Shop Manual WB146 5

CEBM016501
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 recommended that customers contact their distributor for information on the latest revision.
August 2006 Printed in USA
Copyright 2006 Komatsu DataKom Publishing Division 00-1
FOREWORD
CONTENTS
CONTENTS
01 10 20 30 90 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . Will be issued at a later time OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WB146-5
FOREWORD
SAFETY
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully before operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. or when grinding parts with a grinder, etc. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 2. 1. lock all the control levers and hang warning signs on them. 3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
4.
2.
PRECAUTIONS DURING WORK
3.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
4.
3.
5.
4.
PREPARATIONS FOR WORK 1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to 5.
2.
6.
WB146-5
00-3
FOREWORD
7.
SAFETY
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents. 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 installed.
8. 9.
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 correctly. 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 measurements. 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 machine.
00-4
WB146-5
FOREWORD
GENERAL
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WB146-5
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Engine volume: Electrical volume: Issued for every machine model Issued for each engine series Each issued as one to cover all models
REVISED EDITION MARK

When a manual is revised, an edition mark (EFG) is recorded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
SYMBOLS
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol Item Safety Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc. Places that require special attention for tightening torque during assembly. Places to be coated with adhesives and lubricants etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item
Caution
2.
Weight
Torque
Coat Oil, water
3.
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
Drain
10-4 10-4-1 Added pages 10-4-2 10-5
00-6
WB146-5
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WARNING!Heavy parts (25kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
1.
2.
3.
WIRE ROPES
1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
WARNING!Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident
Wire ropes, standard Z or S twist ropes without galvanizing Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0 4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120 hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
WB146-5
00-7
FOREWORD
QUICK DISCONNECT COUPLER

WARNING!Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING!Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
TYPE 1
DISCONNECTION 1. Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold the rubber cap portion (4).
2.
3.
After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks. Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare an oil receiving container.
4.
CONNECTION 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). After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality.
2.
00-8
WB146-5
FOREWORD TYPE 2
DISCONNECTION 1. Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and turn the lever (4) to the right, clockwise.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1. 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
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FOREWORD TYPE 3
DISCONNECTION 1. Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end.
2.
Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
3.
Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it.
CONNECTION 1. Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.
00-10
WB146-5
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below. Category Code LT-1A Part No. 790-129-9030 Quantity 150 g Container Tube
Main applications, features Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
LT-1B
790-129-9050
20 g (2 pes.)
Polyethylene container
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030 790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120
50 g Adh : 1 kg Hardening agent: 500 g 250 g 75 g
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
LT-3 Adhesives
Can
Used as adhesive or sealant for metal, glass or plastic.
LT-4 Holtz MH 705 3 Bond 1735
Polyethylene container Tube
Used as sealant for machined holes. Used as heat-resisting sealant for repairing engine.
179-129-9140
2g
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
Aron-alpha 201
790-129-9130
50 g
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50 LG-1
79A-129-9110
50 cc
Polyethylene container Tube
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
790-129-9010
200 g
Used as adhesive or sealant for gaskets and packing of power train case, etc.
Gasket sealant LG-3 790-129-9070 1 kg Can
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
00-11
WB146-5
FOREWORD
Category Code Part No. Quantity Container
COATING MATERIALS
Main applications, features Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case.
LG-4
790-129-9020
200 g
Tube
LG-5 Gasket sealant LG-6
790-129-9080
1 kg
Used as sealant for various threads, pipe joints, flanges. for tapered plugs, elbows, nipples of hydraulic piping.
09940-00011
250 g
Tube
Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc.
LG-7
09920-00150
150 g
Tube
Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
3 Bond 1211 Molybdenum disulphide lubricant LM-G
790-129-9090 09940-00051
100 g 60 g
Tube Can
Used as heat-resisting sealant for repairing engines. Used as lubricant for sliding parts (to prevent squeaking).
LM-P
09940-00040 SYG2-400LI SYG2-350LI
200 g
Tube
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
G2-LI
SYG2-400LI-A SYG2-160LI
SYGA160CNLI
Various
Various
General purpose type
SYG2-400CA Grease G2-CA SYG2-350CA

SYG2-400CA-A
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
SYG2-160CA
SYG2-160CNCA
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Used for places with heavy load.
00-12
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FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm

11.8 - 14.7 27 - 34 59 - 74 98 - 123 153 - 190 235 - 285 320 - 400 455 - 565 610 - 765 785 - 980 1150 - 1440 1520 - 1910 1960 - 2450 2450 - 3040 2890 - 3630
lbf ft
8.70 - 10.84 19.91 - 25.07 43.51 - 54.57 72.28 - 90.72 112.84 - 140.13 173.32 - 210.20 236.02 - 295.02 335.59 - 416.72 449.91 - 564.23 578.98 - 722.81 848.19 - 1062.09 1121.09 - 1408.74 1445.62 - 1807.02 1807.02 - 2242.19 2131.55 - 2677.35
Thread diameter of bolt mm 6 8 10 12
Width across flats mm 10 13 14 27 Nm

5.9 - 9.8 13.7 - 23.5 34.3 - 46.1 74.5 - 90.2
lbf ft
4.35 - 7.22 10.10 - 17.33 25.29 - 34.00 54.94 - 66.52
00-13
WB146-5
FOREWORD TIGHTENING TORQUE OF HOSE NUTS

Use these torques for hose nuts. Nominal No. 02 03 04 05 06 10 12 14 Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55
Tightening torque Nm 19.6 - 29.4 29.4 - 68.6 58.9 - 98.1 107.9 - 166.7 147.1 - 205.9 147.1 - 245.1 196.2 - 294.2 245.2 - 343.2 lbf ft 14.5 - 21.7 21.7 - 50.6 44.4 - 72.4 79.6 - 123.0 108.5 - 151.9 108.5 - 180.8 144.7 - 217.0 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts. Thread diameter mm 10 12 16 Width across flat mm 14 17 22 Nm
59 - 74 98 - 123 235 - 285
Tightening torque kgm

43.51 - 54.57 72.28 - 90.72 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.
Thread diameter mm 14 18 22 24 30 33 36 42
Width across flat mm 19 24 27 32 36 41 46 55 Nm

24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49
Tightening torque lbf ft

18.0 3.6 36.1 14.4 57.8 14.4 101.2 21.6 130.1 21.6 144.6 36.1 180.8 36.1 216.9 36.1
00-14
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FOREWORD
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Norminal No. 02 03, 04 05, 06 10, 12 14 Thread diameter mm 14 20 24 33 42 Width across flat mm Varies depending on type of connector. Tightening torque - Nm (lbf ft) Range Target 35 - 63 (25.81 - 46.46) 44 (32.45)) 84 - 132 (61.95 - 97.35) 103 (75.96) 128 - 186 (94.40 - 137.18) 157 (115.79) 363 - 480 (267.73 - 354.02) 422 (311.25) 746 - 1010 (550.22 - 744.93) 883 (651.26)
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diameter mm 08 10 12 14 16 18 20 24 30 33 36 42 52 Width across flat mm 14 17 19 22 24 27 30 32 32 _ 36 _ _ Tightening torque - Nm (lbf lb) Range Target 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42) 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31) 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01) 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62) 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68) 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91) 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14) 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59) 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50) 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75) 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03) 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40) 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52)
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque - Nm (lbf ft) Range 34 - 54 (25.0 - 39.8) 34 - 63 (25.0 - 46.4) 54 - 93 (39.8 - 68.5) 59 - 98 (43.5 - 72.2) 84 - 132 (61.9 - 97.3) 128 - 186 (94.4 - 137.1) 177 - 245 (130.5 - 180.7) 177 - 245 (130.5 - 180.7) 197 - 294 (145.3 - 216.8) 246 - 343 (181.4 - 252.9) Target 44 (32.4) 44 (32.4) 74 (54.5) 78 (57.5) 103 (75.9) 157 (115.7) 216 (159.3) 216 (159.3) 245 (180.7) 294 (216.8) Taper seal Thread size (mm) 14 18 22 24 30 33 36 42 Face seal Nominal thread Root diameter (mm) size - TPI (Reference) 9/16 - 18UN 14.3 11/16 -16UN 17.5 13/16 - 16UN 20.6 1 - 14UNS 25.4 1 3/16 - 12UN 30.2 -
Nominal hose size 02 03 04 05 06 (10) (12) (14)
Width across flats 19 22 24 27 32 36 41 46 55
00-15
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FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

