WB140-2N (ING) komatsu
Short Description
Retro komatsu...
Description
CEBM012700
Shop Manual
WB140-2N WB150-2N BACKHOE LOADER SERIAL NUMBERS
WB140-2N WB150-2N
A20637 A60029
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
August 2005 Printed in USA WB140-2N WB150-2N
Copyright 2005 Komatsu DataKom Publishing Division 00-1
FOREWORD
CONTENTS
12
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . .Will be issued at a later date
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WB140-2N WB150-2N
FOREWORD
SAFETY
12
SAFETY SAFETY NOTICE
00
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
00
PREPARATIONS FOR WORK
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
● ●
3.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.
5.
6.
Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
WB140-2N WB150-2N
PRECAUTIONS DURING WORK
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
00-3
FOREWORD
SAFETY
12 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9.
Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
●
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine.
00-4
WB140-2N WB150-2N
FOREWORD
GENERAL
12
GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WB140-2N WB150-2N
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL VOLUMES
00
00
REVISIONS
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Chassis volume: Engine volume:
SYMBOLS
Issued for every machine model Issued for each engine series
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
DISTRIBUTION AND UPDATING
1. 2.
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
FILING METHOD
00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3
★
Item number (10. Structure and Function) Consecutive page number for each item 3.
00
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
10-4 10-4-1 Added pages 10-4-2 10-5
REVISED EDITION MARK
00
When a manual is revised, an edition mark (bcd…) is recorded on the bottom outside corner of the pages.
00-6
WB140-2N WB150-2N
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
can result. Hooks have maximum strength at the middle portion.
00
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol.
●
1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
WIRE ROPES 1.
3.
WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
00
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Allowable load
mm
kN
tons
10
9.8
1.0
11.2
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.3
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
WB140-2N WB150-2N
00-7
FOREWORD
PUSH PULL COUPLER
12
PUSH PULL COUPLER
00
WARNING! Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
TYPE 1 DISCONNECTION 1.
2.
3.
4.
2.
00
Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold the rubber cap portion (4). After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks. Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 1.
00
00
Hold the hose adapter (1) or hose (5) and insert it in the mating adapter (3), aligning them with each other. Do not hold the rubber cap portion (4). After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality.
00-8
WB140-2N WB150-2N
FOREWORD
TYPE 2 DISCONNECTION
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and turn the lever (4) to the right clockwise.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1.
00
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-9
WB140-2N WB150-2N
FOREWORD 12 TYPE
3
DISCONNECTION
PUSH PULL COUPLER 00
00
1.
Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1.
00
Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-10
WB140-2N WB150-2N
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
★ The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Adhesives
LT-1A
Part No. 790-129-9030
Quantity
Container
150 g
Tube
LT-1B
790-129-9050
20 g (2 pes.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
179-129-9140
2g
Polyethylene container
Main applications, features ●
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
●
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and nonmetal.
●
● ●
●
Used as adhesive or sealant for metal, glass or plastic.
●
Used as sealant for machined holes.
●
Used as heat-resisting sealant for repairing engine.
●
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
● ● ●
Aronalpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
50 g
Polyethylene container
● ● ● ●
LG-3
790-129-9070
1 kg
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature. Used as adhesive or sealant for gaskets and packing of power train case, etc.
●
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Can ●
00-11
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals.
●
●
Gasket sealant
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
WB140-2N WB150-2N
FOREWORD Category
Code
COATING MATERIALS Part No.
Quantity
Container
Main applications, features ● ●
LG-4
790-129-9020
200 g
Tube
● ● ●
LG-5
790-129-9080
1 kg
Polyethylene container
Gasket sealant
● ●
LG-6
09940-00011
250 g
Tube
● ●
Molybdenum disulphide lubricant
●
LG-7
09920-00150
150 g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2160CNCA
Various
Various
400 g (10 per case)
Belows type
Molybdenum disulphide lubricant
Grease
00-12
SYG2-400M
●
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
●
Used as heat-resisting sealant for repairing engines.
●
Used as lubricant for sliding parts (to prevent squeaking).
● ●
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
●
General purpose type
●
Used for normal temperature, light load bearing at places in contact with water or steam.
●
Used for places with heavy load.
WB140-2N WB150-2N
FOREWORD
STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE
00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
11.8 - 14.7
8.70 - 10.84
8
13
27 - 34
19.91 - 25.07
10
17
59 - 74
43.51 - 54.57
12
19
98 - 123
72.28 - 90.72
14
22
153 - 190
112.84 - 140.13
16
24
235 - 285
173.32 - 210.20
18
27
320 - 400
236.02 - 295.02
20
30
455 - 565
335.59 - 416.72
22
32
610 - 765
449.91 - 564.23
24
36
785 - 980
578.98 - 722.81
27
41
1150 - 1440
848.19 - 1062.09
30
46
1520 - 1910
1121.09 - 1408.74
33
50
1960 - 2450
1445.62 - 1807.02
36
55
2450 - 3040
1807.02 - 2242.19
39
60
2890 - 3630
2131.55 - 2677.35
Thread diameter of bolt
Width across flats
mm
mm
Nm
lbf ft
6
10
5.9 - 9.8
4.35 - 7.22
8
13
13.7 - 23.5
10.10 - 17.33
10
14
34.3 - 46.1
25.29 - 34.00
12
27
74.5 - 90.2
54.94 - 66.52
00-13
WB140-2N WB150-2N
FOREWORD 12 TIGHTENING
STANDARD TIGHTENING TORQUE
TORQUE OF HOSE NUTS
00
Use these torques for hose nuts. Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
lbf ft
02
14
19
19.6 - 29.4
14.5 - 21.7
03
18
24
29.4 - 68.6
21.7 - 50.6
04
22
27
58.9 - 98.1
44.4 - 72.4
05
24
32
107.9 - 166.7
79.6 - 123.0
06
30
36
147.1 - 205.9
108.5 - 151.9
10
33
41
147.1 - 245.1
108.5 - 180.8
12
36
46
196.2 - 294.2
144.7 - 217.0
14
42
55
245.2 - 343.2
180.9 - 253.1
Nominal No.
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
00
Use these torques for split flange bolts. Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
14
59 - 74
43.51 - 54.57
12
17
98 - 123
72.28 - 90.72
16
22
235 - 285
173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS
00
Use these torques for flared part of nut.
Thread diameter
Width across flat
mm
mm
Nm
lbf ft
14
19
24.5 ± 4.9
18.0 ± 3.6
18
24
49 ± 19.6
36.1 ± 14.4
22
27
78.5 ± 19.6
57.8 ± 14.4
24
32
137.3 ± 29.4
101.2 ± 21.6
30
36
176.5 ± 29.4
130.1 ± 21.6
33
41
196.1 ± 49
144.6 ± 36.1
36
46
245.2 ± 49
180.8 ± 36.1
42
55
294.2 ± 49
216.9 ± 36.1
00-14
Tightening torque
WB140-2N WB150-2N
FOREWORD 12 TABLE
STANDARD TIGHTENING TORQUE
OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42
Norminal No. 02 03, 04 05, 06 10, 12 14
Width across flat mm Varies depending on type of connector.
