Komatsu Backhoe Loader WB142 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB142, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB142 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.
CEAM018501 - Backhoe Loader WB142-5 Operation & Maintenance Manual.pdf
CEAM018502 - Backhoe Loader WB142-5 Operation & Maintenance Manual.pdf
CEBM018903 - Backhoe Loader WB142-5 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 912 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM018501 - Backhoe Loader WB142-5 Operation & Maintenance Manual...1
COVER...1
INTRODUCTION...3
FOREWORD...4
SAFETY INFORMATION...5
APPROVED AND NON-APPROVED USES...6
NON-APPROVED...6
PRODUCT INFORMATION...7
MAIN FEATURES...7
BREAK-IN PERIOD...7
SYNTHETIC BIODEGRADABLE OIL TYPES...7
PRODUCT IDENTIFICATION...8
MACHINE SERIAL NUMBER...8
MACHINE IDENTIFICATION PLATE...8
ENGINE SERIAL NUMBER AND EMISSION LABEL...9
FRONT AXLE SERIAL NUMBER...9
REAR AXLE SERIAL NUMBER...9
TRANSMISSION SERIAL NUMBER...10
CANOPY SERIAL NUMBER...10
SERIAL NUMBERS AND DEALER INFORMATION...11
MODEL: WB142-5...11
CONTENTS...12
SAFETY...21
SAFETY AND WARNING DECALS...22
LOCATION OF THE SAFETY DECALS...24
WORK ZONE...24
ROTATING PARTS...24
HYDRAULIC OIL...24
BLOCK WHEELS...24
BEFORE MOVING MACHINE...25
BEFORE STANDING UP FROM OPERATOR’S SEAT...25
WHILE ENGINE IS RUNNING...26
ALWAYS USE SEAT BELT...26
MACHINE OPERATION...26
IMPROPER OPERATION AND MAINTENANCE...26
DO NOT WELD ONTO ROPS...27
BOOM LOCK...27
ELECTROCUTION HAZARD...27
CRUSH HAZARD: KEEP CLEAR...28
PINCH POINT...28
INCORRECT STARTING PROCEDURES...28
BRAKE PEDAL CONNECTOR...28
4 WHEEL DRIVE...29
HYDRAULIC OIL...29
HYDRAULIC OIL LEVEL...29
HYDRAULIC OIL FILTER...29
FUEL...29
FUEL FILTER...30
ENGINE LUBRICATION OIL FILTER...30
ENGINE AIR FILTER...30
ENGINE COOLANT...30
COOLANT PRESSURE CAP...30
TRANSMISSION OIL LEVEL...31
TRANSMISSION OIL FILTER...31
POWER OUTLET...31
BOOM LOCK...31
SWING LOCK...31
ANCHORAGE POINT...32
EMERGENCY EXIT...32
BRAKE OIL...32
DO NOT LIFT WARNING...32
GENERAL SAFETY RULES AND PRECAUTIONS...33
GENERAL SAFETY RULES...33
UNAUTHORIZED MODIFICATIONS...34
GENERAL SAFETY AT JOB SITE...34
WORKING ON LOOSE GROUND...34
SAFETY FEATURES...35
PERSONAL PROTECTIVE EQUIPMENT...35
FIRE AND EXPLOSION PREVENTION...36
FIRE CAUSED BY FUEL OR OIL...36
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...36
FIRE FROM ELECTRICAL SYSTEM...37
FIRE FROM HYDRAULIC LINE...37
ACTION IF FIRE OCCURS...37
ASBESTOS DUST HAZARD PREVENTION...37
KEEP OPERATOR'S CAB CLEAN...37
UNAUTHORIZED MODIFICATIONS...38
LEAVING OPERATOR’S COMPARTMENT...39
MOUNTING AND DISMOUNTING...40
CRUSH OR PINCH POINT DANGERS...40
FIRE EXTINGUISHER AND FIRST AID KIT...41
INSIDE OPERATOR’S COMPARTMENT...41
PRECAUTIONS WHEN USING ROPS...42
PRECAUTIONS FOR ATTACHMENTS...42
QUICK COUPLER ATTACHMENT...42
LARGE ATTACHMENTS...42
PRECAUTIONS BEFORE STARTING OPERATIONS...43
