Komatsu Backhoe Loader WB140PS, WB150PS Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB140PS-2, WB150PS-2, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB140PS-2, WB150PS-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.
CEBM009200 - Backhoe Loader Transmission WB140PS-2, WB150PS-2 Power-Shift Shop Manual.pdf
WEAM002201 - Backhoe Loader WB140PS-2, WB150PS-2 Operation & Maintenance Manual.pdf
WEAM002202 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Operation & Maintenance Manual.pdf
WEAM002203 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Operation & Maintenance Manual.pdf
WEBM002502 - Backhoe Loader WB140PS-2, WB150PS-2 Shop Manual.pdf
WEBM004300 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Shop Manual.pdf
WEBM004700 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,877 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEBM009200 - Backhoe Loader Transmission WB140PS-2, WB150PS-2 Power-Shift Shop Manual....1
COVER....1
INDEX....3
GENERAL INFORMATION....4
MANUAL USE....5
AGREEMENTS AND DEFINITIONS....7
GENERAL DESCRIPTION....10
GENERAL RECOMMENDATIONS FOR DISASSEMBLY AND ASSEMBLY OPERATIONS....11
SAFETY INSTRUCTIONS....13
GENERAL SAFETY RECOMMENDATIONS....14
SAFETY SYMBOLS....15
GENERAL PRECAUTIONS....16
GENERAL SPECIFICATIONS....18
FORESEEN USES....19
PRODUCT IDENTIFICATION....20
TECHNICAL FEATURES....21
SEALING COMPOUNDS AND ADHESIVES....25
MAIN POINTS NOMENCLATURE....29
FILLING AND CHECKS....33
SERVICE SCHEDULE....36
LUBRICATION/GREASING: GRADES AND APPLICATION RANGE....37
TIGHTENING TORQUES....38
HYDRAULIC COMPONENTS....41
TORQUE CONVERTER....45
OIL PUMP....47
MANIFOLD....48
ELECTRONIC GEAR MANAGEMENT....49
ELECTRIC CONNECTIONS....61
KINEMATIC SCHEME....63
POWER FLOW....64
DISASSEMBLY AND ASSEMBLY OPERATIONS....69
CONVERTER 2WS/4WS....70
PLUGS AND FILTERS 2WS/4WS....74
OIL PUMP 2WS/4WS....78
PIPES AND SENSORS 2WS/4WS....81
HYDRAULIC CONTROL VALVE 2WS/4WS....92
TRANSMISSION HOUSING 4WS....96
TRANSMISSION HOUSING 2WS....111
SHAFT A - D 2WS/4WS....127
SHAFT B 2WS/4WS....145
SHAFT C 2WS/4WS....156
SHAFT E 2WS/4WS....177
TROUBLESHOOTING....187
TROUBLESHOOTING....188
TROUBLESHOOTING OF TRANSMISSION....193
CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT....196
NUMERICAL ERROR....200
SPECIAL TOOLS....202
SPECIAL TOOLS....203
CEBM012801 - Backhoe Loader WB140PS-2N, WB150PS-2N Shop Manual....205
COVER....205
FOREWORD....206
CONTENTS....206
SAFETY....213
SAFETY NOTICE....213
IMPORTANT SAFETY NOTICE....213
GENERAL PRECAUTIONS....213
PREPARATIONS FOR WORK....213
PRECAUTIONS DURING WORK....213
GENERAL....215
HOW TO READ THE SHOP MANUAL....216
VOLUMES....216
DISTRIBUTION AND UPDATING....216
FILING METHOD....216
REVISED EDITION MARK....216
REVISIONS....216
SYMBOLS....216
HOISTING INSTRUCTIONS....217
HOISTING....217
WIRE ROPES....217
QUICK DISCONNECT COUPLER....218
TYPE 1....218
DISCONNECTION....218
CONNECTION....218
TYPE 2....219
DISCONNECTION....219
CONNECTION....219
TYPE 3....220
DISCONNECTION....220
CONNECTION....220
COATING MATERIALS....221
STANDARD TIGHTENING TORQUE....223
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....223
TIGHTENING TORQUE OF HOSE NUTS....224
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....224
TIGHTENING TORQUE FOR FLARED NUTS....224
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS....225
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS....225
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)....225
ELECTRIC WIRE CODE....226
CLASSIFICATION BY THICKNESS....226
CLASSIFICATION BY COLOR AND CODE....226
CONVERSION TABLES....227
METHOD OF USING THE CONVERSION TABLE....227
01 GENERAL....233
SPECIFICATIONS....234
WEIGHT TABLE....235
FUEL COOLANT AND LUBRICANTS....236
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....239
ENGINE MOUNTING....241
TIER I ENGINE....241
TIER II ENGINE....242
POWER TRAIN....243
DESCRIPTION....243
POWER FLOW....243
TRANSMISSION DIAGRAM....245
TRANSMISSION....247
COMPLETE ASSEMBLY....247
FORWARD REVERSE CLUTCH....250
2ND GEAR CLUTCH....250
1ST, 3RD AND 4TH GEAR CLUTCH....251
4WD SHAFT....251
CONTROL VALVE....252
FRONT AXLE....253
COMPLETE ASSEMBLY....253
DIFFERENTIAL....254
PLANETARY....255
REAR AXLE....256
COMPLETE ASSEMBLY....256
DIFFERENTIAL....257
PLANETARY....258
BRAKES....259
DIFFERENTIAL LOCK....260
HYDRAULIC PUMP....261
FUNCTION....265
STRUCTURE....265
OPERATION....266
PUMP OPERATION....266
CONTROL OF DELIVERY....266
PC VALVE, LS VALVE, SERVO PISTON....267
LS VALVE FUNCTION....267
OPERATION....268
PC VALVE FUNCTION....273
WORKING MODE SOLENOID VALVE....278
STEERING UNIT....280
TECHNICAL DATA....280
OPERATION....280
LOADER VALVE....281
2 SPOOL....281
3 SPOOL VALVE....283
BACKHOE CONTROL VALVE....285
MECHANICAL CONTROL....285
INLET SECTION VIEWS A-A AND B-B....286
ARM SECTION VIEW C-C....287
SWING SECTION VIEW D-D....288
LEFT OUTRIGGER SECTION VIEW E-E....289
RIGHT OUTRIGGER SECTION VIEW F-F....290
BUCKET SECTION VIEW G-G....291
BOOM SECTION VIEW H-H....292
OUTLET SECTION VIEW J-J....292
TELESCOPIC ARM SECTION VIEW K-K....293
HAMMER SECTION VIEW L-L....294
EXCAVATOR CONTROL....295
INLET SECTION VIEWS A-A AND B-B....296
ARM SECTION VIEW C-C....297
SWING SECTION VIEW D-D....298
LEFT OUTRIGGER SECTION VIEW E-E....299
RIGHT OUTRIGGER SECTION VIEW F-F....300
BUCKET SECTION VIEW G-G....301
BOOM SECTION VIEW H-H....302
OUTLET SECTION VIEW J-J....302
TELESCOPIC ARM SECTION VIEW K-K....303
HAMMER SECTION VIEW L-L....304
CLSS....305
CHARACTERISTICS....305
STRUCTURE....305
OPERATING PRINCIPLES....306
UNLOADING VALVE....308
FUNCTION....308
OPERATION....308
INTRODUCTION OF THE LS PRESSURE....311
OPERATION....311
DELIVERY COMPENSATION....312
INTRODUCTION....312
OPERATION....312
LIFD CONTROL SYSTEM....315
FUNCTION....315
OPERATION....315
LS DECOMPRESSION VALVE....316
DESCRIPTION....316
OPERATION....316
PRESSURE CUT OFF VALVE....317
DESCRIPTION....317
OPERATION....317
PRIORITY VALVE....318
FUNCTION....318
PPC JOYSTICK....319
LEFT VALVE....319
RIGHT VALVE....320
SOLENOID VALVE....321
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK....321
PPC SUPPLY VALVE - ST2....322
PPC TELESCOPIC ARM....323
PPC HAMMER....324
PPC ARM AND HAMMER....325
LOADER CYLINDERS....326
BOOM ARM....326
CHARACTERISTICS....326
BUCKET....327
CHARACTERISTICS....327
MP BUCKET....328
CHARACTERISTICS....328
BACKHOE CYLINDERS....329
BOOM....329
CHARACTERISTICS....329
ARM....330
CHARACTERISTICS....330
BUCKET....331
CHARACTERISTICS....331
TELESCOPIC ARM CYLINDER....332
CHARACTERISTICS....332
SWING....333
CHARACTERISTICS....333
OUTRIGGER....334
CHARACTERISTICS....334
BOOM LOCK CYLINDER....335
FRONT WORK EQUIPMENT....336
REAR WORK EQUIPMENT....338
AIR CONDITIONING....340
20 TESTING, ADJUSTING AND TROUBLESHOOTING....343
STANDARD VALUE TABLES FOR ENGINE....345
STANDARD VALUE TABLES FOR CHASSIS....346
WB140PS-2N....346
WB150PS-2N....356
SPECIAL TOOLS....366
ENGINE SPEED....367
TIER I ENGINE....367
TIER II ENGINE....367
VALVE CLEARANCE....368
TIER I ENGINE....368
ADJUSTING PROCEDURE....368
VALVE COVER INSTALLATION....368
TIER II ENGINE....369
ADJUSTING PROCEDURE....369
COMPRESSION PRESSURE....373
TIER I ENGINE....373
TIER II ENGINE....374
FUEL INJECTION TIMING....376
TIER I ENGINE....376
TIER II ENGINE....377
FAN BELT....380
TENSION CHECK....380
TENSION ADJUSTMENT....380
COMPRESSOR DRIVE BELT....381
CHECKING TENSION....381
TENSION ADJUSTMENT....381
ACCELERATOR PEDAL AND LEVER....382
ACCELERATOR PEDAL TRAVEL....382
ACCELERATOR LEVER TRAVEL....383
BRAKE PEDAL TRAVEL....384
TIER I ENGINE....384
MASTER CYLINDER ROD ADJUSTMENT....384
MICROSWITCHES ADJUSTMENT....384
CHECKING ADJUSTMENT....384
TIER II ENGINE....385
MASTER CYLINDER ROD....385
CHECKING ADJUSTMENT....385
BLEEDING AIR....386
HYDRAULIC PUMP....386
CYLINDERS....386
HYDRAULIC OIL TANK....387
HYDRAULIC OIL TANK PRESSURIZATION....387
WORK CIRCUITS....387
BRAKE CIRCUIT....387
CHECK BRAKE CIRCUIT....388
HYDRAULIC CIRCUIT....389
INTRODUCTION....389
LOADER CONTROL VALVES....390
BACKHOE CONTROLS STYLE VALVE....391
EXCAVATOR CONTROLS STYLE VALVE....392
MAIN RELIEF VALVES....393
TESTING....393
LOADER CONTROL VALVE (2 OR 3 SPOOL)....393
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)....393
SETTING RELIEF PRESSURE....393
LOADER CIRCUIT RELIEF VALVES....395
TESTING PRESSURE....395
SETTING PRESSURE....396
BACKHOE CIRCUIT RELIEF VALVES....397
TESTING PRESSURE....397
SETTING PRESSURE....398
UNLOADING VALVE....399
TESTING....399
ADJUSTMENT....399
LOAD SENSING (LS) VALVE....400
TESTING....400
ADJUSTMENT....400
FLOW VALVE....401
PRIORITY VALVE....402
TESTING....402
CLEANING PRIORITY VALVE....402
STEERING SYSTEM....403
TESTING....403
SETTING....403
BRAKE SYSTEM....404
CIRCUIT AND BRAKE PUMP TEST....404
BRAKING GROUP LEAK TEST....405
ENGINE SPEED UNDER LOAD....406
PREPARING THE MACHINE....406
TORQUE CONVERTER STALL....406
TORQUE CONVERTER AND HYDRAULIC STALL....407
POWER TRAIN GROUP....408
PREPARING THE MACHINE....408
CONVERTER OIL PRESSURE....408
CLUTCH PRESSURE....408
TRANSMISSION CLUTCHES....410
PREPARATION OF THE MACHINE....410
TESTING....410
RETURN TO DIG DEVICE....411
HYDRAULIC DRIFT....412
LOADER....412
LIFT CYLINDER....412
BUCKET CYLINDER....413
BACKHOE....414
BOOM CYLINDER....414
ARM CYLINDER....414
BUCKET CYLINDER....415
OUTRIGGER TESTING....416
AIR CONDITIONING UNIT....417
TESTING THE WORKING TEMPERATURE....417
CHECKING THE UNIT....417
EMPTYING THE AC UNIT....418
TROUBLESHOOTING GUIDE....419
FRONT AXLE....419
REAR AXLE....424
TRANSMISSION....429
30 REMOVAL AND INSTALLATION....433
METHOD OF USING THIS MANUAL....435
PARTS OR ASSEMBLIES....435
PRECAUTIONS DURING SERVICE OPERATIONS....436
REMOVAL PRECAUTIONS....436
INSTALLATION PRECAUTIONS....436
SPECIAL TOOLS....437
LISTING....437
SKETCHES....440
ENGINE COMPONENTS....443
LOADER CYLINDER LOCK....444