Tightening torque (Nm {lbf ft}) Range Target 35 - 63 {25.81 - 46.46} 44 {32.45} 84 - 132 {61.95 - 97.35} 103 {75.96} 128 - 186 {94.40 - 137.18} 157 {115.79} 363 - 480 {267.73 - 354.02} 422 {311.25} 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Thread diameter mm 08 10 12 14 16 18 20 24 30 33 36 42 52
Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 _ 36 _ _
Tightening torque (Nm {lbf lb}) Range Target 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42} 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31} 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01} 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62} 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68} 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91} 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14} 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59} 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50} 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75} 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03} 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40} 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {lbf ft}) Nominal Width size of hose across flats
02 03 04 05 06 (10) (12) (14)
00-15
19 22 24 27 32 36 41 46 55
Range
Target
34 - 54 {25.0 - 39.8} 34 - 63 {25.0 - 46.4} 54 - 93 {39.8 - 68.5} 59 - 98 {43.5 - 72.2} 84 - 132 {61.9 - 97.3} 128 - 186 {94.4 - 137.1} 177 - 245 {130.5 - 180.7} 177 - 245 {130.5 - 180.7} 197 - 294 {145.3 - 216.8} 246 - 343 {181.4 - 252.9}
44 {32.4} 44 {32.4} 74 {54.5} 78 57.5} 103 {75.9} 157 {115.7} 216 {159.3} 216 {159.3} 245 {180.7} 294 {216.8}
Taper seal type
Face seal type
Nominal thread Thread size Root diameter (mm) size - Threads per (mm) (Reference) inch, Thread series 9/16 - 18UN 14.3 14 11/16 -16UN 17.5 18 22 13/16 - 16UN 20.6 24 1 - 14UNS 25.4 30 1 3/16 - 12UN 30.2 33 36 42 -
WB140-2N WB150-2N
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire Nominal numNumber of Dia. Of strand Cross section ber strands (mm) (mm)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.85
11
0.32
0.88
2.4
12
Starting, lighting, signal etc.
2
26
0.32
2.09
3.1
20
Lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
CLASSIFICATION BY COLOR AND CODE
1
Circuits Classification Primary
Priority
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
Black & White
Red & White
Yellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Yellow & Black
Green & Red
Blue & Red
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
2
Auxiliary
3
4
00
5
Black & YelRed & Black low
6
00-16
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
CONVERSION TABLES
00
METHOD OF USING THE CONVERSION TABLE
00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ● Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b. B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c. C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2.
Convert 550 mm into inches. A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. c
Millimeters to inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
d b
00-17
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
Millimeters to Inches
1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
00-18
1 kg = 2.2046 lb 0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
Liter to U.S. Gallon
1 L = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon
1 L = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
WB140-2N WB150-2N
00-19
FOREWORD
CONVERSION TABLES
12
kgm to ft. lb.
00-20
1 kgm = 7.233 ft. lb. 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63 1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1439.4
1432.1
WB140-2N WB150-2N
FOREWORD
CONVERSION TABLES
12
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
WB140-2N WB150-2N
00-21
FOREWORD
CONVERSION TABLES
12 Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C °F °C °F °C °F °C °F -40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8 -37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6 -34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4 -31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2 -28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0 -28.3 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-22
WB140-2N WB150-2N
01
GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
WB140-2N WB150-2N
01-1
GENERAL
SPECIFICATIONS
12
SPECIFICATIONS Weight
Description
Minimum
Operating weight
Maximum Loader
Bucket capacity
Performance
Unit
Backhoe
kg m³
Travel speeds
Forward 1st Forward 2nd Forward 3rd Forward 4th Reverse 1st Reverse 2nd Reverse 3rd Reverse 4th
km/h
Max rimpull
Forward Reverse
kg
Gradeability
Dimensions
Min. Turning Radius
01-2
WB140-2N - A20637 and UP
WB150-2N - A60029 and UP
7400
7400
8800
8800
1.03
1.03
0.2
0.2
6 11 21 39 6 11 21 39
6 11 21 39 6 11 21 39
Degrees Outside Wheel Tip of BOCE
mm
mm
WB140-2N WB150-2N
GENERAL 12
SPECIFICATIONS Description
Unit
Engine Power Train Wheels and Axle
WB150-2N - A60029 and UP
Komatsu S4D106-1FH diesel en- Komatsu S4D106-1FA diesel engine four cycle, water cooled, four gine four cycle, water cooled, four cylinder, direct injection with turbo-cylinder, direct injection with turbocharger charger
Model Type
Steering Brakes
WB140-2N - A20637 and UP
No. of cylinders - bore x stroke Piston displacement
mm L
Flywheel horsepower @ 2000 rpm Maximum torque @ 1400 rpm Min fuel consumption High idle Low idle
kW N•m g/kWh rpm rpm
Starting motor Alternator Battery
V kW VA V Ah
64 330
72 375
24, 7.5 24, 35 24, 112x2
Torque converter Transmission Reduction gear Differential Final drive Drive type Front axle Rear axle Tire Wheel rim Inflation pressure
Front tire Rear tire
kg/cm²
Main brake Parking brake Type Structure
WB140-2N WB150-2N
01-3
GENERAL 12
SPECIFICATIONS
Hydraulic system Cylinders Pumps
Torque converter Steering Hydraulic
Work
Description
Link type Bucket edge type
Unit
WB140-2N - A20637 and UP
WB150-2N - A60029 and UP
L/min L/min L/min mm
Work equipment valveType Set pressure Travel control valveType Set pressure Cooling fan motorType
01-4
kg/cm² kg/cm²
Simple link Flat edge with BOCE and bolt on teeth
WB140-2N WB150-2N
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE ★ This table is a guide for use when transporting or handling components. Unit : kg Machine Model
WB140-2N WB150-2N
WB140-2N A20637 and UP
WB150-2N A60029 and UP
01-5
GENERAL
FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recommended for this machine. Reservoir
Kind of fluid
Ambient Temperature -30
-20
-10
0
10
20
30
Capacity 40
50°C
Specified
Refill
7.9 L
7.9 L
150 L
92 L
150 L
92 L
6.5 L
6.5 L
1 L each
1 L each
Rear axle diff
14.5 L
14.5 L
Final gear
1.5 L each
1.5 L each
20 L
17 L
0.8 L
0.8 L
130 L
-
14 L
-
SAE 5W-30
Engine oil pan
Oil API CI-4 or JASO SH-1
SAE 10W SAE 20W-20 SAE 30 SAE 40 SAE 10W-30 SAE 15W-40 SAE 5W* SAE 10W
Hydraulic system
SAE 30 SAE 10W-30
Hydraulic system with biodegrad-
See page 3-12
Front axle diff Final gear
See Note 1
Transmission GM DEXRON® II D
ATF Brakes
Fuel tank
Engine cooling system
Diesel fuel
Coolant
ASTM D975 No. 1
ASTM D975 No. 2 AF-NAC
OPTION FOR VERY COLD AREAS:If the temperature is below 10°C, contact your distributor for advise on the type of oil to be used.
01-6
WB140-2N WB150-2N
GENERAL
FUEL COOLANT AND LUBRICANTS
12 API American Petroleum Institute ASTMAmerican Society of Testing and Materials NLGINational Lubricating Grease Institute SAESociety of Automotive Engineers Specified CapacityTotal amount of oil including oil for components and piping. Refill CapacityAmount of oil needed to refill system during normal maintenance. Other equipment may be necessary when operating the machine at temperatures below -20°C. Consult your Komatsu distributor for your specific needs. NOTE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high pressure fuel injection device to obtain good fuel consumption and good exhaust characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a significant drop in durability.