PRE-OPERATIONAL CHECKS...43
STARTING YOUR WORK OPERATIONS...43
WORK SITE HAZARDS...43
AVOIDING DANGEROUS SITUATIONS...44
WORKING CLEARANCES...46
HIGH VOLTAGE LINES...46
RULES FOR ROAD TRAVEL...47
PRECAUTIONS WHEN TRAVELING...47
RULES FOR TRAVELING IN REVERSE...49
TRAVELING ON ICY OR SNOW-COVERED SURFACES...49
WORKING ON LOOSE OR UNSTABLE GROUND...49
TRAVEL ON SLOPES...49
PARKING THE MACHINE...51
PRECAUTIONS DURING MAINTENANCE OPERATIONS...52
WARNING TAGS...52
EQUIPMENT STORAGE...52
WORKING UNDER THE MACHINE...53
USING DROP LAMPS...53
KEEPING THE MACHINE CLEAN...53
RUNNING THE MACHINE DURING MAINTENANCE...54
RULES FOR REFUELING THE MACHINE...54
COOLING SYSTEM PRECAUTIONS...54
BATTERY PRECAUTIONS...55
STARTING THE MACHINE...55
HIGH-PRESSURE HOSES...56
HANDLING HIGH-PRESSURE HOSES...56
PRECAUTION FOR HIGH FUEL PRESSURE...56
HIGH TEMPERATURES AREAS...56
ROTATING PARTS...57
DISPOSAL OF WASTE MATERIALS...57
INFLATING TIRES...57
ACCUMULATOR...58
CRITICAL PARTS...58
TRANSPORTING THE MACHINE...59
LOADING AND SECURING THE MACHINE...59
OPERATION...61
GENERAL VIEW OF MACHINE...62
FRONT VIEW OF MACHINE...62
REAR VIEW OF MACHINE...63
DESCRIPTION OF MACHINE OPERATION CONTROLS...64
CONTROL LOCATIONS...64
FRONT INSTRUMENT BEZEL AND CONTROLS...65
LOW FUEL ALERT LAMP...65
FOUR-WHEEL DRIVE (IN/OUT) INDICATOR...66
DIFFERENTIAL (LOCK/UNLOCK) INDICATOR...66
PARKING BRAKE ALERT LAMP...66
TRANSMISSION OIL TEMPERATURE ALERT...66
LEFT DIRECTION INDICATOR LAMP...67
RIGHT DIRECTION INDICATOR LAMP...67
LOW PRESSURE OR BRAKE FLUID ALERT...67
MAIN ALARM LAMP...67
HIGH BEAM INDICATOR LAMP...68
LOW BEAM INDICATOR LAMP...68
WORK LIGHTS ALERT LAMP...68
STEERING COLUMN SWITCHES...69
DIRECTIONAL CONTROL SWITCH (STANDARD)...69
MULTIFUNCTIONAL SWITCH...69
SIDE INSTRUMENT BEZEL AND CONTROLS...70
FUEL LEVEL GAUGE...71
ENGINE COOLANT TEMPERATURE GAUGE...71
TACHOMETER AND HOUR METER...72
HYDRAULIC OIL FILTER CLOG INDICATOR...72
ALTERNATOR ALERT...72
GLOW PLUGS PREHEAT INDICATION...73
ENGINE COOLANT TEMPERATURE ALERT...73
ENGINE OIL PRESSURE ALERT...73
AIR CLEANER RESTRICTION ALERT...73
AUDIBLE WARNING SYSTEM...74
BACKHOE SPEED CONTROL BUTTON...74
BACKHOE BOOM LOCK SWITCH...74
REAR HORN...74
HAZARD FLASHERS...75
PARKING LIGHTS AND LOW BEAM SWITCH...75
FOUR-WHEEL DRIVE SWITCH...75
ROTATING BEACON LAMP...75
FRONT WORK LIGHT SWITCH...76
REAR WORK LIGHT SWITCH...76
OPTIONAL EQUIPMENT SWITCHES...76
IGNITION SWITCH...76
FRONT END LOADER CONTROLS...77
LOADER DECLUTCH CONTROL BUTTON...77
DIFFERENTIAL LOCK BUTTON...77
FRONT END LOADER SPEED CONTROL BUTTON...78
BACKHOE CONTROLS...79
GEAR SHIFT LEVER CONTROLS...80
DECLUTCH BUTTON...80
CHANGING SPEED RANGES...80
DIRECTIONAL CONTROL LEVER...80
BRAKES, PARKING BRAKE, ACCELERATOR AND THROTTLE CONTROL...81
BRAKE PEDALS...81
PARKING BRAKE...81
ACCELERATOR PEDAL...82
HAND THROTTLE...82
SEAT...83
SEAT BELT...84
DOCUMENT STORAGE...84
GUARDS...85
DRIVER’S OVERHEAD GUARD...85