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
Copper wire Nominal number 0.85 2 5 15 40 60 100 Number of Dia. Of Cross section strands strand (mm) (mm) 11 26 65 84 85 127 217 0.32 0.32 0.32 0.45 0.80 0.80 0.80 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) 2.4 3.1 4.6 7.0 11.4 13.6 17.6 Current rating (A) 12 20 37 59 135 178 230 Applicable circuit Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Priority 1 Circuits Classification
Primary
Charging W White WR White & Red WB White & Black WL White & Blue WG White & Green
Ground B Black
Starting B Black BW Black & White BY
Lighting R Red RW Red & White RB
Instrument Y Yellow YR Yellow & Red YB Yellow & Black YG Yellow & Green YL Yellow & Blue YW Yellow & White
Signal G Green GW Green & White GR Green & Red GY Green & Yellow GB Green & Black GL Green & Blue
Other L Blue LW Blue & White LR Blue & Red LY Blue & Yellow LB Blue & Black
Code Color Code
2 Color Code 3 Color Auxiliary Code Color Code 5 Color Code 6 Color
Black & YelRed & Black low BR Black & Red RY Red & Yellow RG Red & Green RL Red & Blue
00-16
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FOREWORD
CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches. Convert 55 mm into inches. A. Locate the number 50 in the vertical column at the left side, take this as E, then draw a horizontal line from E. B. Locate the number 5 in the row across the top, take this as F, then draw a perpendicular line down from F. C. Take the point where the two lines cross as G. This point G gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches.
1.
2.
Convert 550 mm into inches. A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. F
Millimeters to inches 0 0 10 20 30 40 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 G E 50 60 70 80 90 1.969 2.362 2.756 3.150 3.543 2.008 2.402 2.795 3.189 3.583 2.047 2.441 2.835 3.228 3.622 2.087 2.480 2.874 3.268 3.661 2.126 2.520 2.913 3.307 3.701 2.165 2.559 2.953 3.346 3.740 2.205 2.598 2.992 3.386 3.780 6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 0.276 0.669 1.063 1.457 1.850 8 0.315 0.709 1.102 1.496 1.890 9 0.354 0.748 1.142 1.536 1.929
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-17
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FOREWORD
CONVERSION TABLES
Millimeters to Inches 0 0 10 20 30 40 0 0.394 0.787 1.181 1.575 1 0.039 0.433 0.827 1.220 1.614 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 7 0.276 0.669 1.063 1.457 1.850
1 mm = 0.03937 in 8 0.315 0.709 1.102 1.496 1.890 9 0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to Pound 0 0 10 20 30 40 0 22.05 44.09 66.14 88.18 1 2.20 24.25 46.30 68.34 90.39 2 4.41 26.46 48.50 70.55 92.59 3 6.61 28.66 50.71 72.75 94.80 4 8.82 30.86 51.91 74.96 97.00 5 11.02 33.07 55.12 77.16 99.21 6 13.23 35.27 57.32 79.37 101.41 7 15.43 37.48 59.53 81.57 103.62
1 kg = 2.2046 lb 8 17.64 39.68 61.73 83.78 105.82 9 19.84 41.89 63.93 85.98 108.03
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
00-18
WB146-5
FOREWORD
CONVERSION TABLES
Liter to U.S. Gallon 0 0 10 20 30 40 0 2.642 5.283 7.925 10.567 1 0.264 2.906 5.548 8.189 10.831 2 0.528 3.170 5.812 8.454 11.095 3 0.793 3.434 6.076 8.718 11.359 4 1.057 3.698 6.340 8.982 11.624 5 1.321 3.963 6.604 9.246 11.888 6 1.585 4.227 6.869 9.510 12.152 7
1 L = 0.2642 U.S. Gal 8 2.113 4.755 7.397 10.039 12.680 9 2.378 5.019 7.661 10.303 12.944
1.849 4.491 7.133 9.774 12.416
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 0 0 10 20 30 40 0 2.200 4.399 6.599 8.799 1 0.220 2.420 4.619 6.819 9.019 2 0.440 2.640 4.839 7.039 9.239 3 0.660 2.860 5.059 7.259 9.459 4 0.880 3.080 5.279 7.479 9.679 5 1.100 3.300 5.499 7.699 9.899 6 1.320 3.520 5.719 7.919 10.119 7
1 L = 0.21997 U.K. Gal 8 1.760 3.950 6.159 8.359 10.559 9 1.980 4.179 6.379 8.579 10.778
1.540 3.740 5.939 8.139 10.339
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
WB146-5
00-19
FOREWORD
CONVERSION TABLES
Nm to lbf. ft. 0 0 10 20 30 40 0 7.37 14.74 22.11 29.48 1 0.737 8.107 15.477 22.847 30.217 2 1.474 8.884 16.214 23.584 30.954 3 2.211 9.581 16.951 24.321 31.691 4 2.948 10.318 17.688 25.058 32.428 5 3.685 11.055 18.425 25.795 33.165 6 4.422 11.792 19.126 26.532 33.902 7 5.159 12.259 19.899 27.269 34.639
1 Nm = 0.737 lbf. ft. 8 5.896 13.266 20.636 28.006 35.376 9 6.63 14.003 21.373 28.743 36.113
50 60 70 80 90
36.85 44.22 51.59 58.96 66.33
37.587 44.957 52.327 59.697 67.067
38.324 45.694 53.064 60.434 67.804
39.061 46.431 53.801 61.171 68.541
39.798 47.168 54.538 61.908 69.278
40.535 47.905 55.275 62.645 70.015
41.272 48.642 56.012 63.382 70.752
42.009 49.379 56.749 64.119 71.489
42.746 50.116 57.486 64.856 72.226
43.483 50.853 58.223 65.593 72.963
100 110 120 130 140
73.7 81.07 88.44 95.81 103.18
74.437 81.807 89.177 96.547 103.917
75.174 82.544 89.914 97.284 104.654
75.911 83.281 90.651 98.021 105.391
76.648 84.018 91.388 98.758
77.385 84.755 92.125
78.122 85.492 92.862
78.859 86.229 93.599
79.596 86.966 94.336
80.333 87.703 95.073 102.443 109.813
99.495 100.232
100.969 101.706 108.339 109.076
106.128 106.865 107.602
150 160 170 180 190
110.55 117.92 125.29 132.66 140.03
111.287 118.657 126.027 133.397 140.767
112.024 119.394 126.764 134.134 141.504
112.761 120.131 127.501 134.871 142.241
113.498
114.235
114.972
115.709
116.446
117.183 124.553 131.923 139.293 146.663
120.868 121.605 122.342 128.238 128.975 129.712 135.608 136.345 137.082 142.978 143.715 144.452
123.079 123.816 130.449 131.186 137.819 138.556 145.189 145.926
00-20
WB146-5
FOREWORD
CONVERSION TABLES
Nm to lbf. inf 0 0 10 20 30 40 0 88.5 177 265.5 354 8.85 97.35 185.85 274.35 362.85 1 17.7 106.2 194.7 283.2 371.7 2 3 26.55 115.05 203.55 292.05 380.55 35.4 123.9 212.4 300.9 389.4 4 5 44.25 132.75 221.25 309.75 398.25 53.1 141.6 230.1 318.6 407.1 6 7 61.95 150.45 238.95 327.45 415.95
1 Nm = 8.85 lbf. inf 8 70.8 159.3 247.8 336.3 424.8 9 79.65 168.15 256.65 345.15 433.65
50 60 70 80 90
442.5 531 619.5 708 796.5
451.35 539.85 628.35 716.85 805.35
460.2 548.7 637.2 725.7 814.2
469.05 557.55 646.05 734.55 823.05
477.9 566.4 654.9 743.4 831.9
486.75 575.25 663.75 752.25 840.75
495.6 584.1 672.6 761.1 849.6
504.45 592.95 681.45 769.95 858.45
513.3 601.8 690.3 778.8 867.3
522.15 610.65 699.15 787.65 876.15
100 110 120 130 140
885 973.5 1062 1150.5 1239
893.85 982.35
902.7 991.2
911.55
920.4
929.25
938.1
946.95
955.8
964.65 1053.15 1141.65 1230.15 1318.65
1000.05 1008.9 1088.55 1097.4 1177.05 1185.9 1265.55 1274.4
1017.75 1026.6 1106.25 1115.1 1194.75 1203.6 1283.25 1292.1
1035.45 1044.3 1123.95 1132.8 1212.45 1221.3 1300.95 1309.8
1070.85 1079.7 1159.35 1168.2 1247.85 1256.7
150 160 170 180 190
1327.5 1416 1504.5 1593 1681.5
1336.35 1345.2 1424.85 1433.7 1513.35 1522.2 1601.85 1610.7 1690.35 1699.2
1354.05 1362.9 1442.55 1451.4 1531.05 1539.9 1619.55 1628.4 1708.05 1716.9
1371.75 1380.6 1460.25 1469.1 1548.75 1557.6 1637.25 1646.1 1725.75 1734.6
1389.45 1398.3 1477.95 1486.8 1566.45 1575.3 1654.95 1663.8 1743.45 1752.3
1407.15 1495.65 1584.15 1672.65 1761.15
WB146-5
00-21
FOREWORD
Temperature
CONVERSION TABLES
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. C -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 F -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 C -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
-40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
00-22
WB146-5
01
GENERAL
SPECIFICATIONS ................................................................................................................................................................ 01-2 WEIGHT TABLE .................................................................................................................................................................. 01-3 FUEL COOLANT AND LUBRICANTS .............................................................................................................................. 01-4
WB146-5
01-1
GENERAL
SPECIFICATIONS
SPECIFICATIONS
ITEM Minimum Operating weight Maximum GP w/BOCE Loader MP w/BOCE 305 mm Edge Bucket capacity Backhoe 457 mm Edge 609 mm Edge 762 mm Edge 915 mm Edge Model Diesel engine Max power Max torque Alternator Output Electrical system Ground Battery Starter Forward 1st Forward 2nd Forward 3rd Forward 4th Travel speeds Reverse 1st Reverse 2nd Reverse 3rd Reverse 4th Front Front tire pressure Rear kg/cm 1.83 - 1.93 km/h 6.3 11.4 21.3 37.8 3.26 - 3.36 kW Nm V A --Ah @ V kW m 0.99 0.07 0.12 0.18 0.23 0.29 S4D102LE-2 69 407 12 95 NEG 100 3.2 6.3 11.4 21.3 37.8 0.95 kg UNIT WB146-5 A23001 and UP
01-2
WB146-5
GENERAL
WEIGHT TABLE
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

