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WB146-5 - Shop Manual - 200p. - Decryped
WB146-5 - Shop Manual - 200p. - Decryped
Shop
Manual
WB146-5
BACKHOE LOADER
SERIAL NUMBERS WB146-5 A23001 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 recom-
mended that customers contact their distributor for information on the latest revision.
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 WB146-5
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00 00
GENERAL PRECAUTIONS 00 lock all the control levers and hang warning signs on
them.
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully be- 3. When disassembling or assembling, support the ma-
fore operating the machine. chine with blocks, jacks or stands before starting work.
1. Before carrying out any greasing or repairs, read all the 4. Remove all mud and oil from the steps or other places
precautions given on the decals which are fixed to the used to get on and off the machine. Always use the
machine. handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is im-
2. When carrying out any operation, always wear safety possible to use the handrails, ladders or steps, use a
shoes and helmet. Do not wear loose work clothes, or stand to provide safe footing.
clothes with buttons missing.
PRECAUTIONS DURING WORK 00
4. When carrying out any operation with two or more 2. The water and oil in the circuits are hot when the engine
workers, always agree on the operating procedure be- is stopped, so be careful not to get burned. Wait for the
fore starting. Always inform your fellow workers before oil and water to cool before carrying out any work on
starting any step of the operation. Before starting work, the oil or water circuits.
hang UNDER REPAIR signs on the controls in the oper-
3. Before starting work, remove the leads from the battery.
ator's compartment.
ALWAYS remove the lead from the negative (-) termi-
5. Keep all tools in good condition and learn the correct nal first.
way to use them. Decide a place in the repair workshop
4. When raising heavy components, use a hoist or crane.
to keep tools and removed parts. Always keep the tools
Check that the wire rope, chains and hooks are free from
and parts in their correct places. Always keep the work
damage. Always use lifting equipment which has ample
area clean and make sure that there is no dirt or oil on
capacity. Install the lifting equipment at the correct plac-
the floor. Smoke only in the areas provided for smoking.
es. Use a hoist or crane and operate slowly to prevent
Never smoke while working.
the component from hitting any other part. Do not work
PREPARATIONS FOR WORK with any part still raised by the hoist or crane.
00
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.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 in-
stalled.
10. 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 cor-
rectly.
11. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
12. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
13. 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.
14. 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 ma-
chine.
00-4 WB146-5
FOREWORD GENERAL
12GENERAL
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand 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 comple-
tion 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.
WB146-5 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
Shop manuals are issued as a guide to carrying out repairs. When a manual is revised, an edition mark ( …) is re-
They are divided as follows: corded on the bottom outside corner of the pages.
Engine volume: Issued for each engine series Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
Electrical volume: Each issued as one to cover all models
SYMBOLS 00
10-4
10-4-1
Added pages
10-4-2
10-5
00
00
00
00
00
00
00-6 WB146-5
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when hoist-
11.2 13.7 1.4 ing is made with two ropes, each of which is allowed to
12.5 15.7 1.6 sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
14 21.6 2.2 total weight can be suspended. This weight becomes
16 27.5 2.8 1000 kg when two ropes make a 120° hanging angle. On
the other hand, two ropes are subject to an excessive
18 35.3 3.6 force as large as 4000 kg if they sling a 2000 kg load at a
20 43.1 4.4 lifting angle of 150°
WB146-5 00-7
FOREWORD QUICK DISCONNECT COUPLER
12
QUICK DISCONNECT COUPLER 00
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. 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).
3. After the hose joint (2) is pushed into the adapter (3), press the rub-
ber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some hy-
draulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. 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).
2. 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 in-
dicate an abnormality.
00-8 WB146-5
FOREWORD QUICK DISCONNECT COUPLER
12
TYPE 2 00
DISCONNECTION 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 00
1. 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 WB146-5
FOREWORD QUICK DISCONNECT COUPLER
12
TYPE 3 00
DISCONNECTION 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) con-
tacts 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 00
1. 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
00-10 WB146-5
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
3 Bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-al- ● Quick cure type (max. strength after 30 min-
Polyethylene
pha 790-129-9130 50 g utes).
container
201 ● Used mainly for adhesion of rubbers, plas-
tics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high temper-
648-50 container
ature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-11 WB146-5
FOREWORD COATING MATERIALS
squeaking).
disulphide
lubricant
SYG2-400LI
SYG2-350LI
SYG2-160LI
SYGA160CNLI
SYG2-400CA
Grease SYG2-350CA
● Used for normal temperature, light load
G2-CA SYG2-400CA-A Various Various bearing at places in contact with water or
steam.
SYG2-160CA
SYG2-160CNCA
Molybdenum
disulphide
lubricant
00-12 WB146-5
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
mm mm N•m 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
mm mm N•m lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
00-13 WB146-5
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
00-14 WB146-5
FOREWORD STANDARD TIGHTENING TORQUE
12
TABLE 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 Width across flat Tightening torque - N•m (lbf ft)
Norminal No.
mm mm Range Target
02 14 35 - 63 (25.81 - 46.46) 44 (32.45))
03, 04 20 84 - 132 (61.95 - 97.35) 103 (75.96)
Varies depending on
05, 06 24 128 - 186 (94.40 - 137.18) 157 (115.79)
type of connector.
10, 12 33 363 - 480 (267.73 - 354.02) 422 (311.25)
14 42 746 - 1010 (550.22 - 744.93) 883 (651.26)
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque - N•m (lbf lb)
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42)
10 10 17 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31)
12 12 19 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01)
14 14 22 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62)
16 16 24 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68)
18 18 27 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91)
20 20 30 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14)
24 24 32 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59)
30 30 32 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50)
33 33 _ 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75)
36 36 36 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03)
42 42 _ 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40)
52 52 _ 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.
00-15 WB146-5
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 Cable O.D. Current
Number of Dia. Of Cross section Applicable circuit
number (mm) rating (A)
strands strand (mm) (mm)
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
Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 WB146-5
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 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
A. Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from .
B. Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .
C. Take the point where the two lines cross as . This point gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 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.
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.
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
00-17 WB146-5
FOREWORD CONVERSION TABLES
12
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
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
00-18 WB146-5
FOREWORD CONVERSION TABLES
12
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
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
WB146-5 00-19
FOREWORD CONVERSION TABLES
12
50 36.85 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.22 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.59 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.96 59.697 60.434 61.171 61.908 62.645 63.382 64.119 64.856 65.593
90 66.33 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.7 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.07 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.44 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.81 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.18 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.55 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.92 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.29 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.66 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.03 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-20 WB146-5
FOREWORD CONVERSION TABLES
12
50 442.5 451.35 460.2 469.05 477.9 486.75 495.6 504.45 513.3 522.15
60 531 539.85 548.7 557.55 566.4 575.25 584.1 592.95 601.8 610.65
70 619.5 628.35 637.2 646.05 654.9 663.75 672.6 681.45 690.3 699.15
80 708 716.85 725.7 734.55 743.4 752.25 761.1 769.95 778.8 787.65
90 796.5 805.35 814.2 823.05 831.9 840.75 849.6 858.45 867.3 876.15
100 885 893.85 902.7 911.55 920.4 929.25 938.1 946.95 955.8 964.65
110 973.5 982.35 991.2 1000.05 1008.9 1017.75 1026.6 1035.45 1044.3 1053.15
120 1062 1070.85 1079.7 1088.55 1097.4 1106.25 1115.1 1123.95 1132.8 1141.65
130 1150.5 1159.35 1168.2 1177.05 1185.9 1194.75 1203.6 1212.45 1221.3 1230.15
140 1239 1247.85 1256.7 1265.55 1274.4 1283.25 1292.1 1300.95 1309.8 1318.65
150 1327.5 1336.35 1345.2 1354.05 1362.9 1371.75 1380.6 1389.45 1398.3 1407.15
160 1416 1424.85 1433.7 1442.55 1451.4 1460.25 1469.1 1477.95 1486.8 1495.65
170 1504.5 1513.35 1522.2 1531.05 1539.9 1548.75 1557.6 1566.45 1575.3 1584.15
180 1593 1601.85 1610.7 1619.55 1628.4 1637.25 1646.1 1654.95 1663.8 1672.65
190 1681.5 1690.35 1699.2 1708.05 1716.9 1725.75 1734.6 1743.45 1752.3 1761.15
WB146-5 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, con-
sider 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
00-22 WB146-5
01 GENERAL
WB146-5 01-1
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
ITEM UNIT WB146-5 A23001 and UP
Minimum
Operating weight kg
Maximum
GP w/BOCE 0.95
Loader
MP w/BOCE 0.99
Model S4D102LE-2
Alternator V 12
Output A 95
Battery Ah @ V 100
Starter kW 3.2
01-2 WB146-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This table is a guide for use when transporting or handling components.
Unit: kg
Component WB146-5 A23001 and UP
WB146-5 01-3
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 recom-
mended for this machine.
SAE 5W-30
SAE 10W
SAE 20W-20
Engine oil
SAE 30 11 L 13 L
pan
Oil API CI-4
SAE 40
SAE 10W-30
SAE 15W-40
SAE 5W*
SAE 10W
Hydraulic 150 L 92 L
SAE 30
system
SAE 10W-30+
HEES 150 L 92 L
Front axle
6.5 L 6.5 L
diff
Oil API CI-4
Transmission 20 L 17 L
ATF GM DEXRON® II D
Brakes 0.8 L 0.8 L
ASTM
Diesel D975 No. 1
Fuel tank 130 L -
fuel
ASTM D975 No. 2
Engine cool-
Coolant AF-NAC 14 L -
ing system
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.
01-4 WB146-5
GENERAL FUEL COOLANT AND LUBRICANTS
12
Note 1:
SHELL ..................................................................DONAX TD
CALTEX ...............................................................RPM TRACTOR HYDRAULIC FLUID
CHEVRON ...........................................................TRACTOR HYDRAULIC FLUID
TEXACO ..............................................................TEXTRAN TDH OIL
MOBIL..................................................................MOBILFLUID 422 or 424
NOTE Use only diesel fuel. The engine mounted in this machine employs electronic control and a high pres-
sure 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 lu-
bricating ability is used, there will be a significant drop in durability.