WB140-2N WB150-2N
01-7
GENERAL
FUEL COOLANT AND LUBRICANTS
12
MEMORANDA
01-8
WB140-2N WB150-2N
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
12 ENGINE
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 2WD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 POWER FLOW - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 FORWARD REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 1ST THROUGH 4TH SPEED SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 4WD SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 CENTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45 WB140-2N WB150-2N
10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC VALVE, LS VALVE, SERVO PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LS VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WORKING MODE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MECHANICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEFT OUTRIGGER SECTION VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXCAVATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEFT OUTRIGGER SECTION ˜ VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION OF THE LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DELIVERY COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10-45 10-45 10-46 10-46 10-47 10-52 10-57 10-59 10-59 10-59 10-60 10-60 10-62 10-64 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-80 10-81 10-81 10-82 10-83 10-84 10-84 10-84 10-85 10-87 10-87 10-87 10-90 10-90 10-91 10-91 10-91 10-94
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94 LS DECOMPRESSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95 PRESSURE CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97 PPC JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98 LEFT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98 RIGHT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100 DIFFERENTIAL LOCK - BACKHOE BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . 10-100 PPC SUPPLY VALVE - ST2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101 PPC TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102 PPC HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103 PPC ARM AND HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104 LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 BOOM ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106 MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107 BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108 ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113 BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114 FRONT WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115 REAR WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
WB140-2N WB150-2N
10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
ENGINE MOUNTING
1212
ENGINE MOUNTING TIER I ENGINE 4WD MACHINES
10-4
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
ENGINE MOUNTING
MACHINES
B Tier I Engine C Transmission D Engine Mount WB140-2N WB150-2N
e Transmission Mount F Rear Axle Input G Front Axle Input - 4WD 10-5
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS 12 TIER
ENGINE MOUNTING
II ENGINE
4WD MACHINES
10-6
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
ENGINE MOUNTING
MACHINE
B Tier II Engine C Transmission D Engine Mount WB140-2N WB150-2N
e Transmission Mount F Rear Axle Input G Front Axle Input - 4WD 10-7
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS
POWER TRAIN
12
POWER TRAIN 4WD MACHINES
B C D E
Engine Torque Converter Transmission Hydraulic Pump
F G H I
Front Axle Rear Axle Front Drive Shaft Rear Drive Shaft
DESCRIPTION ●
● ●
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydraulic oil to convert the torque transmitted by the engine b into driving power. The converter transmits motion to the drive shaft of the transmission d and to the drive shaft of the hydraulic pump e. The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector. It also has manual gear selection (four forward gears and four reverse gears). The driving power is transmitted from the transmission flanges to the front f and rear g axles through the drive shafts h and i. The driving power transmitted to the front and rear axles is reduced by the differentials and then transmitted to the planetary gear through the differential shafts.
10-8
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 POWER Gears
POWER TRAIN
FLOW - 4WD Front Axle Trans
1st
4.28
2nd
2.372
3rd
1.239
4th
0.662
Diff
2.385
b Engine c Convert Transmission d Hydraulic Pump WB140-2N WB150-2N
Rear Axle Planet
6.000
Total
Trans
61.238
5.350
33.939
2.965
17.685
1.544
9.472
0.827
E Rear Drive Shaft F Rear Axle G Rear Tires
Diff
Planet
Total 91.362
2.846
6.000
50.633 26.367 14.123
H Front Drive Shaft I Front Axle J Front Tires 10-9
STRUCTURE, FUNCTION & MAINTENANCE STANDARDS 12 2WD
POWER TRAIN
MACHINES
B Engine C Torque Converter D Transmission
e Hydraulic Pump F Rear Drive Shaft G Rear Axle
DESCRIPTION ●
● ●
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydraulic oil to convert the torque transmitted by the engine b into driving power. The converter transmits motion to the drive shaft of the transmission d and to the drive shaft of the hydraulic pump e. The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector. It also has manual gear selection (four forward gears and four reverse gears). The driving power is transmitted from the transmission flange to the rear g axle through the drive shaft h. The driving power transmitted to rear axle is reduced by the differential and then transmitted to the planetary gear through the differential shafts.
10-10
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
POWER TRAIN
Rear Axle Trans
Diff
Planet
5.350 2.965 1.544
Total 91.362
2.846
0.827
b Engine c Convert Transmission d Hydraulic Pump
WB140-2N WB150-2N
6.000
50.633 26.367 14.123
E Rear Drive Shaft F Rear Axle G Rear Tires
10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
TRANSMISSION DIAGRAM 4WD MACHINES
b Engine c Torque Converter d Forward Clutch
10-12
E Transmission F Reverse Clutch G Hydraulic Pump
H Rear Axle Flange I 4WD Clutch J Front Axle Flange
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
B C D E F
Converter Valve Converter Engine Oil Cooler Forward Clutch
WB140-2N WB150-2N
G H I J 1)
Reverse Clutch Max Pressure Valve Spin On Filter Pump Suction Strainer
1! 1@ 1# 1$ 1%
Control Valve Check Valve Check Valve 4WD Solenoid 4WD Clutch
10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 2WD
MACHINES
b Engine c Torque Converter d Forward Clutch
10-14
TRANSMISSION DIAGRAM
E Transmission F Reverse Clutch G Hydraulic Pump
H Rear Axle Flange
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12
B C D E
Converter Valve Converter Engine Oil Cooler
WB140-2N WB150-2N
F G H I
Forward Clutch Reverse Clutch Max Pressure Valve Spin On Filter
J 1) 1! 1@
Pump Suction Strainer Control Valve Check Valve
10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
TRANSMISSION COMPLETE ASSEMBLY
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
10-16
F G H I
Suction Strainer
a From Oil Cooler
Reverse Solenoid
b To Oil Cooler
Forward Solenoid
c To Solenoid Valves
4WD Solenoid
d From Solenoid Valves
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
WB140-2N WB150-2N
F G H I
Suction Strainer
a From Oil Cooler
Reverse Solenoid
b To Oil Cooler
Forward Solenoid
c To Solenoid Valves
4WD Solenoid
d From Solenoid Valves
10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
10-18
F Suction Strainer G Reverse Solenoid H Forward Solenoid
a From Oil Cooler b To Oil Cooler c To Solenoid Valves d From Solenoid Valves
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
WB140-2N WB150-2N
F Suction Strainer G Reverse Solenoid H Forward Solenoid
a From Oil Cooler b To Oil Cooler c To Solenoid Valves d From Solenoid Valves
10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft Drive Gears and Shaft
10-20
H I J 1) 1! 1@
Rear Axle Flange 3rd Driven Gear 4th Driven Gear 4WD Drive Gear 1st Driven Gear
1# 1$ 1% 1^ 1&
4WD Clutch 4WD Clutch Shaft Front Axle Flange 2nd Driven Gear Rear Output Shaft
4WD Driven Gear
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft Drive Gears and Shaft
WB140-2N WB150-2N
H I J 1) 1! 1@
Rear Axle Flange 3rd Driven Gear 4th Driven Gear 4WD Drive Gear 1st Driven Gear
1# 1$ 1% 1^ 1&
4WD Clutch 4WD Clutch Shaft Front Axle Flange 2nd Driven Gear Rear Output Shaft
4WD Driven Gear
10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft
10-22
G H I J 1)
Drive Gears and Shaft Rear Axle Flange 3rd Driven Gear
1! 1st Driven Gear 1@ 2nd Driven Gear 1# Rear Output Shaft
4th Driven Gear Gear Spacer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft
WB140-2N WB150-2N
G H I J 1)
Drive Gears and Shaft Rear Axle Flange 3rd Driven Gear
1! 1st Driven Gear 1@ 2nd Driven Gear 1# Rear Output Shaft
4th Driven Gear Gear Spacer
10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F G
Gear Shift Lever Centering Spring Return Spring Check Ball 3rd And 4th Selecting Fork 1st And 2nd Selecting Rod
10-24
H I J 1) 1! 1@
3rd And 4th Selecting Rod 1st And 2nd Selecting Fork 4th Selecting Sensor 3rd And 4th Selector 1st And 2nd Selector
1# 1$ 1% 1^ 1&
Spin On Filter Cold Oil Relief Valve Return Spring Return Spring Return Spring
Suction Strainer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
B C D E F
Check Ball Return Spring Piston Return Spring Return Spring
WB140-2N WB150-2N
G H I J 1)
Spring Guide Pin Valve Return Spring Valve Rod
1! 1@ 1# 1$ 1%
Return Spring Spool Return Spring Spool Forward Solenoid Reverse Solenoid
10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 FORWARD
TRANSMISSION
REVERSE CLUTCH
B Reverse Gear C Forward Gear D Forward Clutch Piston
E Reverse Clutch Piston F Thrust Ring G Shaft
a Reverse Clutch Port b Forward Clutch Port c Lubrication Port
1ST THROUGH 4TH SPEED SHAFT
B 2nd Driver Gear C 1st Driven Gear D 4WD Gear
10-26
E 4th Driven Gear F 3rd Driven Gear g Rear Output Shaft
H Thrust Ring I Synchronizer J Gear Spacer
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 4WD
TRANSMISSION
SHAFT
B Front Output Shaft C 4WD Driven Gear D Thrust Ring
WB140-2N WB150-2N
E Cylinder F Spring G Disc
a 4WD Pressure Port
10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12
FRONT AXLE 4WD COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut
h Mounting Pin Bushing a Left Cylinder Port b Right Cylinder Port
Unit:mm Check Item i Pin and Bushing Clearance
Standard Size 50
Criteria Tolerance Shaft Bushing 0 +0.04 50 50.19 -0.039 0
Standard Clearance
Clearance Limit
Remedy
---
---
Replace
DIFFERENTIAL 10-28
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
B C D E F G
Side Gear Ring Gear Driven Gear Adjustment Lock Nut Axle Shaft Dowel Pin
H I J 1) 1! 1@
FRONT AXLE
Differential Housing Bearing Spacer Outboard Pinion Bearing Lip Seal Ring Input Flange
1# 1$ 1% 1^ 1&
Pinion Bearing Lock Nut Inboard Pinion Bearing Pinion Gear Dowel Pin Oil Drain Plug
Lip Seal Ring Cover
Unit : mm Check Item 1* 1( 2) 2!