ENGINE HOOD...85
ELECTRICAL...86
SWITCHES AND EXTRA ACCESSORIES...86
BATTERY DISCONNECT...86
FUSES AND RELAYS...87
FUSE AND RELAY PANEL LOCATION...87
FUSE AND RELAY PANEL LAYOUT...88
OPERATING THE MACHINE...91
CHECKING THE FUEL SUPPLY...91
STARTING THE ENGINE...91
STARTING THE ENGINE IN COLD WEATHER...92
WARMING THE MACHINE UP...93
SHUTTING THE ENGINE DOWN...93
OPERATING THE FRONT END LOADER AND BACKHOE...94
PRE-OPERATIONAL CHECKS...94
PERFORM A WALK-AROUND CHECK OF YOUR MACHINE...94
UNDER THE HOOD...95
IN THE OPERATOR’S CANOPY...95
START-UP CHECKS...95
STARTING YOUR WORK OPERATIONS...96
AVOIDING DANGEROUS SITUATIONS...96
WORKING CLEARANCES...99
OPERATING THE FRONT END LOADER...100
CONTROL LEVER POSITIONS...101
PERFORMING LOADING OPERATIONS...102
ORGANIZING YOUR WORK AREA...102
LOADING HEAPED MATERIAL...102
LOADING A TRUCK BED OR TRAILER...104
WORKING ON SLOPES WITH A LOADED BUCKET...104
CHANGING THE FRONT BUCKET...105
OPERATING THE BACKHOE...106
POSITIONING THE MACHINE...106
UNLOCKING THE BACKHOE...106
ISO BACKHOE CONTROLS...109
KOMATSU BACKHOE CONTROLS...110
DIGGING METHODS...111
CHANGING THE BACKHOE BUCKET...112
ADJUSTING THE BUCKET...112
SAFETY LOCK USAGE...113
FRONT END LOADER CYLINDER LOCK...113
BACKHOE LOCKS...114
MOVING OR TRAVELING WITH THE MACHINE...116
TRAVELING...116
TRAVELING ON SLOPES...117
TRAVELING OR WORKING IN SWAMPY OR WET AREAS...118
PARKING THE MACHINE...119
FOR SHORT OR LONG PERIODS...119
PARKING ON AN INCLINE...120
TRANSPORTING THE MACHINE...121
LOADING AND SECURING THE MACHINE...121
EMERGENCY RECOVERY...122
HOW TO MOVE THE MACHINE...122
PRECAUTIONS DURING SEASONAL CHANGES...123
COLD SEASONS...123
FUEL AND LUBRICANTS...123
COOLANT...123
BATTERY...124
WARM SEASONS...124
BASIC TROUBLESHOOTING...125
THE BATTERY...125
SERVICING THE BATTERY...125
REMOVAL AND INSTALLATION...125
STARTING THE ENGINE WITH BOOSTER CABLE...126
ELECTRICAL CIRCUITS...128
HYDRAULIC SYSTEM...128
BRAKING SYSTEM...129
TRANSMISSION...129
ENGINE...130
MAINTENANCE...131
GUIDE TO MAINTENANCE...132
MAINTENANCE NOTES...133
ENGINE...134
ENGINE OIL...134
COOLANT...134
FUEL...134
HYDRAULIC SYSTEM...135
ELECTRICAL SYSTEM...135
LUBRICATION...135
PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...136
FUEL, COOLANT, AND LUBRICANTS...137
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE...137
GREASE...138
FUEL REMARKS...138
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS...139
LUBRICATION DIAGRAMS...140
GENERAL VIEW...140
PERIODIC REPLACEMENT OF COMPONENTS...141
CRITICAL PARTS FOR SAFETY...142
FUEL SUPPLY SYSTEM...142
DELIVERY / RETURN HYDRAULIC SYSTEM...142
LOADER AND BACKHOE HYDRAULIC SYSTEM...142
OPERATOR’S SAFETY...143
STANDARD TIGHTENING TORQUE...144
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...144
SPECIFIC TIGHTENING TORQUES...144
MAINTENANCE SCHEDULE...144
MAINTENANCE SCHEDULE CHART...145
CHECKS BEFORE STARTING...148