WB146-5 01-5
GENERAL
12
MEMORANDA
01-6 WB146-5
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
POWER TRAIN ...................................................................................................................................................... 10-3
DESCRIPTION..................................................................................................................................................... 10-3
POWER FLOW .................................................................................................................................................... 10-3
TRANSMISSION DIAGRAM................................................................................................................................ 10-5
TRANSMISSION .................................................................................................................................................... 10-7
COMPLETE ASSEMBLY ................................................................................................................................... 10-7
FORWARD REVERSE CLUTCH..................................................................................................................... 10-11
1ST THROUGH 4TH SPEED SHAFT .............................................................................................................. 10-11
4WD SHAFT ...................................................................................................................................................... 10-12
FRONT AXLE....................................................................................................................................................... 10-13
COMPLETE ASSEMBLY ................................................................................................................................. 10-13
REAR AXLE ......................................................................................................................................................... 10-16
COMPLETE ASSEMBLY ................................................................................................................................. 10-16
DIFFERENTIAL ................................................................................................................................................ 10-17
PLANETARY..................................................................................................................................................... 10-18
WORK BRAKES................................................................................................................................................ 10-19
DIFFERENTIAL LOCK .................................................................................................................................... 10-20
HYDRAULIC PUMP ............................................................................................................................................ 10-21
MAIN PUMP ...................................................................................................................................................... 10-22
DELIVERY CONTROL VALVE ...................................................................................................................... 10-26
MAIN CONTROL VALVE .................................................................................................................................. 10-32
CLSS ...................................................................................................................................................................... 10-39
DESCRIPTION................................................................................................................................................... 10-39
OPERATING PRINCIPLES .............................................................................................................................. 10-40
STEERING UNIT.................................................................................................................................................. 10-55
TECHNICAL DATA.......................................................................................................................................... 10-55
OPERATION ...................................................................................................................................................... 10-55
PPC VALVE.......................................................................................................................................................... 10-56
LOADER ............................................................................................................................................................ 10-56
OUTRIGGER ..................................................................................................................................................... 10-61
BACKHOE ......................................................................................................................................................... 10-65
SOLENOID VALVE ............................................................................................................................................. 10-67
HYDRAULIC CONTROLS W/O MP BUCKET .............................................................................................. 10-67
HYDRAULIC CONTROLS WITH MP BUCKET............................................................................................ 10-68
LOADER CYLINDERS........................................................................................................................................ 10-69
BOOM................................................................................................................................................................. 10-69
BUCKET............................................................................................................................................................. 10-70
MP BUCKET...................................................................................................................................................... 10-71
WB146-5 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
BACKHOE CYLINDERS..................................................................................................................................... 10-72
BOOM................................................................................................................................................................. 10-72
ARM ................................................................................................................................................................... 10-73
BUCKET............................................................................................................................................................. 10-74
TELESCOPIC ARM CYLINDER ..................................................................................................................... 10-75
SWING ............................................................................................................................................................... 10-76
OUTRIGGER ..................................................................................................................................................... 10-77
WORK EQUIPMENT ........................................................................................................................................... 10-78
LOADER ............................................................................................................................................................ 10-78
BACKHOE ......................................................................................................................................................... 10-80
AIR CONDITIONING .......................................................................................................................................... 10-83
10-2 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
DESCRIPTION
● The driving power for the engine b is transmitted through the flywheel to the converter c. The converter uses hydraulic oil
to convert the torque transmitted by the engine 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.
The same switch also controls the four speed clutch packs.
● 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 f and rear g axles is reduced by the differentials and then transmitted to
the planetary gear through the differential shafts.
POWER FLOW
Front Axle
Gear Transmission Differential Planet Total
1st 5.533 81.722
2nd 3.36 49.627
2.462 6
3rd 1.532 22.627
4th 0.81 11.963
Rear Axle
Gear Transmission Differential Planet Total
1st 5.533 97.338
2nd 3.36 59.136
2.75 6.4
3rd 1.532 26.963
4th 0.81 14.256
WB146-5 10-3
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD POWER TRAIN
12
10-4 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION DIAGRAM
12
TRANSMISSION DIAGRAM
WB146-5 10-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION DIAGRAM
12
10-6 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
TRANSMISSION
COMPLETE ASSEMBLY
WB146-5 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
10-8 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
B Gear Shift Lever H 3rd & 4th Selecting Rod 1# Spin On Filter
C Centering Spring I 1st &2nd Selecting Fork 1$ Cold Oil Relief Valve
D Return Spring J 4th Selecting Sensor 1% Return Spring
E Check Ball 1) 3rd & 4th Selector 1^ Return Spring
F 3rd & 4th Selecting Fork 1! 1st & 2nd Selector 1& Return Spring
G 1st & 2nd Selecting Rod 1@ Suction Strainer
WB146-5 10-9
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
10-10 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
FORWARD REVERSE CLUTCH
WB146-5 10-11
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRANSMISSION
12
4WD SHAFT
10-12 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FRONT AXLE
12
FRONT AXLE
COMPLETE ASSEMBLY
Unit:mm
Criteria
Check Item Standard Tolerance Standard Clearance Remedy
Size Shaft Bushing Clearance Limit
0 +0.04
i Pin and Bushing Clearance 50 50 -0.039 50.19 0 --- --- Replace
WB146-5 10-13
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FRONT AXLE
12
DIFFERENTIAL
B Side Gear F Adjustment Lock Nut J Bearing Spacer 1# Bearing Lock Nut
C Ring Gear G Axle Shaft 1) Outboard Bearing 1$ Inboard Bearing
D Dowel Pin H Dowel Pin 1! Lip Seal Ring 1% Pinion Gear
E Driven Gear I Differential Housing 1@ Lip Seal Ring Cover 1^ Oil Drain Plug
Unit : mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1& Axle Clearance --- ---
1* Ring and Pinion Gear Backlash 0.18 to 0.28 0.28
Adjust
1( Pinion Preload - w/o lip seal 92 to 137 N•m
2) Ring and Pinion Gear Preload - w/o lip seal 129.5 to 194.5 N•m
10-14 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD FRONT AXLE
12
PLANETARY
WB146-5 10-15
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD REAR AXLE
12
REAR AXLE
COMPLETE ASSEMBLY
10-16 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD REAR AXLE
12
DIFFERENTIAL
B Tapered Roller Bearing F Differential Housing J Bearing Lock Nut 1# Pinion Gear
C Side Gear G Bearing Lock Nut 1) Lip Oil Seal 1$ Differential Housing
D Rotating Gear H Axle Shaft 1! Input Flange
E Ring Gear I Tapered Roller Bearing 1@ Bearing Spacer
Unit:mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1% Axle Clearance --- ---
1^ Ring And Pinion Gear Backlash 0.21 to 0.29 mm 0.29 mm
Adjust
1& Pinion Gear Preload - w/o seal ring 115 to 138 N•m
1* Pinion Ring Gear Preload - w/o seal ring 148 to 188 N•m
WB146-5 10-17
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD REAR AXLE
12
PLANETARY
10-18 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD REAR AXLE
12
WORK BRAKES
WB146-5 10-19
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD REAR AXLE
12
DIFFERENTIAL LOCK
10-20 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
WB146-5 10-21
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
MAIN PUMP
10-22 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
WB146-5 10-23
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.
STRUCTURE
● The rotation of the cylinder block B pressurises the oil inside the
chambers of the block; pressure is adjusted by the valve plate 1). 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.
OPERATION
Pump Operation
1. The cylinder block B rotates with the shaft c, and the shoe g
slides on the flat surface A. When this happens, the swash plate h
rotates on the ball j, and the angle a between the axis of the cylin-
der block and the axis X of the swash plate changes. The angle a is
known as the swash plate angle.
10-24 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
2. When the axis X of the swash plate h retains the angle a in relation
12
to the axis of the cylinder block B, flat surface A acts as a cam for
the shoe g. This is why the piston f slides inside the cylinder
block, creating a difference between volumes E and F and there-
fore causing the suction and delivery of oil in a quantity that is
equivalent to the difference between those volumes (F – E = deliv-
ery). When the cylinder block rotates, chamber F decreases in vol-
ume causing oil to be delivered to the circuits, while chamber E
increases in volume causing oil to be suctioned. The illustration
shows the state of the pump when suction at chamber F and deliv-
ery at chamber E are complete.
3. When the center line X of the swash plate h and the center line of
the cylinder block B are perfectly aligned, the swash plate angle a
= 0, the difference between the volumes E and F within the cylin-
der block becomes 0 and the pump does not take in or deliver any
oil. The angle of the swash plate a is proportional to pump deliv-
ery.
Control of Delivery
WB146-5 10-25
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
DELIVERY CONTROL VALVE
PORT FUNCTIONS P1 Delivery Control Group Feed PE Delivery Control Signal Output
T Drain Pd4 Drain PM Operating Mode Signal Input
10-26 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
WB146-5 10-27
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
LS VALVE FUNCTION
12
PC VALVE FUNCTION
10-28 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
PC VALVE OPERATION
Spring Operation
● The force applied by the pressure against the spool e decreases, and
the spool f shifts slightly to the right. At the same time, a connection
opens between ports C and D, and pressurised oil from valve LS is
sent for discharge, PT.
● When the control piston c moves, the lever d moves to the left, and
the spring b expands, thereby reducing its load on the spool f. Con-
sequently, the spool moves to the left and stops the oil flow between
ports C and D, and a passage opens between ports B and C. The
pressure at port C increases, and the control piston stops.
WB146-5 110-29
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
When Pump Pressure PA Is High
● The force applied by the pressure against the spool e increases, and
the spool f shifts slightly to the left. At the same time, a connection
opens between ports C and B, and the pressure of the oil sent to
valve LS becomes equivalent to the pump's delivery pressure, PA.
● When the control piston c moves, the lever d moves to the right,
and the spring b compresses, thereby increasing its load on the spool
f. Consequently, the spool moves to the right and stops the oil flow
between ports C and B, and a passage opens between ports D and C.
The pressure at port C decreases, and the control piston c stops.