Axle Clearance Ring and Pinion Gear Backlash Pinion Preload * Ring and Pinion Gear Preload *
Criteria Standard Clearance Clearance Limit ----0.17 to 0.23 0.23 92 to 137 N•m 95.9 to 142.9 N•m
Remedy
Adjust
* - Without lip seal ring.
WB140-2N WB150-2N
10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 PLANETARY
B C D E F G H I
Planetary Carrier Planetary Gear Ring Gear Carrier Gear Wheel Hub Lip Ring Seal Upper King Pin Adjustment Shim
Check Item 2% Hub Rotation Torque 2^ Axle Shaft Clearance
10-30
J 1) 1! 1@ 1# 1$ 1% 1^
Belleville Washer Upper King Pin Bushing Lip Ring Seal Axle Housing Spherical Bearing Lower King Pin Bushing Lower King Pin Belleville Washer Criteria -----
1& 1* 1( 2) 2! 2@ 2# 2$
Lip Ring Seal Tapered Roller Bearing Retaining Ring Bolt Bushing Stud Bolt Oil Drain Plug Sun Gear Retaining Ring Remedy Adjust
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 2WD
COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut
h Mounting Pin Bushing a Left Cylinder Port b Right Cylinder Port
Unit : mm Check Item i Pin and Bushing Clearance
WB140-2N WB150-2N
Standard Size 50
Criteria Tolerance Shaft Bushing 0 +0.04 50 50.19 -0.039 0
Standard Clearance
Clearance Limit
Remedy
---
---
Replace
10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 CENTER
HOUSING
B Flange Plug
10-32
FRONT AXLE
c Flange Housing
d Axle Housing
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 STEERING
B C D E F G H I
2@
FRONT AXLE
KNUCKLE
Housing Cover Shaft Plug Screw Bearing Retainer Wheel Hub Lip Ring Seal Upper King Pin Adjustment Shim Check Item Hub Rotation Torque
WB140-2N WB150-2N
J 1) 1! 1@ 1# 1$ 1% 1^
Belleville Washer Upper King Pin Bushing Housing Plug Axle Housing Spherical Bearing
1& 1* 1( 2) 2!
Housing Plug Tapered Roller Bearing Oil Drain Plug Bolt Bushing Stud Bolt
Lower King Pin Bushing Lower King Pin Belleville Washer Criteria ---
Remedy Adjust
10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12
REAR AXLE COMPLETE ASSEMBLY
B C D E
Input Flange Differential Portion Brake Portion Axle Housing
10-34
F G H I
Parking Brake Levers
J Oil Drain Plug 1) Axle Housing Breather
Brake Bleeder Screws
a Brake Port ................. 40.8 kg/cm²
Oil Fill And Level Plugs
b Diff Lock Port ......... 1295.4 kg/cm²
Planetary Portion
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 DIFFERENTIAL
B C D E F
Tapered Roller Bearing Side Gear Rotating Gear Ring Gear Differential Housing
G H I J 1)
1! 1@ 1# 1$ 1%
Bearing Lock Nut Axle Shaft Dowel Pin Tapered Roller Bearing Bearing Lock Nut
Lip Oil Seal Input Flange Bearing Spacer Pinion Gear Differential Housing
Unit : mm Check Item
1^ 1& 1* 1(
Axle Clearance Ring And Pinion Gear Backlash Pinion Gear Preload * Pinion Ring Gear Preload *
Criteria Standard Clearance
Clearance Limit
---
---
0.17 to 0.23
0.23 92 to 138 N•m
Remedy
Adjust
95.23 to 141.84 N•m
* - Without lip seal ring.