LOCKING PROCEDURES....444
STARTER....445
REMOVAL....445
INSTALLATION....445
ALTERNATOR....446
REMOVAL....446
INSTALLATION....446
AC COMPRESSOR....447
REMOVAL....447
INSTALLATION....448
INJECTION PUMP....449
TIER I ENGINE....449
TIER II ENGINE....452
VALVE COVER....455
TIER I ENGINE....455
TIER II ENGINE....455
INJECTION NOZZLE....458
TIER I ENGINE....458
TIER II ENGINE....459
THERMOSTAT....461
TIER I ENGINE....461
TIER II ENGINE....462
COOLANT PUMP....463
TIER I ENGINE....463
TIER II ENGINE....465
TURBOCHARGER....468
REMOVAL....468
INSTALLATION....470
CYLINDER HEAD....471
TIER I ENGINE....471
TIER II ENGINE....475
BATTERY DISCONNECT SWITCH....480
REMOVAL....480
INSTALLATION....480
COUNTERWEIGHT....481
REMOVAL....481
INSTALLATION....481
90 OTHER....759
HYDRAULIC CIRCUIT....761
BACKHOE STYLE CONTROLS FOR WB140PS-2N (1 OF 2)....761
BACKHOE STYLE CONTROLS FOR WB140PS-2N (2 OF 2)....762
BACKHOE STYLE CONTROLS FOR WB150PS-2N (1 OF 2)....763
BACKHOE STYLE CONTROLS FOR WB150PS-2N (2 OF 2)....764
EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (1 OF 3)....765
EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (2 OF 3)....766
EXCAVATOR STYLE CONTROLS FOR WB140PS-2N (3 OF 3)....767
EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (1 OF 3)....768
EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (2 OF 3)....769
EXCAVATOR STYLE CONTROLS FOR WB150PS-2N (3 OF 3)....770
ELECTRICAL CIRCUIT....771
CAB WIRING SCHEMATIC (1 OF 5)....771
CAB WIRING SCHEMATIC (2 OF 5)....772
CAB WIRING SCHEMATIC (3 OF 5)....773
CAB WIRING SCHEMATIC (4 OF 5)....774
CAB WIRING SCHEMATIC (5 OF 5)....775
LEGEND FOR CAB WIRING SCHEMATIC....776
CANOPY WIRING SCHEMATIC (1 OF 5)....777
CANOPY WIRING SCHEMATIC (2 OF 5)....778
CANOPY WIRING SCHEMATIC (3 OF 5)....779
CANOPY WIRING SCHEMATIC (4 OF 5)....780
CANOPY WIRING SCHEMATIC (5 OF 5)....781
LEGEND FOR CANOPY WIRING SCHEMATIC....782
TIER I ENGINE HARNESS....783
TIER II ENGINE HARNESS....784
LEGEND FOR TIER I AND II ENGINE HARNESS....785
FRONT HARNESS....786
LEGEND FOR FRONT HARNESS....787
LATERAL HARNESS AND SIDE DASHBOARD....788
TIER I ENGINE (1 OF 2)....788
TIER I ENGINE (2 OF 2)....789
LEGEND FOR TIER I ENGINE....790
TIER II ENGINE (1 OF 2)....791
TIER II ENGINE (2 OF 2)....792
LEGEND FOR TIER II ENGINE....793
PPC FRAME AND SIDE DASH BOARD HARNESS....794
FRAME HARNESS....794
SIDE DASH BOARD HARNESS....795
LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS....796
WORK LIGHT HARNESS....797
TRANSMISSION HARNESS....798
LEGEND FOR TRANSMISSION HARNESS....799
FUSE AND RELAY PANEL....800
LEGEND FOR FUSE AND RELAY PANEL....800
WEAM002201 - Backhoe Loader WB140PS-2, WB150PS-2 Operation & Maintenance Manual....801
COVER....801
TABLE OF CONTENTS....802
FOREWORD....810
INFROMATION ON SAFETY....811
INTRODUCTION....813
INTENDED USES....813
IMPROPER OR UNAUTHORIZED USES....813
MAIN CHARACTERISTICS....814
RUNNING-IN....814
PRODUCT IDENTIFICATION....815
MACHINE SERIAL NUMBER ....815
MACHINE IDENTIFICATION PLATE....815
ENGINE SERIAL NUMBER AND EMISSION LABLE....816
FRONT AXLE SERIAL NUMBER ....816
REAR AXLE SERIAL NUMBER....816
TRANSMISSION SERIAL NUMBER ....817
CAB SERIAL NUMBER....817
CANOPY SERIAL NUMBER....817
SERIAL NUMBER AND DEALER'S ADDRESS....818
SAFETY AND ACCIDENT PREVENTION....820
1. GENERAL PRECAUTIONS....821
1.1 GENERAL SAFETY RULES....821
1.2 SAFETY DEVICES AND GUARDS....821
1.3 CLOTHING AND PERSONAL PROTECTION....821
1.4 UNAUTHORIZED MODIFICATIONS....822
1.5 LEAVING THE OPERATOR'S SEAT....822
1.6 GETTING ON AND OFF THE MACHINE....823
1.7 CHECKING THE REAR-VIEW MIRROR....823
1.8 PREVENTING FIRES DUE TO FUEL AND OIL....824
1.9 PREVENTING BURNS....824
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....825
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....825
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT....826
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....826
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT....826
PRECAUTIONS....828
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....829
2.1 SAFETY ON THE WORK SITE....829
2.2 FIRE PREVENTIONS....829
2.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....829
2.4 ROOM VENTILATION....830
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS....830
3. PRECAUTIONS TO BE TAKEN WHEN WORKING....831
3.1 STARTING THE ENGINE....831
3.2 RULES FOR ROAD TRAVEL....831
3.3 CHECKS FOR TRAVELING IN REVERSE....832
3.4 MOVING THE MACHINE....833
3.5 WORKING ON SLOPES....833
3.6 PREVENTING ELECTROCUTION....834
3.7 VISIBILITY....835
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES....835
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....835
3.10 WORKING ON LOOSE GROUND....835
3.11 PARKING THE MACHINE....836
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES....837
4.1 LOADING AND UNLOADING....837
4.2 THE ROUTE....837
5. THE BATTERY....838
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....838
5.2 STARTING THE ENGINE WITH JUMP LEADS....839
6. PRECAUTIONS FOR EMERGENCY RECOVERY....840
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....841
7.1 WARNING PLATES....841
7.2 TOOLS....841
7.3 PERSONAL PRECAUTIONS....841
7.4 EQUIPMENT....842
7.5 WORKING UNDER THE MACHINE....842
7.6 KEEPING THE MACHINE CLEAN....842
7.7 RUNNING THE ENGINE DURING MAINTENANCE....843
7.8 RULES FOR REFUELING AND ADDING OIL....843
7.9 LEVEL OF COOLANT IN THE RADIATOR....843
7.10 USING LAMPS....844
7.11 PRECAUTIONS CONCERNING THE GEARSHIFT....844
7.12 BATTERY AND ALTERNATOR PRECAUTIONS....844
7.13 PRECAUTIONS CONCERNING THE STARTER....845
7.14 PRECAUTIONS REGARDING HIGH PRESSURE HOSES....845
7.15 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS....846
7.16 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURE AND PRESSURES....846
7.17 THE RADIATOR COOLING FAN AND FAN BELT....846
7.18 WASTE MATERIALS....847
7.19 PRECAUTIONS FOR INFLATING TIRES....847
7.20 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE....847
8. SAFETY PLATES....848
8.1 POSITION OF THE SAFETY PLATES....848
8.2 POSITION OF PICTOGRAMS....862
8.3 PICTOGRAMS AND RELEVANT MEANINGS....864
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....867
TECHNICAL SPECIFICATION....868
9. TECHNICAL DATA....869
9.1 STANDARD OVERALL DIMENSIONS....869
9.2 TECHNICAL CHARACTERISTICS OF WB140PC-2....870
9.3 TECHNICAL CHARACTERISTICS OF WB150PS-2....871
9.4 LIFTING CAPACITIES....872
9.4.1 SYMBOL TABLE....872
9.4.2 LIFTING CAPACITY WB140PS-2....873
9.4.3 LIFTING CAPACITY WB150PS-2....875
DESCRIPTION AND USE OF THE MACHINE....878
10. SAFETY LOCKS....879
10.1 FRONT LOADER LOCK....879
10.2 BACKHOE LOADERS....881
11. GENERAL VIEWS....882
11.1 FRONT GENERAL VIEW....882
11.2 BACKHOE GENERAL VIEW....883
11.3 CAB INSIDE GENERAL VIEW....884
12. INSTRUMENTS AND CONTROLS....885
12.1 FRONT INSTRUMENTS....885
12.2 SIDE INSTRUMENTS....888
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER....892
12.4 ELECTRICAL ACCESSORIES....893
12.5 MACHINE CONTROLS....894
13. FUSES AND RELAYS....914
13.1 EQUIPMENT FUSES AND RELAYS....914
13.2 ENGINE FUSES AND RELAYS....916
14. GUARDS, CAB AND DRIVER'S SEAT....918
14.1 ENGINE HOOD....918
14.2 CANOPY....918
14.3 CAB....919
14.4 VENTILATION AND HEATING....921
14.5 SEAT....922
14.6 SAFETY BELT....922
14.7 FIRE EXTINGUISHER....923
14.8 FIRST AID KIT....923
14.9 TECHNICAL DOCUMENTATION....923
14.10 ADDITIONAL TOOL CASE (IF PROVIDED)....923
15. USE OF THE MACHINE....924
15.1 CHECKS BEFORE STARTING THE ENGINE....924
15.1.1 VISUAL CHECKS....924
15.1.2 DAILY CHECKS....924
15.1.3 OPERATIONAL CHECKS....925
15.2 STARTING THE ENGINE....926
15.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATE (MORE THAN 0°C (32°F))....926
15.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES (UP TO -16°C (3°F))....927
15.2.3 STARTING THE ENGINE IN VERY COLD AREAS (UP TO -30°C (-22°F))....927
15.3 WARMING THE ENGINE....928
15.4 HEATING THE HYDRAULIC OIL....928
15.5 HOW TO MOVE THE MACHINE....929
15.5.1 LOCKING THE DIFFERENTIAL....930
15.5.2 ENGAGING THE FOUR-WHEEL DRIVE....930
15.5.3 WORKING ON SLOPES....931
15.5.4 MAXIMUM IMMERSION DEPTH....932
16. PARKING THE MACHINE....933
16.1 PARKING ON LEVEL GROUND....933
16.2 PARKING ON SLOPES....934
17. STOPPING THE ENGINE....935
18. TRANSPORTING THE MACHINE ON OTHER VEHICLES....936
18.1 LOADING AND UNLOADING THE MACHINE....936
18.2 TRANSPORT....937
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....938
19.1 FUEL AND LUBRICANTS....938
19.2 COOLANT....938
19.3 BATTERY....938
19.4 OTHER PRECAUTIONS....939
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....939
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....940
21. USING THE MACHINE AS A LOADER....941
21.1 BUCKET POSITION INDICATOR....941
21.2 ORGANIZING THE WORK AREA....941
21.2.1 LOADING HEAPED AND LEVEL MATERIAL....942
21.2.2 LOADING OPERATIONS ON SLOPES....942
21.3 CHANGING THE STANDARD FRONT BUCKET....943
22. USING THE MACHINE AS AN EXCAVATOR....944
22.1 POSTIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT....944
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....945
22.3 DIGGING METHOD....946
22.4 CHANGINE THE BACKHOE BUCKET....947
23. TROUBLESHOOTING....948
23.1 IF THE FUEL HAS BEEN COMPLETELY DEPLETED ....948
23.2 IF THE BATTERY IS DEPLETED....948
23.2.1 STARTING WITH BOOSTER CABLES....949
23.3 OTHER TROUBLES....950
23.3.1 ELECTRICAL CIRCUIT....950
23.3.2 HYDRAULIC SYSTEM....950
23.3.3 BRAKING SYSTEM....951
23.3.4 TORQUE CONVERTER SYSTEM....951
23.3.5 ENGINE....952
MAINTENANCE....954
24. GUIDE TO MAINTENANCE....955
25. MAINTENANCE NOTES....957
25.1 NOTES REGARDING THE ENGINE....957
25.1.1 ENGINE OIL....957
25.1.2 COOLANT....957
25.1.3 FUEL....958
25.2 NOTES REGARDING THE HYDRAULIC SYSTEM....958
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM....959