10-30 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
12
When Equilibrium Has Been Reached
WB146-5 110-31
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
10-32 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
WB146-5 110-33
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
B ACV - Jig Arm Extend 1) ASCV - Loader Bucket Curl 1( Backhoe Boom Spool
C ACV - Backhoe Bucket Curl 1! ACV - Backhoe Boom Lower 2) Loader Bucket Spool
d ASCV - Backhoe Boom Raise 1@ ACV - Backhoe Bucket Dump 2! Backhoe Swing Spool
e ACV - Loader Bucket Dump 1# ACV - Jig Arm Retract 2@ Backhoe Arm Spool
f ASCV - Backhoe Left Swing 1$ ACV - MP Loader Bucket Dump 2# Priority Valve Spool
g ACV - Backhoe Arm Out 1% Loader Boom Arm Spool 2$ Unloading Valve
h Safety Valve 1^ Jig Arm Spool 2% LS By Pass Plug
i ACV - Backhoe Arm In 1& MP Bucket Spool
j ASCV - Backhoe Right Swing 1* Backhoe Bucket Spool
ACV - Anti-Cavitation Valve ASCV - Anti-Shock/Cavitation Valve
10-34 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
Unit : mm
Spring Criteria
Standard Size Repair Limit Remedy
Check Item Free Length Installed Length Installed Load Free Length Installed Load
2^ Backhoe Arm In Spool Spring 24.2 23.7 30.4 N -- 24.3N
2& Backhoe Arm Out Spool Spring 27.2 26.7 30.38 N -- 24.3 N
2* Prioroty Valve Spring 56.8 48.5 29.6 N -- 23.7 N
2( Unloading Valve Spring 25.5 18.0 121.5 N -- 97.2 N
3) Backhoe Swing Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3! Loader Bucket Spool Spring 42.3 40.5 54.9 N -- 43.9 N
3@ Backhoe Boom Spool Spring 41.1 40.5 34.3 N -- 27.4 N Replace
3# Backhoe Bucket Spool Spring 41.1 40.5 34.3 N -- 27.4 N
3$ MP Bucket Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3% Backhoe Jig Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3^ Loader Boom Raise Spool Spring 27.1 26.7 14.7 N -- 11.8 N
3& Loader Boom Lower Spool Spring 38.7 27.6 355.7 N -- 284.5 N
3* Loader Boom Float Spool Spring 19.4 19.0 14.7 N -- 11.8 N
Unit : mm
Spring Criteria
Standard Size Repair Limit Remedy
Check Item Free Length Installed Length Installed Load Free Length Installed Load
2* PDV Tension Spring 15.4 8.0 7.44 N -- 5.96 N
2( PDV Tension Spring 31.4 21.8 63.7 N -- 51.0 N
3) PDV Tension Spring 18.9 15.0 15.7 N -- 12.5 N
3! PDV Tension Spring 37.1 24.0 34.3 N -- 27.4 N
Replace
3@ PDV Tension Spring 20.0 15.0 4.32 N -- 3.45 N
3# Check Valve Spring 27.2 21.0 4.7 N -- 3.76 N
3$ Check Valve Spring 27.2 22.0 3.92 N -- 3.14 N
3% Check Valve Spring 21.9 15.8 1.96 N -- 1.57 N
WB146-5 110-35
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
10-36 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
b Backhoe Right Outrigger Spool e Backhoe Swing Spool H Backhoe Boom Spool
c Backhoe Left Outrigger Spool f Loader Boom Spool
d Loader Bucket Spool g Backhoe Bucket Spool
Unit : mm
Spring Criteria
Standard Size Repair Limit Remedy
Check Item Free Length Installed Length Installed Load Free Length Installed Load
i Outrigger Spool Outer Spring 18.0 17.5 39.2 N -- 31.4 N
Replace
j Outrigger Spool Inner Spring 20.2 10.4 30.4 N -- 24.3 N
WB146-5 110-37
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
10-38 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
CLSS
DESCRIPTION
CHARACTERISTICS
The term CLSS means Closed center Load Sensing System, which
has the following characteristics:
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.
WB146-5 110-39
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
OPERATING PRINCIPLES
PUMPING PLATE CONTROL ANGLE
● The angle of the swash plate and the pump delivery, is controlled in
such a way that the differential pressure UPLS between the delivery
pressure PP of the pump and the pressure PLS at the outlet of the con-
trol valve towards the actuator is maintained at a constant value. UPLS
= pump delivery pressure PP minus pressure PLS of delivery to the ac-
tuator.
● If the differential pressure UPLS becomes lower than the set pressure
of the LS valve, the angle of the swash plate increases, delivery in-
creasing.
● If the differential pressure UPLS increases, the angle of the swash plate
decreases.
10-40 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
PRESSURE COMPENSATION CONTROL
WB146-5 110-41
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
MAIN CONTROL VALVE
4. Check Valve
9. Priority Valve
10-42 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
UNLOADING VALVE
Neutral Position
FUNCTION
OPERATING
WB146-5 110-43
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
Control Valve Fine Control
FUNCTION
● When the actuators' delivery needs during fine control are within the
delivery values related to the minimum angle of the swash plate, the
pump's delivery pressure PP is regulated by pressure PLS at +28 kg/
cm². Since the unloading valve opens when the differential pressure
between the pump's delivery pressure PP and pressure PLS of the
LS equals spring load c, 28 kg/cm², the differential pressure UPLS be-
comes 28 kg/cm².
OPERATING
● When fine controls are performed at the control valve, a PLS pres-
sure is generated. This pressure acts on surface S3 on the right hand
side of the spool b. Since pressure PLS of LS is low, because the
control valve passage is small, the difference with the pump's deliv-
ery pressure PP is great.
10-44 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
Control Valve Is In Use
FUNCTION
● When the request for oil flow from the actuators exceeds the mini-
mum delivery of the pump during use of the control valve, the con-
nection to the tank circuit is eliminated and the entire pump delivery
Q is sent to the actuators.
OPERATING
● For this reason, since the differential pressure between the pump's de-
livery pressure PP and the pressure PLS of the LS fails to reach the
spring loading pressure value of spring c 28 kg/cm², the spool b is
pushed to the left by 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 Q
is sent to the actuators.
WB146-5 110-45
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
LS PRESSURE
Function
10-46 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
● At the same time, pressurised oil is introduced into the PLS circuit of
the LS through holes b.
WB146-5 110-47
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
LS BY PASS PLUG
Description
● The LS by pass plug unloads residual pressure from the load sens-
ing's PLS circuit.
Operation
● Pressurised oil in the Load Sensing PLS circuit flows through filter
a, through orifice b and into the tank circuit T.
10-48 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
PRESSURE COMPENSATION VALVES
Function
Operation
● The delivery control valve c and the pressure reducing valve b are
balanced out at a point where the differential pressure between PA
and PLS, these two acting on both surfaces of the pressure reducing
valve, equals the loss of pressure between PP and PPA, these two
acting on both surfaces of the delivery control valve.
WB146-5 110-49
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
PRESSURE COMPENSATION VALVE
Function
Compensation Characteristics
● When the ratio is 1.00 : Pump pressure PP minus pressure PPA up-
stream of spool ≅ load sensing PLS pressure - actuator PA pressure
(= A). Delivery is distributed proportionally to the opening surfaces
of the spool.
● When the ratio is > 1.00: PP - PPA > PLS - PA (= A). Delivery
distribution is lower than the proportion of the opening surfaces of
the spool.
● When the ratio is < 1.00: PP - PPA < PLS - PA (= A). Delivery
distribution is higher than the proportion of the opening surfaces of
the spool.
10-50 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
PRIORITY VALVE
Function
WB146-5 110-51
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
PPC REDUCING VALVE
Function
● This valve regulates the PPC feed pressure at 30 kg/cm². When ac-
tuator pressure is low, the sequential valve closes to permit an in-
crease in the pump's delivery pressure PP in order to supply pressure
to the servocontrols.
Neutral Condition
10-52 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
Control Valve Operated
● The spool b of the unloading valve moves to the left, and the pump's
delivery pressure exceeds the pressure of the actuator circuit f by an
amount equivalent to LS differential pressure.
WB146-5 110-53
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD CLSS
12
● When the pump's delivery pressure PP is lower than 30 kg/cm², the se-
quential reducing valve shifts to the right, thereby reducing the flow of
the PP pressure to the actuator circuit f.
10-54 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD STEERING UNIT
12
STEERING UNIT
a Port L - To Steering Cylinder c Port T - To Hydraulic Oil Tank e Port P - From Control Valve
b Port R - To Steering Cylinder d Port P - To control valve
TECHNICAL DATA
Steering unit type ......................................................... OSPC200LS
Normal flow ............................................................................... 20 .
OPERATION
● The steering unit consists of a control valve and a rotating oil dispens-
er, 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 rotat-
ing oil dispenser, to one side of the steering cylinder.
● The rotating dispenser ensures that the oil volume upplied to the cyl-
inder is proportionate to the angle of rotation of the steering wheel. In
the event of malfunction, the rotating oil dispenser will function au-
tomatically as a hand pump, thus guaranteeing auxiliary steering.
WB146-5 110-55
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
PPC VALVE
LOADER
10-56 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
OPERATION
Neutral Position
BUCKET PORTION
● Control valve ports A and B and PPC valve ports P1 and P2 are
connected to discharge chamber D by means of the calibrated hole f
in spool b.
WB146-5 110-57
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
BOOM PORTION
● Control valve ports A and B and PPC valve ports P3 and P4 are
connected to discharge chamber D by means of the calibrated hole f
in spool b.
● When the disk f starts pushing down on piston e and piston 1), the
retainer j moves as a result. This movement will compress the
spring c which will in turn act on the spool b and push it down-
wards.
● Pressure in the loader control circuit will flow through the calibrated
hole f and into the circuit thereby increasing the pressure in port P1/
B.
10-58 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
● When the disk f is released and moved to neutral position, the piston
e is pushed upwards by the spring d acting on the retainer j, and
spool b is thrusted upwards both by the force of spring c and by the
force that the pressure in section B/P1 applies against the stem. This
movement moves the calibrated hole f of spool into the discharge
chamber D, thereby allowing pressure in section B/P1 to be re-
leased.