WB140-2N WB150-2N
10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 PLANETARY
B C D E F G
Planetary Gear Carrier Wheel Stud Wheel Hub Planet Gear Gear Carrier Tapered Roller Bearings Check Item
1& 1*
10-36
H I J 1) 1! 1@
1# 1$ 1% 1^
Lip Ring Seal Shaft Coupler Inner Axle Shaft Sun Gear Shaft
Outer Ring Gear Oil Fill And Drain Plug Bolt Bushing Planet Gear Shaft
Shaft Bushing Retaining Ring Criteria
Hub Rotation Torque
---
Axle Shaft Clearance
---
Remedy Adjust
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 BRAKES
B C D E
Disc Plate Bushing Parking Brake Control Rod Brake Bleeder Valve Parking Brake Lever
f g h i
Parking Brake Control Cam Brake Disc Plate
j Inner Disc Separator Plate 1) Outer Disc Separator Plate
Actuator Piston Brake Disc Plate Return Spring
Unit : mm
Check Item
1! Brake Disc Return Spring 1@ Disc Return Spring 1# Disc Thickness
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
27
13
127 N•m
21
10 N•m
35
19
369 N•m
21
10 N•m
4.85 to 5
Remedy
Replace
3.3
10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 DIFFERENTIAL
B Engagement Sleeve C Locking Pin D Control Rod
10-38
REAR AXLE
LOCK
e Fork Spacer f Shift Fork g Piston
h Piston Cover i Retaining Ring a Diff Lock Port ......... 1295.4 kg/cm²
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
HYDRAULIC PUMP
b Delivery Variation Valve c Valve Working Mode Solenoid d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line b Case Drain To Suction Line c LS Pressure From Loader Control Valve d Output To Loader Control Valve
WB140-2N WB150-2N
10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
b Delivery Variation Valve c Valve Working Mode Solenoid d Delivery Control Valve
a P Port From Hydraulic Tank Suction Line b Case Drain To Suction Line c LS Pressure From Loader Control Valve d Output To Loader Control Valve
10-40
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
b c d e f g
Lip Seal Ring Tapered Roller Bearing Centering Spring Tapered Roller Bearing Drive Shaft Swash Plate
WB140-2N WB150-2N
H I J 1) 1! 1@
Positioning Piston Swash Plate Positioning Spring Cylinder Block Swash Plate Positioning Piston Pump Piston Guide Shoe
10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 Unit : mm Check Item 1# Bearing Preload
Criteria 0 to 0.05 Standard Size
1$ 1% 1^
1&
Piston To Cylinder Backlash Piston To Shoe Backlash Drive Shaft Diameter
Swash Plate Positioning Spring
10-42
20
Tolerance Shaft Hole ---
Remedy Adjust Standard Clearance
Clearance Limit
Remedy
0.065 0.15
34.91
Free Length ---
Standard Size Installed Installed Length Load 88.7 276 ±12 N
Repair Limit Free Installed Length Load
Remedy Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
Piston Rod
f g h
Bushing
PC VALVE
Initial Adjust Spring
i
POWER GOVERNOR
b c d e
Spring
Pressure Cut Off Screw
j 1)
Initial Adjust Screw
LS VALVE
Pressure Cut Off Spring
Spool
1! 1@
Internal Spring External Spring
1# 1$ 1%
Throttles Throttles Spool
External Spring Internal Spring
Unit : mm
Check Item 1^ 1& 1* 1( 2)
Piston Rod Return Spring Internal Power Reg Spring External Power Reg Spring External LS/PC Spring Internal LS/PC Spring
WB140-2N WB150-2N
Spring Criteria Standard Size Repair Limit Installed Install Installed Free Length Free Length Length Load Load ----------125.4 ±10 N 180.2 ±12 N 40.2 ±3 N 81.7 ±14 N
Remedy
Replace
10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 FUNCTION The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered according to the load requirements. The amount of oil delivered can be modified by changing the angle of the swash plate.
STRUCTURE The cylinder block g is supported and connected to the shaft b by the spline a and the shaft is supported by the front and rear tapered roller bearings. The tip of the piston g is ball shaped. The shoe e is caulked to it to form one unit in such a way that the piston f and the shoe together form a spherical bearing. The swash plate d has a flat surface A and the shoe e remains pressed against this surface while sliding in a circular movement. The swash plate brings highly pressurized oil onto the cylindrical surface B fashioned in the pump body c, which means that the swash plate slides on a hydrostatically supported bearing. The pistons f perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the cylinder block g. The oil is brought up to pressure in the chambers of the cylinder block g by the rotatory movement of the block itself. The areas of pressure and suction are determined by the swash plate f. The surface of the swash plate is so designed that the oil pressure always remains within acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate h.
10-44
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 OPERATION
PUMP OPERATION 1.
The cylinder block g rotates together with the shaft b and the shoe e slides on the flat surface A. The swash plate d moves along the cylindrical surface B. The angle α formed between the center line of the shaft and the center line X of the swash plate changes, thus modifying the axial position of the pistons in relation to the cylinder block. Angle α is known as the swash plate angle.
2.
When the center line X of the swash plate d maintains the angle α in relation to the center line of the shaft b, and hence also of the cylinder block g, the flat surface A acts as a cam for the shoe e. As the piston f rotates and slides inside the cylinder block, it creates a difference between the volumes C and D which provokes intake and discharge of the oil in quantities equal to the difference between the volumes (D - C = delivery). As the cylinder block rotates, chamber D loses volume while the volume of chamber C is increased, thus provoking an intake of oil. The figure indicates the state of the pump when the intake of chamber D and the delivery of chamber C have been completed.
3.
When the center line X of the swash plate d and the center line of the cylinder block g are perfectly aligned (the swash plate angle α = 0), the difference between the volumes C and D within the cylinder block becomes 0 and the pump does not take in or deliver any oil. In practice the swash plate angle α never becomes = 0. Pump delivery is directly proportional to the swash plate angle α.
CONTROL OF DELIVERY 1.
As the swash plate angle α grows larger, the difference between volumes C and D increases, and the delivery Q also increases. The swash plate angle is modified by servo pistons I and J.
2.
The servo piston I moves in a reciprocating linear motion caused by pressure signals from the PC and LS valves. The linear movement is transmitted to the swash plate D, which is supported by the cylindrical surface of the cradle C. The swash plate therefore has a semi-circular reciprocating movement.
3.
The surfaces of the servo pistons receiving the pressures PP and LS are dissimilar. The delivery pressure PP of the main pump is always passed into the smaller (upper) pressure chamber, whereas the pressure PEN coming from the LS valve is passed into the larger (lower) pressure chamber. The movement of the servo piston is governed by the relationship between pressures PP and PEN, as well by the proportions between the surfaces (larger and smaller) of the servo piston.
WB140-2N WB150-2N
10-45
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PC
VALVE, LS VALVE, SERVO PISTON
POWER GOVERNOR
b c
HYDRAULIC PUMP
Spring Servo Piston
D
Servo Piston
LS VALVE
PC VALVE
E F
G H
Piston Spring
Servo Piston Spring
LS VALVE FUNCTION ●
●
The LS valve controls the pump delivery according to the stroke of the control valve level, i.e., in function of the delivery demands made by the actuators. The LS valve detects the actuators delivery needs by means of the differential pressure PLS existing between the pump delivery pressure PP and the pressure PLS coming from the control valve. This reading permits control of the main pump delivery Q. PP, PLS and PLS are, respectively, the pump pressure, the Load Sensing pressure, and the difference in pressure between these two values. The LS valve detects the pressure difference PLS generated by the passage of the oil flow through the surface freed by the control valve spool, and controls the pump delivery Q so as to keep the pressure drop constant. Pump delivery is proportional to the demands made known by the control valve.
10-46
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 OPERATION 1.
When the control valve is in a NEUTRAL position.
●
The pressure PLS of the LS coming from the control valve outlet passes into chamber a of the spring of the LS valve. The pressure PP of the pump passes into chamber b of the opposite side. The piston rod movement e is determined by the combination of the force generated by the pressure PLS, the force of the spring g and the force generated on the side opposite the piston rod by the pressure PP. Before the engine is started the servo piston d is pushed to the right by the spring b, corresponding to the maximum angle of the swash plate. If all the control valve spools are in their NEUTRAL position when the engine is started, the pressure PLS of the LS will remain at 4.1 to 8.16 kg/cm² because no oil is flowing through the control valve. At the same time the pump pressure PP increases and is maintained at a value of about 27.54 kg/cm². For this reason the piston e is thrust to the right ( ) and a passage is formed between the delivery lines c and d. This opening enables the pump pressure PP to enter chamber X of the servo piston d. Although the pump pressure PP is always passed into chamber Y of the servo piston c, since the force exerted by that pressure on piston d exceeds the force exerted on piston, the servo piston b moves to the right ( ), i.e. towards the side of the minimum angle of the swash plate.
● ● ●
● ●
WB140-2N WB150-2N
10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 2. When a control valve lever is activated
● ● ●
●
When the control valve lever is moved out of its NEUTRAL position, the opening f is determined, allowing an LS signal to be generated. Until the PLS generates a force less than the force exerted by the spring g on the spool e, the system will remain stable. When the opening f is such as to provoke a reduction in PLS, the spool moves to the left ( ) to form a passage between delivery lines d and e. The chamber X loses pressure and the servo piston causes the swash plate to move towards maximum displacement. Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force exerted by the spring g, and the passage between delivery lines c and d is reopened.
