GEARSHIFT LEVER....328
12.5 ELECTRICAL ACCESSORIES....328
12.6 MACHINE CONTROLS....329
13. FUSES AND RELAYS....342
13.1 EQUIPMENT FUSES AND RELAYS....342
13.2 ENGINE FUSES AND RELAYS....344
14. GUARDS, CAB AND DRIVER'S SEAT....347
14.1 ENGINE HOOD....347
14.2 CANOPY....347
14.3 CAB....348
14.4 VENTILATION AND HEATING....350
14.5 SEAT....351
14.6 SAFETY BELT....351
14.7 FIRE EXTINGUISHER....352
14.8 FIRST AID KIT....352
14.9 TECHNICAL DOCUMENTATION....352
14.10 ADDITIONAL TOOL CASE (IF PROVIDED)....352
15. USE OF MACHINE....353
15.1 CHECKS BEFORE STARTING THE ENGINE....353
15.1.1 VISUAL CHECKS....353
15.1.2 DAILY CHECKS....353
15.1.3 OPERATIONAL CHECKS....354
15.2 STARTING THE ENGINE....355
15.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES (MORE THAN 0°C (32°F))....355
15.2.2 STARTOMG WITH COLD ENGINE OR IN COLD CLIMATES (UP TO -16°C (3°F))....356
15.2.3 STARTING ENGINE IN VERY COLD AREAS (UP TO -30°C (-22°F))....356
15.3 WARMING THE ENGINE....357
15.4 HEATING THE HYDRAULIC OIL....357
15.5 HOW TO MOVE THE MACHINE....358
15.5.1 LOCKING THE DIFFERENTIAL....359
15.5.2 ENGAGING THE FOUR-WHEEL DRIVE....359
15.5.3 WORKING ON SLOPES....360
15.5.4 MAXIMUM IMMERSION DEPTH....361
16. PARKING THE MACHINE....362
16.1 PARKING ON LEVEL GROUND....362
16.2 PARKING ON SLOPES....363
17. STOPPING THE ENGINE....364
18. TRANSPORTING THE MACHINE ON OTHER VEHICLES....365
18.1 LOADING AND UNLOADING THE MACHINE....365
18.2 TRANSPORT....366
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....367
19.1 FUEL AND LUBRICANTS....367
19.2 COOLANT....367
19.3 BATTERY....367
19.4 OTHER PRECAUTIONS....368
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....368
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....369
21. USING THE MACHINE AS A LOADER....370
21.1 BUCKET POSITION INDICATOR....370
21.2 ORGANIZING WORK AREA....370
21.2.1 LOADING HEAPED AND LEVEL MATERIAL....371
21.2.2 LOADING OPERATIONS ON SLOPES....371
21.3 CHANGING THE STANDARD FRONT BUCKET....372
22. USING THE MACHINE AS AN EXCAVATOR....373
22.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT....373
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....374
22.3 DIGGING METHOD....375
22.4 CHANGING THE BACKHOE BUCKET....376
23. TROUBLESHOOTING....377
23.1 HOW TO REMOVE THE MACHINE....377
23.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....377
23.3 IF THE BATTERY IS DEPLETED....378
23.3.1 STARTING WITH BOOSTER CABLES....379
23.4 OTHER TROUBLES....380
23.4.1 ELECTRICAL CIRCUIT....380
23.4.2 HYDRAULIC SYSTEM....380
23.4.3 BRAKING SYSTEM....381
23.4.4 TORQUE CONVERTER SYSTEM....381
23.4.5 ENGINE....382
MAINTENANCE....383
24. GUIDE TO MAINTENANCE....384
25. MAINTENANCE NOTES....386
25.1 NOTES REGARDING THE ENGINE....386
25.1.1 ENGINE OIL....386
25.1.2 COOLANT....386
25.1.3 FUEL....387
25.2 NOTES REGARIDNG THE HYDRAULIC SYSTEM....387
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM....388
25.4 NOTES REGARDING LUBRICATION....388
25.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....389
26. FUEL, COOLAND AND LUBRICANTS....390
26.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....394
26.2 LUBRICATION DIAGRAM....395
26.3 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)....396
26.4 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS)....397
26.5 LUBRICANT DIAGRAM (TELESCOPIC ARM)....398
26.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....399
26.6.1 CRITICAL PARTS FOR SAFETY....400
27. NUT AND BOLT TIGHTENING TORQUES....404
27.1 STANDARD TIGHTENING TORQUES....404
27.2 SPECIFIC TIGHTENING TORQUES....404
28. MAINTENANCE PLAN....405
28.1 CHECK BEFORE STARTING....409
28.1.A VARIOUS CHECKS....409
28.1.B CHECKING THE FUEL LEVLE....409
28.1.C CHECKING THE COOLANT LEVEL....410
28.1.D CHECKING THE ENGINE OIL LEVEL....410
28.1.E CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL....411
28.1.F DRAINING THE WATER SEPARATOR....412
28.2 MAINTENANCE EVERY 10 HOURS OF OPERATION....412
28.2.A LUBRICATING THE JOINTS....412
28.3 MAINTENANCE AFTER FIRST 50 HOURS OF OPERATION....415
28.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....415
28.4.A CHECKING THE RADIATOR FLUID LEVEL....415
28.4.B CHECKING THE BRAKING SYSTEM OIL LEVEL....415
28.4.C LUBRICATING THE PROPELLER SHAFTS....416
28.4.D LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING....417
28.4.E CHECKING THE TIRE PRESSURE....417
28.4.F CHECKING THE ELECTRICAL SYSTEM....418
28.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....419
28.5.A CHANGE FRONT AXLE OIL....430
28.5.B CHANGE REAR AXLE OIL....431
28.5.C CHANGE HYDRAULIC TRANSMISSION OIL....432
28.5.D CHANGE HYDRAULIC TRANSMISSION OIL FILTER....433
28.5.E CHECK AND ADJUST ENGINE VALVE CLEARANCE....433
28.5.F CHANGE HYDRAULIC OIL DRAIN FILTER....426
28.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....419
28.6.A ADJUSTING THE FAN BELT TENSION....419
28.6.B CLEANING THE OUTSIDE OF THE RADIATORS....420
28.6.C CHECKING THE BATTERY ELECTROLYTE LEVEL....421
28.6.D CHECKING THE FRONT AXLE OIL LEVELS....422
28.6.E CHECKING THE REAR AXLE OIL LEVELS....422
28.6.F CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL....423
28.6.G CHECKING THE WHEEL NUT DRIVING TORQUE....423
28.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION....424
28.7.A CHANGE AND CLEAN HYDRAULIC OIL AND SUCTION FILTER....434
28.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....424
28.8.A CHANGING THE ENGINE OIL....424