25.4 NOTES REGARDING LUBRICATION....959
25.5 PARTS THAT ARE SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....960
26. FUEL, COOLANT AND LUBRICANTS....961
26.1 LUBRICATION DIAGRAM....965
26.2 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)....966
26.3 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS)....967
26.4 LUBRICATION DIAGRAM (TELESCOPIC ARM)....968
27. NUT AND BOLT TIGHTENING TORQUES....969
27.1 STANDARD TIGHTENING TORQUES....969
27.2 SPECIFIC TIGHTENING TORQURE....969
28. MAINTENANCE PLAN....970
28.1 CHECKS BEFORE STARTING ....973
28.1.A VARIOUS CHECKS....973
28.1.B CHECKING THE FUEL LEVEL....973
28.1.C CHECKING THE COOLANT LEVEL....974
28.1.D CHECKING THE ENGINE OIL LEVEL....974
28.1.E CHECKING THE HYDRUALIC CIRCUIT OIL LEVEL....975
28.1.F LUBRICATING THE JOINTS....975
28.2 MAINTENANCE EVERY 50 HOURS OF OPERATION....978
28.2.A CHECKING THE RADIATOR LEVEL....978
28.2.B CHECKING THE BRAKING SYSTEM OIL LEVEL....978
28.2.C LUBRICATING THE PROPELLER SHAFTS....979
28.2.D LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING....980
28.2.E DRAINING THE WATER SEPARATOR....980
28.2.F CHECKING THE TIRE PRESSURE....981
28.2.G CHECKING THE ELECTRICAL SYSTEM....981
28.3 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....982
28.4 MAINTENANCE EVERY 250 HOURS OF OPERATION....982
28.4.A ADJUSTING THE FAN BELT TENSION....982
28.4.B CLEANING THE OUTSIDE OF THE RADIATORS....983
28.4.C CHECKING THE BATTERY ELECTROLYTE LEVEL....983
28.4.D CHECKING THE FRONT AXLE OIL LEVELS....984
28.4.E CHECKING THE REAR AXLE OIL LEVELS....984
28.4.F CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL....985
28.4.G CHECKING THE WHEEL NUT DRIVING TORQUE....985
28.5 MAINTENANCE EVERY 500 HOURS OF OPERATION....986
28.5.A CHANGING THE ENGINE OIL....986
28.5.B CHANGING THE ENGINE OIL FILTER....986
28.5.C CHANGING THE HYDRAULIC OIL FILTER....987
28.5.D CHANGING THE FUEL FILTER....988
28.5.E DRAINING THE FUEL TANK....989
28.6 MAINTENANCE EVERY 1000 HOURS OF OPERATION....990
28.6.A CHANGING THE FRONT AXLE OIL....990
28.6.B CHANGING THE REAR AXLE OIL....991
28.6.C CHANGING THE HYDRAULIC TRANSMISSION OIL....992
28.6.D CHANGING THE HYDRAULIC TRANSMISSION FILTER....993
28.6.E CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....993
28.7 MAINTENANCE EVERY 2000 HOURS OF OPERATION....994
28.7.A CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....994
28.7.B CHANGING THE COOLANT....996
28.7.C CHANGING THE BRAKING SYSTEM OIL....997
28.7.D CHECKING THE ALTERNATOR AND THE STARTER....997
28.8 WHEN REQUIRED....998
28.8.A CHECKING, CLEANING OR CHANGING THE AIR CLEANRER CARTRIDGE....998
28.8.B CHECKING AND CLEANING THE CAB AIR FILTER....999
28.8.C BLEEDING THE BRAKING CIRCUIT....1000
28.8.D WASHING THE COOLING CIRCUIT....1000
28.8.E CLEANING THE WATER SEPARATOR....1002
28.8.F CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN....1002
28.8.G CHECKING AND ADJUSTING THE PARKING BRAKE....1003
28.8.H CHECKING THE BRAKING EFFICIENCY....1004
28.8.J CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE....1005
28.8.K ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION....1005
29. LONG PERIODS OF INACTIVITY....1006
29.1 BEFORE THE PERIOD OF INACTIVITY....1006
29.2 AFTER THE PERIOD OF INACTIVITY....1006
AUTHORIZED OPTIONAL EQUIPMENT....1008
30. AUTHORIZED OPTIONAL EQUIPMENT....1009
30.1 PRECAUTIONS REGARDING SAFETY....1009
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB140PS-2....1010
30.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB150PS-3....1011
31. FRONT EQUIPMENT RAPID COUPLING DEVICES....1012
31.1 MANUAL CONTROL RAPID COUPLING....1012
31.2 HYDRAULIC CONTROL RAPID COUPLING FOR STANDARD BUCKET....1013
31.3 HYDRAULIC CONTROL RAPID COUPLING FOR MULTIPURPOSE BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....1013
32. MULTIPURPOSE BUCKET....1014
32.1 DESCRIPTION AND CONTROLS....1014
32.2 SAFETY DEVICES....1014
32.3 INSTALLING THE MULTIPURPOSE BUCKET....1015
32.4 USING THE MULTIPURPOSE BUCKET....1016
32.5 MAINTENANCE....1016
33. PALLET FORKS....1017
33.1 DESCRIPTION....1017
33.2 SAFETY DEVICES....1017
33.3 USING THE FORKS....1017
33.3.1 PREPARING THE PALLET FORKS FOR USE....1018
33.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS....1018
33.4 REMOVING THE FORKS....1019
33.5 INSTALLING THE FORKS....1019
33.6 MAINTENANCE....1019
34. BACKHOE TELESCOPIC ARM....1020
34.1 DESCRIPTION AND CONTROL....1020
34.2 SAFETY DEVICES....1020
34.3 USING THE TELESCOPIC ARM....1021
34.4 MAINTENANCE....1021
34.4.1 ADJUSTING THE GUIDE SLACK....1021
35. ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....1023
35.1 DESCRIPTION AND CONTROL....1023
35.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....1024
35.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER ....1028
35.3.1 INSTALLING THE HAMMER....1028
35.3.2 REMOVING THE HAMMER....1030
35.4 MAINTENANCE....1030
36. ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....1031
36.1 DESCRIPTION AND CONTROL....1031
36.2 INSTALLING AND CONNECTING THE EQUIPMENT....1031
36.3 MAINTENANCE....1032
37. ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET....1033
37.1 DESCRIPTION AND CONTROL....1033
37.2 INSTALLING THE CLAMSHELL BUCKET....1034
37.3 USING THE CLAMSHELL BUCKET....1035
37.4 MAINTENANCE....1035
38. ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER....1036
38.1 DESCRIPTION AND CONTROL....1036
38.2 CONNECTING AND REMOVING THE HAMMER....1037
38.2.1 CONNECTING THE HAMMER....1037
38.2.2 REMOVING THE CONNECTIONS....1037
38.3 USING THE HAMMER....1038
38.4 MAINTENANCE....1038
39. LOAD STABILIZER SYSTEM (LSS) (OPTIONAL)....1039
39.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)....1039
40. AIR CONDITIONER (OPTIONAL)....1040
WEAM002202 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Operation & Maintenance Manual....1042
COVER....1042
TABLE OF CONTENTS....1043
FOREWORD....1051
INFORMATION ON SAFETY....1052
INTRODUCTION....1054
Intended Uses....1054
Improper or Unauthrozied Uses....1054
Main Characteristics....1055
Running-In....1055
Product Identification....1056
Machine Serial Number....1056
Machine Identification Plate....1056
Engine Serial Number and Emission Label....1057
Front Axle Serial Number....1057
Rear Axle Serial Number....1057
Transmission Serial Number....1058
Cab Serial Number....1058
Canopy Serial Number....1058
Serial Numbers and Dealer's Address....1059
SAFETY AND ACCIDENT PREVENTION....1061
1. General Precautions....1062
1.1 General Safety Rules....1062
1.2 Safety Devices and Guards....1062
1.3 Clothing and Personal Protection Items....1062
1.4 Unauthorized Modifications....1063
1.5 Leaving the Operator's Seat....1063
1.6 Getting On and Off the Machine....1064
1.7 Checking the Rear-View Mirror....1064
1.8 Preventing Fires Due to Fuel and Oil....1065
1.9 Preventing Burns....1065
1.10 Preventing Damage Due to Asbestos Powder....1066
1.11 Preventing Damage Caused by the Work Equipment....1066
1.12 Fire Extinguishers and First Aid Kit....1067
1.13 Precautions Concerning the Cab Structure....1067
1.14 Precautions Concerning the Equipment....1067
PRECAUTIONS....1069
2. Precautions to be Taken Before Starting the Engine....1070
2.1 Safety on the Work Site....1070
2.2 Fire Prevention....1070
2.3 Precautions to be Taken for the Operator's Cab....1070
2.4 Room Ventilation....1071
2.5 Cleaning Windows, Mirrors and Lights - Checking the Windshield Wiper Blades and the Bulbs....1071
3. Precautions to be Taken When Working....1072
3.1 Starting the Engine....1072
3.2 Rules for Road Travel....1072
3.3 Checks for Traveling in Reverse....1073
3.4 Moving the Machine....1074
3.5 Working on Slopes....1074
3.6 Preventing Electrocution....1075
3.7 Visibility....1076
3.8 Working on Icy or Snow-covered Surfaces....1076
3.9 Preventing Damage Caused by the Work Equipment....1076
3.10 Working of Loose Ground....1076
3.11 Parking the Machine....1077
4. Transporting the Machine on Other Vehicles....1078
4.1 Loading and Unloading....1078
4.2 The Route....1078
5. The Battery....1079
5.1 Safety Precautions for Work on Batteries....1079
5.2 Starting the Engine with Jump Leads....1080
6. Precautions for Emergency Recovery....1081
7. Precautions to be Taken During Maintenance....1082
7.1 Warning Plates....1082
7.2 Tools....1082
7.3 Personal Precautions....1082
7.4 Equipment....1083
7.5 Working Under the Machine....1083
7.6 Keeping the Machine Clean....1083
7.7 Running the Engine During Maintenance....1084
7.8 Periodical Change of the Parts That Are Critical for Safety....1084
7.9 Rules for Refueling and Adding Oil....1085
7.10 Level of Coolant in the Radiator....1085
7.11 Using Lamps....1085
7.12 Precautions Concerning the Gearshift....1086
7.13 Battery and Alternator Precautions....1086
7.14 Precautions Concerning the Starter....1087
7.15 Precautions Regarding High Pressure Hoses....1087
7.16 Precautions to be Taken When Working on High Pressure Systems....1088
7.17 Precautions for Maintenance Work Involving High Temperatures and Pressures....1088
7.18 The Radiator Cooling Fan and Fan Belt....1088
7.19 Waste Materials....1089
7.20 Precautions for Inflating Tires....1089
7.21 Precautions for the Installation of the Exhaust System Tailpipe....1089
7.22 Precautions for the Use of the Synthetic Biodegradable Oil Type HEES....1090
8. Safety Plates....1091
8.1 Position of the Safety Plates....1091
8.2 Position of the Pictograms....1105
8.3 Pictograms and Relevant Meanings....1107
8.4 Vibrations to Which the Operator is Subjected....1110
TECHNICAL SPECIFICATIONS....1111
9. Technical Data....1112
9.1 Standard Overall Dimensions....1112
9.2 Techical Characteristics WB140PS-2....1113
9.3 Technical Characteristics WB150PS-2....1114
9.4 Lifting Capacities....1115
9.4.1 Symbol Table....1115
9.4.2 Lifting Capacity WB140PS-2....1116