VARIOUS CHECKS...148
FUEL LEVEL...148
COOLANT LEVEL...149
ENGINE OIL LEVEL...149
HYDRAULIC OIL LEVEL...150
DRAINING WATER SEPARATOR...151
MAINTENANCE EVERY 10 HOURS OF OPERATION...152
LUBRICATING JOINTS (GREASE FITTINGS)...152
WORK EQUIPMENT LUBRICATION POINTS...153
FRONT LOADER LUBRICATION LOCATIONS...153
BACKHOE LUBRICATION LOCATIONS...154
MAINTENANCE AFTER FIRST 50 HOURS OF OPERATION...155
MAINTENANCE EVERY 50 HOURS OF OPERATION...156
CHECKING RADIATOR FLUID LEVEL...156
CHECKING BRAKE SYSTEM OIL LEVEL...156
LUBRICATING DRIVE SHAFTS...157
LUBRICATING FRONT AXLE JOINTS...158
CHECKING TIRE PRESSURE...158
CHECKING ELECTRICAL SYSTEM...159
MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...160
MAINTENANCE EVERY 250 HOURS OF OPERATION...161
CHECKING SERPENTINE BELT...161
CLEANING OUTSIDE OF RADIATOR...162
CHECKING BATTERY ELECTROLYTE...163
CHECKING FRONT AXLE OIL LEVELS...163
CHECKING REAR AXLE OIL LEVELS...164
TRANSMISSION OIL LEVEL...164
CHECKING WHEEL LUG NUT TORQUE...164
MAINTENANCE AFTER FIRST 500 HOURS OF OPERATION...165
MAINTENANCE EVERY 500 HOURS OF OPERATION...166
CHANGING ENGINE OIL...166
CHANGING ENGINE OIL FILTER...167
CHANGING FUEL FILTER...171
FUEL FILTER...171
BLEEDING THE CIRCUIT...171
DRAINING FUEL TANK...172
DRAINING HYDRAULIC OIL TANK...173
MAINTENANCE EVERY 1000 HOURS...174
CHANGING FRONT AXLE OIL...174
DIFFERENTIAL...174
PLANETARY...174
CHANGING THE REAR AXLE OIL...175
DIFFERENTIAL...175
PLANETARY...175
CHANGING TRANSMISSION OIL AND FILTER...176
CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE...177
MAINTENANCE EVERY 2000 HOURS OF OPERATION...178
CHANGING HYDRAULIC SYSTEM OIL FILTER...178
CHANGING COOLANT...181
CHANGING THE BRAKING SYSTEM OIL...182
CHECKING THE ALTERNATOR AND THE STARTER...183
CHANGING THE ALTERNATOR BELT...183
WHEN REQUIRED...184
CLEANING OR CHANGING THE ENGINE AIR FILTERS...184
BLEEDING BRAKE SYSTEM...186
CHECKING AND ADJUSTING FRONT WHEEL TOE-IN...187
CHECKING AND ADJUSTING PARKING BRAKE...188
CHECK...188
ADJUSTMENT...189
CHECKING THE BRAKING EFFICIENCY...189
CHECKING AND ADJUSTING BRAKE PEDAL STROKE...190
MAINTENANCE INTERVALS FOR DEMOLITION HAMMER USE...191
CHANGING HYDRAULIC OIL FILTER...191
CHANGING HYDRAULIC OIL...191
LONG TERM STORAGE...192
BEFORE STORAGE...192
DURING STORAGE...193
AFTER STORAGE...193
SPECIFICATIONS...195
SPECIFICATIONS...196
MACHINE DIMENSIONS AND WEIGHTS...196
BACKHOE ARM...197
MACHINE SYSTEMS SPECIFICATIONS...198
ENGINE...198
ELECTRICAL SYSTEM...198
SERVICE REFILL CAPACITIES...198
TRANSMISSION...199
TOTAL MASS...199
STANDARD BUCKET CAPACITY...199
LOADER...199
OPTIONAL ATTACHMENTS...201
AUTHORIZED OPTIONAL EQUIPMENT...202
BASIC PRECAUTIONS...202
OPTIONAL EQUIPMENT MEASUREMENTS FOR WB142-5...203
FRONT END LOADER...203
BACKHOE UNIT...203
DEMOLITION HAMMER...204
DESCRIPTION AND CONTROL...204
RULES FOR HAMMER USAGE...205
ALWAYS AVOID THE FOLLOWING USES:...206