28.8.B CHANGING THE ENGINE OIL FILTER....425
28.8.C CHANGING THE HYDRAULIC SYSTEM OIL FILTER....426
28.8.D CHANGING THE FUEL FILTER....427
28.8.E DRAINING THE FUEL TANK....428
28.8.F DRAINING THE HYDRAULIC OIL TANK....429
28.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....430
28.9.A CHANGING THE FRONT AXLE OIL....430
28.9.B CHANGING THE REAR AXLE OIL....431
28.9.C CHANGING THE HYDRAULIC TRANSMISSION....432
28.9.D CHANGING THE HYDRAULIC TRANSMISSION FILTER....433
28.9.E CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....433
28.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....434
28.10.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....434
28.10.B CHANGING THE COOLANT....437
28.10.C CHANGING THE BRAKING SYSTEM OIL....438
28.10.D CHECKING THE ALTERNATOR AND THE STARTER....438
28.11 WHEN REQUIRED....439
28.11.A CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....439
28.11.B CHECKING AND CLEANING THE CAB AIR FILTER....440
28.11.C BLEEDING THE BRAKING CIRCUIT....441
28.11.D WASHING THE COOLING CIRCUIT....441
28.11.E CLEANING THE WATER SEPARATOR....443
28.11.F CHECKING AND ADJUSTIONG THE FRONT WHEEL TOE-IN....443
28.11.G CHECKING AND ADJUSTING THE PARKING BRAKE....444
28.11.H CHECKING THE BRAKING EFFICIENCY....445
28.11.J CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE....446
28.11.K ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION....446
28.12 MAINTANANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER....447
28.12.A CHANGING THE HYDRAULIC OIL FILTER....447
28.12.B CHANGING THE HYRAULIC OIL....447
29. LONG PERIODS OF INACTIVITY....448
29.1 BEFORE THE PERIOD OF INACTIVITY....448
29.2 DURING THE PERIOD OF INACTIVITY....450
29.3 AFTER THE PERIOD OF INACTIVITY....450
AUTHORIZED OPTIONAL EQUIPMENT....451
30. AUTHORIZED OPTIONAL EQUIPMENT....452
30.1 PRECAUTIONS REGARDING SAFETY....452
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB140-2....453
30.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB150-2....454
31. FRONT EQUIPMENT QUICK COUPLING DEVICES....455
31.1 MANUAL CONTROL QUICK COUPLING....455
31.2 HYDRAULIC CONTROL QUICK COUPLING....456
31.3 HYDRAULIC CONTROL QUICK COUPLING FOR MULTIPURPOSE BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....456
32. MULTIPURPOSE BUCKET....457
32.1 DESCRIPTION AND CONTROLS....457
32.2 SAFETY DEVICES....457
32.3 INSTALLING THE MULTIPURPOSE BUCKET....458
32.4 USING THE MULTIPURPOSE BUCKET....459
32.5 MAINTENANCE....459
33. PALLET FORKS....460
33.1 DESCRIPTION....460
33.2 SAFETY DEVICES....460
33.3 USING THE FORKS....460
33.3.1 PREPARING THE PALLET FORKS FOR USE....461
33.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS....461
33.4 REMOVING THE FORKS....462
33.5 INSTALLING THE FORKS....462
33.6 MAINTENANCE....462
34. BACKHOE TELESCOPIC ARM....463
34.1 SAFETY DEVICES....463
34.2 SAFETY DEVICES....464
34.3 MAINTENANCE....464
34.4 ADJUSTING THE GUIDE SLACK....464
34.4.1 ADJUSTING THE GUIDE SLACK....464
35. ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....466
35.1 DESCRIPTION AND CONTROL....466
35.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....467
35.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....471
35.3.1 INSTALLING THE HAMMER....471
35.3.2 REMOVING THE HAMMER....473
35.4 MAINTENANCE....473
36. ARRANGEMENT FOR THE OPERATION OF THE OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....474
36.1 DESCRIPTION AND CONTROL....474
36.2 INSTALLING AND CONNECTING THE EQUIPMENT....474
36.3 MAINTENANCE....475
37. ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET....476
37.1 DESCRIPTION AND CONTROL....476
37.2 INSTALLING THE CLAMSHELL BUCKET....477
37.3 USING THE CLAMSHELL BUCKET....478
37.4 MAINTENANCE....478
38. ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER....479
38.1 DESCRIPTION AND CONTROL....479
38.2 CONNECTING AND REMOVING THE HAMMER....480
38.2.1 CONNECTING THE HAMMER....480
38.2.2 REMOVING THE CONNECTIONS....480
38.3 USING THE HAMMER....481
38.4 MAINTENANCE....481
39. LOAD STABILIZER SYSTEM (LSS) (OPTIONAL)....482
39.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)....482
40. AIR CONDITIONER (OPTIONAL)....483
WEAM000904 - Backhoe Loader WB140-2, WB150-2 Operation & Maintenance Manual....485
COVER....485
TABLE OF CONTENTS....486
FORWARD....494
INFORMATION ON SAFETY....495
INTRODUCTION....497
INTENDED USES....497
IMPROPER OR UNAUTHORIZED USES....497
MAIN CHARACTERISTICS....498
RUNNING-IN....498
PRODUCT IDENTIFICATION....499
MACHINE SERIAL NUMBER....499
MACHINE IDENTIFICATION PLATE....499
ENGINE SERIAL NUMBER AND EMISSION LABEL....500
FRONT AXLE SERIAL NUMBER....500
REAR AXLE SERIAL NUMBER....500
TRANSMISSION SERIAL NUMBER....501
CAB SERIAL NUMBER....501
CANOPY SERIAL NUMBER....501
SERIAL NUMBERS AND DEALER'S ADDRESS....502
SAFETY AND ACCIDENT PREVENTION....504
1. GENERAL PRECAUTIONS....505
1.1 GENERAL SAFETY RULES....505
1.2 SAFETY DEVICES AND GUARDS....505
1.3 CLOTHING AND PERSONAL PROTECTION ITEMS....505
1.4 UNAUTHORIZED MODIFICATIONS....505
1.5 LEAVING THE OPERATOR'S SEAT....506
1.6 GETTING ON AND OFF THE MACHINE....506
1.7 CHECKING THE REAR-VIEW MIRROR....507
1.8 PREVENTING FIRES DUE TO FUEL AND OIL....507
1.9 PREVENTING BURNS....507
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....508
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....508
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT....508
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....509