9.4.3 Lifting Capacity WB150PS-2....1118
DESCRIPTION AND USE OF THE MACHINE....1121
10. Safety Locks....1122
10.1 Front Loader Lock....1122
10.2 Backhoe Locks....1124
11. General Views....1125
11.1 Front General View....1125
11.2 Backhoe General View....1126
11.3 Cab Inside General View....1127
12. Instruments and Controls....1128
12.1 Front Instruments....1128
12.2 Side Instruments....1131
12.3 Push Buttons on the Front Loader Control Lever....1135
12.4 Electrical Accessories....1136
12.5 Machine Controls....1137
13. Fuses and Relays....1157
13.1 Equipment Fuses and Relays....1157
13.2 Engine Fuses and Relays....1159
14. Guards, Cab and Driver's Seat....1163
14.1 Engine Hood....1163
14.2 Canopy....1163
14.3 Cab....1164
14.4 Ventilation and Heating....1166
14.5 Seat....1167
14.6 Safety Belt....1167
14.7 Fire Extinguisher....1168
14.8 First Aid Kit....1168
14.9 Technical Documentation....1168
14.10 Additional Tool Case ( if provided )....1168
15. Use of the Machine....1169
15.1 Checks Before Starting the Engine....1169
15.1.1 Visual Checks....1169
15.1.2 Daily Checks....1169
15.1.3 Operational Checks....1170
15.2 Starting the Engine....1171
15.2.1 Starting with Warm Engine or in Temperate Climates ( more than 0 degrees centigrade / 32 degrees fahrenheit )....1171
15.2.2 Starting with Cold Engine or in Cold Climates ( up to -16 degrees centigrade / 3 degrees fahrenheit )....1172
15.2.3 Starting the Engine in Very Cold Areas ( up to -30 degrees centigrade / -22 degrees fahrenheit )....1172
15.3 Warming the Engine....1173
15.4 Heating the Hydraulic Oil....1173
15.5 How to Move the Machine....1174
15.5.1 Locking the Differential....1175
15.5.2 Engaging the Four-Wheel Drive....1175
15.5.3 Working on Slopes....1176
15.5.4 Maximum Immersion Depth....1177
16. Parking the Machine....1178
16.1 Parking on Level Ground....1178
16.2 Parking on Slopes....1179
17. Stopping the Machine....1180
18. Transporting the Machine on other Vehicles....1181
18.1 Loading and Unloading the Machine....1181
18.2 Transport....1182
19. Precautions to be Taken in the Cold Season....1183
19.1 Fuel and Lubricants....1183
19.2 Coolant....1183
19.3 Battery....1183
19.4 Other Precautions....1184
19.5 Precautions to be Taken at the End of Work....1184
20. Precautions to be Taken in the Warm Season....1185
21. Using the Machine as a Loader....1186
21.1 Bucket Position Indicator....1186
21.2 Organizing the Work Area....1186
21.2.1 Loading Heaped and Level Material....1187
21.2.2 Loading Operations on Slopes....1187
21.3 Changing the Standard Front Bucket....1188
22. Using the Machine as an Excavator....1189
22.1 Positioning the Bucket According to the Work that Must be Carried Out....1189
22.2 Positioning the Machine for Digging Operations....1190
22.3 Digging Method....1191
22.4 Changing the Backhoe Bucket....1192
23. Troubleshooting....1193
23.1 How to Remove the Machine....1193
23.2 If the Fuel has Been Completely Depleted....1193
23.3 If the Battery is Depleted....1194
23.3.1 Starting with Booster Cables....1195
23.4 Other Troubles....1196
23.4.1 Electrical Circuit....1196
23.4.2 Hydraulic System....1196
23.4.3 Braking System....1197
23.4.4 Torque Converter System....1197
23.4.5 Engine....1198
MAINTENANCE....1199
24. Guide to Maintenance....1200
25. Maintenance Notes....1202
25.1 Notes Regarding the Engine....1202
25.1.1 Engine Oil....1202
25.1.2 Coolant....1202
25.1.3 Fuel....1203
25.2 Notes Regarding the Hydraulic System....1203
25.3 Notes Regarding the Electrical System....1204
25.4 Notes Regarding the Lubrication....1204
25.5 Parts Subject to Wear that Periodically Need Changing....1205
26. Fuel, Coolant and Lubricants....1206
26.1 Homologated HEES Synthetic Biodegradable Lubricants....1210
26.2 Lubrication Diagram....1211
26.3 Lubrication Diagram ( multipurpose bucket and pallet forks )....1212
26.4 Lubrication Diagram ( front bucket rapid couplings )....1213
26.5 Lubrication Diagram ( telescopic arm )....1214
26.6 Periodical Change of the Components Connected with Safety....1215
26.6.1 Critical Parts for Safety....1216
27. Nut and Bolt Tightening Torques....1220
27.1 Standard Tightening Torques....1220
27.2 Specific Tightening Torques....1220
28. Maintenance Plan....1221
28.1 Checks Before Starting....1225
28.1.a Various Checks....1225
28.1.b Checking the Fuel Level....1225
28.1.c Checking the Coolant Level....1226
28.1.d Checking the Engine Oil Level....1226
28.1.e Checking the Hydraulic Circuit Oil Level....1227
28.1.f Draining the Water Separator....1228
28.2 Maintenance Every 10 Hours of Operation....1228
28.2.a Lubricating the Joints....1228
28.3 Maintenance After the First 50 Hours of Operation ( only for machines in which the synthetic biodegradable oil type HEES is used )....1231
28.3.a Change Hydraulic Oil Drain Filter....1242
28.4 Maintenance Every 50 Hours of Operation....1231
28.4.a Checking the Radiator Fluid Level....1231
28.4.b Checking the Braking System Oil Level....1231
28.4.c Lubricating the Propeller Shafts....1232
28.4.d Lubricating the Front Axle Joints Central Coupling....1233
28.4.e Checking the Tire Pressure....1233
28.4.f Checking the Electrical System....1234
28.5 Maintenance After the First 250 Hours of Operation....1235
28.5.a Change Front Axle Oil....1246
28.5.b Change Rear Axle Oil....1247
28.5.c Change Hydraulic Transmission Oil....1248
28.5.d Change Hydraulic Transmission Oil Filter....1249
28.5.e Checking and Adjusting Engine Valve Clearance....1249
28.5.f Changing Hydraulic Oil Drain....1242
28.6 Maintenance Every 250 Hours of Operation....1235
28.6.a Adjusting the Fan Belt Tension....1235
28.6.b Cleaning the Outside of the Radiators....1236
28.6.c Checking the Battery Electrolyte Level....1237
28.6.d Checking the Front Axle Oil Levels....1238
28.6.e Checking the Rear Axle Oil Levels....1238
28.6.f Checking the Hydraulic Transmission Oil Level....1239
28.6.g Checking the Wheel Nut Driving Torque....1239
28.7 Maintenance After the First 500 Hours of Operation ( Only for machines in which the synthetic biodegradable oil type HEES is used )....1240
28.7.a Changing Hydraulic Oil and Cleaning Suction Filter....1250
28.8 Maintenance Every 500 Hours of Operation....1240
28.8.a Changing the Engine Oil....1240
28.8.b Changing the Engine Oil Filter....1241
28.8.c Changing the Hydraulic System Oil Filter ....1242
28.8.d Changing the Fuel Filter....1243
28.8.e Draining the Fuel Tank....1244
28.8.f Draining the Hydraulic Oil Tank ( Only for machines in which the synthetic biodegradable oil type HEES is used )....1245
28.9 Maintenance Every 1000 Hours of Operation....1246
28.9.a Changing the Front Axle Oil....1246
28.9.b Changing the Rear Axle Oil....1247
28.9.c Changing the Hydraulic Transmission Oil....1248
28.9.d Changing the Hydraulic Transmission Filter....1249
28.9.e Checking and Adjusting the Engine Valve Clearance....1249
28.10 Maintenance Every 2000 Hours of Operation ....1250
28.10.a Changing the Hydraulic System Oil and Cleaning the Suction Filter....1250
28.10.b Changing the Coolant....1253
28.10.c Changing the Braking System Oil....1254
28.10.d Checking the Alternator and the Starter....1254
28.11 When Required....1255
28.11.a Checking, Cleaning or Changing the Air Cleaner Cartridge....1255
28.11.b Checking and Cleaning the Cab Air Filter....1256
28.11.c Bleeding the Braking Circuit....1257
28.11.d Washing the Cooling Circuit....1257
28.11.e Cleaning the Water Separator....1259
28.11.f Checking and Adjusting the Front Wheel Toe-In....1259
28.11.g Checking and Adjusting the Parking Brake....1260
28.11.h Checking the Braking Efficiency....1261
28.11.j Checking and Adjusting the Brake Pedal Stroke....1262
28.11.k Adjusting the Automatic Return of the Front Bucket to the Digging Position....1262
28.12 Maintenance Intervals in Case of Use of the Demolition Hammer....1263
28.12.a Changing the Hydraulic Oil Filter....1263
28.12.b Changing the Hydraulic Oil....1263
29. Long Periods of Inactivity....1264
29.1 Before the Period of Inactivity....1264
29.2 During the Period of Inactivity....1266
29.3 After the Period of Inactivity....1266
AUTHORIZED OPTIONAL EQUIPMENT....1267
30. Authorized Optional Equipment....1268
30.1 Precautions Regarding Safety....1268
30.2 Characteristics of the Optional Equipment for Model WB140PS-2....1269
30.3 Characteristics of the Optional Equipment for Model WB150PS-2....1270
31. Front Equipment Quick Coupling Devices....1271
31.1 Manual Control Quick Coupling....1271
31.2 Hydraulic Control Quick Coupling for Standard Bucket....1272
31.3 Hydraulic Control Quick Coupling for Multipurpose Bucket and Optional Equipment with Unidirectional Oil Flow....1272
32. Multipurpose Bucket....1273
32.1 Description and Controls....1273
32.2 Safety Devices....1273
32.3 Installing the Multipurpose Bucket....1274
32.4 Using the Multipurpose Bucket....1275
32.5 Maintenance....1275
33. Pallet Forks....1276
33.1 Description....1276
33.2 Safety Devices....1276
33.3 Using the Forks....1276
33.3.1 Preparing the Pallet Forks for Use....1277
33.3.2 Overturning the Forks for Travel on Roads....1277
33.4 Removing the Forks....1278
33.5 Installing the Forks....1278
33.6 Maintenance....1278
34. Backhoe Telescopic Arm....1279
34.1 Description and Control....1279
34.2 Safety Devices....1279
34.3 Using the Telescopic Arm....1280
34.4 Maintenance....1280
34.4.1 Adjusting the Guide Slack....1280
35. Arrangement for the Installation of the Demolition Hammer....1282
35.1 Description and Control....1282
35.2 Use of the Demolition Hammer and Rules to be Observed....1283
35.3 Installing and Removing the Demolition Hammer....1287
35.3.1 Installing the Hammer....1287
35.3.2 Removing the Hammer....1289
35.4 Maintenance....1289
36. Arrangement for the Operation of Optional Equipment with Unidirectional Oil Flow....1290