INSTALLATION AND REMOVAL OF THE DEMOLITION HAMMER...208
INSTALLATION...208
REMOVAL...208
CONNECTING AND REMOVING THE JACK HAMMER...209
USING THE JACK HAMMER...209
CEAM018502 - Backhoe Loader WB142-5 Operation & Maintenance Manual...211
CEBM018903 - Backhoe Loader WB142-5 Shop Manual...421
COVER...421
CONTENTS...422
FOREWORD...423
SAFETY...429
SAFETY NOTICE...429
IMPORTANT SAFETY NOTICE...429
GENERAL PRECAUTIONS...429
PREPARATIONS FOR WORK...429
PRECAUTIONS DURING WORK...429
GENERAL...431
HOW TO READ THE SHOP MANUAL...432
VOLUMES...432
DISTRIBUTION AND UPDATING...432
FILING METHOD...432
REVISED EDITION MARK...432
REVISIONS...432
SYMBOLS...432
HOISTING INSTRUCTIONS...433
HOISTING...433
WIRE ROPES...433
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...434
COATING MATERIALS...436
STANDARD TIGHTENING TORQUE...438
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...438
TIGHTENING TORQUE OF HOSE NUTS...439
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...439
TIGHTENING TORQUE FOR FLARED NUTS...439
CONNECTING PUSH-PULL TYPE COUPLER...442
CONVERSION TABLES...445
METHOD OF USING THE CONVERSION TABLE...445
01 GENERAL...451
SPECIFICATION DRAWING...452
MACHINE SYSTEMS SPECIFICATIONS...452
BACKHOE ARM...453
ENGINE...454
ELECTRICAL SYSTEM...454
SERVICE REFILL CAPACITIES...454
TRANSMISSION...455
TOTAL MASS...455
STANDARD BUCKET CAPACITY...455
LOADER...455
TIRE PRESSURE...455
WEIGHT TABLE...456
FUEL, COOLANT, AND LUBRICANTS...457
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE...457
GREASE...458
FUEL AND ENGINE OIL REMARKS...458
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS...459
LUBRICATION DIAGRAMS...460
GENERAL VIEW...460
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...461
POWER TRAIN...463
SYSTEM OVERVIEW...463
DESCRIPTION...463
4 WHEEL DRIVE SYSTEM...464
TRANSMISSION COMPONENTS...465
CONVERTER AND TRANSMISSION CIRCUIT DIAGRAM...466
TRANSMISSION...467
CASE...467
TRANSMISSION INTERNAL VIEW...468
GEAR SHIFTER AND FILTERING SYSTEM...469
CLUTCH PACKS AND DRIVEN GEAR SET...470
CLUTCH PACK...470
DRIVEN GEAR SET...470
4 WHEEL DRIVE SHAFT...471
CONTROL VALVE BLOCK...473
TRANSMISSION CASE SPECIFICATIONS...474
TORQUE VALUES...474
INTERNAL SPECIFICATIONS...475
GEAR SHIFTER AND COMPONENTS SPECIFICATIONS...476
TORQUE VALUES...477
FRONT AXLE ASSEMBLY...478
DIFFERENTIAL...478
FINAL DRIVE END...479
STEERING CYLINDER...480
AXLE CARRIER SPECIFICATIONS...481
TORQUE VALUES...481
TORQUE VALUES...482
AXLE END SPECIFICATIONS...483
TORQUE VALUES...483
STEERING UNIT CYLINDER SPECIFICATIONS...484
TORQUE VALUES...484
REAR AXLE ASSEMBLY...485
DIFFERENTIAL...485
AXLE END...486
AXLE CARRIER SPECIFICATIONS...488
TORQUE VALUES...489
AXLE END SPECIFICATIONS...490
TORQUE VALUES...490
REAR BRAKES...491
BRAKE SPECIFICATIONS...492
TORQUE VALUES...492
DIFFERENTIAL LOCK...493
LOCK SPECIFICATIONS...494
TORQUE VALUES...494
HYDRAULIC SYSTEM...495
HYDRAULIC CIRCUIT DIAGRAM...495