10-48
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 3. When the control valve opening is at its maximum, lever at the end of its stroke.
● ●
● ●
When the control lever is moved to full stroke, the spool opening reaches its maximum, the difference between the pump pressure PP and the LS pressure PLS becomes smaller, differential pressure PLS. The LS pressure PLS introduced into the chamber a of the LS valve becomes about the same as the pump pressure PP and the piston e is moved to the left ( ) by the combined forces generated by the pressure PLS and the spring g. The piston movement closes the delivery line c and forms a passage between lines d and e. The pressurized oil present in the chamber X of the servo cylinder D flows through the lines d and e and reaches the pump drainage chamber, so that the pressure in chamber X of the servo cylinder B becomes equal to the drainage pressure. The servo piston D is thus moved to the right ( ) by swash plate movement due to the pressure PP in the chamber Y of the servo cylinder C. It is drawn in the direction of the increase in angle of the swash plate.
WB140-2N WB150-2N
10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 4. When the spool makes very small movements, fine control.
● ●
● ●
●
When the control valve lever moves in very small increments towards the NEUTRAL position, when the control valve opening f diminishes, the differential pressure PLS between the pump pressure PP and the LS pressure PLS increases. If the differential pressure PLS generates on the spool e a difference in force that exceeds the force exerted by the spring g, the spool moves to the right ( ) and a passage is formed between the delivery lines c and d. The pressure PP is introduced into the chamber X and the swash plate moves towards its minimum angle. When the control valve lever performs small movements towards the position of maximum opening, when the opening f of the control valve increases, the differential pressure PLS diminishes. If the differential pressure PLS generates on the spool e a force difference that does not exceed the force exerted by the spring g, the spool moves to the left ( ) and a passage is formed between the delivery lines d and e. The chamber X loses pressure and the servo piston provokes a movement of the swash plate towards maximum displacement. Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force exerted by the spring g, and hence the passage between delivery lines c and d is also reopened.
10-50
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 5. When pump flow matches the demands of the control valve
● ●
●
● ●
A1 will be the surface of the servo piston d, A2 the surface of the servo piston (2), PEN the pressure acting on the piston b and PP the pressure acting on the piston side c. When pump delivery reaches the quantity demanded by the control valve, the pump pressure PP in chamber b of the LS valve is in equilibrium with the combined forces of the LS pressure PLS in chamber a, and the force exerted by the spring g. Once equilibrium has been reached the piston e stops in the central position. In this condition the passage from chamber c to chamber d remains only slightly open in order to maintain pressure in chamber d. A flow of oil is introduced into the servo cylinder d at a pressure that balances the force generated by the pump pressure PP in the cylinder c. PEN x A1 = PP x A2. The stability of the equilibrium is guaranteed by a flow stabilized by the throttle g. The force of the spring g is regulated so that the piston e is in equilibrium when PP - PLS = PLS = 18.36 kg/cm². The pump flow is made proportional to the section of the opening of the control valve, which maintains the differential pressure. PLS = 18.36 kg/cm².
WB140-2N WB150-2N
10-51
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 PC
VALVE FUNCTION
●
The PC valve performs an approximate power check, and ensures that the hydraulic horse power absorbed by the pump does not exceed the horse power delivered by the endothermal engine. This is achieved by limiting the pump delivery Q in function of the delivery pressure PP, even if the LS valve requests an increase in delivery Q due to the larger section freed by the control valve spool, in the presence of high pressure pump delivery. During operation the delivery Q increases and the delivery pressure PP also increases simultaneously, the PC valve reduces the pump delivery Q. When the delivery pressure PP decreases, the PC valve increases the pump flow. The relationships between the pump delivery pressure PP and the delivery Q are shown in the diagram.
●
●
●
10-52
HYDRAULIC PUMP
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 Operation 1.
When the load on the actuators is heavy, high pump delivery pressure
●
When a higher delivery is required, the LS valve receives a signal from the control valve to bring the pump up to maximum displacement. When the swash plate moves it also moves the bushing c joined to it by the pin b, which releases the spring d. As the pressure of the actuators increases, pressure also increases in the delivery line c. When the calibrated setting of the spring d is reached, the piston rod e is thrust to the left ( ) and the passage between chamber b and the pump drainage chamber a is opened. The opening of the passage between the chambers b and a generates a flow of oil and hence, due to the calibrated hole g, a P is generated between chambers f and g at the sides opposite the spool f. P = PP - PPC When the value of PP exceeds the value of the spring loading h the spool f moves to the right ( ) opening the passage between the delivery lines d and e and sending the pump pressure PP towards the servo cylinder i. The pressure PP introduced into chamber X of the cylinder pushes it towards the minimum angle of the swash plate ( ).
●
● ●
WB140-2N WB150-2N
10-53
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 2. When equilibrium has been reached
●
● ●
●
When the piston i is pushed to the left ( ) the bushing c is also moved. The oil flow between the chambers b and a is reduced and the PPC pressure tends to approach the PP pressure value. The P decreases and the spool f is pushed to the left ( ) by the force of the spring h. Equilibrium is reached when the force generated by the PP pressure, the force generated by the PPC pressure, and the force of the spring h are all balanced. The force generated by PP = the force generated by the PPC + the spring force. In this condition the passage from chamber d to chamber e remains only slightly open in order to maintain pressure in chamber e. A flow of oil is introduced into the cylinder i at a pressure that balances the force generated by the pump pressure PP acting on the cylinder j. PEN x A1 = PP x A2 The stability of this equilibrium is generated by a continuous stabilized flow from the throttle 1).
10-54
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 3. When the load on the actuators decreases, pump delivery pressure drops
● ●
● ●
When the load on the actuators diminishes and the pump delivery pressure PP drops, the PPC. pressure also drops. The reduction in the PPC causes the spool e to move and the passage between chambers b, d and a is closed. The PPC pressure and the PP pressure of the pump are equalized due to the interruption of the oil flow through the calibrated hole g and the P becomes zero P = PP - PPC = 0. The spring h pushes the spool f to the left ( ) closing the passage between the chambers d and e and opening the passage between chambers e and g. The pressurized oil present in chamber X of the servo cylinder i passes through chambers e and g and reaches the pump drainage chamber, so that the pressure in chamber X of the servo cylinder becomes equal to the drainage pressure. The servo piston j is caused to move by the PP pressure in chamber Y of the servo cylinder, in the direction of the increase in the angle of the swash plate.
WB140-2N WB150-2N
10-55
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 4. The function of the spring
●
●
●
The loading on the springs d and 1! of the PC valve changes in proportion to the angle of inclination of the pump swash plate. The compression of the spring varies with the movements of the servo piston i. When the piston moves to the left ( ), the spring is compressed. If the piston moves even further to the left ( ), the spring 1! comes into action to increase the loading. The overall loading of the springs is varied by the piston, which either compresses or releases them. The pump absorption torque curve, which indicates the relationship between the pump delivery pressure PP and the delivery Q, is a broken line. The position in which the piston i stops, the pump absorption torque, is determined by the position in which the PPC pressure applied to the spool e is balanced by the force exerted by the springs d and 1!. As pump delivery pressure PP increases, delivery Q decreases, and as pressure PP diminishes, pump delivery Q increases.
10-56
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 WORKING
HYDRAULIC PUMP
MODE SOLENOID VALVE
Function ●
Calibration of the pump absorption torque is normally performed for the working mode E. When the solenoid valve of the working mode is commutated the absorbed power of the pump is increased, as indicated by the working mode curve.
