WB140-2N (ING) komatsu

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