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT....509
PRECAUTIONS....510
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....511
2.1 SAFETY ON THE WORK SITE....511
2.2 FIRE PREVENTION....511
2.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....511
2.4 ROOM VENTILATION....512
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS-CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS....512
3. PRECAUTIONS TO BE TAKEN WHEN WORKING....513
3.1 STARTING THE ENGINE....513
3.2 RULES FOR ROAD TRAVEL....513
3.3 CHECKS FOR TRAVELING IN REVERSE....514
3.4 MOVING THE MACHINE....515
3.5 WORKING ON SLOPES....515
3.6 PREVENTING ELECTROCUTION....516
3.7 VISIBILITY....517
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES....517
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....517
3.10 WORKING ON LOOSE GROUND....517
3.11 PARKING THE MACHINE....518
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES....519
4.1 LOADING AND UNLOADING....519
4.2 THE ROUTE....519
5. THE BATTERY....520
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....520
5.2 STARTING THE ENGINE WITH JUMP LEADS....521
6. PRECAUTIONS FOR EMERGENCY RECOVERY....522
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....523
7.1 WARNING PLATES....523
7.2 TOOLS....523
7.3 PERSONAL PRECAUTIONS....523
7.4 EQUIPMENT....524
7.5 WORKING UNDER THE MACHINE....524
7.6 KEEPING THE MACHINE CLEAN....524
7.7 RUNNING THE ENGINE DURING MAINTENANCE....525
7.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....525
7.9 RULES FOR REFUELING AND ADDING OIL....526
7.10 LEVEL OF COOLANT IN THE RADIATOR....526
7.11 USING LAMPS....526
7.12 BATTERY AND ALTERNATOR PRECAUTIONS....527
7.13 PRECAUTIONS CONCERNING THE STARTER....527
7.14 PRECAUTIONS REGARDING HIGH PRESSURE HOSES....528
7.15 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGIH PRESSURE SYSTEMS....528
7.16 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....528
7.17 THE RADIATOR COOLING FAN AND FAN BELT....529
7.18 WASTE MATERIALS....529
7.19 PRECAUTIONS FOR INFLATING TIRES....529
7.20 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE....530
7.21 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....530
8. SAFETY PLATES....531
8.1 POSITION OF THE SAFETY PLATES....531
8.2 POSITION OF PICTOGRAMS....545
8.3 PICTOGRAMS AND RELEVANT MEANINGS....547
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....550
TECHNICAL SPECIFICATIONS....552
9. TECHNICAL DATA....553
9.1 STANDARD OVERALL DIMENSIONS....553
9.2 TECHNICAL CHARACTERISTICS WB140R-2 (ASPIRATED ENGINE)....554
9.3 TECHNICAL CHARACTERISTICS WB140R-2 (TURBOCHARGED ENGINE)....555
9.4 TECHNICAL CHARACTERISTICS WB150R-2....556
9.5 LIFTING CAPACITIES....557
THE MACHINE AND ITS OPERATIONS....562
10. SAFETY LOCKS....563
10.1 FRONT LOADER LOCK....563
10.2 BACKHOE LOCKS....565
11. GENERAL VIEWS....566
11.1 FRONT GENERAL VIEW....566
11.2 BACKHOE GENERAL VIEW....567
11.3 CAB INSIDE GENERAL VIEW....568
12. INSTRUMENTS AND CONTROLS....569
12.1 FRONT INSTRUMENTS....569
12.2 SIDE INSTRUMENTS....573
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVEL....578
12.4 PUSH BUTTONS ON THE GEARSHIFT LEVER....579
12.5 ELECTRICAL ACCESSORIES....579
12.6 MACHINE CONTROLS....580
13. FUSES AND RELAYS....593
13.1 EQUIPMENT FUSES AND RELAYS....593
13.2 ENGINE FUSES AND RELAYS....595
14. GUARDS, CAB AND DRIVER'S SEAT....598
14.1 ENGINE HOOD....598
14.2 CANOPY....598
14.3 CAB....599
14.4 VENTILATION AND HEATING....601
14.5 SEAT....602
14.6 SAFETY BELT....602
14.7 FIRE EXTINGUISHER....603
14.8 FIRST AID KIT....603
14.9 TECHNICAL DOCUMENTATION ....603
14.10 ADDITIONAL TOOL CASE (IF PROVIDED)....603
15. USE OF THE MACHINE....604
15.1 CHECKS BEFORE STARTING THE ENGINE....604
15.1.1 VISUAL CHECKS....604
15.1.2 DAILY CHECKS....604
15.1.3 OPERATIONAL CHECKS....605
15.2 STARTING ENGINE....606
15.2.1 STARTING WITH WARM ENGINE OR TEMPERATE CLIMATES (MORE THAN 0°C (32°F)....606
15.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATE (UP TO -16°C (3°F)....607
15.2.3 STARTING THE ENGINE IN VERY COLD AREAS (UP TO -20°C (-22°F)....607
15.3 WARMING THE ENGINE....608
15.4 HEATING THE HYDRAULIC OIL....608
15.5 HOW TO MOVE THE MACHINE....609
15.5.1 LOCKING THE DIFFERENTIAL....610
15.5.2 ENGAGING THE FOUR-WHEEL DRIVE....610
15.5.3 WORKING ON SLOPES....611
15.5.4 MAXIMUM IMMERSION DEPTH....612
16. PARKING THE MACHINE....613
16.1 PARKING ON LEVEL GROUND....613
16.2 PARKING ON SLOPES....614
17. STOPPING THE ENGINE....615
18. TRANSPORTING THE MACHINE ON OTHER VEHICLES....616
18.1 LOADING AND UNDLOADING THE MACHINE....616
18.2 TRANSPORT....617
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASONN....618
19.1 FUEL AND LUBRICANTS....618
19.2 COOLANT....618
19.3 BATTERY....618
19.4 OTHER PRECAUTIONS....619
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....619
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....620
21. USING THE MACHINE AS A LOADER....621
21.1 BUCKET POSITION INDICATOR....621
21.2 ORGANIZING THE WORK AREA....621
21.2.1 LOADING HEAPED AND LEVEL MATERIAL....622
21.2.2 LOADING OPERATIONS ON SLOPES....622
21.3 CHANGING THE STANDARD FRONT BUCKET....623
22. USING THE MACHINE AS AN EXCAVATOR....624
22.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT....624
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....625
22.3 DIGGING METHOD....626
22.4 CHANGING THE BACKHOE BUCKET....627
23. TROUBLESHOOTING....628
23.1 HOW TO REMOVE THE MACHINE....628