36.1 Description and Control....1290
36.2 Installing and Connecting the Equipment....1290
36.3 Maintenance....1291
37. Arrangement for the Installation of the Clamshell Bucket....1292
37.1 Description and Control....1292
37.2 Installing the Clamshell Bucket....1293
37.3 Using the Clamshell Bucket....1294
37.4 Maintenance....1294
38. Arrangement for the Installation of the Manual Hydraulic Hammer....1295
38.1 Description and Control....1295
38.2 Connecting and Removing the Hammer....1296
38.2.1 Connecting the Hammer....1296
38.2.2 Removing the Connections....1296
38.3 Using the Hammer....1297
38.4 Maintenance....1297
39. Load Stabilizer System ( LSS ) (Optional)....1298
39.1 Accumulator of the Load Stabilizer System ( LSS )....1298
40. Air Conditioner....1299
WEAM002203 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Operation & Maintenance Manual....1301
COVER....1301
TABLE OF CONTENTS....1302
FOREWORD....1310
INFORMATION ON SAFETY....1311
INTRODUCTION....1313
INTENDED USES....1313
IMPROPER OR UNAUTHORIZED USES....1313
MAIN CHARACTERISTICS....1314
RUNNING-IN....1314
PRODUCT IDENTIFICATION....1315
MACHINE SERIAL NUMBER....1315
MACHINE IDENTIFICATION PLATE....1315
ENGINE SERIAL NUMBER AND EMISSION LABEL....1316
FRONT AXLE SERIAL NUMBER....1316
REAR AXLE SERIAL NUMBER....1316
TRANSMISSION SERIAL NUMBER....1317
CAB SERIAL NUMBER....1317
CANOPY SERIAL NUMBER....1317
SERIAL NUMBERS AND DEALER'S ADDRESS....1318
SAFETY AND ACCIDENT PREVENTION....1320
1. GENERAL PRECAUTIONS....1321
1.1 GENERAL SAFETY RULES....1321
1.2 SAFETY DEVICES AND GUARDS....1321
1.3 CLOTHING AND PERSONAL PROTECTION ITEMS....1321
1.4 UNAUTHORIZED MODIFICATIONS....1322
1.5 LEAVING THE OPERATOR'S SEAT....1322
1.6 GETTING ON AND OFF THE MACHINE....1323
1.7 CHECKING THE REAR-VIEW MIRROR....1323
1.8 PREVENTING FIRES DUE TO FUEL AND OIL....1324
1.9 PREVENTING BURNS....1324
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....1325
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....1325
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT....1326
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....1326
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT....1326
PRECAUTIONS....1328
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....1329
2.1 SAFETY ON THE WORK SITE....1329
2.2 FIRE PREVENTION....1329
2.3 PRECAUTIOSN TO BE TAKEN FOR THE OPERATOR'S CAB....1329
2.4 ROOM VENTILATION....1330
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS- CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS....1330
3. PRECATUIONS TO BE TAKEN WHEN WORKING....1331
3.1 STARTING THE ENGINE....1331
3.2 RULES FOR ROAD TRAVEL....1331
3.3 CHECKS FOR TRAVELING IN REVERSE....1332
3.4 MOVING THE MACHINE....1333
3.5 WORKIGN ON SLOPES....1333
3.6 PREVENTING ELECTROCUTION....1334
3.7 VISIBILITY....1335
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES....1335
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....1335
3.10 WORKING ON LOOSE GROUND....1335
3.11 PARKING THE MACHINE....1336
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES....1337
4.1 LOADING AND UNLOADING....1337
4.2 THE ROUTE....1337
5. THE BATTERY....1338
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....1338
5.2 STARTING THE ENGINE WITH JUMP LEADS....1339
6. PRECAUTIONS FOR EMERGENCY RECOVERY....1340
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....1341
7.1 WARNING PLATES....1341
7.2 TOOLS....1341
7.3 PERSONAL PRECAUTIONS....1341
7.4 EQUIPMENT....1342
7.5 WORKING UNDER THE MACHINE....1342
7.6 KEEPING THE MACHINE CLEAN....1342
7.7 RUNNING THE ENGINE DURING MAINTENANCE....1343
7.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....1343
7.9 RULES FOR REFUELING AND ADDING OIL....1344
7.10 LEVEL OF COOLANT IN THE RADIATOR....1344
7.11 USING LAMPS....1344
7.12 PRECAUTIONS CONCERNING THE GEARSHIFT....1345
7.13 BATTERY AND ALTERNATOR PRECAUTIONS....1345
7.14 PRECAUTIONS CONCERNING THE STARTER....1346
7.15 PRECAUTIONS REGARDING HIGH PRESSURE HOSES....1346
7.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS....1347
7.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....1347
7.18 THE RADIATOR COOLING FAN AND FAN BELT....1347
7.19 WASTE MATERIALS....1348
7.20 PRECAUTIONS FOR INFLATING TIRES....1348
7.21 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE....1348
7.22 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....1349
8. SAFETY PLATES....1350
8.1 POSITION OF THE SAFETY PLATES....1350
8.2 POSITION OF THE PICTOGRAMS....1364
8.3 PICTOGRAMS AND RELEVANT MEANINGS....1366
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....1369
TECHNICAL SPECIFICATIONS....1370
9. TECHNICAL DATA....1371
9.1 STANDARD OVERALL DIMENSIONS....1371
9.2 TECHNICAL CHARACTERISTICS WB140PS-2....1372
9.3 TECHNICAL CHARACTERISTICS WB150PS-2....1373
9.4 LIFTING CAPACITIES....1374
9.4.1 SYMBOL TABLE....1374
9.4.2 LIFTING CAPACITY WB140PS-2....1375
9.4.3 LIFTING CAPACITY WB150PS-2....1377
THE MACHINE AND ITS OPERATIONS....1380
10. SAFETY LOCKS....1381
10.1 FRONT LOADER LOCK....1381
10.2 BACKHOE LOCKS....1383
11. GENERAL VIEWS....1384
11.1 FRONT GENERAL VIEW....1384
11.2 BACKHOE GENERAL VIEW....1385
11.3 CAB INSIDE GENERAL VIEW....1386
12. INSTRUMENTS AND CONTROLS....1387
12.1 FRONT INSTRUMENTS....1387
12.2 SIDE INSTRUMENTS....1390
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER....1394
12.4 ELECTRICAL ACCESSORIES....1395
12.5 MACHINE CONTROLS....1396
13. FUSES AND RELAYS....1416
13.1 EQUIPMENT FUSES AND RELAYS....1416
13.2 ENGINE FUSES AND RELAYS....1418
14. GUARDS, CAB AND DRIVER'S SEAT....1422
14.1 ENGINE HOOD....1422
14.2 CANOPY....1422
14.3 CAB....1423
14.4 VENTILATION AND HEATING....1425
14.5 SEAT....1426
14.6 SAFETY BELT....1426
14.7 FIRE EXTINGUISHER....1427
14.8 FIRST AID KIT....1427
14.9 TECHNICAL DOCUMENTATION....1427
14.10 ADDITIONAL TOOL CASE (IF PROVIDED)....1427
15. USE OF THE MACHINE....1428
15.1 CHECKS BEFORE STARTING THE ENGINE....1428
15.1.1 VISUAL CHECKS....1428
15.1.2 DAILY CHECKS....1428
15.1.3 OPERATIONAL CHECKS....1429
15.2 STARTING THE ENGINE....1430
15.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATRE CLIMATES....1430
15.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....1431
15.2.3 STARTING THE ENGINE IN VERY COLD AREAS....1431
15.3 WARMING THE ENGINE....1432
15.4 HEATING THE HYDRAULIC OIL....1432
15.5 HOW TO MOVE THE MACHINE....1433
15.5.1 LOCKING THE DIFFERENTIAL....1434
15.5.2 ENGAGING THE FOUR-WHEEL DRIVE....1434
15.5.3 WORKING ON SLOPES....1435
15.5.4 MAXIMUM IMMERSION DEPTH....1436
16. PARKING THE MACHINE....1437
16.1 PARKING ON LEVEL GROUND....1437
16.2 PARKING ON SLOPES....1438
17. STOPPING THE ENGINE....1439
18. TRANSPORTING THE MACHINE ON OTHER VEHICLES....1440
18.1 LOADING AND UNLOADING THE MACHINE....1440
18.2 TRANSPORT....1441
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....1442
19.1 FUEL AND LUBRICANTS....1442
19.2 COOLANT....1442
19.3 BATTERY....1442
19.4 OTHER PRECAUTIONS....1443
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....1443
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....1444
21. USING THE MACHINE AS A LOADER....1445
21.1 BUCKET POSITION INDICATOR....1445
21.2 ORGANIZING WORK AREA....1445
21.2.1 LOADING HEAPED AND LEVEL MATERIAL....1446
21.2.2 LOADING OPERATIONS ON SLOPES....1446
21.3 CHANGING THE STANDARD FRONT BUCKET....1447
22. USING THE MACHINE AS AN EXCAVATOR....1448
22.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT....1448
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS....1449
22.3 DIGGING METHOD....1450
22.4 CHANGING THE BACKHOE BUCKET....1451
23. TROUBLESHOOTING....1452
23.1 HOW TO REMOVE THE MACHINE....1452
23.2 IF THE FUEL HAS BEEN COMLETELY DEPLETED....1452
23.3 IF THE BATTERY IS DEPLETED....1453
23.3.1 STARTING WITH BOOSTER CABLES....1454
23.4 OTHER TROUBLES....1455
23.4.1 ELECTRICAL CIRCUIT....1455
23.4.2 HYDRAULIC SYSTEM....1455
23.4.3 BRAKING SYSTEM....1456
23.4.4 TORQUE CONVERTER SYSTEM....1456
23.4.5 ENGINE....1457
MAINTENANCE....1458
24. GUIDE TO MAINTENANCE....1459
25. MAINTENANCE NOTES....1461
25.1 NOTES REGARDING THE ENGINE....1461
25.1.1 ENGINE OIL....1461
25.1.2 COOLANT....1461
25.1.3 FUEL....1462
25.2 NOTES REGARDING THE HYDRAULIC SYSTEM....1462
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM....1463
25.4 NOTES REGARDING LUBRICATION....1463
25.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....1464
26. FUEL, COOLANT AND LUBRICANTS....1465
26.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS....1469
26.2 LUBRICATION DIAGRAM....1470
26.3 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)....1471
26.4 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS)....1472
26.5 LUBRICATION DIAGRAM (TELESCOPIC ARM)....1473
26.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....1474
26.6.1 CRITICAL PARTS FOR SAFETY....1475
27. NUT AND BOLT TIGHTENING TORQUES....1479
27.1 STANDARD TIGHTENING TORQUES....1479
27.2 SPECIFIC TIGHTENING TORQUES....1479
28. MAINTENANCE PLAN....1480
28.1 CHECK BEFORE STARTING....1484
28.1.a VARIOUS CHECKS....1484
28.1.b CHECKING THE FUEL LEVEL....1484
28.1.c CHECKING THE COOLANT LEVEL....1485
28.1.d CHECKING THE ENGINE OIL LEVEL....1485
28.1.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL....1486
28.1.f DRAINING THE WATER SEPERATOR....1487
28.2 MAINTENANCE EVERY 10 HOURS OF OPERATION....1487
28.2.a LUBRICATING THE JOINTS....1487
28.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....1490
28.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....1490
28.4.a CHECKING THE RADIATOR FLUID LEVEL....1490
28.4.b CHECKING THE BRAKING SYSTEM OIL LEVEL....1490
28.4.c LUBRICATING THE PROPELLER SHAFTS....1491
28.4.d LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING....1492
28.4.e CHECKING THE TIRE PRESSURE....1492