It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recommended for this machine. Ambient Temperature - C -30 -20 -10 0 10 20 30 40 50 Capacity Specified Refill
Reservoir
Kind of fluid
SAE 5W-30 SAE 10W SAE 20W-20 Engine oil pan Oil API CI-4 SAE 30 SAE 40 SAE 10W-30 SAE 15W-40 SAE 5W* SAE 10W Hydraulic system 150 L SAE 30 SAE 10W-30+ HEES Front axle diff Final gear Rear axle diff Final gear Transmission ATF Brakes Diesel fuel Coolant ASTM D975 No. 1 ASTM D975 No. 2 AF-NAC 14 L GM DEXRON II D 0.8 L 0.8 L 150 L 6.5 L See Note 1 1 L each 14.5 L 1.5 L each 20 L 92 L 6.5 L 1 L each 14.5 L 1.5 L each 17 L 92 L 11 L 13 L
Oil API CI-4
Fuel tank
130 L
Engine cooling system
OPTION FOR VERY COLD AREAS:If the temperature is below 10C, contact your distributor for advise on the type of oil to be used.
01-4
WB146-5
GENERAL
Note 1: For axle oil, use only the recommended oil as follows. SHELL ..................................................................DONAX TD
CALTEX ...............................................................RPM TRACTOR HYDRAULIC FLUID CHEVRON ...........................................................TRACTOR HYDRAULIC FLUID TEXACO ..............................................................TEXTRAN TDH OIL MOBIL..................................................................MOBILFLUID 422 or 424 API ................................ American Petroleum Institute ASTM............................ American Society of Testing and Materials NLGI ............................. National Lubricating Grease Institute SAE ............................... Society of Automotive Engineers Specified Capacity ........ Total amount of oil including oil for components and piping. Refill Capacity .............. Amount of oil needed to refill system during normal maintenance. Other equipment may be necessary when operating the machine at temperatures below -20C. Consult your Komatsu distributor for your specific needs.
NOTE Use only diesel fuel. The engine mounted in this machine employs electronic control and a high pressure fuel injection device to obtain good fuel consumption and good exhaust characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a significant drop in durability.
WB146-5
01-5
GENERAL
MEMORANDA
01-6
WB146-5
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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
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
POWER TRAIN
POWER TRAIN
B C D E
Engine Torque Converter Transmission Hydraulic Pump
F G H I
Front Axle Rear Axle Front Drive Shaft Rear Drive Shaft
DESCRIPTION
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter 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 Differential
Gear 1st 2nd 3rd 4th Gear 1st 2nd 3rd 4th
Transmission 5.533 3.36 1.532 0.81 Transmission 5.533 3.36 1.532 0.81
Planet
2.462
Total 81.722 49.627 22.627 11.963 Total 97.338 59.136 26.963 14.256
Rear Axle Differential
Planet
2.75
6.4
WB146-5
10-3
POWER TRAIN
b c d e
Engine Convert Transmission Hydraulic Pump
F G H I
Front Axle Rear Axle Front Drive Shaft Rear Drive Shaft
j Rear Tires 1) Front Tires
10-4
WB146-5
TRANSMISSION DIAGRAM
b Engine c Torque Converter d Forward Clutch
E Transmission F Reverse Clutch G Hydraulic Pump
H Rear Axle Flange I 4WD Clutch J Front Axle Flange
WB146-5
10-5
B C D E F
Converter Valve Converter Engine Oil Cooler Forward Clutch
G H I J 1)
Reverse Clutch Max Pressure Valve Spin On Filter Pump Suction Strainer
1! 1@ 1# 1$ 1%
Control Valve Check Valve Check Valve 4WD Solenoid 4WD Clutch
10-6
WB146-5
TRANSMISSION
TRANSMISSION
COMPLETE ASSEMBLY
B C D E
Shift Lever Torque Converter Spin On Filter Oil Temperature Sender
F G H I
Suction Strainer 4th Gear Sensor Reverse Solenoid Forward Solenoid
J 4WD Solenoid
a From Oil Cooler b To Oil Cooler
WB146-5
10-7
TRANSMISSION
B C D E F G
Pump Drive Shaft Forward Reverse Shaft Reverse Gear Clutch Forward Gear Clutch Reverse Idler Gear Shaft Drive Gears and Shaft
H Rear Axle Flange I 3rd Driven Gear J 4th Driven Gear 1) 4WD Drive Gear 1! 1st Driven Gear 1@ 4WD Driven Gear
1# 1$ 1% 1^ 1& 1*
4WD Clutch 4WD Clutch Shaft Front Axle Flange 2nd Driven Gear Rear Output Shaft Torque Converter
10-8
WB146-5
TRANSMISSION
B C D E F G
Gear Shift Lever Centering Spring Return Spring Check Ball 3rd & 4th Selecting Fork 1st & 2nd Selecting Rod
H 3rd & 4th Selecting Rod I 1st &2nd Selecting Fork J 4th Selecting Sensor 1) 3rd & 4th Selector 1! 1st & 2nd Selector 1@ Suction Strainer
1# 1$ 1% 1^ 1&
Spin On Filter Cold Oil Relief Valve Return Spring Return Spring Return Spring
WB146-5
10-9
TRANSMISSION
B C D E F G
Forward Reverse Solenoid 4WD Solenoid Piston Return Spring Return Spring Spring Guide Pin
H Valve I Return Spring J Valve 1) Rod 1! Return Spring 1@ Spool Return Spring
1# 1$ 1% 1^ 1&
Spool Forward Solenoid Reverse Solenoid Check Ball Return Spring
10-10
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FORWARD REVERSE CLUTCH
TRANSMISSION
B Reverse Gear C Forward Gear D Forward Clutch Piston
E Reverse Clutch Piston F Thrust Ring G Shaft
a Reverse Clutch Port b Forward Clutch Port c Lubrication Port
1ST THROUGH 4TH SPEED SHAFT
B 2nd Driver Gear C 1st Driven Gear D 4WD Gear
E 4th Driven Gear F 3rd Driven Gear g Rear Output Shaft
H Thrust Ring I Synchronizer
WB146-5
10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4WD SHAFT
TRANSMISSION
B Front Output Shaft C 4WD Driven Gear D Thrust Ring
E Cylinder F Spring G Disc
a 4WD Pressure Port
10-12
WB146-5
FRONT AXLE
FRONT AXLE
COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut

Criteria
h Mounting Pin Bushing

a Left Cylinder Port b Right Cylinder Port Unit:mm
Check Item i Pin and Bushing Clearance
Standard Size 50
Tolerance Shaft 50
0 -0.039
Bushing 50.19
+0.04 0
Standard Clearance ---
Clearance Limit ---
Remedy Replace
WB146-5
10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
FRONT AXLE
B C D E
Side Gear Ring Gear Dowel Pin Driven Gear
F G H I
Adjustment Lock Nut Axle Shaft Dowel Pin Differential Housing
J Bearing Spacer 1) Outboard Bearing 1! Lip Seal Ring 1@ Lip Seal Ring Cover
Criteria
1# 1$ 1% 1^
Bearing Lock Nut Inboard Bearing Pinion Gear Oil Drain Plug Unit : mm
Check Item
Standard Clearance --0.18 to 0.28
Clearance Limit --0.28
Remedy
1& 1* 1( 2)
Axle Clearance Ring and Pinion Gear Backlash Pinion Preload - w/o lip seal Ring and Pinion Gear Preload - w/o lip seal
92 to 137 Nm 129.5 to 194.5 Nm
Adjust
10-14
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PLANETARY
FRONT AXLE
B C D E F G H I
Planetary Carrier Planetary Gear Ring Gear Carrier Gear Wheel Hub Lip Ring Seal Upper King Pin Adjustment Shim
J Belleville Washer 1) Upper King Pin Bushing 1! Lip Ring Seal 1@ Axle Housing 1# Spherical Bearing 1$ Lower King Pin Bushing 1% Lower King Pin 1^ Belleville Washer
1& Lip Ring Seal 1* Tapered Roller Bearing 1( Retaining Ring 2) Bolt Bushing 2! Stud Bolt 2@ Oil Drain Plug
Unit:mm
2# Hub Rotation Torque 2$ Axle Shaft Clearance
-----
Adjust
WB146-5
10-15
REAR AXLE
REAR AXLE
COMPLETE ASSEMBLY
B C D E
Input Flange Differential Portion Brake Portion Axle Housing
F G H I
Planetary Portion Parking Brake Levers Brake Bleeder Screws Oil Fill And Level Plugs
J Oil Drain Plug 1) Axle Housing Breather
a Brake Port .......................40.8 kg/cm b Diff Lock Port............. 1295.4 kg/cm
10-16
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL
REAR AXLE
B C D E
Tapered Roller Bearing Side Gear Rotating Gear Ring Gear
F G H I
Differential Housing Bearing Lock Nut Axle Shaft Tapered Roller Bearing
J Bearing Lock Nut 1) Lip Oil Seal 1! Input Flange 1@ Bearing Spacer
1# Pinion Gear 1$ Differential Housing
Unit:mm Check Item Criteria Standard Clearance Clearance Limit ----0.21 to 0.29 mm 115 to 138 Nm 148 to 188 Nm 0.29 mm Remedy
1% 1^ 1& 1*
Axle Clearance Ring And Pinion Gear Backlash Pinion Gear Preload - w/o seal ring Pinion Ring Gear Preload - w/o seal ring
Adjust
WB146-5
10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PLANETARY
REAR AXLE
B C D E
Stud Bolt Planet Gear Wheel Hub Sun Gear Check Item
F G H I
Axle Shaft Pressure Plate Retaining Ring Ring Nut Criteria -----
J Tapered Roller Bearing 1) Oil Seal 1! Wheel Flange

Unit : mm Remedy Adjust
1@ Hub Rotation Torque 1# Axle Shaft Clearance
10-18
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK BRAKES
REAR AXLE
B Bleed Screw C Brake Piston D Friction Disc

Check Item
E Middle Plate F Outer Plate G Belleville Washer

Criteria ---
H Bushing I Parking Brake Control Caliper J Set Screw

Unit : mm Remedy Adjust
1) Hub Rotation Torque
WB146-5
10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL LOCK
REAR AXLE
B Engagement Pin C Sleeve D Cover
E Piston F Bushing G Control Rod
h Fork i Spacer
a Diff Lock Port
10-20
WB146-5
HYDRAULIC PUMP
HYDRAULIC PUMP
COMPONENTS
Ps From Hydraulic Tank P1L From Control Valve Pp PLS From Control Valve LS PM From EV1 Solenoid Valve PORT FUNCTIONS P1 Pump Delivery Pd Drain
b c Delivery Control Valve d Oil Refil Plug

Hydraulic Pump PORT CONNECTIONS P1 To Loader Valve Pd To Hydraulic Tank
Ps Oil Intake P1L Pump Delivery Pressure Input P1C QD For Pump Delivery Pressure Pd2 Drain Plug Pen Delivery Control Pressure Check PLS LS Signal Input PM Operarting Mode Control Signal
WB146-5
10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN PUMP
HYDRAULIC PUMP
PORT FUNCTIONS Pa Delivery Control Group Feed
Pe Delivery Control Signal Pd4 Drain
Pd5 Drain PM2 Opera ting Mode Signal
10-22
WB146-5
HYDRAULIC PUMP
B C D E F
Bearing Input Shaft Pump Housing Swash Plate Shoe
G Piston H Cylinder Block I Swash Plate J Cover 1) Shoe Guide
1! Control Piston 1@ Spring 1# Seal Ring 1$ Ball
WB146-5
10-23

FUNCTION The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered according to the load requirements. The amount of oil delivered can be modified by changing the angle of the swash plate. STRUCTURE
HYDRAULIC PUMP
Groove a supports and makes the cylinder block B an integral part of the shaft c. The shaft is supported by front d and rear e bearings. The end of piston f is a concave ball, and the shoe g is staked to it to form one unit. The piston and shoe form a spherical bearing.
The swash plate h is supported by the pump body i and ball j, and has a flat surface A. The shoe g remains in contact with the swash plate and slides in a circular movement. Pressurised oil is introduced between the shoe and swash plate forming a static bearing that allows the shoes to slip.
The pistons f perform their relative movements in an axial direction, inside the cylindrical chambers fashioned in the cylinder block B. 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 cylinder block and the axis X of the swash plate changes. The angle a is known as the swash plate angle.
10-24
WB146-5

2. When the axis X of the swash plate h retains the angle a in relation 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 therefore causing the suction and delivery of oil in a quantity that is equivalent to the difference between those volumes (F E = delivery). When the cylinder block rotates, chamber F decreases in volume 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 delivery at chamber E are complete. 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 cylinder 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 delivery.
HYDRAULIC PUMP
3.
Control of Delivery 1. When angle a of the swash plate increases, the difference between volumes E and F increases too, and this makes delivery Q increase accordingly. Angle a of the swash plate is varied by the servo piston 1!. The servo piston 1! moves in a reciprocating linear motion caused by pressure signals from the PC and LS valves. The linear motion is transmitted to the swash plate h. The swash plate is supported by the pump body i through the ball j, and this is the reason why the swash plate moves in a semicircular alternate motion.
2.
WB146-5
10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DELIVERY CONTROL VALVE
HYDRAULIC PUMP
PORT FUNCTIONS T Drain
P1 Delivery Control Group Feed Pd4 Drain
PE Delivery Control Signal Output PM Operating Mode Signal Input
10-26
WB146-5
HYDRAULIC PUMP
COMPONENTS
b c d e f g h
Lever Spring Retainer Seal Spool Sleeve Piston
i j 1) 1! 1@ 1# 1$ 1%
Gasket Piston Spool Plug Seat Spring Nut Plug T PA PM PPL PE PLS
PORT FUNCTION Drain Pump Delivery Pressure Operating Mode Signal Output Delivery Control Signal Input Delivery Control Signal LS Signal Input
PPLS LS Pump Signal Input
WB146-5
10-27

LS VALVE FUNCTION
HYDRAULIC PUMP
The LS valve controls the pump delivery according to the stroke of the control valve lever, the function of the delivery demands made by the actuators. The LS valve detects the actuator s delivery needs by means of the differential pressure UPLS existing between pressure PPLS, control valve input pressure, and pressure PLS, control valve output pressure. The sensing of this differential pressure permits control of the main pump delivery Q. PPLS, PLS and UPLS are, respectively, the pump pressure, the Load Sensing pressure, and the difference in pressure between these two values. The LS valve detects the pressure difference UPLS generated by the passage of the oil flow through the surface freed by the control valve spool, and controls the pump delivery Q so as to keep the pressure drop constant. It can therefore be assumed that the pump delivery is proportional to the demands made known by the control valve. Pump pressure PPLS, pump pressure at control valve input, and pressure PLS, Load Sensing pressure, are introduced into the LS valve. The relation between differential pressure UPLS and pump delivery varies as shown in the diagram on the right.
PC VALVE FUNCTION
The PC, Power Control, valve performs an approximate power check, and ensures that the hydraulic horsepower absorbed by the pump does not exceed the horsepower delivered by the endothermal engine. This is achieved by limiting the pump delivery Q function of the delivery pressure PPLS, even if the LS valve requests an increase in delivery Q due to the larger section freed by the control valve spool, in the presence of high pressure pump delivery. When during operation the delivery Q increases and the delivery pressure PPLS also increases simultaneously, the PC valve reduces the pump delivery Q. When the delivery pressure PPLS decreases, the PC valve increases the pump flow. As pressure PC increases, the relation between pressure PA and delivery Q is switched in accordance with the force applied by pressure PC. When the force applied by pressure PC is added to the force applied by the pump's delivery pressure against the spool f, the relation between pump delivery pressure and delivery is switched from b to in accordance with increment X.
10-28
WB146-5