23.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....628
23.3 IF THE BATTERY IS DEPLETED....629
23.3.1 STARTING WITH BOOSTER CABLES....630
23.4 OTHER TROUBLES....631
23.4.1 ELECTRICAL CIRCUIT....631
23.4.2 HYDRAULIC SYSTEM....631
23.4.3 BRAKING SYSTEM....632
23.4.4 TORQUE CONVERTER SYSTEM....632
23.4.5 ENGINE....633
MAINTENANCE....634
24. GUIDE TO MAINTENANCE....635
25. MAINTENANCE NOTES....637
25.1 NOTE REGARDING THE ENGINE....637
25.1.1 ENGINE OIL ....637
25.1.2 COOLANT....637
25.1.3....638
25.2 NOTES REGARDING THE HYDRAULIC SYSTEM....638
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM....639
25.4 NOTES REGARDING LUBRICATION....639
25.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....640
26. FUEL, COOLANT AND LUBRICANTS....641
26.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....645
26.2 LUBRICATION DIAGRAM....646
26.3 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)....647
26.4 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS)....648
26.5 LUBRICATION DIAGRAM (TELESCOPIC ARM)....649
26.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....650
26.6.1 CRITICAL PARTS FOR SAFETY....651
27. NUT AND BOLT TIGHTENING TORQUES....655
27.1 STANDARD TIGHTENING TORQUES....655
27.2 SPECIFIC TIGHTENING TORQUES....655
28. MAINTENANCE PLAN....656
28.1 CHECKS BEFORE STARTING....660
28.1.A VARIOUS CHECKS....660
28.1.B CHECKING THE FUEL LEVEL....660
28.1.C CHECKING THE COOLANT LEVEL....661
28.1.D CHECKING THE ENGINE OIL LEVEL....661
28.1.E CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL....662
28.1.F DRAINING THE WATER SEPARATOR....663
28.2 MAINTENANCE EVERY 10 HOURS OF OPERATION....663
28.2.A LUBRICATING THE JOINTS....663
28.3 MAINTENACE AFTER THE FIRST 50 HOURS OF OPERATION(ONLY FOR MACHINES IN WHICH THE SYTHETIC BIODEGRADABLE OIL TYPE HEES IS USED)....666
28.3.A CHANGE HYDRAULIC OIL DRAIN FILTER....677
28.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....666
28.4.A CHECKING THE RADIATOR FLUID LEVEL....666
28.4.B CHECKING THE BRAKING SYSTEM OIL LEVEL....666
28.4.C LUBRICATING THE PROPELLER SHAFTS....667
28.4.D LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING....668
28.4.E CHECKING THE TIRE PRESSURE....668
28.4.F CHECKING THE ELECTRICAL SYSTEM....669
28.5 MAINTENANCE AFTER THER FIRST 250 HOURS OF OPERATION....670
28.5.A CHANGE FRONT AXLE OIL....670
28.5.B CHANGE REAR AXLE OIL....670
28.5.C CHANGE HYDRAULIC TRANSMISSION OIL....670
28.5.D CHANGE HYDRAULIC TRANSMISSION OIL FILTER....670
28.5.E CHECK AND ADJUST ENGINE VALVE CLEARANCE....670
28.5.F CHANGE HYDRAULIC OIL DRAIN FILTER....670
28.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....670
28.6.A ADJUSTING THE FAN BELT TENSION....670
28.6.B CLEANING THE OUTSIDE OF THE RADIATORS....671
28.6.C CHECKING THE BATTERY ELETROLYTE LEVEL....672
28.6.D CHECKING THE FRONT AXLE OIL LEVELS....673
28.6.E CHECKING THE REAR AXLE OIL LEVELS....673
28.6.F CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL....674
28.6.G CHECKING THE WHEEL NUT DRIVING TORQUE....674
28.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION....675
28.7.A CHANGING THE HYDRAULIC SYTEM OIL AND CLEANING THE SUCTION FILTER....675
28.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....675
28.8.A CHANGING THE ENGINE OIL....675
28.8.B CHANGING THE ENGINE OIL FILTER....676
28.8.C CHANGING THE HYDRAULIC SYSTEM OIL FILTER....677
28.8.D CHANGING THE FUEL FILTER....678
28.8.E DRAINING THE FUEL TANK....679
28.8.F DRAINING THE HYDRAULIC OIL TANK (ONLY FOR MACHINES IN WHICH THE SYTHETIC BIODEGRADABLE OIL TYPES HEES IS USED)....680
28.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....681
28.9.A CHANGING THE FRONT AXLE OIL....681
28.9.B CHANGING THE REAR AXLE OIL....682
28.9.C CHANGING THE HYDRAULIC TRANSMISSION OIL....683
28.9.D CHANGING THE HYDRAULIC TRANSMISSION FILTER....684
28.9.E CHECKING AND ADJUSTING THE ENGINE VALVA CLEARANCE....684
28.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....685
28.10.A CHANGING THE HYDRAULIC SYTEM OIL AND CLEANING THE SUCTION FILTER....685
28.10.B CHANGING THE COOLANT....687
28.10.C CHANGING THE BRAKING SYSTEM OIL....689
28.10.D CHECKING THE ALTERNATOR AND THE STARTER....689
28.11 WHEN REQUIRED....690
28.11.A CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....690
28.11.B CHECKING AND CLEANING THE CAB AIR FILTERS....691
28.11.C BLEEDING THE BRAKING CIRCUIT....692
28.11.D WASHING THE COOLING CIRCUIT....693
28.11.E CLEANING THE WATER SEPARATOR....695
28.11.F CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN....695
28.11.G CHECKING AND ADJUSTING THE PARKING BRAKE....696
28.11.H CHECKING THE BRAKE EFFICIENCY....697
28.11.J CHECKING AND ADJUSTIN THE BRAKE PEDAL STROKE....698
28.11.K ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION....698
28.12 MAINTENANCE INTERVALS IN CASE OF USE OF DEMOLITION HAMMER....699
28.12.A CHANGING THE HYDRAULIC OIL FILTER....699
28.12.B CHANGING THE HYDRAULIC OIL....699
29. LONG PERIODS OF INACTIVITY....700
29.1 BEFORE THE PERIOD OF INACTIVITY....700
29.2 DURING THE PERIOD OF INACTIVITY....702
29.3 AFTER THE PERIOD OF INACTIVITY....702
AUTHORISED OPTIONAL EQUIPMENT....704
30. AUTHORIZED OPTIONAL EQUIPMENT....705
30.1 PRECAUTIONS REGARDING SAFETY....705
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB140-2....706
30.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB150-2....707
31. FRONT EQUIPMENT QUICK COUPLING DEVICES....708