● When the spool of the control valve returns, oil flows back into
chamber D, through calibrated hole f, and into chamber B of the con-
trol valve spool opposite the operating one. Oil flows through duct
P2 and into chamber B to ensure it is filled properly.
● When the disk f pushes down on the piston e, and the retainer j
pushes down on the spool b, calibrated hole f is put in direct connec-
tion with chamber PP, which is in turn connected to a constantly
pressurised loader control circuit.
● Oil is then allowed to flow directly into section B/P1 thereby push-
ing the stem of the main control valve to the end of its travel. This
causes the main control valve to send the oil contained in chamber
AB towards input P2, through calibrated hole f and into relief
chamber D.
WB146-5 110-59
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
Control Lever To Float Position
● If piston e and piston 1) of the spool controlling the arm, port P4,
are pushed downwards by disk f, the mechanism inside the PPC
valve will start locking the spool halfway along its travel.
● At the same time, the control valve will also be activated and retained
in the arm float position.
● The floating state can also be cancelled, and the lever can move back
to neutral position, denergizing the solenoid.
10-60 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
OUTRIGGER
WB146-5 110-61
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
OPERATION
Neutral Position
● Ports A and B of the main control valve and ports P1 and P2 of the
outrigger valve are connected to the tank circuit, the spool is in neu-
tral position.
10-62 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
● When the lever b is moved in the direction shown by the arrow, the
valves c are rotated and a passage is opened between delivery duct a
and port P1, while port P2 remains conected to the tank circuit.
WB146-5 110-63
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
● When lever b is moved fully to the left, the valves c are fully rotat-
ed.
10-64 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
BACKHOE
LEFT VALVE
PORTS 4 To Swing Left Valve, PA2 Port 1 To Swing Right Valve, PB2 Port
1 To Arm Out Valve, PB1 Port 3 To Arm In Valve, PA1 Port
T To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port
WB146-5 110-65
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD PPC VALVE
12
RIGHT VALVE
PORTS 4 To Bucket Dump Valve, PA5 Port 1 To Bucket Curl Valve, PB5 Port
1 To Boom Raise Valve, PB4 Port 3 To Boom Lower Valve, PA4 Port
T To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port
10-66 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
HYDRAULIC CONTROLS W/O MP BUCKET
PORTS VBH To Bakchoe PPC Valves, Port P C Boom Lock Solenoid, Y95
ACC Accumulator VL To Loader PPC Valves, Port P D Backhoe PPC Solenoid, Y90
P1 Pressure Tap PM To Hydraulic Pump, Port PM E Loader PPC Solenoid, Y93
P2 To Outrigger PPC Valve, Port P P From Control Valve, Port PPPC F Ecopower Solenoid, Y91
A2 To Boom Lock Cylinder T To Hydraulic Tank
B2 To Rear Axle B Differential Lock Solenoid, Y94
WB146-5 110-67
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD SOLENOID VALVE
12
HYDRAULIC CONTROLS WITH MP BUCKET
10-68 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD LOADER CYLINDERS
12
LOADER CYLINDERS
BOOM
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 50
Max Cylinder Length ....................................................................... 1740
Min Cylinder Length ........................................................................ 1170
Cylinder Barrel Bore ............................................................................ 90
Piston Stroke....................................................................................... 570
Rod Thread for Piston Nut ................................................................M36
WB146-5 110-69
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD LOADER CYLINDERS
12
BUCKET
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 45
Max Cylinder Length ....................................................................... 2145
Min Cylinder Length ........................................................................ 1400
Cylinder Barrel Bore ............................................................................ 70
Piston Stroke....................................................................................... 745
Rod Thread for Piston Nut ................................................................M33
10-70 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD LOADER CYLINDERS
12
MP BUCKET
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 40
Max Cylinder Length ......................................................................... 705
Min Cylinder Length .......................................................................... 475
Cylinder Barrel Bore ............................................................................ 85
Piston Stroke....................................................................................... 230
Rod Thread for Piston Nut ................................................................M24
WB146-5 110-71
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
BACKHOE CYLINDERS
BOOM
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 60
Max Cylinder Length ....................................................................... 2160
Min Cylinder Length ........................................................................ 1310
Cylinder Barrel Bore .......................................................................... 120
Piston Stroke....................................................................................... 850
Rod Thread for Piston Nut ................................................................M42
10-72 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
ARM
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 60
Max Cylinder Length ....................................................................... 1795
Min Cylinder Length ........................................................................ 1065
Cylinder Barrel Bore .......................................................................... 115
Piston Stroke....................................................................................... 700
Rod Thread for Piston Nut ................................................................M42
WB146-5 110-73
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
BUCKET
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 55
Max Cylinder Length ....................................................................... 1850
Min Cylinder Length ........................................................................ 1085
Cylinder Barrel Bore .......................................................................... 110
Piston Stroke....................................................................................... 765
Rod Thread for Piston Nut ................................................................M36
10-74 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
TELESCOPIC ARM CYLINDER
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 40
Max Cylinder Length ....................................................................... 2590
Min Cylinder Length ........................................................................ 1450
Cylinder Barrel Bore ............................................................................ 85
Piston Stroke..................................................................................... 1140
Piston Rod Thread.............................................................................M30
WB146-5 110-75
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
SWING
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 50
Max Cylinder Length ...................................................................... 514.5
Min Cylinder Length ............................................................................. --
Cylinder Barrel Bore .......................................................................... 100
Piston Stroke....................................................................................... 230
Piston Rod Thread.............................................................................M42
10-76 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
OUTRIGGER
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 50
Max Cylinder Length ....................................................................... 1365
Min Cylinder Length .......................................................................... 850
Cylinder Barrel Bore .......................................................................... 100
Piston Stroke....................................................................................... 515
Piston Rod Thread.............................................................................M39
WB146-5 110-77
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT
LOADER
10-78 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Unit : mm
Criteria
Check Item Standard Tolerance Standard Clearance Remedy
Size OD ID Clearance Limit
52.10 52.20 -0.20
b Bushing in Boom 52 to 52.40 to 52.30 to 0.20
44.911 45.08 0.13
c Pin to Bushing 45 to 44.95 to 45.24 to 0.329
52.10 52.20 -0.20
d Bushing in Lever 52 to 52.40 to 52.30 to 0.20
44.911 45.08 0.13
e Pin to Bushing 45 to 44.95 to 45.24 to 0.329
54.85 55.00 -0.15
f Bushing in Lever 55 to 55.15 to 55.046 to 0.196
44.911 45.08 0.13
g Pin to Bushing 45 to 44.95 to 45.24 to 0.329
75.046 75.00 -0.076
h Bushing in Lever and Cylinder 75 to 75.076 to 75.046 to 0.0
Replace
59.894 60.137 0.197
i Pin to Bushing 60 to 59.94 to 60.197 to 0.303
57.2 57.25 -0.05
J Bushing in Cylinder 57 to 57.3 to 57.25 to 0.05
49.911 50.08 0.13
1) Pin to Bushing 50 to 49.95 to 50.24 to 0.329
57.2 57.25 -0.05
1! Bushing in Boom 57 to 57.3 to 57.25 to 0.05
49.911 50.08 0.13
1@ Pin to Bushing 50 to 49.95 to 50.24 to 0.329
67.10 67.2 -0.20
1# Bushing in Cylinder 67 to 67.40 to 67.2 to 0.10
59.894 60.13 0.19
1$ Pin to Bushing 60 to 59.94 to 60.29 to 0.396
WB146-5 110-79
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
BACKHOE
10-80 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
Unit : mm
Criteria
Check Item Standard Tolerance Standard Clearance Remedy
Size OD ID Clearance Limit
80.059 80.00 -0.005
b Top Bushing in Main Frame 80 to 80.089 to 80.054 to -0.089 Replace
64.894 65.19 0.25
c Pin to Bushing 65 to 64.94 to 65.264 to 0.37
50.034 50.0 -0.009
d Inner Bushing on Cylinder Stud 50 to 50.05 to 50.025 to -0.05
75.043 75.0 -0.013
e Outer Bushing in Bracket 75 to 75.062 to 75.03 to -0.062
59.894 60.06 0.12
f Inner Bushing in Outer Bushing 60 to 59.94 to 60.09 to 0.196
g Outer Bushing in Frame to to to
54.894 55.137 0.257
h Pin to Bushing 55 to 54.94 to 55.197 to 0.303
80.059 80.0 -0.029
i Bottom Bushing in Swing Frame 80 to 80.089 to 80.03 to -0.089
64.894 65.19 0.25
j Pin to Bushing 65 to 64.94 to 65.264 to 0.37
44.911 45.08 0.13
1) Pin to Rod Bushing 45 to 44.95 to 45.24 to 0.329
44.911 45.08 0.13
1! Pin to Head Bushing 45 to 44.95 to 45.24 to 0.329
54.985 55.0 -0.015
1@ Bushing in Stabilizer 55 to 55.015 to 55.03 to 0.045
44.911 45.08 0.13
1# Pin to Bushing 45 to 44.95 to 45.24 to 0.329
75.137 75.0 -0.107
1$ Bushing in Boom 75 to 75.197 to 75.03 to -0.197
59.894 60.137 0.197
1% Pin to Bushing 60 to 59.94 to 60.197 to 0.303
59.95 60.0 -0.08
1^ Bushing in Boom 60 to 60.15 to 60.03 to -0.15
49.911 50.08 0.13
1& Pin to Bushing 50 to 49.95 to 50.024 to 0.329
52.10 52.0 -0.07
1* Bushing in Bucket Lever 52 to 52.40 to 52.03 to -0.40
44.911 45.08 0.13
1( Pin to Bushing 45 to 44.95 to 45.24 to 0.329
44.911 45.08 0.13
2) Pin to Cylinder Bushing 45 to 44.95 to 45.24 to 0.329
52.2 52.10 -0.13
2! Lever Bushing in Arm 52 to 52.23 to 52.40 to -0.20
44.911 45.08 0.13
2@ Pin to Bushing 45 to 44.95 to 45.24 to 0.329
52.10 52.0 -0.07
2# Bushing in Bucket Lever 52 to 52.40 to 52.03 to -0.40
44.911 45.08 0.13
2$ Pin to Bushing 45 to 44.95 to 45.24 to 0.329
56.45 57.20 -0.85
2% Bucket Bushing in Arm 57 to 58.05 to 57.23 to 0.78
49.911 50.08 0.13
2^ Pin to Bushing 50 to 49.95 to 50.24 to 0.329
59.894 60.10 0.16
2& Pin to Boom Rod Bushing 60 to 59.94 to 60.174 to 0.28
59.894 60.10 0.16
2* Pin to Boom & Arm Head Bushing 60 to 59.94 to 60.174 to 0.28
49.911 50.08 0.13
2( Pin to Arm Rod Bushing 50 to 49.95 to 50.142 to 0.231
44.911 45.08 0.13
3) Pin to Bucket Head Bushing 45 to 44.95 to 45.142 to 0.231
39.911 40.05 0.10
3! Pin to Jig Head Bushing 40 to 39.95 to 40.10 to 0.189
39.911 40.05 0.10
3@ Pin to Jig Rod Bushing 40 to 39.95 to 40.10 to 0.189
WB146-5 110-81
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD WORK EQUIPMENT
12
10-82 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD AIR CONDITIONING
12
AIR CONDITIONING
10-83 1 WB146-5
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD AIR CONDITIONING
12
The compressor b is driven directly by the engine shaft by means of a
belt, and made to rotate by a pulley fitted with an electromagnetically
engaged clutch a. A thermostatic sensor h controls the engagement
and disengagement of the clutch. It disengages the clutch when the
evaporator reaches the lower temperature limit and engages when the
evaporator reaches the upper temperature limit.