28.4.f CHECKING THE ELECTRICAL SYSTEM....1493
28.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....1494
28.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....1494
28.6.a ADJUSTING THE FAN BELT TENSION....1494
28.6.b CLEANING THE OUTSIDE OF TH RADIATORS....1495
28.6.c CHECKING THE BATTERY ELECTROLYTE LEVEL....1496
28.6.d CHECKING THE FRONT AXLE OIL LEVELS....1497
28.6.e CHECKING THE REAR AXLE OIL LEVELS....1497
28.6.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL....1498
28.6.g CHECKING THE WHEEL NUT DRIVING TORQUE....1498
28.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION....1499
28.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....1499
28.8.a CHANGING THE ENGINE OIL....1499
28.8.b CHANGING THE ENGINE OIL FILTER....1500
28.8.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER....1501
28.8.d CHANING THE FUEL FILTER....1502
28.8.e DRAINING THE FUEL TANK....1503
28.8.f DRAINING THE HYDRAULIC OIL TANK....1504
28.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....1505
28.9.a CHANGING THE FRONT AXLE OIL....1505
28.9.b CHANGING THE REAR AXLE OIL....1506
28.9.c CHANGING THE HYDRAULIC TRANSMISSION OIL....1507
28.9.d CHANGING THE HYDRAULIC TRANSMISSION FILTER....1508
28.9.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....1508
28.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....1509
28.10.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....1509
28.10.b CHANGING THE COOLANT....1511
28.10.c CHANGING THE BRAKING SYSTEM OIL....1513
28.10.d CHECKING THE ALTERNATOR AND THE STARTER....1513
28.11 WHEN REQUIRED....1514
28.11.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....1514
28.11.b CHECKING AND CLEANING THE CAB AIR FILTERS....1515
28.11.c BLEEDING THE BRAKING CIRCUIT....1516
28.11.d WASHING THE COOLING CIRCUIT....1517
28.11.e CLEANING THE WATER SEPARATOR....1519
28.11.f CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN....1519
28.11.g CHECKING AND ADJUSTING THE PARKING BRAKE....1520
28.11.h CHECKING THE BRAKING EFFICIENCY....1521
28.11.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE....1522
28.11.k ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION....1522
28.12 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER....1523
28.12.a CHANGING THE HYDRAULIC OIL FILTER....1523
28.12.b CHANGING THE HYDRAULIC OIL....1523
29. LONG PERIODS OF INACTIVITY....1524
29.1 BEFORE THE PERIOD OF INACTIVITY....1524
29.2 DURING THE PERIOD OF INACTIVITY....1526
29.3 AFTER THE PERIOD OF INACTIVITY....1526
AUTHORIZED OPTIONAL EQUIPMENT....1528
30. AUTHORIZED OPTIONAL EQUIPMENT....1529
30.1 PRECAUTIONS REGARDING SAFETY....1529
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB140PS-2....1530
30.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB150PS-2....1531
31. FRONT EQUIPMENT QUICK COUPLING DEVICES....1532
31.1 MANUAL CONTROL QUICK COUPLING....1532
31.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET....1533
31.3 HYDRAULIC CONTROL QUICK COUPLING FOR MULTIPURPOSE BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....1533
32. MULTIPURPOSE BUCKET....1534
32.1 DESCRIPTION AND CONTROLS....1534
32.2 SAFETY DEVICES....1534
32.3 INSTALLING THE MULTIPURPOSE BUCKET....1535
32.4 USING THE MULTIPURPOSE BUCKET....1536
32.5 MAINTENANCE....1536
33. PALLET FORKS....1537
33.1 DESCRIPTION....1537
33.2 SAFETY DEVICES....1537
33.3 USING THE FORKS....1537
33.3.1 PREPARING THE PALLET FORKS FOR USE....1538
33.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS....1538
33.4 REMOVING THE FORKS....1539
33.5 INSTALLING THE FORKS....1539
33.6 MAINTENANCE....1539
34. BACKHOE TELESSCOPIC ARM....1540
34.1 DESCRIPTION AND CONTROL....1540
34.2 SAFETY DEVICES....1540
34.3 USING THE TELESCOPIC ARM....1541
34.4 MAINTENANCE....1541
34.4.1 ADJUSTING THE GUIDE SLACK....1541
35. ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER....1543
35.1 DESCRIPTION AND CONTROL....1543
35.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED....1544
35.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER....1548
35.3.1 INSTALLING THE HAMMER....1548
35.3.2 REMOVING THE HAMMER....1550
35.4 MAINTENANCE....1550
36. ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....1551
36.1 DESCRIPTION AND CONTROL....1551
36.2 INSTALLING AND CONNECTING THE EQUIPMENT....1551
36.3 MAINTENANCE....1552
37. ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET....1553
37.1 DESCRIPTION AND CONTROL....1553
37.2 INSTALLING THE CLAMSHELL BUCKET....1554
37.3 USING THE CLAMSHELL BUCKET....1555
37.4 MAINTENANCE....1555
38. ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER....1556
38.1 DESCRIPTION AND CONTROL....1556
38.2 CONNECTING AND REMOVING THE HAMMER....1557
38.2.1 CONNECTING THE HAMMER....1557
38.2.2 REMOVING THE CONNECTIONS....1557
38.3 USING THE HAMMER....1558
38.4 MAINTENANCE....1558
39. LOAD STABILIZER SYSTEM (LSS) (OPTIONAL)....1559
39.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)....1559
40. AIR CONDITIONER (OPTIONAL)....1560
WEBM002502 - Backhoe Loader WB140PS-2, WB150PS-2 Shop Manual....1562
COVER....1562
CONTENTS....1563
10 STRUCTURE AND FUNCTION....1580
POWER TRAIN....1581
TRANSMISSION....1583
DRIVE SHAFTS....1587
CONTROL VALVE BLOCK....1589
FRONT AXLE....1591
REAR AXLE....1594
HYDRAULIC PUMP....1599
HYDRAULIC STEERING SYSTEM....1620
HYDRAULIC CIRCUIT (WB140PS-2)....1622
HYDRAULIC CIRCUIT (WB150PS-2)....1623
SHOVEL CONTROL VALVE....1625
BACKHOE CONTROL VALVE....1629
CLSS....1636
SAFETY VALVE....1651
SOLENOID VALVE....1653
BRAKE PUMP....1654
SHOVEL CYLINDERS....1655
BACKHOE CYLINDERS....1656
AIR-CONDITIONING UNIT....1659
HOW THE AIR-CONDITIONING UNIT FUNCTIONS....1660
ELECTRICAL DIAGRAM (1/7)....1662
ELECTRICAL DIAGRAM (2/7)....1664
ELECTRICAL DIAGRAM (3/7)....1666
ELECTRICAL DIAGRAM (4/7)....1668
ELECTRICAL DIAGRAM (5/7)....1670
ELECTRICAL DIAGRAM (6/7)....1672
ELECTRICAL DIAGRAM (7/7)....1674
20 TESTING AND ADJUSTMENTS....1677
NORMAL OR STANDARD TECHNICAL DATA....1678
SPECIAL TOOLS....1704
MEASURING ENGINE SPEED....1705
ADJUSTING VALVE CLEARANCE....1706
MEASURING COMPRESSION PRESSURE....1707
TESTING AND ADJUSTING FUEL INJECTION TIMING....1708
CHECKING AND TIGHTENING THE FAN - BELT....1710
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT....1711
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....1712
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....1714
AIR BLEEDING - RELEASING RESIDUAL PRESSURE....1715
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....1718
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)....1724
CHECKING UNLOADING VALVE FUNCTIONALITY....1725
TESTING PUMP DELIVERY....1726
TESTING PRIORITY VALVE OPERATION....1728
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....1729
TESTING BRAKE SYSTEM....1730
CONTROL OF ENGINE SPEED UNDER LOAD....1732
TESTING PRESSURES IN THE POWER TRAIN GROUP....1734
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES....1736
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....1737
ANALYSIS OF CAUSES HYDRAULIC DRIFT....1738
TESTING THE AIR-CONDITIONING UNIT....1743
30 REMOVAL AND INSTALLATION....1746
HOW TO READ THE MANUAL....1748
PRECAUTIONS TO BE TAKEN WHILE WORKING....1749
SPECIAL TOOLS....1750
STARTING MOTOR....1754
REMOVAL....1754
INSTALLATION....1754
ALTERNATOR....1755
REMOVAL....1755
INSTALLATION....1755
AIR-CONDITIONING UNIT COMPRESSOR....1756
REMOVAL....1756
INSTALLATION....1757
INJECTION PUMP....1758
REMOVAL....1758
INSTALLATION ....1761
INJECTION NOZZLES....1762
REMOVAL....1762
INSTALLATION....1762
THERMOSTAT....1763
REMOVAL....1763
INSTALLATION....1763
COOLING LIQUID PUMP....1764
REMOVAL....1764
INSTALLATION....1765
TURBOCOMPRESSOR....1766
REMOVAL ....1766
INSTALLATION....1767
CYLINDER HEAD....1768
REMOVAL ....1768
INSTALLATION....1771
ACCUMULATOR DISCONNECTING SWITCH....1772
REMOVAL....1772
INSTALLATION....1772
FRONT COUNTERWEIGHT....1773
REMOVAL....1773
INSTALLATION....1773
RADIATOR-OIL COOLER UNIT....1774
REMOVAL ....1774
INSTALLATION....1776
CONDENSER....1777
REMOVAL....1777
INSTALLATION....1777
HYDRAULIC OIL COOLER....1778
REMOVAL....1778
INSTALLATION....1779
TRANSMISSION OIL COOLER....1780
REMOVAL....1780
INSTALLATION....1780
MUFFLER....1781
REMOVAL....1781
INSTALLATION....1781
EXHAUST PIPE....1781
REMOVAL....1781
INSTALLATION....1781
ENGINE HOOD....1782
REMOVAL....1782
INSTALLATION....1783
CAB....1784
REMOVAL....1784
INSTALLATION....1787
HEAT AND AIR-CONDITIONING GROUP....1788
REMOVAL....1788
INSTALLATION....1789
FUEL TANK....1790
REMOVAL....1790
INSTALLATION....1790
HYDRAULIC OIL TANK....1791
REMOVAL....1791
INSTALLATION....1791
ENGINE-GEARBOX- PUMP GROUP....1792
REMOVAL....1792
INSTALLATION....1797
PISTON PUMP....1798
REMOVAL....1798
INSTALLATION....1799
TRANSMISSION....1800
REMOVAL....1800
INSTALLATION....1803
CONVERTOR....1804
REMOVAL....1804
INSTALLATION....1804
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEARM CONTROL GROUP....1805
REMOVAL....1805
INSTALLATION....1805
STEERING UNIT....1806
REMOVAL....1806
INSTALLATION....1806
WORKING BRAKE PUMP GROUP....1807
REMOVAL....1807
INSTALLATION....1807
FRONT WORKING EQUIPMENT CONTROL VALVE....1808
REMOVAL....1808
INSTALLATION....1808
FRONT AXLE....1809
REMOVAL....1809
INSTALLATION....1810
DISASSEMBLY....1811
ASSEMBLY....1829
REAR AXLE....1851
REMOVAL....1851
INSTALLATION....1852
REAR AXLE FINAL DRIVE....1853
DISASSEMBLY....1853
ASSEMBLY....1859
REAR AXLE ....1865
DISASSEMBLY....1865
ASSEMBLY....1886
FRONT BUCKET BOOM-RAISING CYLINDER....1910
REMOVAL....1910
INSTALLATION....1910
FRONT BUCKET TILT CYLINDERS....1911
REMOVAL....1911
INSTALLATION....1911
FRONT BUCKET....1912
REMOVAL....1912
INSTALLATION....1912
FRONT WORKING EQUIPMENT....1913
REMOVAL....1913
INSTALLATION....1914
BACKHOE CONTROL VALVE....1915
REMOVAL....1915
INSTALLATION....1916
BACKHOE BOOM CYLINDER....1917