31.1 MANUAL CONTROL QUICK COUPLING....708
31.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET....709
31.3 HYDRAULIC CONTROL QUICK COUPLING FOR MULTIPURPOSE BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....709
32. MULTIPURPOSE BUCKET....710
32.1 DESCRIPTION AND CONTROLS....710
32.2 SAFETY DEVICES....710
32.3 INSTALLING THE MULTIPURPOSE BUCKET....711
32.4 USING THE MULTIPURPOSE BUCKET....712
32.5 MAINTENANCE....712
33. PALLET FORKS....713
33.1 DESCRIPTION....713
33.2 SAFETY DEVICES....713
33.3 USING THE FORKS....713
33.3.1 PREPARING THE PALLET FORKS FOR USE....714
33.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS....714
33.4 REMOVING THE FORKS....715
33.5 INSTALLING THE FORKS....715
33.6 MAINTENANCE....715
34. BACKHOE TELESCOPIC ARM....716
34.1 DESCRIPTION AND CONTROL....716
34.2 SAFETY DEVICES....716
34.3 USING THE TELESCOPIC ARM....717
34.4 MAINTENANCE....717
34.4.1 ADJUSTING THE GUIDE SLACK....717
35. ARRANGEMENT FOR THE INSTALLATION FO THE DEMOLITION HAMMER....719
35.1 DESCRIPTION AND CONTROL....719
35.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....720
35.3 INSTALLATION AND REMOVING THE DEMOLITION HAMMER....724
35.3.1 INSTALLING THE HAMMER....724
35.3.2 REMOVING THE HAMMER....726
35.4 MAINTENANCE....726
36. ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....727
36.1 DESCRIPTION AND CONTROL....727
36.2 INSTALLING AND CONNECTING THE EQUIPMENT....727
36.3 MAINTENANCE....728
37. ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET....729
37.1 DESCRIPTION AND CONTROL....729
37.2 INSTALLING THE CLAMSHELL BUCKET....730
37.3 USING THE CLAMSHELL BUCKET....731
37.4 MAINTENANCE....731
38. ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER....732
38.1 DESCRIPTION AND CONTROL....732
38.2 CONNECTING AND REMOVING THE HAMMER....733
38.2.1 CONNECTING THE HAMMER....733
38.2.2 REMOVING THE CONNECTIONS....733
38.3 USING THE HAMMER....734
38.4 MAINTENANCE....734
39. LOAD STABILIZER SYSTEM (LSS) (OPTIONAL)....735
39.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)....735
40. AIR CONDITIONER (OPTIONAL)....736
WEBM001102 - Backhoe Loader WB140-2, WB150-2 Shop Manual....738
COVER....738
CONTENTS....739
FOREWARD....742
FOREWARD....744
HOW TO READ THE MANUAL....745
HOISTING INSTRUCTIONS....746
STANDARD TIGHTENING TORQUE....747
COATING MATERIALS....749
ELECTRIC WIRE CODE....750
WEIGHT TABLE....751
TABLE OF OIL AND COOLANT QUANTITIES....752
10 STRUCTURE AND FUNCTION....755
POWER TRAIN....756
TRANSMISSION....758
DRIVE SHAFTS....763
CONTROL VALVE BLOCK....765
FRONT AXLE....766
REAR AXLE....769
HYDRAULIC PUMP....773
HYDRAULIC STEERING SYSTEM....794
HYDRAULIC CIRCUIT (WB140-2)....795
HYDRAULIC CIRCUIT (WB150-2)....796
SHOVEL CONTROL VALVE....797
BACKHOE CONTROL VALVE....801
CLSS....807
SAFETY VALVE....821
SOLENOID VALVE....823
BRAKE PUMP....824
SHOVEL CYLINDERS....825
BACKHOE CYLINDERS....827
AIR-CONDITIONING UNIT....833
HOW THE AIR-CONDITIONING UNIT FUNCTIONS....834
ELECTRICAL DIAGRAM (1/5)....835
ELECTRICAL DIAGRAM (2/5)....836
ELECTRICAL DIAGRAM (3/5)....837
ELECTRICAL DIAGRAM (4/5)....838
ELECTRICAL DIAGRAM (5/5)....839
20 TESTING AND ADJUSTING....841
NORMAL OR STANDARD TECHNICAL DATA....842
SPECIAL TOOLS....870
MEASURING ENGINE SPEED....871
ADJUSTING VALVE CLEARANCE....872
MEASURING COMPRESSION PRESSURE....873
TESTING AND ADJUSTING FUEL INJECTION TIMING....874
CHECKING AND TIGHTENING THE FAN - BELT....876
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT....877
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....878
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....880
AIR BLEEDING - RELEASING RESIDUAL PRESSURE....881
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....884
TESTING AND ADJUSTING OF LOADING SENSING SIGNAL (LS VALVE)....890
CHECKING UNLOADING VALVE FUNCTIONALITY....891
TESTING PUMP DELIVERY....892
TESTING PRIORITY VALVE OPERATION....894
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....895
TESTING BRAKE SYSTEM....896
CONTROL OF THE ENGINE SPEED UNDER LOAD....898
TESTING PRESSURES IN THE POWER TRAIN GROUP....900
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTHES....902
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....903
ANALYSIS OF CAUSES HYDRAULIC DRIFT....904
TESTING THE AIR-CONDITIONING UNIT....909
30 REMOVAL AND INSTALLATION....912
HOW TO READ THE MANUAL....914
PRECAUTIONS TO BE TAKEN WHILE WORKING....915
SPECIAL TOOLS....916
STARTING MOTOR....919
REMOVAL....919
INSTALLATION....919
ALTERNATOR....920
REMOVAL....920
INSTALLATION....920
AIR-CONTIONING UNIT COMPRESSOR....921
REMOVAL....921
INSTALLATION....922
INJECTION PUMP....923
REMOVAL....923
INSTALLATION....926
INJECTION NOZZLES....927
REMOVAL....927
INSTALLATION....927
THERMOSTAT....928
REMOVAL....928
INSTALLATION....928
COOLING LIQUID PUMP....929
REMOVAL....929
INSTALLATION....930
TURBOCOMPRESSOR....931
REMOVAL....931
INSTALLATION....932
CYLINDER HEAD....933
REMOVAL....933
INSTALLATION....936
ACCUMULATOR DISCONNECTING SWITCH....937
REMOVAL....937
INSTALLATION....937
FRONT COUNTERWEIGHT....938
REMOVAL....938
INSTALLATION....938
RADIATOR-OIL COOLER UNIT....939
REMOVAL....939
INSTALLATION....941
CONDENSER....942
REMOVAL....942
INSTALLATION....942
HYDRAULIC OIL COOLER....943
REMOVAL....943
INSTALLATION....944
TRANSMISSION OIL COOLER....945
REMOVAL....945
INSTALLATION....945
MUFFLER....946
REMOVAL....946
INSTALLATION....946
EXHAUST PIPE....946
REMOVAL....946
INSTALLATION....738