Operation WORKING MODE E
● ●
During normal operation, working mode E, the PC valve intervenes when a P1 is generated equal to the loading on the spring e. The P1 is generated by the calibrated hole d in the spool of the PC valve c when, at a determined pump delivery pressure P1, the valve b puts the delivery line a into discharge, thus generating a flow F1 in the delivery line a.
WB140-2N WB150-2N
10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 WORKING MODE P
● ●
● ●
When the solenoid valve g is commutated, working Mode P, the pressurized oil coming from the pump changes its route and passes through the throttle f, which has a larger diameter than the calibrated hole d. Because the throttle f has a larger diameter, the P2 generated is less than is needed to overcome the force generated by the spring e. The spool of the PC valve c is therefore pushed to the left ( ) by the force of the spring. This shift obliges the pump to increase displacement and hence the delivery. The increase in flow causes an increment of the P2 which, when the loading value of the spring is reached, allows the spool to shift to the right ( ). The pump starts to work in normal fashion once again, and all the valves recommence normal functioning.
10-58
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING UNIT
12
STEERING UNIT
a. b. c. d. e.
Port LS Port T Port L Port D Port P
From the loader control valve To the hydraulic oil tank To the steering cylinder To the steering cylinder From the loader control valve
TECHNICAL DATA Steering unit type .................................................LAGCSDS160P Displacement ............................................................... 160 cc/rev.
OPERATION ●
●
The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering wheel is turned, the control valve sends oil from the pump P2, by means of the rotating oil dispenser, to one side of the steering cylinder. The rotating dispenser ensures that the volume of oil supplied to the cylinder is proportionate to the angle of rotation of the steering wheel. In the event of malfunction, the rotating oil dispenser will function automatically as a hand pump, thus guaranteeing auxiliary steering.
WB140-2N WB150-2N
10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
LOADER VALVE 2 SPOOL
a b c d e f g h j
b c d e f g
Port D - To the Hydraulic Steering Unit Port A2 - To the Bucket Cylinders Port A1 - To the Boom Cylinders Port LS - To the Pump Port T - To the Hydraulic Oil Tank Port P - From the Pump
Loader Relief Valve Plug Ball Check Valve Spring Priority Valve Piston Rod Priority Valve Spring
Port B1 - To the Boom Cylinders Port B2 - To the Bucket Cylinders Port DLS - To the Hydraulic Steering Unit
Unit : mm
Check Item h i
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Check Valve Spring Priority Valve Spring
10-60
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
b c d e f
Port Plug Boom Raise Spool Spool Return Spring Spool Locking Spring
Detent Ball
G H I J 1)
Detent Lock Ball Compensator Anti Cavitation Valve
1! Holding Coil 1@ Check Valve Spring 1# Check Valve
Bucket Dump Spool Spool Return Spring
Unit : mm
Check Item 1$ 1% 1^ 1&
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Spool Return Spring Spool Locking Spring Spool Return Spring Check Valve Spring
WB140-2N WB150-2N
10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 3 SPOOL
a b c d e f g h j
LOADER VALVE
VALVE
k m b c d e f g
Port D - To the Hydraulic Steering Unit Port A3 - To the Auxiliary Cylinders Port A2 - To the Bucket Cylinders Port A1 - To the Boom Cylinders Port LS - To the Pump Port T - To the Hydraulic Oil Tank Port P - From the Pump Port B1 - To the Boom Cylinders
Port B3 - To the Auxiliary Cylinders Port DLS - To the Hydraulic Steering Unit Loader Relief Valve Plug Ball Check Valve Spring Priority Valve Piston Rod Priority Valve Spring
Port B2 - To the Bucket Cylinders
Unit : mm
Check Item h i
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Check Valve Spring Priority Valve Spring
10-62
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER VALVE
12
b c d e f
Port Plug Boom Raise Spool Spool Return Spring Spool Locking Spring
Detent Ball
G H I J 1)
Detent Lock Ball Compensator Anti Cavitation Valve Bucket Dump Spool
1! 1@ 1# 1$
Holding Coil Check Valve Spring Check Valve Auxiliary Spool
Spool Return Spring
Unit : mm
Check Item 1% 1^ 1& 1*
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Spool Locking Spring Spool Return Spring Check Valve Spring Spool Return Spring
WB140-2N WB150-2N
10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CONTROL VALVE
12
BACKHOE CONTROL VALVE MECHANICAL CONTROL
10-64
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
A B C D E F G H I
J Arm Cylinder Section A1 Swing Cylinder Section A2 Right Outrigger Cylinder Section A3 Left Outrigger Cylinder Section A4 Bucket Cylinder Section A5 Boom Cylinder Section A6 Telescopic Arm Cylinder Section A7 Hammer Cylinder Section A8 Inlet Section
BACKHOE CONTROL VALVE Outlet Section Arm Cylinder Barrel Right Swing Cylinder Barrel Right Outrigger Cylinder Barrel Left Outrigger Cylinder Barrel Bucket Cylinder Barrel Boom Cylinder Barrel Telescopic Arm Cylinder Barrel
B1 B2 B3 B4 B5 B6 B7 B8
Arm Cylinder Rod Right Swing Cylinder Rod Right Outrigger Cylinder Rod Left Outrigger Cylinder Rod Bucket Cylinder Rod Boom Cylinder Rod Telescopic Arm Cylinder Rod Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve b Return Spring
C Retainer Plug D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item f
Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-65
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 ARM
BACKHOE CONTROL VALVE
SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-66
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 SWING
BACKHOE CONTROL VALVE
SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LEFT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW E-E
a Port Plug D Left Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-68
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 RIGHT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BUCKET
BACKHOE CONTROL VALVE
SECTION VIEW G-G
a Circuit Relief Valve D Bucket Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-70
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BOOM
BACKHOE CONTROL VALVE
SECTION VIEW H-H
a Adjustable Circuit Relief Valve D Boom Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball WB140-2N WB150-2N
10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 TELESCOPIC
BACKHOE CONTROL VALVE
ARM SECTION VIEW K-K
a Port Plug D Telescopic Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Anti Cavitation Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-72
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 HAMMER
BACKHOE CONTROL VALVE
SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 EXCAVATOR
10-74
BACKHOE CONTROL VALVE
CONTROL
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12
A B C D E F G H I
J Arm Cylinder Section A1 Swing Cylinder Section A2 Right Outrigger Cylinder Section A3 Left Outrigger Cylinder Section A4 Bucket Cylinder Section A5 Boom Cylinder Section A6 Telescopic Arm Cylinder Section A7 Hammer Cylinder Section A8 Inlet Section
BACKHOE CONTROL VALVE Outlet Section Arm Cylinder Barrel Right Swing Cylinder Barrel Right Outrigger Cylinder Barrel Left Outrigger Cylinder Barrel Bucket Cylinder Barrel Boom Cylinder Barrel Telescopic Arm Cylinder Barrel
B1 B2 B3 B4 B5 B6 B7 B8
Arm Cylinder Rod Right Swing Cylinder Rod Right Outrigger Cylinder Rod Left Outrigger Cylinder Rod Bucket Cylinder Rod Boom Cylinder Rod Telescopic Arm Cylinder Rod Hammer Inlet Port
Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve b Return Spring
C Retainer Plug D Pressure Cut Out Valve
E Unloading Valve
Unit : mm
Check Item f
Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 ARM
BACKHOE CONTROL VALVE
SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-76
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 SWING
BACKHOE CONTROL VALVE
SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 LEFT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION Ù VIEW E-E
a Port Plug b LIFD - Load Independent Flow Divider C Port Plug
D Left Outrigger Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-78
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 RIGHT
BACKHOE CONTROL VALVE
OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BUCKET
BACKHOE CONTROL VALVE
SECTION VIEW G-G
a Adjustable Circuit Relief Valve D Bucket Cylinder Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Adjustable Circuit Relief Valve f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-80
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 BOOM
BACKHOE CONTROL VALVE
SECTION VIEW H-H
a Adjustable Circuit Relief Valve b LIFD - Load Independent Flow Divider C Adjustable Circuit Relief Valve
D Boom Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball WB140-2N WB150-2N
10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 TELESCOPIC
BACKHOE CONTROL VALVE
ARM SECTION VIEW K-K
a Port Plug b LIFD - Load Independent Flow Divider C Anti Cavitation Valve
D Telescopic Arm Cylinder Spool e Spool Return Spring f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
10-82
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 HAMMER
BACKHOE CONTROL VALVE
SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool b LIFD - Load Independent Flow Divider e Spool Return Spring C Port Plug f Check Valve
g Check Valve Return Spring
Unit : mm
Check Item h i
Spool Return Spring Check Valve Return Spring
WB140-2N WB150-2N
Free Length
Spring Criteria Standard Size Installed Installed Length Load
Repair Limit Free Installed Length Load
Remedy
Replace
10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
CLSS CHARACTERISTICS The term CLSS means Closed Center Load Sensing System, which has the following characteristics: ● High precision control that is independent of the load applied to the movement; ● High precision control of digging action even during delicate manoeuvres. ● Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the shuttles. ● Energy savings guaranteed by control of pump delivery.