HYDRAULIC PUMP...496
DESCRIPTION...497
OPERATION...497
LOADER 3 - SPOOL VALVE...498
(WITH FLOAT AND RETURN TO DIG)...498
LOADER SPOOL VIEW...499
BACKHOE CONTROL VALVE...500
(8 - SPOOL VALVE)...500
BACKHOE SPOOL VIEW...501
SOLENOID VALVE...504
(ST1 VALVE LOCK - DIFFERENTIAL LOCK - BACKHOE BOOM LOCK)...504
MASTER CYLINDER (BRAKES)...505
SPECIFICATIONS...505
LOADER CYLINDERS...506
ARM CYLINDERS...506
BUCKET CYLINDER...506
SPECIFICATIONS...506
ARM CYLINDER TOLERANCE...507
BUCKET CYLINDER TOLERANCE...507
TORQUE VALUES...507
BACKHOE CYLINDERS...508
BOOM cylinder...508
ARM cylinder...508
BUCKET SPECIFICATIONS...509
OUTRIGGER SPECIFICATIONS...509
BOOM SWING SPECIFICATIONS...510
SPECIFICATIONS...510
BOOM CYLINDER TOLERANCE...513
ARM CYLINDER TOLERANCE...513
BUCKET CYLINDER TOLERANCE...513
BOOM SWING CYLINDER TOLERANCE...514
TORQUE VALUES...514
PIN AND BUSHING CLEARANCES...516
LOADER WORK EQUIPMENT...516
BACKHOE WORK EQUIPMENT...519
20 STANDARD VALUE TABLES...525
STANDARD VALUE TABLE FOR ENGINE...526
STANDARD VALUE TABLE FOR CHASSIS...527
30 TESTING AND ADJUSTING...535
BLEED AIR FROM CIRCUITS...537
BLEED AIR FROM BRAKING CIRCUIT...537
RELEASING RESIDUAL PRESSURE...537
ACCELERATOR PEDAL AND THROTTLE LEVER...538
ACCELERATOR PEDAL TRAVEL...538
THROTTLE LEVER TRAVEL...539
BRAKE SYSTEM...540
CONTROL...540
ADJUSTMENT...540
CHECKS...541
LEAKAGE CHECKS...541
INDIVIDUAL PUMP CHECK...542
BRAKE ASSEMBLY LEAKAGE...543
PARKING BRAKE ADJUSTMENT...544
HYDRAULIC CIRCUIT...545
INTRODUCTION...545
3-SPOOL VALVE...546
7-SPOOL VALVE...546
MAIN RELIEF VALVE...547
SETTING (PRESSURE CUT-OFF)...547
PUMP P2 PRESSURE RELIEF VALVE CALIBRATION...547
SECONDARY VALVES SETTING...548
Calibration Values For 3-element Control Valve Secondary Valves...549
Calibration Values For 7 and 8-element Control Valve Secondary Valves...549
SETTING THE MAIN RELIEF AND REDUCING VALVES...550
SECONDARY VALVES AND P2 PUMP RELIEF VALVE...551
CHECKING LOAD SENSING SIGNAL (LS VALVE)...552
UNLOADING VALVE CALIBRATION...552
CHECKING COMPENSATED FLOW VALVE...553
OPERATION OF THE PRIORITY VALVE...554
TESTING AND SETTING STEERING SYSTEM PRESSURE...555
CONTROL...555
SETTING...555
CHECKING FOR LEAKS IN THE STEERING CYLINDERS...556
POWER TRAIN...557
CONVERTER OIL PRESSURE...557
CLUTCH ENGAGEMENT PRESSURE...557
CLUTCH FUNCTION...559
MACHINE PREPARATION...559
CONTROL...559
HYDRAULIC DRIFT...560
LOADER...560
BOOM CIRCUIT...560
BUCKET CIRCUIT...561
BACKHOE...562
BOOM CIRCUIT...562
ARM CIRCUIT...562
BUCKET CIRCUIT...563
OUTRIGGERS TESTING...564
40 TROUBLESHOOTING...565
POINTS TO REMEMBER WHEN TROUBLESHOOTING...566
SEQUENCE OF EVENTS IN TROUBLESHOOTING...568
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...569
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT...569
HANDLING ELECTRONIC CONTROL UNIT...574
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS...575
HOW TO READ ELECTRIC WIRE CODE...576