ENGINE HOOD....947
REMOVAL....947
INSTALLATION....948
CAB....949
REMOVAL....949
INSTALLATION....952
HEAT AND AIR CONDITIONING GROUP....953
REMOVAL....953
INSTALLATION....954
FUEL TANK....955
REMOVAL....955
INSTALLATION....955
HYDRAULIC OIL TANK....956
REMOVAL....956
INSTALLATION....956
ENGINE-GEARBOX-PUMP GROUP....957
REMOVAL....957
INSTALLATION....962
PISTON PUMP....963
REMOVAL....963
INSTALLATION....964
TRANSMISSION....965
REMOVAL....965
INSTALLATION....968
OVERHAULING....969
CONVERTOR....1050
REMOVAL....1050
INSTALLATION....1050
REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR DIPPER BEAM CONTROL GROUP....1051
REMOVAL....1051
INSTALLATION....1051
STEERING UNIT....1052
REMOVAL....1052
INSTALLATION....1052
WORKING BRAKE PUMP GROUP....1053
REMOVAL....1053
INSTALLATION....1053
FRONT WORKING EQUIPMENT CONTROL VALVE....1054
REMOVAL....1054
INSTALLATION....1054
FRONT AXLE....1055
REMOVAL....1055
INSTALLATION....1056
DISASSEMBLY....1057
ASSEMBLY....1075
REAR AXLE....1097
REMOVAL....1097
INSTALLATION....1098
DISASSEMBLY....1111
ASSEMBLY....1132
FRONT BUCKET BOOM-RASING CYLINDERS....1156
REMOVAL....1156
INSTALLATION....1156
FRONT BUCKET TILT CYLINDERS....1157
REMOVAL....1157
INSTALLATION....1157
FRONT BUCKET....1158
REMOVAL....1158
INSTALLATION....1158
FRONT WORKING EQUIPMENT....1159
REMOVAL....1159
INSTALLATION....1160
BACKHOE CONTROL VALVE....1161
REMOVAL....1161
INSTALLATION....1162
BACKHOE BOOM CYLINDER....1163
REMOVAL....1163
INSTALLATION....1163
BACKHOE ARM CYLINDER....1164
REMOVAL....1164
INSTALLATION....1164
TELESCOPIC ARM CYLINDER....1165
REMOVAL....1165
INSTALLATION....1165
BACKHOE BUCKET CYLINDER....1166
REMOVAL....1166
INSTALLATION....1166
OUTRIGGER CYLINDERS....1167
REMOVAL....1167
INSTALLATION....1167
BACKHOE SWING CYLINDERS....1168
REMOVAL....1168
INSTALLATION....1168
CYLINDERS (FRONT BUCKET RAISE AND TILT, OUTRIGGERS, BOOM, ARM, BUCKET AND TELESCOPIC ARM)....1169
DISASSEMBLY....1169
ASSEMBLY....1171
CYLINDERS (FRONT BUCKET RAISE AND TILT) ONLY FOR WB140-2 FROM SERIAL NUMBER 30026 AND UP....1174
DISASSEMBLY....1174
ASSEMBLY....1176
CYLINDERS (OUTRIGGER) ONLY FOR WB140-2 FROM SERIAL NUMBER 30026 AND UP....1178
DISASSEMBLY....1178
ASSEMBLY....1181
BOOM SWING CYLINDER....1185
DISASSEMBLY....1185
ASSEMBLY....1188
BOOM SAFETY CYLINDER....1194
REMOVAL....1194
INSTALLATION....1194
BACKHOE WORKING EQUIPMENT....1195
REMOVAL....1195
INSTALLATION....1195
BACKHOE BUCKET....1196
REMOVAL....1196
INSTALLATION....1196
ARM ....1197
REMOVAL....1197
INSTALLATION....1197
TELESCOPIC ARM....1198
REMOVAL....1198
INSTALLATION....1198
2ND ARM....1199
REMOVAL....1199
INSTALLATION....1199
2ND ARM GUIDES....1200
REMOVAL....1200
INSTALLATION....1200
BACKHOE BOOM....1201
REMOVAL....1201
INSTALLATION....1201
BACKHOE SWING BRACKET....1202
REMOVAL....1202
INSTALLATION....1202
BACKHOE SUPPORTS....1203
REMOVAL....1203
INSTALLATION....1204
40 MAINTENANCE STANDARD....1206
TRANSMISSION....1207
FRONT AXLE....1212
DIFFERENTIAL....1212
PLANETARY - JOINT....1213
STEERING UNIT CYLINDER....1214
REAR AXLE....1215
DIFFERENTIAL....1215
PLANETARY - JOINT....1216
BRAKES....1217
DIFFERENTIAL LOCK....1218
HYDRAULIC PUMP....1219
2-SPOOL CONTROL VALVE....1221
3-SPOOL CONTROL VALVE....1223
6-SPOOL CONTROL VALVE....1225
7-SPOOL CONTROL VALVE....1228
8-SPOOL CONTROL VALVE....1230
BRAKE PUMP....1231
SHOVEL CYCLINDER....1232
BACKHOE CYLINDERS....1234
FRONT WORKING EQUIPMENT....1240
SWING BRACKET....1242
BACKHOE WORKING EQUIPMENT....1244
WEBM004200 - Backhoe Loader WB140-2, WB150-2 Shop Manual....1247
COVER....1247
CONTENTS....1249
SAFETY....1253
FOREWORD....1255
HOW TO READ THE SHOP MANUAL....1257
HOISTING INSTRUCTIONS....1257
STANDARD TIGHTENING TORQUE....1258
COATING MATERIALS....1260
ELECTRIC....1261
WEIGHT TABLE....1262
TABLE OF OIL AND COOLANT QUANTITIES....1263
CONVERSION TABLE....1265
10 STRUCTURE AND FUNCTION....1275
POWER TRAIN....1276
TRANSMISSION....1278
DRIVE SHAFTS....1283
CONTROL VALVE BLOCK....1285
FRONT AXLE....1286
REAR AXLE....1289
HYDRAULIC PUMP....1294
STEERING UNIT....1315
HYDRAULIC CIRCUIT (WB140-2)....1317
HYDRAULIC CIRCUIT (WB150-2)....1318
SHOVEL CONTROL VALVE....1320
BACKHOE CONTROL VALVE....1324
CLSS....1331
SOLENOID VALVE....1345
SAFETY VALVE....1346
BRAKE PUMP....1348
SHOVEL CYLINDER....1349
BACKHOE CYLINDER....1350
AIR-CONDITIONING UNIT....1353
HOW THE AIR-CONDITIONING UNIT FUNCTIONS....1354
ELECTRICAL DIAGRAM....1355
ELECTRICAL DIAGRAM (AIR CONDITIONING)....1357
20 TESTING AND ADJUSTMENTS....1361
NORMAL OR STANDARD TECHNICAL DATA....1368
SPECIAL TOOLS....1386
MEASURING ENGINE SPEED....1387
ADJUSTING VALVE CLEARANCE....1388
MEASURING COMPRESSION PRESSURE....1389
TESTING AND ADJUSTING FUEL INJECTION TIMING....1390
CHECKING AND TIGHTENING THE FAN -BELT....1392
CHECKING AND TIGHTENING THE COMPRESSOR FAN -BELT....1393
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....1394
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....1396
AIR BLEEDING - RELEASING RESIDUAL PRESSURE....1397
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....1400
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)....1406
TESTING AND ADJUSTING OF UNLOADING VALVE....1407
CHECKING UNLOADING VALVE FUNCTIONALITY....1408
TESTING PRIORITY VALVE OPERATION....1409
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....1410
TESTING BRAKE SYSTEM....1411
CONTROL OF THE ENGINE SPEED UNDER LOAD....1413
TESTING PRESSURES IN THE POWE TRAIN GROUP....1415