PC VALVE OPERATION Spring Operation
HYDRAULIC PUMP
PC valve spring loading d is defined by swash plate position. If control piston g moves to the right, spring d is compressed by the lever c and the spring load increases.
When Pump Pressure PA is Low
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. Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J is sent for relief, PT; the control piston c shifts to the left. Pump delivery increases as a result. 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. Consequently, 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

When Pump Pressure PA Is High
HYDRAULIC PUMP
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. Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J becomes equivalent to the pump's delivery pressure, PA, and the control piston c shifts to the right. Pump delivery decreases as a result. 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

When Equilibrium Has Been Reached
HYDRAULIC PUMP
The equilibrium between the force applied by pressure PA against spool e and the force applied by spring b against spool f is what determines the position at which the control piston c, pump stops.
WB146-5
110-31
MAIN CONTROL VALVE
MAIN CONTROL VALVE
10-32 1
WB146-5
MAIN CONTROL VALVE
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B7
B5
Arm Cylinder Rod Swing Cylinder Head Loader Bucket Cylinder Head Backhoe Boom Cylinder Head Backhoe Bucket Cylinder Rod Mp Bucket Cylinder Head Jig Arm Cylinder Head Loader Boom Cylinder Head Right Outrigger Cylinder Head Left Outrigger Cylinder Head Arm Cylinder Head Swing Cylinder Rod Loader Bucket Cylinder Rod Backhoe Boom Cylinder Rod Backhoe Bucket Cylinder Head Mp Bucket Cylinder Rod
B8 B9 B10 LS P D DLS PP T TS PPPC PA1 PA2 PA3 PA4 PA5
Loader Boom Cylinder Rod PA6 Right Outrigger Cylinder Rod PA7 Left Outrigger Cylinder Rod PA8 Hydraulic Pump, PLS Port PA9 Hydraulic Pump, P1 Port PA10 Steering Unit, P Port PB1 Steering Unit, LS Port PB2 Hydraulic Pump, P1L Port PB3 Drain PB4 Drain PB5 Solenoid Valve EV1, P Port PB6 Left Backhoe PPC Valve Port 3 PB7 Left Backhoe PPC Valve Port 4 PB8 Loader PPC Valve, P2 Port PB9 Right Backhoe PPC Valve Port 3 PB10 Right Backhoe PPC Valve Port 4
Solenoid Valve EV1, A1 Port Solenoid Valve EV2, A2 Port Loader PPC Valve, P3 Port Outrigger PPC Valve, P1 Port Outrigger PPC Valve, P3 Port Left Backhoe PPC Valve Port 1 Left Backhoe PPC Valve Port 2 Loader PPC Valve, P1 Port Right Backhoe PPC Valve Port 1 Right Backhoe PPC Valve Port 2 Solenoid Valve EV1, B1 Port Solenoid Valve EV2, B2 Port Loader PPC Valve, P4 Port Outrigger PPC Valve, P1 Port Outrigger PPC Valve, P4 Port
WB146-5
110-33
MAIN CONTROL VALVE
B C d e f g h i j
ACV - Jig Arm Extend ACV - Backhoe Bucket Curl ASCV - Backhoe Boom Raise ACV - Loader Bucket Dump ASCV - Backhoe Left Swing ACV - Backhoe Arm Out Safety Valve ACV - Backhoe Arm In ASCV - Backhoe Right Swing
1) ASCV - Loader Bucket Curl 1! ACV - Backhoe Boom Lower 1@ ACV - Backhoe Bucket Dump 1# ACV - Jig Arm Retract 1$ ACV - MP Loader Bucket Dump 1% Loader Boom Arm Spool 1^ Jig Arm Spool 1& MP Bucket Spool 1* Backhoe Bucket Spool
ASCV - Anti-Shock/Cavitation Valve
1( Backhoe Boom Spool 2) Loader Bucket Spool 2! Backhoe Swing Spool 2@ Backhoe Arm Spool 2# Priority Valve Spool 2$ Unloading Valve 2% LS By Pass Plug
ACV - Anti-Cavitation Valve
10-34 1
WB146-5
MAIN CONTROL VALVE
Unit : mm
Spring Criteria Standard Size Check Item
Free Length Installed Length Installed Load
Repair Limit
Free Length Installed Load
Remedy
2^ Backhoe Arm In Spool Spring 2& Backhoe Arm Out Spool Spring 2* Prioroty Valve Spring 2( Unloading Valve Spring 3) Backhoe Swing Spool Spring 3! Loader Bucket Spool Spring 3@ Backhoe Boom Spool Spring 3# Backhoe Bucket Spool Spring 3$ MP Bucket Spool Spring 3% Backhoe Jig Spool Spring 3^ Loader Boom Raise Spool Spring 3& Loader Boom Lower Spool Spring 3* Loader Boom Float Spool Spring
24.2 27.2 56.8 25.5 29.0 42.3 41.1 41.1 29.0 29.0 27.1 38.7 19.4
23.7 26.7 48.5 18.0 28.5 40.5 40.5 40.5 28.5 28.5 26.7 27.6 19.0
30.4 N 30.38 N 29.6 N 121.5 N 22.5 N 54.9 N 34.3 N 34.3 N 22.5 N 22.5 N 14.7 N 355.7 N 14.7 N
--------------
24.3N 24.3 N 23.7 N 97.2 N 18.0 N 43.9 N 27.4 N 27.4 N 18.0 N 18.0 N 11.8 N 284.5 N 11.8 N Replace
Unit : mm
Repair Limit
Remedy
2* PDV Tension Spring 2( PDV Tension Spring 3) PDV Tension Spring 3! PDV Tension Spring 3@ PDV Tension Spring 3# Check Valve Spring 3$ Check Valve Spring 3% Check Valve Spring
15.4 31.4 18.9 37.1 20.0 27.2 27.2 21.9
8.0 21.8 15.0 24.0 15.0 21.0 22.0 15.8
7.44 N 63.7 N 15.7 N 34.3 N 4.32 N 4.7 N 3.92 N 1.96 N
---------
5.96 N 51.0 N 12.5 N 27.4 N 3.45 N 3.76 N 3.14 N 1.57 N Replace
WB146-5
110-35
MAIN CONTROL VALVE
Pressure Reducing Valve
B C d e f g h i
Loader Boom Backhoe Jig Arm MP Bucket Backhoe Bucket Backhoe Boom Loader Bucket Backhoe Swing Backhoe Arm
Delivery Control Valve Backhoe Arm j 1) Backhoe Swing
1! Loader Bucket 1@ Backhoe Boom 1# Backhoe Bucket 1$ MP Bucket 1% Backhoe Jig Arm 1^ Loader Boom 1& Main Relief Valve
1* Check Valve 1( Check Valve 2) Check Valve 2! Check Valve 2@ Check Valve 2# Check Valve 2$ Check Valve 2% Check Valve 2^ LS By Pass Plug 2& LS, DLS Pressure Check Valve
10-36 1
WB146-5
MAIN CONTROL VALVE
b Backhoe Right Outrigger Spool c Backhoe Left Outrigger Spool d Loader Bucket Spool
e Backhoe Swing Spool f Loader Boom Spool g Backhoe Bucket Spool
H Backhoe Boom Spool
Unit : mm
Repair Limit
Remedy
i Outrigger Spool Outer Spring j Outrigger Spool Inner Spring
18.0 20.2
17.5 10.4
39.2 N 30.4 N
---
31.4 N 24.3 N
Replace
WB146-5
110-37
MAIN CONTROL VALVE
b PPC Maximum Pressure Valve c Maximum Pressure Valve Spool d Sequential Reducing Valve
e Blow Out Plug f Unloading Valve g LS By Pass Plug
H Arm Spool
Unit : mm
Repair Limit
Remedy
i Outrigger Spool Outer Spring
18.0
17.5
39.2 N
--
31.4 N
Replace
10-38 1
WB146-5
CLSS
CLSS
DESCRIPTION
CHARACTERISTICS The term CLSS means Closed center Load Sensing System, which has the following characteristics:
High precision control that is independent of the load applied to the movement; High precision control of digging action even during delicate manoeuvres. Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the shuttles. Energy savings guaranteed by control of pump delivery.
STRUCTURE
The CLSS system includes the variable flow pump, the control valve and the working equipment. The pump includes the main pump, the PC valve and the LS valve.
WB146-5
110-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD OPERATING PRINCIPLES