CLASSIFICATION BY COLOR AND CODE...578
POINTS TO REMEMBER WHEN LHANDLING HUYDRAULIC EQUIPMENT...579
CHECKS BEFORE TROUBLESHOOTING...581
TROUBLESHOOTING GUIDE...582
FRONT AXLE...582
REAR AXLE...587
TRANSMISSION...592
50 DISASSEMBLY AND ASSEMBLY...595
HOW TO USE THIS MANUAL...600
PRECAUTIONS WHEN CARRYING OUT AN OPERATION...602
SPECIAL TOOL LIST...604
CONNECTOR REPAIR PROCEDURES...606
ENGINE HOOD...613
REMOVAL...613
INSTALLATION...614
FRONT GUARD...615
REMOVAL...615
INSTALLATION...615
RADIATOR...616
REMOVAL...616
INSTALLATION...619
MUFFLER...620
REMOVAL...620
INSTALLATION...622
AIR FILTER...623
REMOVAL...623
INSTALLATION...623
EXHAUST STACK...624
REMOVAL...624
INSTALLATION...625
OPERATORS SEAT...626
REMOVAL...626
INSTALLATION...626
SIDE PANEL AND INSTRUMENT GROUP...627
LOWER ELECTRICAL GROUP...627
REMOVAL...627
INSTALLATION...628
DASH BEZEL AND COVER...629
REMOVAL...629
INSTALLATION...631
BATTERY...632
REMOVAL...632
INSTALLATION...633
FUEL TANK...634
REMOVAL...634
INSTALLATION...635
STEERING AND FRONT DASH ASSEMBLY...636
STEERING WHEEL...636
REMOVAL...636
INSTALLATION...637
FRONT DASH ASSEMBLY...638
REMOVAL...638
INSTALLATION...639
STEERING UNIT...640
REMOVAL...640
INSTALLATION...641
BRAKE SYSTEM...642
REMOVAL...642
INSTALLATION...644
BLEED AIR FROM BRAKING CIRCUIT...645
STEERING UNIT...646
REMOVAL...646
INSTALLATION...647
CANOPY...648
REMOVAL...648
INSTALLATION...655
HYDRAULIC OIL TANK...656
REMOVAL...656
INSTALLATION...661
HYDRAULIC PUMP...662
REMOVAL...662
INSTALLATION...663
TRANSMISSION...664
REMOVAL...664
INSTALLATION...668
TRANSMISSION OVERHAUL PROCEDURES...669
TORQUE CONVERTER...669
REMOVAL...669
INSTALLATION...669
PLUGS AND FILTERS...670
DISASSEMBLY...670
ASSEMBLY...674
PUMP...677
DISASSEMBLY...677
ASSEMBLY...679
OIL LINE...681
REMOVAL...681
ASSEMBLY...681
VALVE BODY...682
DISASSEMBLY...682
ASSEMBLY...690
4 WHEEL DRIVE SOLENOID VALVE...698
DISASSEMBLY...698
ASSEMBLY...700
TRANSMISSION HOUSING...702
DISASSEMBLY...702
ASSEMBLY...712
CLUTCH PACK (A) AND GEAR SHAFT (D)...722
DISASSEMBLY...722
Shaft A (Clutch Pack)...723
Gear Shaft D...730
Clutches And Disc Inspections...731
ASSEMBLY...732
Shaft (A) Clutch Pack...732
Gear Shaft D...740
CHECKING CLUTCH FUNCTION...741
GEAR SHAFTS (B) AND (C)...742
DISASSEMBLY...742
Gear Shaft (C)...743
Gear Shaft B...750
ASSEMBLY...751
Gear Shaft C...751
Gear Shaft B...758
GEAR SHAFT (E)...760
DISASSEMBLY...760
ASSEMBLY...764
SHIFTER TOWER AND FORKS...770
DISASSEMBLY...770
ASSEMBLY...773
BACKHOE CONTROL VALVE...776
REMOVAL...776
INSTALLATION...777
FRONT AXLE ASSEMBLY...778
REMOVAL...778
INSTALLATION...779
FRONT AXLE OVERHAUL PROCEDURES...780
STEERING CYLINDER ASSEMBLY...780
DISASSEMBLY...780
ASSEMBLY...781
Checking Toe-in...783
Camber Angle Adjustment...785
FRONT AXLE END PLANETARY ASSEMBLY...786
DISASSEMBLY...786
Removing The Planetary Gears (If Necessary)...787
ASSEMBLY...787
AXLE END HUB ASSEMBLY...796
DISASSEMBLY...796