STRUCTURE ● ●
The CLSS system includes the variable flow pump, the control valve and the working equipment. The pump includes the main pump, the PC valve and the LS valve.
10-84
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
OPERATING PRINCIPLES 1.
Control of the angle of the pumping plate. ● The angle of the swash plate and the pump delivery, is controlled in such a way that the differential pressure PLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards the actuator is maintained at a constant value. PLS = pump delivery pressure PP minus pressure PLS of delivery to the actuator. ● If the differential pressure PLS becomes lower than the set pressure of the LS valve, the angle of the swash plate increases, delivery increasing. ● If the differential pressure PLS increases, the angle of the swash plate decreases.
WB140-2N WB150-2N
10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 2. Pressure compensation control. ● The pressure compensation valves are installed downstream from the control valve in order to balance the differential pressure between the loads. ● When two or more movements (cylinders) are activated simultaneously, the pressure differences P between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
10-86
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 UNLOADING
CLSS
VALVE
FUNCTION 1.
When the control valve is in the NEUTRAL position, the flow of the pump, due to the swash plate being in the minimum angle position, is sent to the control valve. In these conditions, the pump delivery pressure PP is regulated to 27.5 kg/cm² by the spring a inside the valve. PP = PLS + spring load with PLS = 6.1 kg/cm²
OPERATION When the control valve is in the NEUTRAL position ● On the two surfaces of the shuttle b, the pump pressure PP acts on the right side, while the LS signal with pressure PLS acts on the left side. ● Because a LS signal is generated with a pressure PLS 6.1 ± 2 kg/cm², when the control valve is in the NEUTRAL position, the pump delivery pressure PP is regulated by the combination of the pressure provided by the spring and by the LS pressure PLS. ● While the pump delivery pressure PP increases until it compensates for the loading on the spring a and for the LS pressure 27.5 kg/cm², the shuttle b moves to the left ( ) and the PP circuit is put into communication with the tank circuit T. ● This system ensures that the pump delivery pressure PP stays regulated at 27.5 kg/cm².
WB140-2N WB150-2N
10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 1. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by the pressure PLS + 21.5 kg/cm². Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and the PLS LS pressure becomes equivalent to the loading of the spring a (21.5 kg/cm²), the differential LS pressure PLS LS becomes 21.5 kg/cm².
Final control of control valve ● When final control are performed with the control valve, a pressure PLS is generated that pressurizes the spring chamber, acts on the left extremity of the valve b. The actuator pressure is introduced into the LS circuit and then into the spring chamber. As a result, the pump pressure PP tends to increase. ● When the differential pressure between the pump delivery pressure PP and the LS pressure PLS has the same value as the loading on the spring a (21.5 kg/cm²), the shuttle b moves to the left ( ) and the pump circuit PP puts itself into communication with the tank circuit T. The exceeding pump delivery, relative to the actuator request, is sent to the tank circuit. ● The pump delivery pressure PP is regulated by the combination of the pressure provided by the spring (21.5 kg/cm²) and by the LS pressure PLS, i.e. when the pressure differential PLS reaches the value of 21.5 kg/cm².
10-88
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 2. When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control valve, the connection to the tank circuit is eliminated and all the pump delivery is sent to the actuators.
When the control valve is in use ● When the control valve shuttle is operated to execute a bigger stroke, the opening section of spool becomes bigger and consequently the controlled delivery. Because the control valve passage is large, the difference between the LS pressure PLS and the pump delivery pressure PP is reduced to 18.4 kg/cm², LS pump valve setting. ● Because the differential pressure between the pump delivery pressure PP and the LS pressure PLS is not equal to the pressure given by the spring loading a (21.5 kg/cm²), the shuttle b is pushed to the right ( ) of the spring. ● The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the entire pump delivery is sent to the actuators.
WB140-2N WB150-2N
10-89
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
INTRODUCTION OF THE LS PRESSURE ●
The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control valve.
OPERATION ● ●
● ●
When the spool b is activated, pump pressure PP starts to flow into the actuator circuit A through chamber b. At the same time the compensator c moves upwards ( ) so that the flow controlled by spool b can flow towards the actuator A. Check valve a do not allow any flow up to when pressure in chamber c is higher than pressure in chamber b. Pressure downstream of the spool flows in the PLS circuit downstream the compensator valve through the orifice d. The PLS circuit of the LS is thus in communication with the tank circuit T by means of the LS decompression valve d. The system stabilizes when a pressure difference of 18.4 kg/cm² is generated across the spool b between pump pressure PP and PLS pressure.
10-90
WB140-2N WB150-2N
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 12 DELIVERY
CLSS
COMPENSATION
INTRODUCTION The flow sent to each actuator is controlled by the opening area of each spool. While performing complex control, in traditional control valves the difference between actuators pressure might cause sudden and unexpected movements acceleration in those actuators operated at lower pressure. The adoption of the pressure compensation valve allow to control those situation guarantying the proportionality between each actuator. Compensation of actuator deliveries occurs when, during the simultaneous activation of two or more movements, the pressure of one actuator drops lower than that of the other, and pump delivery, if not controlled, tends to be supplied the actuator operating at lower. In the diagram the actuator on the left is requesting higher pressure.
OPERATION 1. ●
●
●
When activating an actuator at a pressure lower than the one already working. While operating actuator A starts operating actuator B. Until the pressure PBV downstream from the shuttle b reaches the same value requested by actuator B, no oil passes. When the pressure requested by actuator B is exceeded, movement can commence. This creates a flow that adding to the one controlled by spool d reduces the pressure upstream of spool b and d and therefore the P between PLS and PP. The pump compares the delivery pressures PP and PLS and senses that the difference PPA, the pressure PB will start to increase. Since pressure PB is increasing, the compensator c moves upwards to restore the P between the chambers a and b, and therefore the P does not vary upstream or downstream from the shuttle b. When pressure PB exceeds pressure PA the compensator c is fully open and the pressure PB is introduced into the LS circuit. The increased pressure in the LS circuit obliges the pump to increase delivery until the P is restored to 18.4 kg/cm². Simultaneously the increase in pressure upstream from the shuttle d generates an increase in P upstream and downstream from the shuttle. (PAV
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