The coolant fluid, in gaseous phase is drawn into the compressor where
it is subjected to compression and an intense heating process. In these
conditions the fluid is then sent into the condenser c where, due to the
heat extracted by ambient temperature air flowing over fins, it reaches
condensation temperature, and passes into a high pressure liquid state.
Subsequently the coolant passes into the dryer filter group d which per-
forms three functions: it filters out impurities, absorbs any moisture
present in the circuit and, finally, also functions as a reserve tank. The
coolant in its liquid state is then transferred to the evaporator G, first
passing through an expansion valve F. The task of this valve is the con-
stant metering of the quantity of fluid in order to maintain optimum
evaporation. In the evaporator the coolant fluid is subjected to expan-
sion, bringing it up to the critical evaporation point at a temperature of
approximately -8°C.
The air flow generated by the centrifugal fan I which passes through
the evaporator G at ambient temperature is considerably warmer than -
8°C. For this reason it yields heat to the coolant fluid, bringing it up to
boiling point and complete evaporation. On leaving the evaporator G
the coolant is drawn once more into the compressor d and a new cycle
commences. The yielding of heat from the atmosphere in which the
evaporator is positioned leads to the condensation of the water sus-
pended in the air, and hence to dehumidification. The condensate is
deposited on the evaporator fins where, if a temperature higher than 0°C
is not maintained, it freezes and inhibits the functioning of the evapora-
tor. The task of keeping the temperature of the evaporator above 0°C,
and thus within the optimum limits for heat exchange, is entrusted to a
thermostatic sensor H.
The condensate that forms on the evaporator fins G also contains dust,
pollens and particles suspended in the air. Continual condensation there-
fore effectively purifies the air, and the droplets of condensate are dis-
charged to the exterior. A fixed quantity of anti freeze oil is also
introduced into the circuit, with the function of lubricating all the
mechanical parts of the unit. A percentage of this oil circulates con-
stantly throughout the unit in nebulized form, lubricating the compres-
sor, pistons and bearings and the expansion valve. A pressure switch E
has been inserted in the electrical control circuit to protect the unit in the
case of a lack of coolant fluid or if the quantity becomes insufficient due
to leakages. This switch will inhibit the engagement of the electromag-
netic clutch and hence the functioning of the air conditioning unit.
WB146-5 110-84
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
WB146-5 20-1
TESTING AND ADJUSTING TABLE OF CONTENTS
WARNING! When working with others, use agreed upon signals and do not let unauthorized
persons near the machine.
WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is removed
when the coolant is hot, the coolant will spurt our and cause burns. Be careful when working
close to moving parts, fan, fan belt, etc. Entanglement with moving parts can cause serious
injury.
WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked on
firm, level ground. Check that all machine safety devices are applied and that blocks are in place
to prevent the machine from moving.
20-2 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
STANDARD VALUE TABLE
ENGINE
WB146-5 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
CHASSIS
Permissible
Cat. Item Measurement Condition Unit Standard Value
Value
• Measurement taken on drive shaft pulley Min. 1050 ±50 1000 - 1100
with tachometer.
rpm
• Engine coolant temperature: Within
operation range Max. 2200 2150 - 2250
• Engine oil temperature: Within operation
Accelerator fuel range
• Measurement taken on drive shaft pulley
with tachometer. Min. 1050 ±50 1000 - 1100
l a b c l a b c
Control valve
Raise 95 80 - 110
Bucket arm control lever Neutral J
Lower 95 80 - 110
Dump 95 80 - 110
Bucket control laver Neutral J
Curl 95 80 - 110
Raise 50 40 - 60
Boon backhoe control Neutral J
Travel of levers and pedals
Right 50 40 - 60
Boom swing control lever Neutral J
Left 50 40 - 60
Up 35 25 - 45
Outrigger control lever Neutral J
Down 35 25 - 45
20-4 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
Applicable model WB146-5
Permissible
Cat. Item Measurement condition Unit Standard value
value
• Engine stopped
Levers and pedals
Accelerator pedal • Knob lever: at center and at 90o from Min J Max mm 80 65 - 95
travel
lever.
• Value reading at end of work stroke Right J Left 3.5 3.1 - 3.9
Wheel swing plus half measured backlash rev
• Attachments on ground Left J Right 3.5 3.1 - 3.9
Steering wheel • Force measured on steering wheel knob at min. RPM −−− −−− −−−
for approx. half a rev under steady motion at a speed of
2.5 per rev.
Steering unit • Engine speed: 1500 ±50 rpm 178 173 - 188
WB146-5 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
Applicable model WB146-5
Permissible
Cat. Item Measurement condition Unit Standard value
value
Arm close) • Oil temperature within operating range 274 264 - 284
• Move arm cylinder to end of stroke and measure pres-
Arm out sure kg/cm² 274 264 - 284
• Instrument: 0 to 100 kg/cm² pressure gauge mounted on
Boom swing adapter at port P1C 234 223 - 249
20-6 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
Bucket cylinder 35 50
mm
Working equip-
• In this position check extension of each cylinder and 200 350
ment
leakage with normal load on bucket.
• On level ground.
• Bucket: load with standard arm: 340 kg
• Bucket load with tele arm: 0 kg Fully extend arm
Boom cylinders 10 20
• Engine stopped
• Oil temperature: 45 - 55 °C
Backhoe
Bucket cylinder 8 15
WB146-5 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE
.
Backhoe
mm
• Oil temperature: 45 - 55 °C
• Backhoe balanced.
• Boom and arm cylinders in, bucket cylinder
out
• Outriggers at maximum extension.
• Engine stopped
• Check frame lowering for each side every 5
Outriggers min. for a total of 15 minutes. 7 15
Loader
20-8 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
12 Applicable model WB146-5
Standard Permissible
Cat. Item Measurement condition Unit
value value
Arm bucket
• Engine speed:
Lifting
max.
• Oil tempera- 3.6 3.1 - 4.1
ture: 45 - 55 °C
• Bucket speed
Cylinders fully button: applied
out
Lowering
Loader bucket
Bucket at ground
level
Bucket • Engine speed:
max.
Curl
2.3 2.0 - 2.6
• Oil tempera-
ture: 45 - 55 °C
• Bucket speed
button: applied
Dump
Cylinders fully
2.8 2.4 - 3.2
out
Work equipment speed
Lifting U
Boom cylinder • Engine speed: 2200 rpm
fully in sec. 2.7 2.3 - 3.1
• Oil temperature: 45 - 55
°C
↕ • Backhoe balanced Lowering
• Power mode ON
2.0 1.7-2.3
Bucket on ground
Arm cylinder
Opening
↕ •
•
Backhoe balanced
Power mode ON
Closing U
Bucket cylinder
Dump
WB146-5 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE
Right U
Boom swing to
Work equipment speed
•
↕ • Arm vertical
• Power mode ON
Left U
Boom swing to left
3.2 2.7 - 3.7
end of travel
20-10 WB146-5
TESTING AND ADJUSTING SPECIAL TOOLS
12
SPECIAL TOOLS
Measurement Point Symbol Code Name Qty Note
Oil and coolant temp D 1 Available Locally Digital thermometer 1 -50 to 1200°C
Air Conditioning unit M 2 Available Locally Thermometer hygrometer 1 Sampling every 15 sec
WB146-5 20-11
TESTING AND ADJUSTING ENGINE SPEED
12
ENGINE SPEED
WARNING! When checking the engine speed be careful.
Do not touch high temperature parts or get caught in
rotating parts.
2. Dump the loader bucket and hold the movement; let the engine sta-
bilize and then read the engine speed.
● Normal speed....................................................................600 rpm
● Minimum speed ................................................................600 rpm
2. Hold the brakes while simultaneously engaging 3rd gear; let the en-
gine stabilize, and read the rpm value.
● Minimum speed ..............................................................2125 rpm
● Maximum speed .............................................................2225 rpm
3. Hold the machine stalled as long as necessary, in any case for not
more than 30 sec., and carry out the tests at least 15 sec one from
the other.
20-12 WB146-5
TESTING AND ADJUSTING ENGINE SPEED
12
3. In the above conditions, let the engine stabilize, then read the en-
gine rpm.
● Minimum speed ..............................................................2025 rpm
● Maximum speed .............................................................2125 rpm
4. Hold the machine stalled as little as necessary, in any case for not
more than 30 sec., and carry out the tests at least 15 sec one from
the other.
ANALYSIS
1. If readings are not within the required interval, check the ENGINE
SHOP MANUAL.