REMOVAL....1917
INSTALLATION....1917
BACKHOE ARM CYLINDER....1918
REMOVAL....1918
INSTALLATION....1918
TELESCOPIC ARM CYLINDER....1919
REMOVAL....1919
INSTALLATION....1919
BACKHOE BUCKET CYLINDER....1920
REMOVAL....1920
INSTALLATION....1920
OUTRIGGER CYLINDERS....1921
REMOVAL....1921
INSTALLATION....1921
BACKHOE SWING CYLINDERS....1922
REMOVAL....1922
INSTALLATION....1922
CYLINDERS....1923
DISASSEMBLY....1923
ASSEMBLY....1925
BOOM SWING CYLINDER....1928
DISASSEMBLY....1928
ASSEMBLY....1929
BOOM SAFETY CYLINDER....1931
REMOVAL....1931
INSTALLATION....1931
BACKHOE WORKING EQUIPMENT....1932
REMOVAL....1932
INSTALLATION....1932
BACKHOE BUCKET....1933
REMOVAL....1933
INSTALLATION....1933
ARM....1934
REMOVAL....1934
INSTALLATION....1934
TELESCOPIC ARM....1935
REMOVAL....1935
INSTALLATION....1935
2ND ARM ....1936
REMOVAL....1936
INSTALLATION....1936
2ND ARM GUIDES....1937
REMOVAL....1937
INSTALLATION....1937
BACKHOE BOOM....1938
REMOVAL....1938
INSTALLATION....1938
BACKHOE SWING BUCKET....1939
REMOVAL....1939
INSTALLATION....1939
BACKHOE SUPPORTS....1940
REMOVAL....1940
INSTALLATION....1941
40 STANDARD MAINTENANCE....1943
TRANSMISSION....1945
FRONT AXLE....1948
DIFFERENTIAL....1948
PLANETARY -JOINT....1949
STEERING UNIT CYLINDER....1950
REAR AXLE....1951
DIFFERENTIAL....1951
PLANETARY - JOINT....1952
BRAKES....1953
DIFFERENTIAL LOCK....1954
HYDRAULIC PUMP....1956
2-SPOOL CONTROL VALVE....1958
3- SPOOL CONTROL VALVE....1960
6-SPOOL CONTROL VALVE....1962
7-SPOOL CONTROL VALVE....1965
8-SPOOL CONTROL VALVE....1967
BRAKE PUMP....1968
SHOVEL CYLINDER....1969
BACKHOE CYLINDERS....1971
FRONT WORKING EQUIPMENT....1974
SWING BRACKET....1976
BACKHOE WORKING EQUIPMENT....1978
WEBM004300 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Shop Manual....1981
COVER....1981
CONTENTS....1983
SAFETY....1987
FOREWORD....1989
HOW TO READ THE SHOP MANUAL....1990
HOISTING INSTRUCTIONS....1991
STANDARD TIGHTENING TORQUE....1992
COATING MATERIALS....1994
WEIGHT TABLE....1996
TABLE OF OIL AND COOLANT QUANTITIES....1997
CONVERSION TABLE....1999
10 STRUCTURE AND FUNCTION....2009
POWER TRAIN....2010
TRANSMISSION....2012
DRIVE SHAFTS....2016
CONTROL VALVE BLOCK....2018
FRONT AXLE....2020
REAR AXLE....2023
HYDRAULIC PUMP....2028
STEERING UNIT....2049
HYDRAULIC CIRCUIT (WB140PS-2)....2051
HYDRAULIC CIRCUIT (WB150PS-2)....2052
SHOVEL CONTROL VALVE....2054
BACKHOE CONTROL VALVE....2058
CLSS....2065
SOLENOID VALVE....2079
SAFETY VALVE....2080
BRAKE PUMP....2082
SHOVEL CYLINDERS....2083
BACKHOE CYLINDERS....2084
AIR CONDITIONING UNIT....2087
HOW THE AIR CONDITIONING UNIT FUNCTIONS....2088
ELECTRICAL DIAGRAM....2089
ELECTRICAL DIAGRAM (AIR CONDITIONING)....2091
20 TESTING AND ADJUSTMENTS....2095
NORMAL OR STANDARD TECHNICAL DATA....2096
SPECIAL TOOLS....2120
MEASURING ENGINE SPEED....2121
ADJUSTING VALVE CLEARANCE....2122
MEASURING COMPRESSION PRESSURE....2123
TESTING AND ADJUSTING FUEL INJECTION TIMING....2124
CHECKING AND TIGHTENING THE FAN-BELT....2126
CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT....2127
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....2128
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....2130
AIR BLEEDING - RELEASING RESIDUAL PRESSURE....2131
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....2134
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)....2140
TESTING AND ADJUSTING OF UNLOADING VALVE....2141
CHECKING UNLOADING VALVE FUNCTIONALITY....2142
TESTING PRIORITY VALVE OPERATION....2143
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....2144
TESTING BRAKE SYSTEM....2145
CONTROL OF ENGINE SPEED UNDER LOAD....2147
TESTING PRESSURES IN THE POWER TRAIN GROUP....2149
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES....2151
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....2152
ANALYSIS OF CAUSES HYDRAULIC DRIFT....2153
TESTING THE AIR-CONDITIONING UNIT....2158
EMPTYING THE AIR-CONDITIONING UNIT....2160
TROUBLESHOOTING....2161
FRONT AXLE TROUBLESHOOTING....2162
REAR AXLE TROUBLESHOOTING....2167
TRANSMISSION TROUBLESHOOTING....2172
CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT....2175
30 REMOVAL AND INSTALLATION....2179
HOW TO READ THE MANUAL....2181
PRECAUTIONS TO BE TAKEN WHILE WORKING....2182
SPECIAL TOOLS....2183
STARTING MOTOR....2187
REMOVAL OF STARTING MOTOR....2187
INSTALLATION OF STARTING MOTOR....2187
ALTERNATOR....2188
REMOVAL OF THE ALTERNATOR....2188
INSTALLATION OF THE ALTERNATOR....2189
AIR-CONDITIONING UNIT COMPRESSOR....2190
REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR....2190
INSTALLATION OF THE AIR-CONDITIONING UNIT COMPRESSOR....2191
INJECTION PUMP....2192
REMOVAL OF THE INJECTION PUMP....2192
INSTALLATION OF THE INJECTION PUMP....2195
INJECTION NOZZLES....2196
REMOVAL OF THE INJECTION NOZZLES....2196
INSTALLATION OF THE INJECTION NOZZLES....2196
THERMOSTAT....2197
REMOVAL OF THE THERMOSTAT....2197
INSTALLATION OF THE THERMOSTAT....2197
COOLING LIQUID PUMP....2198
REMOVAL OF THE COOLING LIQUID PUMP....2198
INSTALLATION OF THE COOLING LIQUID PUMP....2199
TURBOCOMPRESSOR....2200
REMOVAL OF THE TURBOCOMPRESSOR....2200
INSTALLATION OF THE TURBOCOMPRESSOR....2201
CYLINDER HEAD....2202
REMOVAL OF THE CYLINDER HEAD....2202
INSTALLATION OF THE CYLINDER HEAD....2204
ACCUMULATOR DISCONNECTING SWITCH....2206
REMOVAL OF THE ACCUMULATOR DISCONNECTING SWITCH....2206
INSTALLATION OF THE ACCUMULATOR DISCONNECTING SWITCH....2206
FRONT COUNTERWEIGHT....2207
REMOVAL OF THE FRONT COUNTERWEIGHT....2207
INSTALLATION OF THE FRONT COUNTERWEIGHT....2207
RADIATOR-OIL COOLER UNIT....2208
REMOVAL OF THE RADIATOR-OIL COOLER UNIT....2208
INSTALLATION OF THE RADIATOR-OIL COOLER GROUP....2210
CONDENSER....2211
REMOVAL OF CONDENSER....2211
INSTALLATION OF THE CONDENSER....2211
HYDRAULIC OIL COOLER....2212
REMOVAL OF HYDRAULIC OIL COOLER....2212
INSTALLATION OF THE HYDRAULIC OIL COOLER....2213
TRANSMISSION OIL COOLER....2214
REMOVAL OF THE TRANSMISSION OIL COOLER....2214
INSTALLATION OF THE TRANSMISSION OIL COOLER....2214
MUFFLER....2215
REMOVAL OF THE MUFFLER....2215
INSTALLATION OF THE MUFFLER....2215
EXHAUST PIPE....2216
REMOVAL OF THE EXHAUST PIPE....2216
INSTALLATION OF THE EXHAUST PIPE....2216
ENGINE HOOD....2217
REMOVAL OF THE ENGINE HOOD....2217
INSTALLATION OF THE ENGINE HOOD....2218
CAB....2219
REMOVAL OF THE CAB....2219
INSTALLATION OF THE CAB....2222
HEAT AND AIR-CONDITIONING GROUP....2223
REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP....2223
INSTALLATION OF THE HEATING AND AIR-CONDITIONING GROUP....2224
FUEL TANK....2225
REMOVAL OF THE FUEL TANK....2225
INSTALLATION OF THE FUEL TANK....2225
HYDRAULIC OIL TANK....2226
REMOVAL OF HYDRAULIC OIL TANK....2226
INSTALLATION OF THE HYDRAULIC OIL TANK....2226
ENGINE-GEARBOX-PUMP GROUP....2227
REMOVAL OF THE ENGINE-GEARBOX-PUMP GROUP....2227
INSTALLATION OF THE ENGINE-GEARBOX-PUMP GROUP....2232
PISTON PUMP....2233
REMOVAL OF THE PISTON PUMP....2233
INSTALLATION OF THE PISTON PUMP....2234
TRANSMISSION....2235
REMOVAL OF THE TRANSMISSION....2235
INSTALLATION OF THE TRANSMISSION....2238
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION....2239
CONVERTOR....2337
REMOVAL OF THE CONVERTOR....2337
INSTALLATION OF THE CONVERTOR....2337
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2338
REMOVALL OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2338
INSTALLATION OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2338
STEERING UNIT....2339
REMOVAL OF THE STEERING UNIT....2339
INSTALLATION OF THE STEERING UNIT....2339
WORKING BRAKE PUMP GROUP....2340
REMOVAL OF THE WORKING BRAKE PUMP GROUP....2340
INSTALLATION OF THE WORKING BRAKE PUMP GROUP....2340
FRONT WORKING EQUIPMENT CONTROL VALVE....2341
REMOVAL OF THE FRONT WORKING EQUIPMENT CONTROL VALVE....2341
INSTALLATION OF THE FRONT WORKING EQUIPMENT CONTROL VALVE....2341
FRONT AXLE....2342
REMOVAL OF THE FRONT AXLE....2342
INSTALLATION OF THE FRONT AXLE....2343
DISASSEMBLY OF FRONT AXLE....2344
ASSEMBLY OF FRONT AXLE....2353
REAR AXLE....2369
REMOVAL OF THE REAR AXLE....2369
INSTALLATION OF THE REAR AXLE....2370
DISASSEMBLY OF REAR AXLE....2371
ASSEMBLY OF REAR AXLE....2386
FRONT BUCKET BOOM-RAISING CYLINDER....2405
REMOVAL OF THE FRONT BUCKET BOOM-RAISING CYLINDER....2405
INSTALLATION OF FRONT BUCKET BOOM-RAISING CYLINDER....2405
FRONT BUCKET TILT CYLINDERS....2406
REMOVAL OF THE FRONT BUCKET TILT CYLINDERS....2406
INSTALLATION OF THE FRONT BUCKET TILT CYLINDERS....2406
FRONT BUCKET....2407
REMOVAL OF THE FRONT BUCKET....2407
INSTALLATION OF THE FRONT BUCKET....2407
FRONT WORKING EQUIPMENT....2408
REMOVAL OF THE FRONT WORKING EQUIPMENT....2408
INSTALLATION OF THE FRONT WORKING EQUIPMENT....2409
BACKHOE CONTROL VALVE....2410
REMOVAL OF THE BACKHOE CONTROL VALVE....2410
INSTALLATION OF THE BACKHOE CONTROL VALVE....2411
BACKHOE BOOM CYLINDER....2412
REMOVAL OF BACKHOE BOOM CYLINDER....2412
INSTALLATION OF THE BACKHOE BOOM CYLINDER....2412
BACKHOE ARM CYLINDER....2413
REMOVAL OF THE BACKHOE ARM CYLINDER....2413
INSTALLATION OF THE BACKHOE ARM CYLINDER....2413
TELESCOPIC ARM CYLINDER....2414
REMOVAL OF THE TELESCOPIC ARM CYLINDER....2414
INSTALLATION OF THE TELESCOPIC ARM CYLINDER....2414
BACKHOE BUCKET CYLINDER....2415
REMOVAL OF THE BACKHOE BUCKET CYLINDER....2415
INSTALLATION OF THE BACKHOE BUCKET CYLINDER....2415
OUTRIGGER CYLINDERS....2416
REMOVAL OF THE OUTRIGGER CYLINDERS....2416
INSTALLATION OF THE OUTRIGGER CYLINDERS....2416
BACKHOE SWING CYLINDERS....2417
REMOVAL OF THE BACKHOE SWING CYLINDERS....2417
INSTALLATION OF THE BACKHOE SWING CYLINDERS....2417
CYLINDERS....2418
DISASSEMBLY OF CYLINDERS....2418
ASSEMBLY OF CYLINDERS....2420
BOOM SWING CYLINDER....2423
DISASSEMBLY OF BOOM SWING CYLINDER....2423
ASSEMBLY OF BOOM SWING CYLINDER....2424
BOOM SAFETY CYLINDER....2426