PUMPING PLATE CONTROL ANGLE
CLSS
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 control valve towards the actuator is maintained at a constant value. UPLS = pump delivery pressure PP minus pressure PLS of delivery to the actuator.
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

PRESSURE COMPENSATION CONTROL
CLSS
The pressure compensation valves are installed downstream from the control valve in order to balance the differential pressure between the loads. When two or more movements, cylinders, are activated simultaneously, the pressure differences UP between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
WB146-5
110-41

MAIN CONTROL VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9. Unloading Valve Pressure ................................. LS + 28.02 kg/cm Main Pressure Relief Valve ........................................ 222.14 kg/cm Safety Valve ............................................................... 275.13 kg/cm Check Valve Anti Shock/Cavitation Valve...................................... 219.08 kg/cm Anti Shock/Cavitation Valve...................................... 224.18 kg/cm Anti Shock/Cavitation Valve...................................... 356.65 kg/cm Pressure Compensation Valve Priority Valve
CLSS
10. PPC Reducing Vave
10-42 1
WB146-5

UNLOADING VALVE Neutral Position FUNCTION
CLSS
When the control valve is in NEUTRAL position, pump delivery Q, resulting from the swash plate being at its min. angle, is sent into the tank circuit. When this happens, the pump's delivery pressure PP is regulated at 28 kg/cm by means of the spring c inside the valve. LS signal with PLS pressure = 0 kg/cm .
OPERATING
Pump pressure PP acts on spool b on surface S1, and on surface S2, whereas PLS pressure acts on surface S2. Since no LS signal with PLS pressure is generated when the control valve is in NEUTRAL position, the only pressure acting on spool in this condition is the pump's delivery pressure PP as regulated by spring compression c.
As the pump's delivery pressure PP increases and the resulting force equals spring loading c, the spool b shifts to the right. The pump's delivery circuit PP is then connected to the tank circuit T by means of the holes in spool. This ensures that the pump delivery pressure PP stays regulated at 28 kg/cm.
PP .................................................................................Pump circuit PLS ................................................................. Load Sensing circuit T ..................................................................................... Tank circuit
WB146-5
110-43

Control Valve Fine Control FUNCTION
CLSS
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/ cm. 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/cm, the differential pressure UPLS becomes 28 kg/cm.
OPERATING
When fine controls are performed at the control valve, a PLS pressure 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 delivery pressure PP is great. When the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring loading c 28 kg/cm, the spool b shifts to the right and, in turn, the pump circuit PP connects to the tank circuit T. The pump's delivery pressure PP is regulated by the combination of the pressure from the spring, 28 kg/cm, and the pressure PLS of the LS, when the differential pressure UPLS reaches a value of 28 kg/ cm.
10-44 1
WB146-5

Control Valve Is In Use FUNCTION
CLSS
When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
OPERATING
When the control valve spool is caused to perform a longer travel, this generates a pressure PLS of the LS, which acts on the right side of the spool b. Since the control valve passage is wide, the difference between the pressure PLS of the LS and the pump's delivery pressure PP is small. For this reason, since the differential pressure between the pump's delivery pressure PP and the pressure PLS of the LS fails to reach the spring loading pressure value of spring c 28 kg/cm, 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

LS PRESSURE Function
CLSS
LS pressure is the actuator's pressure at control valve output. This pressure actually reduces the pump's PP pressure via the pressure compensation group reducing valve D to the same A pressure of the actuator circuit and then sends it into the PLS circuit of the LS. In the outriggers control valve, the actuator's pressure A is introduced directly into circuit PLS of the LS.
Operation w/o Outriggers
When the spool B is operated, pump pressure PP starts flowing into the circuit of actuator A from the delivery control valve C and from the notch a via the duct b. At the same time, the pressure reducing valve D moves to the right making the pump's pressure PP drop as it flows through the bottleneck c, and causing the pressure to flow into the circuit PLS of the LS and into the chamber of spring PLSS. At this point, the PLS circuit of the LS is connected to the tank circuit T by means of the by pass plug E. The pressure acting on the left side of the reducing valve D is pressure PA of the actuator, and the pressure acting on the right hand side is the reduced pressure PP of pump delivery. The reducing valve balances out when pressure PA of the actuators and pressure PLSS of the spring chamber are balanced. This in turn allows the pressure PP, now reduced by the bottleneck c, to be introduced into the PLS circuit of the LS at the same pressure A as the actuator's circuit.
10-46 1
WB146-5

Operation w/o Outriggers
CLSS
When the spool b is operated, pump pressure PP starts flowing into the circuit of actuator A through the duct a.
At the same time, pressurised oil is introduced into the PLS circuit of the LS through holes b.
The outriggers circuit differs from the working equipment circuit in that the operating pressure of ctuator A is introduced directly into the PLS circuit of the LS.
WB146-5
110-47

LS BY PASS PLUG Description
CLSS
The LS by pass plug unloads residual pressure from the load sensing's PLS circuit. This makes the increment rate of load sensing's PLS pressure smoother. By eliminating oil, through the bottleneck, a loss of pressure is generated in the flow that is controlled by the spool, and stability is increased as a result, thereby reducing the actual differential pressure LS.
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

PRESSURE COMPENSATION VALVES Function
CLSS
Pressure compensation occurs during simultaneous operation of several movements, specifically when the pressure of an actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is on the verge of being increased. In this case, the right actuator withstands a higher pressure than the left actuator.
Operation
During operation together, when right actuator pressure increases, delivery in circuit A of the left actuator tends to increase. The PLS pressure of the LS for the right actuator acts on chamber PLS1 of the spring and pushes the pressure reducing valve b and the delivery control valve c to the left. The delivery control valve produces a bottleneck between the pump's delivery PP circuit and the PPA circuit upstream of the control valve spool. This bottleneck generates a pressure loss between circuits PP and PPA. 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. The differential pressure between the upstream pressure PPA and the downstream pressure of both spools in the control valves concerned in the movement together are equalised, and pump delivery is distributed proportionally to the sections a that are responsible for opening the notches of each spool. 110-49
WB146-5

PRESSURE COMPENSATION VALVE Function
CLSS
In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the compensation characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of area S1, delivery control valve c end, to area S2, pressure reducing valve b end. S1 surface of delivery control valve c minus surface of piston d. S2 surface of pressure reducing valve b minus surface of piston d.
Compensation Characteristics
When the ratio is 1.00 : Pump pressure PP minus pressure PPA upstream 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

PRIORITY VALVE Function
CLSS
The purpose of the priority valve is to feed pressurised oil to the steering unit and to the other actuators. Oil distribution is determined by the position of the spool b of the priority valve, which is in turn determined by LS signal, pump delivery, steering circuit pressure, and hydraulic circuit pressure. The position of the spool b is determined in such a way as to ensure that the oil delivered to the steering unit matches the delivery needs at any time.
WB146-5
110-51

PPC REDUCING VALVE Function
CLSS
This valve regulates the PPC feed pressure at 30 kg/cm. When actuator pressure is low, the sequential valve closes to permit an increase in the pump's delivery pressure PP in order to supply pressure to the servocontrols.
Neutral Condition
The spool b of the unloading valve moves, and delivery pressure is regulated at 30 kg/cm.
The spool c and valve d reduce the pump's delivery pressure PP to 30 kg/cm. Pressure is then sent to the controls via port PC.
10-52 1
WB146-5

Control Valve Operated
CLSS
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.
If the pump's delivery pressure PP exceeds 30 kg/cm, valves c and d reduce pressure PP to 30 kg/cm. The reduced pressure is then sent to
the controls via port PC.
When this occurs, the sequential reducing valve e stays open.
WB146-5
110-53
CLSS
When the pump's delivery pressure PP is lower than 30 kg/cm, the sequential reducing valve shifts to the right, thereby reducing the flow of
the PP pressure to the actuator circuit f.
This generates a pressure gap between PP pressure and actuator pressure. PP pressure is incremented in excess of 30 kg/cm and is then reduced to 30 kg/cm by valves c and d to guarantee pressure feed to the controls.
10-54 1
WB146-5
STEERING UNIT
STEERING UNIT
a Port L - To Steering Cylinder b Port R - To Steering Cylinder
c Port T - To Hydraulic Oil Tank d Port P - To control valve
e Port P - From Control Valve
TECHNICAL DATA
Steering unit type ......................................................... OSPC200LS Normal flow ............................................................................... 20 .
OPERATION
The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering wheel is turned, the control valve sends oil from the pump P2, by means of the rotating oil dispenser, to one side of the steering cylinder.
The rotating dispenser ensures that the oil volume upplied to the cylinder is proportionate to the angle of rotation of the steering wheel. In the event of malfunction, the rotating oil dispenser will function automatically as a hand pump, thus guaranteeing auxiliary steering.
WB146-5
110-55
PPC VALVE
PPC VALVE
LOADER
10-56 1
WB146-5