WB146-5 20-13
TESTING AND ADJUSTING VALVE CLEARANCE
12
VALVE CLEARANCE
1. Park the machine on solid, level ground, apply the parking brake,
and remove the ignition key.
2. Remove the air filter and muffler. For details see Section 30.
20-14 WB146-5
TESTING AND ADJUSTING AC COMPRESSOR BELT TENSION
12
AC COMPRESSOR BELT TENSION
1. Turn the screw B clockwise to tension the belt C.
WB146-5 20-15
TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS
12
BLEED AIR FROM CIRCUITS
BLEED AIR FROM CYLINDERS
★ When the hydraulic cylinders or associated tubes have been removed, it is
necessary to bleed air before using the machine again. Perform bleeding on
one cylinder at a time.
1. Start the engine and run at high idle for about 5 min. to heat the oil.
2. Reduce speed to low idle and extend and retract the 1st cylinder to
be bled several times.
★ Extend and retract pistons until about 100 mm from their end
of stroke.
3. Stop the engine, check and top off the oil in the tank.
4. Bring again the engine at high idle and repeat Step 2; return the en-
gine to low idle speed and make a complete travel of the cylinder
until the pump reaches its maximum pressure.
5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil
level in the tank.
1. Make sure that oil in the brake system tank b is at maximum level.
Remove safety plugs on the bleed screws c. Attach a vinyl hose d
to catch oil.
2. Push the brake pedal to the bottom and, while keeping it pushed,
loosen the bleed screw c of the braking unit that is being bled until
the pedal reaches the end of its stroke. Keeping the pedal at the end
of its stroke, tighten the bleed screw.
3. Release the brake pedal, wait for few seconds and repeat above op-
erations 2 or 3 times until, oil flows out the bleeding screw without
air bubbles.
★ Frequently check the oil level in the tank and refill every time
the level approaches minimum.
2. Move all control levers in all directions to fully release cylinder and
PPC circuit residual pressure.
20-16 WB146-5
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR PEDAL AND LEVER
★ Measurement conditions:
● Machine ......................... Shut down with safety features engaged
● Engine................................ Stopped and at operating temperature
● Idle speeds ................................................. Within standard value.
★ In order to check high speed engine idle, push the accelerator pedal
B manually.
2. Push the accelerator pedal until the accelerator lever f contacts the
injection pump high idle adjusting screw.
WB146-5 20-17
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR LEVER TRAVEL
1. Remove the front mat.
2. Remove the metal sheet b closing the bottom of the cab and the up-
right guard c.
8. Check the MAX speed once more by pushing the hand accelerator
to the end of travel.
20-18 WB146-5
TESTING AND ADJUSTING BRAKE SYSTEM
12
BRAKE SYSTEM
★ Working condition:
● Set the machine on level surface with attachments on ground
level
● Apply the parking brake and remove the ignition key
CONTROL
1. Remove the floor mat.
2. Check the height A between the floor and pedal b lower edge.
ADJUSTMENT
1. Remove the front cover c.
WB146-5 20-19
TESTING AND ADJUSTING BRAKE SYSTEM
12
2. Loosen the nuts d and adjust the slack using the stoppers e.
CHECKS
★ Working condition:
● Engine stopped
● Place the vehicle on firm level ground with the equipment raised
and the safety devices activated.
● Independent brake pedals and oil pan at maximum level.
LEAKAGE CHECKS
1. Disconnect the hose B from the tubes c connecting to the axle
braking groups. Plug the tube.
● Plug all open tubes and hoses to prevent contamination.
4. Hold the pressure on the pedal for at least 2 minutes and verify that
the pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside either pump. To confirm whether this is the case, check
the oil. If a leak condition exists, the oil will be stirred.
20-20 WB146-5
TESTING AND ADJUSTING BRAKE SYSTEM
12
INDIVIDUAL PUMP CHECK
1. Remove the front lining d.
5. Disconnect the delivery hoses h from the pump that is being tested.
Connect a pressure gauge E2 to the pump during the inspection.
WB146-5 20-21
TESTING AND ADJUSTING BRAKE SYSTEM
12
7. Hold the pressure on the pedal for at least 2 minutes and verify that
pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside the pump, and in this case the pump needs to be
changed. To confirm whether this is the case, check the oil. If a
leak condition exists, the oil will be stirred.
2. Connect a suitable tool between the delivery hose b and the brak-
ing group.
★ Check to ensure that the pressure tap i is installed between the
braking group and the cut out valve j.
3. Connect a pressure gauge E2 to the tool pressure tap and open the
cut out valve j.
4. Operate the brake pump and pressurize the circuit to 152.8 ±56 kg/
cm² max.
6. Release the brake pedal and monitor the pressure gauge E2 for two
minutes.
★ If the pressure reading changes in the negative, then there is a
brake piston seal failure.
7. Repeat the test for the other brake group using the same procedure
as above.
20-22 WB146-5
TESTING AND ADJUSTING PARKING BRAKE ADJUSTMENT
12
PARKING BRAKE ADJUSTMENT
★ Test conditions:
● Tire pressure ......................................Within the prescribed range
● Machine in operating conditions ...W/O load and on level ground
● Working brake pedals ........................... Connected by a cotter pin
3. Press and hold the microswitch d while engaging 2nd gear and se-
lecting a direction of movement.
WB146-5 20-23
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
INTRODUCTION
INTRODUCTION
1. The machine is equipped with a single control valve with hydrauli-
cally controlled spools. The control valve is protected against over
pressure by a main relief valve, referred to as the LS safety valve,
with an adjustable pressure setting.
3. Pump delivery is shut by the priority valve, inside the control valve,
when the steering unit is used for a steering manoeuvre.
20-24 WB146-5
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
MAIN CONTROL VALVE
WB146-5 20-25
TESTING AND ADJUSTING RELIEF VALVES
12
RELIEF VALVES
TESTING
UNLOADING VALVE
1. Connect a pressure gauge E1 to the tap P1C on the pump. Start
the engine and run at low idle with all levers in neutral position.
SECONDARY VALVES
Boom Swing, Loader Bucket Dump and Hammer
★ Test conditions:
● Engine.................................................. At Operating Temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................. Applied
★ The pressure readings are to be operated from the same check point.
1. Connect a pressure gauge E3 to the tap P1C of the pump. Start the
engine and bring the hand accelerator lever up to 2200 rpm.
20-26 WB146-5
TESTING AND ADJUSTING RELIEF VALVES
12
2. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure.
★ Test conditions:
● Engine.................................................. At Operating Temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................. Applied
1. Set the machine with the arm in the vertical position and the bucket
on level ground.
4. Start the engine, connect a 1500 kg weight to the bucket, and fully
lower the outriggers.
WB146-5 20-27
TESTING AND ADJUSTING RELIEF VALVES
12
5. Slowly extend the arm and boom and take the pressure when the
boom lowers.
★ Normal pressure ...........................................326 - 366.7 kg/cm²
★ Test conditions:
● Engine.................................................. At Operating Temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................. Applied
★ The pressure readings are to be operated from the same check point.
2. Start the engine and bring the hand accelerator lever up to 2200
rpm.
3. Set the main relief valve b to a value 30.5 kg/cm² higher than the
maximum pressure to be tested.
4. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure of the
working equipment.
20-28 WB146-5
TESTING AND ADJUSTING SETTING RELIEF VALVES
12
SETTING RELIEF VALVES
MAIN RELIEF VALVE
1. Loosen lock nut B.
WB146-5 20-29
TESTING AND ADJUSTING SETTING RELIEF VALVES
12
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE
1. Loosen the lock nut B.
20-30 WB146-5
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
12
LS DIFFERENTIAL PRESSURE
CONTROL
★ Test conditions:
★ Engine ..............................Stopped but at working temperature.
★ Hydraulic oil ............................................................ 45 - 55 °C.
★ Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
★ Working mode.............................................................. POWER
1. Disconnect the hose b from the LS line, Install a tee with a pres-
sure tap c and reconnect the hose b.
3. Start the engine and run it at low idle, 1050 ±50 rpm, and, without
any lever movement, in neutral position, read the U pressure.
★ Normal value......................................................41.7 ±4 kg/cm²
★ If UPLS pressure is not within the permissible range, replace
the control valve unloading valve.
ADJUSTMENT
★ If the UPLS value is not within the specified range, adjust the LS valve
as follows:
WB146-5 20-31
TESTING AND ADJUSTING PPC SUPPLY PRESSURE
12
PPC SUPPLY PRESSURE
CHECK
★ Test conditions:
★ Engine ...............................................At operating temperature.
★ Hydraulic oil temperature ......................................... 45 - 55 °C
2. Start the engine and run the engine at low idle with all levers in
neutral position.
ADJUSTMENT
★ If the pressure value is not within the tolerance range, adjust the valve b as
follows:
20-32 WB146-5
TESTING AND ADJUSTING PC VALVE
12
PC VALVE
ADJUSTMENT
★ If pump delivery and LS differential pressure are within permissible val-
ues, but you notice that the engine rpm drops as a result of a change in the
load, or that working equipment is very slow, it is time to adjust the PC
valve b.
WB146-5 20-33
TESTING AND ADJUSTING STEERING CONTROL SYSTEM
12
STEERING CONTROL SYSTEM
★ Test conditions:
● Engine........................................................ Operating temperature
● Hydraulic oil................................................................. 45 - 55 °C
CONTROL
1. Connect a pressure gauge E3 to the tap P1C on the main control
valve.
2. Start the engine and bring it to idle speed 1500 ±50 rpm and carry
out a total steering.
SETTING
★ If pressure is not within permissible value, set the upper valve b of the
steering unit c.
2. Stop the engine and replace the plug d; ensure that the seal f is in
its proper position.
20-34 WB146-5
TESTING AND ADJUSTING STEERING CYLINDER
12
STEERING CYLINDER
★ Test conditions:
● Engine....................................................At operating temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................ Engaged
● Maximum steering pressure .................Within permissible limits.
1. Start the engine and full steer the wheels in either direction, then
stop the engine.
4. Start the engine and operate the engine at high idle speed.
5. Force the steering wheel to the end of its travel and retain the posi-
tion for 30 seconds; measure any leak during the following minute.