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES....1417
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....1418
ANALYSIS OF CAUSES HYDRAULIC DRIFT....1419
TESTING THE AIR -CONDITIONING UNIT....1424
EMPTYING THE AIR-CONDITIONING UNIT....1426
TROUBLESHOOTING....1427
FRONT AXLE TROUBLESHOOTING....1428
REAR AXLE TROUBLESHOOTING....1433
TRANSMISSION TROUBLESHOOTING....1438
30 REMOVAL AND INSTALLATION....1443
HOW TO READ THE MANUAL....1445
PRECAUTIONS TO BE TAKEN WHILE WORKING....1446
SPECIAL TOOLS....1447
STARTING MOTOR....1451
REMOVAL AND INSTALLATION....1451
ALTERNATOR....1452
REMOVAL....1452
INSTALLATION....1453
AIR-CONDITIONING UNIT COMPRESSOR....1454
REMOVAL....1454
INSTALLATION....1455
INJECTION PUMP....1456
REMOVAL....1456
INSTALLATION....1459
INJECTION NOZZLES....1460
REMOVAL AND INSTALLATION....1460
THERMOSTAT....1461
REMOVAL AND INSTALLATION....1461
COOLING LIQUID PUMP....1462
REMOVAL....1462
INSTALLATION....1463
TURBOCOMPRESSOR....1464
REMOVAL....1464
INSTALLATION....1465
CYLINDER HEAD....1466
REMOVAL....1466
INSTALLATION....1468
ACCUMULATOR DISCONNECTING SWITCH....1470
REMOVAL AND INSTALLATION....1470
FRONT COUNTERWEIGHT....1471
REMOVAL AND INSTALLATION....1471
RADIATOR-OIL COOLER UNIT....1472
REMOVAL....1472
INSTALLATION....1474
CONDENSER....1475
REMOVAL AND INSTALLATION....1475
HYDRAULIC OIL COOLER....1476
REMOVAL....1476
INSTALLATION....1477
TRANSMISSION OIL COOLER....1478
REMOVAL AND INSTALLATION....1478
MUFFLER....1479
REMOVAL AND INSTALLATION....1479
EXHAUST PIPE....1480
REMOVAL AND INSTALLATION....1480
ENGINE HOOD....1481
REMOVAL....1481
INSTALLATION....1482
CAB....1483
REMOVAL....1483
INSTALLATION....1486
HEAT AND AIR-CONDITIONING GROUP....1487
REMOVAL....1487
INSTALLATION....1488
FUEL TANK....1489
REMOVAL AND INSTALLATION....1489
HYDRAULIC OIL TANK....1490
REMOVAL AND INSTALLATION....1490
ENGINE-GEARBOX-PUMP GROUP....1491
REMOVAL....1491
INSTALLATION....1496
PISTON PUMP....1497
REMOVAL....1497
INSTALLATION....1498
TRANSMISSION....1499
REMOVAL....1499
INSTALLATION....1502
DISASSEMBLY AND ASSEMBLY....1503
CONVERTOR....1581
REMOVAL AND INSTALLATION....1581
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....1582
REMOVAL AND INSTALLATION....1582
STEERING UNIT....1583
REMOVAL AND INSTALLATION....1583
WORKING BRAKE PUMP GROUP....1584
REMOVAL AND INSTALLATION....1584
FRONT WORKING EQUIPMENT CONTROL VALVE....1585
REMOVAL AND INSTALLATION....1585
FRONT AXLE....1586
REMOVAL....1586
INSTALLATION....1587
DISASSEMBLY....1588
ASSEMBLY....1597
REAR AXLE....1613
REMOVAL....1613
INSTALLATION....1614
DISASSEMBLY....1615
ASSEMBLY....1630
FRONT BUCKET BOOM-RAISING CYLINDER....1649
REMOVAL AND INSTALLATION....1649
FRONT BUCKET TILT CYLINDERS....1650
REMOVAL AND INSTALLATION....1650
FRONT BUCKET....1651
REMOVAL AND INSTALLATION....1651
FRONT WORKING EQUIPMENT....1652
REMOVAL....1652
INSTALLATION....1653
BACKHOE CONTROL VALVE....1654
REMOVAL....1654
INSTALLATION....1655
BACKHOE BOOM CYLINDER....1656
REMOVAL AND INSTALLATION....1656
BACKHOE ARM CYLINDER....1657
REMOVAL AND INSTALLATION....1657
TELESCOPIC ARM CYLINDER....1658
REMOVAL AND INSTALLATION....1658
BACKHOE BUCKET CYLINDER....1659
REMOVAL AND INSTALLATION....1659
OUTRIGGER CYLINDERS....1660
REMOVAL AND INSTALLATION....1660
BACKHOE SWING CYLINDERS....1661
REMOVAL AND INSTALLATION....1661
CYLINDERS....1662
DISASSEMBLY....1662
ASSEMBLY....1664
BOOM SWING CYLINDER....1667
DISASSEMBLY....1667
ASSEMBLY....1668
BOOM SAFETY CYLINDER....1670
REMOVAL AND INSTALLATION....1670
BACKHOE WORKING EQUIPMENT....1671
REMOVAL AND INSTALLATION....1671
BACKHOE BUCKET....1672
REMOVAL AND INSTALLATION....1672
ARM....1673
REMOVAL AND INSTALLATION....1673
TELESCOPIC ARM....1674
REMOVAL AND INSTALLATION....1674
2nd ARM....1675
REMOVAL AND INSTALLATION....1675
2nd ARM GUIDES....1676
REMOVAL AND INSTALLATION....1676
BACKHOE BOOM....1677
REMOVAL AND INSTALLATION....1677
BACKHOE SWING BRACKET....1678
REMOVAL AND INSTALLATION....1678
BACKHOE OUTRIGGERS....1679
REMOVAL....1679
INSTALLATION....1680
40 STANDARD MAINTENANCE....1683
TRANSMISSION....1684
FRONT AXLE....1689
REAR AXLE....1692
HYDRAULIC PUMP....1696
2-SPOOL CONTROL VALVE....1698
3-SPOOL CONTROL VALVE....1700
6-SPOOL CONTROL VALVE....1702
7-SPOOL CONTROL VALVE....1705
8-SPOOL CONTROL VALVE....1707
BRAKE PUMP....1708
SHOVEL CYLINDERS....1709
BACKHOE CYLINDERS....1710
FRONT WORKING EQUIPMENT....1714
SWING BRACKET....1716
BACKHOE WORKING EQUIPMENT....1718
WEBM004601 - Backhoe Loader WB140-2, WB150-2 Shop Manual....1721
COVER....1721
CONTENTS....1723
SAFETY....1727
FOREWORD....1729
HOW TO READ THE SHOP MANUAL....1730
HOISTING INSTRUCTIONS....1731
STANDARD TIGHTENING TORQUE....1732
COATING MATERI ALS....1734
ELECTRIC....1735
WEIGHT TABLE....1736
TABLE OF OIL AND COOLANT QUANTITIES....1737
CONVERSION TABLE....1739
10. STRUCTURE AND FUNCTION....1749
POWER TRAIN....1750
TRANSMISSION....1752
DRIVE SHAFTS....1757
CONTROL VALVE BLOCK....1759
FRONT AXLE....1760
REAR AXLE....1763
HYDRAULIC PUMP....1768
STEERING UNIT....1789
HYDRAULIC CIRCUIT (WB140-2)....1791
HYDRAULIC CIRCUIT (WB150-2)....1792
SHOVEL CONTROL VALVE....1794
BACKHOE CONTROL VALVE....1798
CLSS....1805
SOLENOID VALVE....1819
SAFETY VALVE....1820
BRAKE PUMP....1822
SHOVEL CYLINDERS....1823
BACKHOE CYLINDERS....1824
AIR-CONDITIONING UNIT....1827
HOW THE AIR CONDITIONING UNIT FUNCTIONS....1828
ELECTRICAL DIAGRAM....1829
ELECTRICAL DIAGRAM (AIR CONDITIONING)....1831