PORTS P1 To Control Valve - PB3 Port P2 To Control Valve - PA3 Port P3 To Control Valve - PA8 Port P4 To Control Valve - PB8 Port P From EV1 Solenoid Valve T To Hydraulic Tank
PPC VALVE
Spool - Ports P1, P2 & P4 Spool - Port P3 Plunger - Ports P2 & P3 Plunger - Ports P1 & P4 Adjusting Screw Actuator Disc Handle Mount
Spring Criteria Standard Size
B C D E F G H
I Protective Boot J Electro Detent - Ports P2 & P3 1) Lower Spring Retainer 1! Center Spring Retainer 1@ Upper Spring Retainer 1# Mounting Plate 1$ Valve Housing - Three Section
Unit : mm
Repair Limit
Remedy
Check Item
Free Length
Installed Length Installed Load
1% 1^ 1& 1* 1( 2) 2! 2@ 2# 2$ 2%
Bottom Outer Spring - Ports P1 Bottom Outer Spring - Ports P2 Bottom Outer Spring - Ports P3 Bottom Outer Spring - Ports P4 Bottom Inner Spring - Ports P1 Bottom Inner Spring - Ports P2 Bottom Inner Spring - Ports P3 Bottom Inner Spring - Ports P4 Center Spring - All Ports Top Spring - Ports P1 & P4 Top Spring - Ports P2 & P3
30.6 31.6 31.9 31.6 23.6 24.6 25.3 24.9 21 11.4 11
41.2 N 39.1 N 38.5 N 64.9 N 5.3 N 5.3 N 5.3 N 5.3 N 12.3 N 28.4 N 13.7 N Replace
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

BOOM PORTION
PPC VALVE
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.
Fine Control, Neutral J Actuator
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 downwards. As a result of this action, the calibrated hole f will be isolated from the drain chamber D and at almost at the same time it will be put in connection with the PP chamber, which is directly connected to the loader control circuit. 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. When pressure P1 increases, spool b is pushed upwards, and calibrated hole f is connected back to discharge chamber D thereby compressing the spring c. The floating of the spool b will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP, until the pressure in duct P1, the pressure acting on the section of stem b, offsets the force applied by the spring c. The spring c is compressed proportionally to the movement of the disk f and pressure at P1 increases in proportion to the travel of the disk. The equilibrium position is then kept until the position of piston e is changed.: 1. As long as pressures at ports B and P1 are perfectly balanced; 2. Until pressure in section B/P1, the pressure acting on stem b, is enough to counteract the force of the spring c.
This ensures proportionality between control lever position, B/P1 circuit pressure, and main control valve stem displacement.
10-58 1
WB146-5

Fine Control, Actuator J Neutral
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 released. If pressure P1 drops too quickly, spool b is pushed downwards by spring c and the calibrated hole f becomes cut off from the discharge chamber D; at almost the same time, the calibrated hole f is put in connection with pressure chamber PP and starts supplying pressure to section P1 until the pressure corresponding to the control lever position is balanced. When the spool of the control valve returns, oil flows back into chamber D, through calibrated hole f, and into chamber B of the control valve spool opposite the operating one. Oil flows through duct P2 and into chamber B to ensure it is filled properly.
Fine Control, Neutral J Full Stroke
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 connection 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 pushing 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

Control Lever To Float Position
PPC VALVE
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. If piston e is pushed upwards and the solenoid in the PPC valve is energized, the force generated by the solenoid will retain the piston in place and the arm float condition will be retained, even if the lever is released. At the same time, the control valve will also be activated and retained in the arm float position.
Control Lever From Float Position
The disk f can be moved back to neutral position by applying a force that exceeds the force applied by the solenoid. 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 OUTRIGGER
PPC VALVE
PORTS P1 To Control Valve - PA9 Port P2 To Control Valve - PB9 Port P3 To Control Valve - PA10 Port P4 To Control Valve - PB10 Port
P From EV1 Solenoid Valve T To Hydraulic Tank B Handle Knob
C D
Stop Handle
E F G H
Boot Mounting Plate Left Outrigger Right Outrigger
WB146-5
110-61

OPERATION Neutral Position
PPC VALVE
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 neutral position.
10-62 1
WB146-5

Fine Control, Neutral J Actuator
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. Pressure at port P1 increases as the travel of lever b increases. Consequently, the spool of the control valve moves to the left by a distance that is proportional to the travel of the lever.
WB146-5
110-63

Full Lever, Actuator J Neutral
PPC VALVE
When lever b is moved fully to the left, the valves c are fully rotated. Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool of the control valve performs its full travel.
10-64 1
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BACKHOE

LEFT VALVE
PPC VALVE
PORTS 1 To Arm Out Valve, PB1 Port T To Hydraulic Tank
4 To Swing Left Valve, PA2 Port 3 To Arm In Valve, PA1 Port P To EV1 Solenoid Valve, VBH Port
1 To Swing Right Valve, PB2 Port
WB146-5
110-65

RIGHT VALVE
PPC VALVE
PORTS 1 To Boom Raise Valve, PB4 Port T To Hydraulic Tank
4 To Bucket Dump Valve, PA5 Port 3 To Boom Lower Valve, PA4 Port P To EV1 Solenoid Valve, VBH Port
1 To Bucket Curl Valve, PB5 Port
10-66 1
WB146-5
SOLENOID VALVE
SOLENOID VALVE
HYDRAULIC CONTROLS W/O MP BUCKET
PORTS ACC Accumulator P1 Pressure Tap P2 A2 B2 To Outrigger PPC Valve, Port P To Boom Lock Cylinder To Rear Axle
VBH To Bakchoe PPC Valves, Port P VL To Loader PPC Valves, Port P PM To Hydraulic Pump, Port PM P From Control Valve, Port PPPC T To Hydraulic Tank B Differential Lock Solenoid, Y94
C D E F
Boom Lock Solenoid, Y95 Backhoe PPC Solenoid, Y90 Loader PPC Solenoid, Y93 Ecopower Solenoid, Y91
WB146-5
110-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CONTROLS WITH MP BUCKET
SOLENOID VALVE
PORTS ACC Accumulator P1 Pressure Tap P2 A2 B2 To Outrigger PPC Valve, Port P To Boom Lock Cylinder
VL A1 B1
To Loader PPC Valves, Port P To Control Valve, Port PA6 To Control Valve, Port PB6
To Rear Axle VBH To Bakchoe PPC Valves, Port P
PM To Hydraulic Pump, Port PM P From Control Valve, Port PPPC T To Hydraulic Tank B Differential Lock Solenoid, Y94
C D E f g h
Boom Lock Solenoid, Y95 Backhoe PPC Solenoid, Y90 Loader PPC Solenoid, Y93 Bucket Open Solenoid, Y98 Bucket Close Solenoid, Y99 Ecopower Solenoid, Y91
10-68 1
WB146-5
LOADER CYLINDERS
LOADER CYLINDERS
BOOM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four Piece Piston Seal F Cylinder Piston

Criteria
G Cylinder Rod H Cylinder Head i Piston Stop

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
j Piston Rod to Head 1) Bushing in Piston Rod 1! Bushing in Barrel

CHARACTERISTICS
36 67 67 67.25 67.25 67.2 67.2 0.05 0.05 Replace
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 BUCKET
LOADER CYLINDERS

Criteria
G Cylinder Rod H Cylinder Head

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
i Piston Rod to Head j Bushing in Piston Rod 1) Bushing in Barrel

CHARACTERISTICS
33 52 57 52.25 57.25
52.20 52.30 57.20 57.30 0.05 -0.05 0.05 -0.05
Replace
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 MP BUCKET
LOADER CYLINDERS
A Piston Rod Bushing B Cylinder Rod C Cylinder Head
D Cylinder Piston E Four Piece Piston Seal F Retaining Nut

Criteria
G Cylinder Barrel
Unit : mm Check Item

Standard Size Tolerance OD ID Standard Clearance Clearance Limit
Remedy Replace
h Piston Rod to Head i Bushing in Piston Rod

CHARACTERISTICS
40 50
51.88 52.12 52.39 52.39 0.51 0.27
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
BACKHOE CYLINDERS
BACKHOE CYLINDERS
BOOM
A B C D
Piston Rod Bushing Barrel Bushing Cylinder Barrel Stop Ball
E F G H
Four Piece Piston Seal Cylinder Piston Cylinder Rod Cylinder Head
i Set Screw j Stop Pin 1) Check Valve 1! Check Valve Spring