6. Release the steering wheel, run the engine at low idle, and then stop
the engine.
WB146-5 20-35
TESTING AND ADJUSTING POWER TRAIN GROUP
12
POWER TRAIN GROUP
The power train group can be used to perform pressure tests on the
internal hydraulic circuit. These are useful for identifying malfunctions.
Specifically, the tests involve:
Converter Oil Pressure
Clutch Engagement Pressure
Supply Pressure
★ Test condition:
● Engine............................................................................... Stopped
● Brake pedals ......................................... Connected by a cotter pin
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
● Lower cab closeout........................................................Removed.
2. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5 °C.
3. With the engine at MIN, check the pressure on the pressure gauge
E6.
★ Idle pressure ............................................................3.05 kg/cm²
5. Bring the engine back to MIN and compare the pressure with the
normal value.
★ Min pressure ...........................................................3.05 kg/cm²
★ If the pressure value drops to below the permissible lower
limit, the power train pump needs an replacement.
2. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5 °C.
3. Bring the engine up to low idle and check the pressure on the pres-
sure gauge E6.
★ Normal pressure ...............................................Max. 0.3 kg/cm²
20-36 WB146-5
TESTING AND ADJUSTING POWER TRAIN GROUP
12
4. With the working brakes applied, select reverse gear and gradually
increase rev speed up to MAX, then take a new reading from the
pressure gauge E6.
★ Normal pressure ............................................13.7 - 16.8 kg/cm²
5. Bring the engine back to MIN and the transmission in neutral posi-
tion; compare the pressure with the normal value.
★ Normal pressure ...............................................Max. 0.3 kg/cm²
7. Repeat the same test for the FORWARD gear, reading the pressure
from the orifice protected by the plug P18.
● If the pressures are different for the two travel directions, there is
a loss of pressure on the clutch piston with lower pressure.
SUPPLY PRESSURE
1. Remove the plug P21 and connect the pressure gauge E6.
2. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5 °C.
3. Bring the engine up to low idle and check the pressure on the pres-
sure gauge.
★ Normal pressure ............................................14.2 - 17.3 kg/cm²
WB146-5 20-37
TESTING AND ADJUSTING TRANSMISSION CLUTCH FUNCTION
12
TRANSMISSION CLUTCH FUNCTION
★ Test conditions:
● Engine: stopped.
● Brake pedals: connected by a cotter pin.
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
★ This test must be performed after having checked the pressures
of the power train group.
MACHINE PREPARATION
1. Prepare a tachometer to measure the engine rpm.
CONTROL
1. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5 °C.
4. Engage the 3rd gear while braking and accelerating as above; con-
firm that engine speed decreases to the permissible range
20-38 WB146-5
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
HYDRAULIC DRIFT
★ If working attachments have a hydraulic drift, it is necessary to check if
reason is due to cylinders gaskets or to control valve.
LOADER
BOOM CIRCUIT
1. Put the machine with the bucket edge on blocks A of about 10 cm
and in vertical position in relation to the ground.
3. Disconnect the tubes b and c from the lift cylinders d and plug
them.
4. Plug the cylinders, base side, and apply a temporary tube, rod side,
to catch any possible oil leakage.
5. Start the engine and curl the bucket until the teeth are in the tilt po-
sition by 10°.
6. Stop the engine and check bucket link position for movement 5
minutes.
● If the bucket link has no lowering movement, drift is due to the
control valve.
7. Move the bucket to let the edge lean on the ground in vertical posi-
tion.
8. Remove from one of the cylinders the plug fitted on the cylinder
bottom side in Step 4.
9. Start the engine and retract the bucket to bring the teeth in a tilt po-
sition of about 10° upwards.
10. Stop the engine and check the loader position for 5 minutes.
● If the bucket link lowers, drift is due to seal leakage of the
plugged cylinder.
WB146-5 20-39
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
BUCKET CIRCUIT
1. Put the machine with the loader on level ground and bucket edge
tilted 10°. Put a 1500 kg weight in the bucket.
3. Plug the bucket cylinder, head side, and install a temporary tube on
the rod side to catch oil leakage.
4. Start the engine and raise the loader until the bucket hinge pin is
aligned with boom hinge pin.
5. Stop the engine and check the position of the bucket edge for 5
minutes.
● If the bucket has no movement, drift is due to the control valve.
7. Remove from one of the cylinders the plug fitted on the cylinder
head side in Step 3.
9. Stop the engine and check the position of the bucket edge for 5
minutes.
● If the bucket edge turns, the drift is due to seal leakage of the
plugged cylinder.
BACKHOE
★ Test condition:
★ Backhoe aligned
★ Lifted outriggers
20-40 WB146-5
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
BOOM CIRCUIT
1. Set the machine with the boom in vertical position and with the
bucket on level ground leaned on the side.
8. Stop the engine and check the boom position for 5 minutes.
● If boom has a lowering movement, drift is due to cylinder gas-
kets.
● If boom has no lowering movement, drift is due to control valve.
ARM CIRCUIT
1. Set the machine with the arm fully extended and with the bucket
teeth on ground.
WB146-5 20-41
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
3. Disconnect the tubes b and c the tubes from the arm cylinder d
and plug them to avoid impurity inlet.
★ If a safety valve is fitted, remove it.
4. Plug the arm cylinder hole on the head side and fit a temporary tube
on the base side to catch oil leakage.
6. Stop the engine and check the arm position for 5 minutes.
● If the arm has a lowering movement, drift is due to the cylinder
seals.
● If the arm has no movement, drift is due to the control valve.
BUCKET CIRCUIT
1. Set the machine with the arm vertical and the bucket at level
ground on the side. Put a 450 kg weight in the bucket or fill it with
dirt.
4. Plug the bucket cylinder port on the base side and fit a temporary
tube on the rod side to catch oil leakage.
20-42 WB146-5
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
5. Start the engine and raise the boom.
6. Stop the engine and check the bucket position for 5 minutes.
● If the bucket has an movement, drift is due to the cylinder seals.
● If the bucket has no movement, drift is due to the control valve.
5. Disconnect from the cylinders b, the tubes c and d after the lock
valve e.
6. Plug the cylinders base head tube c. Add a temporary tubes to the
rod side d tube to catch oil leakage.
7. Start the engine, use the boom to raise the machine, and remove the
blocks supporting the outriggers.
WB146-5 20-43
TESTING AND ADJUSTING AIR CONDITIONING
AIR CONDITIONING
★ Test conditions:
● Machine on level ground with the working equipment raised and
in safety conditions with the parking brake engaged
WORK TEMPERATURE
1. Connect the maintenance station to the high pressure, HP, valve
and the low pressure, LP, valve.
5. Close the doors and windows and let the AC unit operate in these
conditions for 5 to 10 minutes.
Ambient temp °C 20 25 30 35
Outgoing air temp °C 6 -8 8 - 10 8 - 12 9 -14
8. If the average value of the temperature measured does not fall with-
in the values given in the table, it will be necessary to thoroughly
check the unit.
20-44 WB146-5
TESTING AND ADJUSTING AIR CONDITIONING
12
UNIT CHECK
Check the unit after the Steps 1, 2, 3 and 5 of the preceding paragraph.
A diagnosis of faults in the unit is based upon the working pressures.
When the pressures do not fall within the values given in the following
table, the causes must be found by checking the high-pressure and low
pressure gauges.
Unit: kg/cm²
Unit with R134a.
Outside Air Temp °C Low Pressure High Pressure
Min Max Min Max
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0
WB146-5 20-45
TESTING AND ADJUSTING AIR CONDITIONING
20-46 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
TROUBLESHOOTING GUIDE
FRONT AXLE
WB146-5 20-47
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Uneven wear of tires
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading/incorrect weight distribution
related to the vehicle
Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft Replace half shaft
Blocked half shaft:
● Abnormal functioning of the differential or ● Verify assembly of all components
breakage/blockage of control device
● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the
with kicks, have steering difficulty or cause pneu- vehicle begins to kick.
matic wear on sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Bent or broken half shaft Replace half shaft
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various
of parts parts of the axle.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading/incorrect weight distribution
related to the vehicle
Bent half shaft Replace half shaft
Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires
20-48 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and ring gear Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of round Replace
Low oil level Oil level
Poor or worn oil Replace
Bent half shaft Replace
Noise while driving in neutral
CAUSES REMEDY
Noises coming from axle are usually heard but not
Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring, sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent half shaft Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
WB146-5 20-49
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment (excessive backlash)
for the adjustment of the bevel gear set free backlash.
Pinion nut loosened
Ring gear tooth broken
CAUSES REMEDY
Load bump
Incorrect gear adjustment insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting
CAUSES REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
20-50 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Prolonged operation at high temperature
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened
worn. Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Insufficient lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
Insufficient lubrication; contaminated oil ule.
WB146-5 20-51
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
REAR AXLE
20-52 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Uneven wear of tires
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading/incorrect weight distribution
related to the vehicle
Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires
Bent or broken half shaft Replace half shaft
Blocked half shaft:
● Abnormal functioning of the differential or break- ● Verify assembly of all components
age/blockage of control device.
● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the
with kicks, have steering difficulty or cause pneu- vehicle begins to kick.
matic wear on sharp turns.
Incorrect wheel adjustment Verify group integrity and wheel side bearings
Friction noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Bent or broken half shaft Replace half shaft
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various
of parts parts of the axle.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading/incorrect weight distribution
related to the vehicle
Bent half shaft Replace half shaft
Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires
WB146-5 20-53
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Noise while driving
CAUSES REMEDY
Excessive backlash between pinion and ring gear Adjust
Worn out pinion and ring gear Replace
Worn out pinion bearings Replace
Pinion bearings loose Adjust
Excessive axial pinion backlash Adjust
Worn out differential bearings Replace
Differential bearings loose Adjust
Ring gear out of round Replace
Low oil level Oil level
Poor or worn oil Replace
Bent half shaft Replace
Noise while driving in neutral
CAUSES REMEDY
Noises coming from axle are usually heard but not
Replace or adjust (see above)
loud when vehicle moves in neutral gear.