ASSEMBLY...793
AXLE HOUSING...796
DISASSEMBLY...796
ASSEMBLY...798
DIFFERENTIAL...799
DISASSEMBLY...799
ASSEMBLY...801
Pinion Gear Contact Test...804
PINION...805
DISASSEMBLY...805
ASSEMBLY...808
CARRIER...812
DISASSEMBLY...812
ASSEMBLY...813
REAR AXLE ASSEMBLY...815
REMOVAL...815
INSTALLATION...817
REAR AXLE OVERHAUL PROCEDURES...818
PARKING BRAKE ASSEMBLY...818
DISASSEMBLY...818
ASSEMBLY...820
MAINTENANCE...822
Brake Pad Adjustment Procedure...822
Ball And Cam Replacement...823
Lining Replacement...823
Sleeve Seal Replacement...824
Replacing The Cable Attachment Bracket...824
SERVICE BRAKE ASSEMBLY...825
DISASSEMBLY...825
ASSEMBLY...830
REAR AXLE END PLANETARY ASSEMBLY...836
DISASSEMBLY...836
ASSEMBLY...841
DIFFERENTIAL...845
DISASSEMBLY...845
ASSEMBLY...847
Contact...849
Movements To Correct...850
DIFFERENTIAL LOCK...852
DISASSEMBLY...852
ASSEMBLY...855
CARRIER...858
DISASSEMBLY...858
ASSEMBLY...862
PINION...866
DISASSEMBLY...866
ASSEMBLY...868
FRONT LOADER CONTROL VALVE ASSEMBLY...872
REMOVAL...872
INSTALLATION...872
SOLENOID VALVE ASSEMBLY...873
REMOVAL...873
INSTALLATION...873
FRONT-END LOADER ASSEMBLY...874
LOADER BOOM CYLINDERS...874
REMOVAL...874
INSTALLATION...875
BLEED AIR FROM HYDRAULIC CYLINDERS...876
BUCKET CYLINDER AND MONO-LINK...877
REMOVAL...877
INSTALLATION...879
LOADER BUCKET...880
REMOVAL...880
INSTALLATION...880
LOADER BOOM ASSEMBLY...881
REMOVAL...881
INSTALLATION...883
BACKHOE ASSEMBLY...884
BUCKET CYLINDER...884
REMOVAL...884
INSTALLATION...885
ARM CYLINDER...886
REMOVAL...886
INSTALLATION...887
BOOM CYLINDER...888
REMOVAL...888
INSTALLATION...890
SWING CYLINDERS...891
REMOVAL...891
INSTALLATION...893
BOOM LOCK CYLINDER...894
REMOVAL...894
INSTALLATION...895
BACKHOE BUCKET...896
REMOVAL...896
INSTALLATION...896
BACKHOE ARM...897
REMOVAL...897
INSTALLATION...899
BACKHOE BOOM...900
REMOVAL...900
INSTALLATION...901
BACKHOE SWING FRAME...902
REMOVAL...902
INSTALLATION...902
OUTRIGGER CYLINDERS...903
REMOVAL...903
INSTALLATION...904
OUTRIGGER ARMS...905
REMOVAL...905
INSTALLATION...905
WORK EQUIPMENT CYLINDER OVERHAUL PROCEDURES...906
LOADER AND BACKHOE CYLINDERS...906
DISASSEMBLY...906
Arm Only...907
Boom Cylinder Rod Only...907
All Cylinders...907
Boom Gland Nut...907
ASSEMBLY...908
Boom Gland Only...908
All Cylinders...908
Assemble Piston...908
Boom Cylinder Only...908
Arm Cylinder Only...909
Boom Cylinder Only...909
All Cylinders...910
Final Assembly...910
SWING CYLINDERS...911
DISASSEMBLY...911
ASSEMBLY...0
Head...913
Piston...913
Assembling the complete Piston...914
Assembling the complete piston...914
Final Assembly...915
90 OTHERS...917
ELECTRICAL SCHEMATIC...919
CONNECTOR DESCRIPTION...919
SIDE INSTRUMENT PANEL...920
FRONT INSTRUMENT PANEL...921
FUSES, SWITCHES AND RELAYS...922
WIRE HARNESS...923
SWITCHES (1)...924
SWITCHES (2)...925
TRANSMISSION HARNESS...926
Komatsu Backhoe Loader WB142 Repair Service Manual