20. TESTING AND ADJUSTMENTS....1835
NORMAL OR STANDARD TECHNICAL DATA....1836
SPECIAL TOOLS....1860
MEASURING ENGINE SPEED....1861
ADJUSTING VALVE CLEARANCE....1862
MEASURING COMPRESSION PRESSURE....1863
TESTING AND ADJUSTING FUEL INJECTION TIMING....1864
CHECKING AND TIGHTENING THE FAN -BELT....1866
CHECKING AND TIGHTENING THE COMPRESSOR FAN -BELT....1867
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....1868
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....1870
AIR BLEEDING -RELEASING RESIDUAL PRESSURE....1871
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....1874
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)....1880
TESTING AND ADJUSTING OF UNLOADING VALVE....1881
CHECKING UNLOADING VALVE FUNCTIONALITY....1882
TESTING PRIORITY VALVE OPERATION....1883
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....1884
TESTING BRAKE SYSTEM....1885
CONTROL OF THE ENGINE SPEED UNDER LOAD....1887
TESTING PRESSURES IN THE POWER TRAIN GROUP....1889
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES....1891
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....1892
ANALYSIS OF CAUSES HYDRAULIC DRIFT....1893
TESTING THE AIR -CONDITIONING UNIT....1898
EMPTYING THE AIR-CONDITIONING UNIT....1900
TROUBLESHOOTING....1901
FRONT AXLE TROUBLESHOOTING....1902
REAR AXLE TROUBLESHOOTING....1907
TRANSMISSION TROUBLESHOOTING....1912
30. REMOVAL AND INSTALLATION....1917
HOW TO READ THE MANUAL....1919
PRECAUTIONS TO BE TAKEN WHILE WORKING....1920
SPECIAL TOOLS....1921
STARTING MOTOR....1925
REMOVAL AND INSTALLATION....1925
ALTERNATOR....1926
REMOVAL....1926
INSTALLATION....1927
AIR-CONDITIONING UNIT COMPRESSOR....1928
REMOVAL....1928
INSTALLATION....1929
INJECTION PUMP....1930
REMOVAL....1930
INSTALLATION....1933
INJECTION NOZZLES....1934
REMOVAL AND INSTALLATION....1934
THERMOSTAT....1935
REMOVAL AND INSTALLATION....1935
COOLING LIQUID PUMP....1936
REMOVAL....1936
INSTALLATION....1937
TURBOCOMPRESSOR....1938
REMOVAL ....1938
INSTALLATION....1939
CYLINDER HEAD....1940
REMOVAL....1940
INSTALLATION....1942
ACCUMULATOR DISCONNECTING SWITCH....1944
REMOVAL AND INSTALLATION....1944
FRONT COUNTERWEIGHT....1945
REMOVAL AND INSTALLATION....1945
RADIATOR GROUP....1946
REMOVAL....1946
INSTALLATION....1948
CONDENSER....1949
REMOVAL AND INSTALLATION....1949
MUFFLER....1950
REMOVAL AND INSTALLATION....1950
EXHAUST PIPE....1951
REMOVAL AND INSTALLATION....1951
ENGINE HOOD....1952
REMOVAL....1952
INSTALLATION....1953
CAB....1954
REMOVAL....1954
INSTALLATION....1957
HEAT AND AIR-CONDITIONING GROUP....1958
REMOVAL....1958
INSTALLATION....1959
FUEL TANK....1960
REMOVAL AND INSTALLATION....1960
HYDRAULIC OIL TANK....1961
REMOVAL AND INSTALLATION....1961
ENGINE-GEARBOX-PUMP GROUP....1962
REMOVAL....1962
INSTALLATION....1967
PISTON PUMP....1968
REMOVAL....1968
INSTALLATION....1969
TRANSMISSION....1970
REMOVAL....1970
INSTALLATION....1973
DISASSEMBLY AND ASSEMBLY....1975
CONVERTOR....2053
REMOVAL AND INSTALLATION....2053
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2054
REMOVAL AND INSTALLATION....2054
STEERING UNIT....2055
REMOVAL AND INSTALLATION....2055
WORKING BRAKE PUMP GROUP....2056
REMOVAL AND INSTALLATION....2056
FRONT WORKING EQUIPMENT CONTROL VALVE....2057
REMOVAL AND INSTALLATION....2057
FRONT AND BACKHOE CONTROL VALVE....2058
DISASSEMBLY AND ASSEMBLY....2058
FRONT AXLE....2072
REMOVAL....2072
INSTALLATION....2073
DISASSEMBLY....2074
ASSEMBLY....2083
REAR AXLE....2099
REMOVAL....2099
INSTALLATION....2100
DISASSEMBLY....2101
ASSEMBLY....2116
FRONT BUCKET BOOM-RAISING CYLINDER....2135
REMOVAL AND INSTALLATION....2135
FRONT BUCKET TILT CYLINDERS....2136
REMOVAL AND INSTALLATION....2136
FRONT BUCKET....2137
REMOVAL AND INSTALLATION....2137
FRONT WORKING EQUIPMENT....2138
REMOVAL....2138
INSTALLATION....2139
BACKHOE CONTROL VALVE....2140
REMOVAL....2140
INSTALLATION....2141
BACKHOE BOOM CYLINDER....2142
REMOVAL AND INSTALLATION....2142
BACKHOE ARM CYLINDER....2143
REMOVAL AND INSTALLATION....2143
TELESCOPIC ARM CYLINDER....2144
REMOVAL AND INSTALLATION....2144
BACKHOE BUCKET CYLINDER....2145
REMOVAL AND INSTALLATION....2145
OUTRIGGER CYLINDERS....2146
REMOVAL AND INSTALLATION....2146
BACKHOE SWING CYLINDERS....2147
REMOVAL AND INSTALLATION....2147
CYLINDERS....2148
DISASSEMBLY....2148
ASSEMBLY....2150
BOOM SWING CYLINDER....2153
DISASSEMBLY....2153
ASSEMBLY....2154
BOOM SAFETY CYLINDER....2156
REMOVAL AND INSTALLATION....2156
BACKHOE WORKING EQUIPMENT....2157
REMOVAL AND INSTALLATION....2157
BACKHOE BUCKET....2158
REMOVAL AND INSTALLATION....2158
ARM....2159
REMOVAL AND INSTALLATION....2159
TELESCOPIC ARM....2160
REMOVAL AND INSTALLATION....2160
2nd ARM....2161
REMOVAL AND INSTALLATION....2161
2nd ARM GUIDES....2162
REMOVAL AND INSTALLATION....2162
BACKHOE BOOM....2163
REMOVAL AND INSTALLATION....2163
BACKHOE SWING BRACKET....2164
REMOVAL AND INSTALLATION....2164
BACKHOE OUTRIGGERS....2165
REMOVAL....2165
INSTALLATION....2166
40. STANDARD MAINTENANCE....2169
TRANSMISSION....2170
FRONT AXLE....2175
REAR AXLE....2178
HYDRAULIC PUMP....2182
2-SPOOL CONTROL VALVE....2184
3-SPOOL CONTROL VALVE....2186
6-SPOOL CONTROL VALVE....2188
7-SPOOL CONTROL VALVE....2191
8-SPOOL CONTROL VALVE....2193
BRAKE PUMP....2194
SHOVEL CYLINDERS....2195
BACKHOE CYLINDERS....2196
FRONT WORKING EQUIPMENT....2200
SWING BRACKET....2202
BACKHOE WORKING EQUIPMENT....2204
Komatsu Backhoe Loader WB140, WB150 Repair Service Manual