Incorrect backlash between pinion and ring sound
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
Bent half shaft Replace
Noise while steering
CAUSES REMEDY
Worn out differential gears Replace
Worn out differential box or spider Replace
Differential thrust washers worn out Replace
Half shaft spline worn out Replace
20-54 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen
Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment, excessive backlash
for the adjustment of the bevel gear set free backlash.
Pinion nut loosened
Ring gear tooth broken
CAUSES REMEDY
Load bump
Incorrect gear adjustment, insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting
CAUSES REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
WB146-5 20-55
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Prolonged operation at high temperature
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened
worn. Replace bevel gear set if required
Pinion axle backlash
Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use
Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Use correct lubricants, fill to proper levels and replace according to the
Lack of lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash. Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
Insufficient lubrication; contaminated oil ule.
20-56 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
TRANSMISSION
WB146-5 20-57
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Overheating
CAUSES REMEDY
Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing, broken gears, shafts, bearings, etc. Check/Repair/Replace
Braking force outside transmission: irregular axle
Check/Repair axle
operation
Clutch plate drag Repair/Replace
Damaged converter Replace
Damaged oil thermostat Replace
Incorrect oil level Add oil
Worn oil pump Replace
Wheels rotate when vehicle is raised
CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wail for oil to reach operating temperature (stall test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace
Noise
CAUSES REMEDY
Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Irregular actuation
CAUSES REMEDY
Damaged control valve Replace
Electrical system fault Repair/Replace
Worn clutch plates Replace
Damaged converter Replace
Low oil temperature (high oil viscosity) Wait for oil to reach operating temperature (stall test)
Overheating See “Overheating”
Damaged hydraulic system Repair/Replace
20-58 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
Gear remains engaged
CAUSES REMEDY
Damaged/jammed shuttle shaft lever Repair/Replace
Electrical system fault Repair/Replace
Damaged control valve Replace
Damaged hydraulic system Repair/Replace
Damaged clutch Repair/Replace
Damaged gear lever rod Replace
Damaged synchronizer Replace
No 4WD power transmission
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Damaged control valve Replace
Faulty brake sensor Check/Replace
Electrical system fault Repair/Replace
Gear shift will not engage
CAUSES REMEDY
Damaged shifter Replace
Damaged synchronizer Replace
WB146-5 20-59
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
20-60 WB146-5
90 OTHERS
WB146-5 90-1
OTHERS
12
90-2 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
1 OF 4
WB146-5 90-3
OTHERS HYDRAULIC CIRCUIT
12
90-4 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
2 OF 4
WB146-5 90-5
OTHERS HYDRAULIC CIRCUIT
12
90-6 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
3 OF 4
WB146-5 90-7
OTHERS HYDRAULIC CIRCUIT
12
90-8 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
4 OF 4
WB146-5 90-9
OTHERS HYDRAULIC CIRCUIT
12
90-10 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
ELECTRICAL SCHEMATIC
WIRING - 1 OF 7
WB146-5 90-11
OTHERS ELECTRICAL SCHEMATIC
12
90-12 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 2 OF 7
WB146-5 90-13
OTHERS ELECTRICAL SCHEMATIC
12
90-14 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 3 OF 7
WB146-5 90-15
OTHERS ELECTRICAL SCHEMATIC
12
90-16 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 4 OF 7
WB146-5 90-17
OTHERS ELECTRICAL SCHEMATIC
12
90-18 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 5 OF 7
WB146-5 90-19
OTHERS ELECTRICAL SCHEMATIC
12
90-20 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 6 OF 7
WB146-5 90-21
OTHERS ELECTRICAL SCHEMATIC
12
90-22 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
WIRING - 7 OF 7
WB146-5 90-23
OTHERS ELECTRICAL SCHEMATIC
12
90-24 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
LEGEND FOR WIRING SCHEMATIC
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
A6 Machine Function Unit F19 Low Beam Light 15A Fuse S24 Starting Switch X27.s AC Harness Connector
B13 Return To Dig Sensor F20 Main Beam Light 15A Fuse S40 Seat Switch X28.s Heater Connector
B59 Brake Oil Low Level Switch F21 Return To Dig Sensor 10A Fuse S41 Rear Horn Switch X44.p Cab Harness Connector
B97 Rear Horn Switch F22 EC Power 7.5A Fuse S46 Parking Brake Switch X44.s Driver Site Harness Connector
B105 Transmission Oil Temperature Sender F23 Steering Unit 10A Fuse S53 Stop Light Switch X65.p Motor Harness Connector
B111 Fuel Level Sender F24 Flasher 7.5A Fuse S54 Stop 4WD Switch X128.s Driver Site Harness Connector
B112 Thermistor F25 Reverse Buzzer Switch 10A Fuse S57 Steering Column Gear Shift X140 Cab Harness Connector
B113 Air Filter Switch F27 General 175A Fuse S60 Steering Column Light Switch X142 Cab Harness Connector
B115 Engine Oil Pressure Switch S80 Ride Control Switch X166.p Switch Harness Connector
B121 Horn G1 Battery S81 Boom Unlock Switch X166.s Cab Harness Connector
G118 Starter Motor S83 EC Power Switch X177.s Work Light Harness Connector
E136 Right Rear Wok Light G119 Alternator S84 EMPI Solenoid Valve Switch
E138 Left Rear Work Light S85 Rear Horn Switch X30 Cigar Lighter
E143 Right Front Wok Light H17 Buzzer S86 General Light Switch Y48 Float Solenoid
E146 Left Front Work Light S87 4WD Switch Y49 Return To Dig Solenoid
E147 Left Indicator K1 Starter Lock Out Unit S88 PPC Switch Y60 EMPI Solenoid
E148 Beacon Lamp K2 Flasher S89 Warning Switch Y90 Rear PPC Solenoid
E151 Right Indicator K3 Low Beam Light Relay S97 Rear Horn Switch Y91 EC Power Solenoid
E152 Cab Light K4 Main Beam Light Relay S104 4th Speed Switch Y92 Back Up Alarm
E154 Rear Left Light K5 Front Horn Relay S107 Declutch Switch Y93 PPC Solenoid
E155 Left Indicator Light K6 Return To Dig Solenoid Relay S167 Beacon Light Switch Y94 Differential Lock Solenoid
E155 Right Indicator Light K7 Stop Light Relay S168 Front Working Light Switch Y95 Boom Unlock Solenoid
E156 Rear Right Light K8 Starter Relay S169 Rear Working Light Switch Y96 Solenoid
E400 Right Front Work Light K9 Forward Speed Relay Y98 MP Bucket Close Solenoid
E401 Left Front Work Light K10 Reverse Speed Relay X1.s Unit Connector Y99 MP Bucket Open Solenoid
E402 Left Rear Work Light K11 Declutch Relay X2.s Unit Connector Y106 4WD Solenoid
E403 Right Rear Work Light K45 Reheating Relay X3.s Unit Connector Y108 Forward Speed Solenoid
K56 Safety Start Relay X4.s Unit Connector
F1 Front Work Light 15A Fuse K61 Services Relay X5.s Unit Connector
F2 Rear Work Light 15A Fuse K111 X7.p Motor Harness Connector
F3 Right Position Light 3a Fuse X7.s Driver Site Harness Connector
F4 Left Position Light 3a Fuse M42 Rear Window Wiper X8.p Gear Harness Connector
F5 Horn 10A Fuse M55 Window Washer Pump X8.s Driver Site Harness Connector
F6 Rear Work Light 15A Fuse M58 Front Window Wiper X9.p Front Dashboard Harness Connector
F7 Front Window Washer 7.5A Fuse M116 AC Compressor Clutch X9.s Driver Site Harness Connector
F8 Stop Light Switch 7.5A Fuse X10.p Front Dashboard Harness Connector
F9 Front Work Light 15A Fuse P43 Instrument Panel X10.s Driver Site Harness Connector
F10 Front Wiper 10A Fuse P63 Front Control Panel X11.p Solenoid Valve Harness Connector
F11 Optional 7.5A Fuse X11.s Driver Site Harness Connector
F12 Instruments And Buzzer 5A Fuse R114 Preheater X12.p Chassis Harness Connector
F13 Lever Grip 10A Fuse X12.s Driver Site Harness Connector
F14 Light And Optional Switch 10A Fuse S2 EC Power Switch Solenoid Valve X15.p Optional Harness Connector
F15 Safety Starter 10A Fuse S3 MP Bucket Close Switch X25.p Switch Panel Harness Connector
F16 Beacon Light 10A Fuse S4 Declutch Switch X25.s Driver Site Harness Connector
F17 Warning Switch 10A Fuse S5 MP Bucket Open Switch X26.p Switch Panel Harness Connector
F18 Cab Light And Cigar Lighter 10A Fuse S6 Differential Locking Switch X26.s Driver Site Harness Connector
WB146-5 90-25
OTHERS ELECTRICAL SCHEMATIC
12
90-26 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
FUSE AND RELAY PANEL
TIER I ENGINE
Position Description
F1 A 15A Light Blue for Low Beam
F1 B 3A Violet for Parking Lights
F1 C 3A Violet for Parking Lights
F2 A 10A Red for Lighter
F2 B 7.5A Brown for Dome Light Radio
F2 C 10A Red for Emergency Power Supply
F3 A 7.5A Brown for Start Enable
F3 B 7.5A Brown for Instruments Switch Lights
F3 C 7.5A Brown for OPT Solenoid
F4 A 7.5A Brown for Diff Lock Solenoid Valve
F4 B 10A Red for Direction Selector
F4 C 15A Light Blue for High Beam
F5 A 15A Light Blue for Heater
F5 B 15A Light Blue for Rear Work Light
F5 C 15A Light Blue for Front Work Light
F6 A 15A Light Blue for Wiper and Beacon
F6 B 7.5A Brown for Dimmer Switch Horn Relay
F6 C 10A Red for Directional Indicators
F7 A 7.5A Brown for Monitor
F7 B 10A Red for Horn
F7 C 7.5A Brown for Alt Excitation Stop Solenoid
WB146-5 90-27
OTHERS ELECTRICAL SCHEMATIC
12
90-28 WB146-5