REMOVAL OF THE BOOM SAFETY CYLINDER....2426
INSTALLATION OF THE BOOM SAFETY CYLINDER....2426
BACKHOE WORKING EQUIPMENT....2427
REMOVAL OF THE BACKHOE WORKING EQUIPMENT....2427
INSTALLATION OF THE BACKHOE WORKING EQUIPMENT....2427
BACKHOE BUCKET....2428
REMOVAL OF THE BACKHOE BUCKET....2428
INSTALLATION OF THE BACKHOE BUCKET....2428
THE ARM....2429
REMOVAL OF THE ARM....2429
INSTALLATION OF THE ARM....2429
COMPLETE TELESCOPIC ARM....2430
REMOVAL OF COMPLETE TELESCOPIC ARM....2430
INSTALLATION OF THE COMPLETE TELESCOPIC ARM....2430
2ND ARM....2431
REMOVAL OF 2ND ARM....2431
INSTALLATION OF 2ND ARM....2431
2ND ARM GUIDES....2432
REMOVAL OF 2ND ARM GUIDES....2432
INSTALLATION OF 2ND ARM GUIDE....2432
BACKHOE BOOM....2433
REMOVAL OF THE BACKHOE BOOM....2433
INSTALLATION OF THE BACKHOE BOOM....2433
BACKHOE SWING BRACKET....2434
REMOVAL OF THE BACKHOE SWING BRACKET....2434
INSTALLATION OF THE BACKHOE SWING BRACKET....2434
BACKHOE OUTRIGGERS....2435
REMOVAL OF THE BACKHOE OUTRIGGERS....2435
INSTALLATION OF THE BACKHOE OUTRIGGERS....2436
40 STANDARD MAINTENANCE....2439
TRANSMISSION....2440
FRONT AXLE....2443
REAR AXLE....2446
HYDRAULIC PUMP....2450
2-SPOOL CONTROL VALVE....2452
3-SPOOL CONTROL VALVE....2454
6-SPOOL CONTROL VALVE....2456
7-SPOOL CONTROL VALVE....2459
8-SPOOL CONTROL VALVE....2461
BRAKE PUMP....2462
SHOVEL CYLINDERS....2463
BACKHOE CYLINDERS....2464
FRONT WORKING EQUIPMENT....2468
SWING BRACKET....2470
BACKHOE WORKING EQUIPMENT....2472
WEBM004700 - Backhoe Loader WB140PS-2, WB150PS-2 Power-Shift Shop Manual....2475
COVER....2475
CONTENTS....2477
SAFETY....2481
FOREWORD....2483
HOW TO READ THE SHOP MANUAL....2484
HOISTING INSTRUCTIONS....2485
STANDARD TIGHTENING TORQUE....2486
COATING MATERIALS....2488
WEIGHT TABLE....2490
TABLE OF OIL AND COOLANT QUANTITIES....2491
CONVERSION TABLE....2493
10 STRUCTURE AND FUNCTION....2503
POWER TRAIN....2504
TRANSMISSION....2506
DRIVE SHAFTS....2510
CONTROL VALVE BLOCK....2512
FRONT AXLE....2514
REAR AXLE....2517
HYDRAULIC PUMP....2522
STEERING UNIT....2543
HYDRAULIC CIRCUIT (WB140PS-2)....2545
HYDRAULIC CIRCUIT (WB150PS-2)....2546
SHOVEL CONTROL VALVE....2548
BACKHOE CONTROL VALVE....2552
CLSS....2559
SOLENOID VALVE....2573
SAFETY VALVE....2574
BRAKE PUMP....2576
SHOVEL CYLINDERS....2577
BACKHOE CYLINDERS....2578
AIR-CONDITIONING UNIT....2581
HOW THE AIR CONDITIONING UNIT FUNCTIONS....2582
ELECTRICAL DIAGRAM....2583
ELECTRICAL DIAGRAM (AIR CONDITIONING)....2585
20 TESTING AND ADJUSTMENTS....2589
NORMAL OR STANDARD TECHNICAL DATA....2590
SPECIAL TOOLS....2614
MEASURING ENGINE SPEED....2615
ADJUSTING VALVE CLEARANCE....2616
MEASURING COMPRESSION PRESSURE....2617
TESTING AND ADJUSTING FUEL INJECTION TIMING....2618
CHECKING AND TIGHTENING THE FAN-BELT....2620
CHECKING AND TIGHTENING THE COMPRESSOR FAN-BELT....2621
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER....2622
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES....2624
AIR BLEEDING- RELEASING RESIDUAL PRESSURE....2625
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT....2628
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)....2634
TESTING AND ADJUSTING OF UNLOADING VALVE....2635
CHECKING UNLOADING VALVE FUNCTIONALITY....2636
TESTING PRIORITY VALVE OPERATION....2637
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....2638
TESTING BRAKE SYSTEM....2639
CONTROL OF THE ENGINE SPEED UNDER LOAD....2641
TESTING PRESSURES IN THE POWER TRAIN GROUP....2643
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES....2645
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE....2646
ANALYSIS OF CAUSES HYDRAULIC DRIFT....2647
TESTING THE AIR-CONDITIONING UNIT....2652
EMPTYING THE AIR-CONDITIONING UNIT....2654
TROUBLESHOOTING....2655
FRONT AXLE TROUBLESHOOTING....2656
REAR AXLE TROUBLESHOOTING....2661
TRANSMISSION TROUBLESHOOTING....2666
CHECKING AND INSPECTION OF THE ELECTRONIC CONTROL UNIT....2669
30 REMOVAL AND INSTALLATION....2673
HOW TO READ THE MANUAL....2675
PRECAUTIONS TO BE TAKEN WHILE WORKING....2676
SPECIAL TOOLS....2677
STARTING MOTOR....2681
REMOVAL OF STARTING MOTOR....2681
INSTALLATION OF THE STARTING MOTOR....2681
ALTERNATOR....2682
REMOVAL OF THE ALTERNATOR....2682
INSTALLATION OF THE ALTERNATOR....2683
AIR-CONDITIONING UNIT COMPRESSOR....2684
REMOVAL OF THE AIR-CONDITIONING UNIT COMPRESSOR....2684
INSTALLATION OF THE AIR-CONDITIONING UNIT COMPRESSOR....2685
INJECTION PUMP....2686
REMOVAL OF THE INJECTION PUMP....2686
INSTALLATION OF THE INJECTION PUMP....2689
INJECTION NOZZLES....2690
REMOVAL AND INSTALLATION OF THE INJECTION NOZZLES....2690
THERMOSTAT....2691
REMOVAL AND INSTALLATION OF THE THERMOSTAT....2691
COOLING LIQUID PUMP....2692
REMOVAL OF THE COOLING LIQUID PUMP....2692
INSTALLATION OF THE COOLING LIQUID PUMP....2693
TURBOCOMPRESSOR....2694
REMOVAL OF THE TURBOCOMPRESSOR....2694
INSTALLATION OF THE TURBOCOMPRESSOR....2695
CYLINDER HEAD....2696
REMOVAL OF THE CYLINDER HEAD....2696
INSTALLATION OF THE CYLINDER HEAD....2698
ACCUMULATOR DISCONNECTING SWITCH....2700
REMOVAL AND INSTALLATION OF THE ACCUMULATOR DISCONNECTING SWITCH....2700
FRONT COUNTERWEIGHT....2701
REMOVAL AND INSTALLATION OF THE FRONT COUNTERWEIGHT....2701
RADIATOR-OIL COOLER UNIT....2702
REMOVAL OF THE RADIATOR-OIL COOLER UNIT....2702
INSTALLATION OF THE RADIATOR GROUP....2704
CONDENSER....2705
REMOVAL AND INSTALLATION OF THE CONDENSER....2705
MUFFLER....2706
REMOVAL AND INSTALLATION OF THE MUFFLER....2706
EXHAUST PIPE....2707
REMOVAL AND INSTALLATION OF THE EXHAUST PIPE....2707
ENGINE HOOD....2708
REMOVAL OF THE ENGINE HOOD....2708
INSTALLATION OF THE ENGINE HOOD....2709
CAB....2710
REMOVAL OF THE CAB....2710
INSTALLATION OF THE CAB....2713
HEAT AND AIR-CONDITIONING GROUP....2714
REMOVAL OF THE HEAT AND AIR-CONDITIONING GROUP....2714
INSTALLATION OF THE HEAT AND AIR-CONDITIONING GROUP....2715
FUEL TANK....2716
REMOVAL AND INSTALLATION OF THE FUEL TANK....2716
HYDRAULIC OIL TANK....2717
REMOVAL AND INSTALLATION OF THE HYDRAULIC OIL TANK....2717
ENGINE GEARBOX-PUMP GROUP....2718
REMOVAL OF THE ENGINE GEARBOX-PUMP GROUP....2718
INSTALLATION OF THE ENGINE GEARBOX-PUMP GROUP....2723
PISTON PUMP....2724
REMOVAL OF THE PISTON PUMP....2724
INSTALLATION OF THE PISTON PUMP....2725
TRANSMISSION....2726
REMOVAL OF THE TRANSMISSION....2726
INSTALLATION OF THE TRANSMISSION....2729
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION....2731
CONVERTOR....2829
REMOVAL AND INSTALLATION OF THE CONVERTOR....2829
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2830
REMOVAL AND INSTALLATION OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....2830
STEERING UNIT....2831
REMOVAL AND INSTALLATION OF THE STEERING UNIT....2831
WORKING BRAKE PUMP GROUP....2832
REMOVAL AND INSTALLATION OF THE WORKING BRAKE PUMP GROUP....2832
FRONT WORKING EQUIPMENT CONTROL VALVE....2833
REMOVAL AND INSTALLATION OF THE FRONT WORKING EQUIPMENT CONTROL VALVE....2833
FRONT AXLE....2834
REMOVAL OF THE FRONT AXLE....2834
INSTALLATION OF THE FRONT AXLE....2835
DISASSEMBLY OF THE FRONT AXLE....2836
ASSEMBLY OF FRONT AXLE....2845
REAR AXLE....2861
REMOVAL OF THE REAR AXLE....2861
INSTALLATION OF THE REAR AXLE....2862
DISASSEMBLY OF REAR AXLE....2863
ASSEMBLY OF REAR AXLE....2878
FRONT BUCKET BOOM-RAISING CYLINDER....2897
REMOVAL AND INSTALLATION OF FRONT BUCKET BOOM-RAISING CYLINDER....2897
FRONT BUCKET TILT CYLINDERS....2898
REMOVAL AND INSTALLATION OF FRONT BUCKET TILT CYLINDERS....2898
FRONT BUCKET....2899
REMOVAL AND INSTALLATION OF FRONT BUCKET....2899
FRONT WORKING EQUIPMENT....2900
REMOVAL OF FRONT WORKING EQUIPMENT....2900
INSTALLATION OF FRONT WORKING EQUIPMENT....2901
BACKHOE CONTROL VALVE....2902
REMOVAL OF THE BACKHOE CONTROL VALVE....2902
INSTALLATION OF THE BACKHOE CONTROL VALVE....2903
BACKHOE BOOM CYLINDER....2904
REMOVAL AND INSTALLATION OF THE BACKHOE BOOM CYLINDER....2904
BACKHOE ARM CYLINDER....2905
REMOVAL AND INSTALLATION OF THE BACKHOE ARM CYLINDER....2905
TELESCOPIC ARM CYLINDER....2906
REMOVAL AND INSTALLATION OF THE TELESCOPIC ARM CYLINDER....2906
BACKHOE BUCKET CYLINDER....2907
REMOVAL AND INSTALLATION OF THE BACKHOE BUCKET CYLINDER....2907
OUTRIGGER CYLINDERS....2908
REMOVAL AND INSTALLATION OF THE OUTRIGGER CYLINDERS....2908
BACKHOE SWING CYLINDERS....2909
REMOVAL AND INSTALLATION OF THE BACKHOE SWING CYLINDERS....2909
CYLINDERS....2910
DISASSEMBLY OF CYLINDERS....2910
ASSEMBLY OF CYLINDERS....2912
BOOM SWING CYLINDER....2915
DISASSEMBLY OF BOOM SWING CYLINDER....2915
ASSEMBLY OF BOOM SWING CYLINDER....2916
BOOM SAFETY CYLINDER....2918
REMOVAL AND INSTALLATION OF THE BOOM SAFETY CYLINDER....2918
BACKHOE WORKING EQUIPMENT....2919
REMOVAL AND INSTALLATION OF THE BACKHOE WORKING EQUIPMENT....2919
BACKHOE BUCKET....2920
REMOVAL AND INSTALLATION OF THE BACKHOE BUCKET....2920
ARM....2921
REMOVAL AND INSTALLATION OF THE ARM....2921
TELESCOPIC ARM....2922
REMOVAL AND INSTALLATION OF THE COMPLETE TELESCOPIC ARM....2922
2ND ARM....2923
REMOVAL AND INSTALLATION OF 2ND ARM....2923
2ND ARM GUIDES....2924
REMOVAL AND INSTALLATION OF 2ND ARM GUIDES....2924
BACKHOE BOOM....2925
REMOVAL AND INSTALLATION OF THE BACKHOE BOOM....2925
BACKHOE SWING BRACKET....2926
REMOVAL AND INSTALLATION OF THE BACKHOE SWING BRACKET....2926
BACKHOE OUTRIGGERS....2927
REMOVAL OF THE BACKHOE OUTRIGGERS....2927
INSTALLATION OF THE BACKHOE OUTRIGGERS....2928
40 STANDARD MAINTENANCE....2931
TRANSMISSION....2932
FRONT AXLE....2935
REAR AXLE....2938
HYDRAULIC PUMP....2942
2-SPOOL CONTROL VALVE....2944
3-SPOOL CONTROL VALVE....2946
6-SPOOL CONTROL VALVE....2948
7-SPOOL CONTROL VALVE....2951
8-SPOOL CONTROL VALVE....2953
BRAKE PUMP....2954
SHOVEL CYLINDERS....2955
BACKHOE CYLINDERS....2956
FRONT WORKING EQUIPMENT....2960
SWING BRACKET....2962
BACKHOE WORKING EQUIPMENT....2964
Komatsu Backhoe Loader WB140PS, WB150PS Repair Service Manual