Unit : mm Criteria
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
1@ Piston Rod to Head 1# Bushing in Piston Rod 1$ Bushing in Barrel
43 75 75 Unit : mm
Spring Criteria
Replace
Check Item
Free Length
Standard Size
Installed Length Installed Load
Repair Limit
Remedy
1% Check Valve Spring

CHARACTERISTICS
35
Replace
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 ARM
BACKHOE CYLINDERS

Criteria
G Cylinder Rod H Cylinder Head i Piston Spacer

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
j Bushing in Piston Rod 1) Bushing in Barrel 1! Piston Rod

CHARACTERISTICS
60 60 60 Replace
WB146-5
110-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BUCKET
BACKHOE CYLINDERS

Criteria

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
i j Bushing in Piston Rod 1) Bushing in Barrel

Piston Rod to Head CHARACTERISTICS
55 55 55 Replace
10-74 1
WB146-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TELESCOPIC ARM CYLINDER
BACKHOE CYLINDERS
D Wear Rings E Piston Seal F Cylinder Piston

Criteria

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
i Piston Rod to Head j Bushing in Piston Rod 1) Bushing in Barrel

CHARACTERISTICS
40 47 47 47.2 47.15
47.21 47.3 47.21 47.3 0.01 0.1 0.01 0.1
Replace
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 SWING
BACKHOE CYLINDERS
A Piston Rod Bushing B Cylinder Rod C Cylinder Barrel
D Cushion Valve E Piston Seal F Cylinder Piston

Criteria
G Retaining Screw H Cylinder Head

Unit : mm
Check Item
Standard Size
Tolerance OD ID
Standard Clearance
Clearance Limit
Remedy
i j 1) 1!
Piston Rod to Head Piston Rod Bushing Inner Pivot Bushing Outer Pivot Bushing
50 68 50 60 Replace
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 OUTRIGGER
BACKHOE CYLINDERS
A B C D
Piston Rod Bushing Barrel Bushing Cylinder Barrel Retarder Pin
E F G H
Piston Seal Cylinder Piston Cylinder Rod Cylinder Head
i Piston Retaining Nut j Detent Ball
Unit : mm Criteria Check Item

Standard Size Tolerance OD ID Standard Clearance Clearance Limit
Remedy
1) Piston Rod to Head 1! Bushing in Piston Rod 1@ Bushing in Barrel

CHARACTERISTICS
50 55 55 Replace
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
WORK EQUIPMENT
WORK EQUIPMENT
LOADER
10-78 1
WB146-5
WORK EQUIPMENT
Unit : mm Criteria
Check Item b Bushing in Boom c Pin to Bushing d Bushing in Lever e Pin to Bushing f Bushing in Lever g Pin to Bushing h Bushing in Lever and Cylinder i Pin to Bushing J Bushing in Cylinder 1) Pin to Bushing 1! Bushing in Boom 1@ Pin to Bushing 1# Bushing in Cylinder 1$ Pin to Bushing
Standard Size
Tolerance OD 52.10 to 52.40 44.911 to 44.95 52.10 to 52.40 44.911 to 44.95 54.85 to 55.15 44.911 to 44.95 75.046 to 75.076 59.894 to 59.94 57.2 to 57.3 49.911 to 49.95 57.2 to 57.3 49.911 to 49.95 67.10 to 67.40 59.894 to 59.94 ID 52.20 to 52.30 45.08 to 45.24 52.20 to 52.30 45.08 to 45.24 55.00 to 55.046 45.08 to 45.24 75.00 to 75.046 60.137 to 60.197 57.25 to 57.25 50.08 to 50.24 57.25 to 57.25 50.08 to 50.24 67.2 to 67.2 60.13 to 60.29
Standard Clearance to to to to to to to to to to to to to to -0.20 0.20 0.13 0.329 -0.20 0.20 0.13 0.329 -0.15 0.196 0.13 0.329 -0.076 0.0 0.197 0.303 -0.05 0.05 0.13 0.329 -0.05 0.05 0.13 0.329 -0.20 0.10 0.19 0.396
Clearance Limit
Remedy
52 45 52 45 55 45 75 60 57 50 57 50 67 60
Replace
WB146-5
110-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BACKHOE
WORK EQUIPMENT
10-80 1
WB146-5
WORK EQUIPMENT
Unit : mm Criteria
Check Item b Top Bushing in Main Frame c Pin to Bushing d Inner Bushing on Cylinder Stud e Outer Bushing in Bracket f Inner Bushing in Outer Bushing g Outer Bushing in Frame h Pin to Bushing i Bottom Bushing in Swing Frame j Pin to Bushing 1) Pin to Rod Bushing 1! Pin to Head Bushing 1@ Bushing in Stabilizer 1# Pin to Bushing 1$ Bushing in Boom 1% Pin to Bushing 1^ Bushing in Boom 1& Pin to Bushing 1* Bushing in Bucket Lever 1( Pin to Bushing 2) Pin to Cylinder Bushing 2! Lever Bushing in Arm 2@ Pin to Bushing 2# Bushing in Bucket Lever 2$ Pin to Bushing 2% Bucket Bushing in Arm 2^ Pin to Bushing 2& Pin to Boom Rod Bushing 2* Pin to Boom & Arm Head Bushing 2( Pin to Arm Rod Bushing 3) Pin to Bucket Head Bushing 3! Pin to Jig Head Bushing 3@ Pin to Jig Rod Bushing
Standard Size
Tolerance OD
to to to to to to 80.059 80.089 64.894 64.94 50.034 50.05 75.043 75.062 59.894 59.94 to to to to to to 54.894 54.94 80.059 80.089 64.894 64.94 44.911 44.95 44.911 44.95 54.985 55.015 44.911 44.95 75.137 75.197 59.894 59.94 59.95 60.15 49.911 49.95 52.10 52.40 44.911 44.95 44.911 44.95 52.2 52.23 44.911 44.95 52.10 52.40 44.911 44.95 56.45 58.05 49.911 49.95 59.894 59.94 59.894 59.94 49.911 49.95 44.911 44.95 39.911 39.95 39.911 39.95 to to to to to to to to to to to to to to to to to to to to to to to to to to 55.137 55.197 80.0 80.03 65.19 65.264 45.08 45.24 45.08 45.24 55.0 55.03 45.08 45.24 75.0 75.03 60.137 60.197 60.0 60.03 50.08 50.024 52.0 52.03 45.08 45.24 45.08 45.24 52.10 52.40 45.08 45.24 52.0 52.03 45.08 45.24 57.20 57.23 50.08 50.24 60.10 60.174 60.10 60.174 50.08 50.142 45.08 45.142 40.05 40.10 40.05 40.10
ID
80.00 80.054 65.19 65.264 50.0 50.025 75.0 75.03 60.06 60.09
Standard Clearance
to to to to to to to to to to to to to to to to to to to to to to to to to to to to to to to to 0.257 0.303 -0.029 -0.089 0.25 0.37 0.13 0.329 0.13 0.329 -0.015 0.045 0.13 0.329 -0.107 -0.197 0.197 0.303 -0.08 -0.15 0.13 0.329 -0.07 -0.40 0.13 0.329 0.13 0.329 -0.13 -0.20 0.13 0.329 -0.07 -0.40 0.13 0.329 -0.85 0.78 0.13 0.329 0.16 0.28 0.16 0.28 0.13 0.231 0.13 0.231 0.10 0.189 0.10 0.189 -0.005 -0.089 0.25 0.37 -0.009 -0.05 -0.013 -0.062 0.12 0.196
Clearance Limit
Remedy Replace
80 65 50 75 60
55 80 65 45 45 55 45 75 60 60 50 52 45 45 52 45 52 45 57 50 60 60 50 45 40 40
to to to to to to to to to to to to to to to to to to to to to to to to to to
WB146-5
110-81
WORK EQUIPMENT
10-82 1
WB146-5
AIR CONDITIONING
AIR CONDITIONING
A B C D
Magnetic Clutch Compressor Condenser Dryer Filter Tank
E F G H
Safety Pressure Switch Expansion Valve Evaporator Clutch Control Sensor
I Cab Air Circulation Fan J Air Conveyor
10-83 1
WB146-5

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 performs 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 constant metering of the quantity of fluid in order to maintain optimum evaporation. In the evaporator the coolant fluid is subjected to expansion, bringing it up to the critical evaporation point at a temperature of approximately -8C. The air flow generated by the centrifugal fan I which passes through the evaporator G at ambient temperature is considerably warmer than 8C. 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 suspended in the air, and hence to dehumidification. The condensate is deposited on the evaporator fins where, if a temperature higher than 0C is not maintained, it freezes and inhibits the functioning of the evaporator. The task of keeping the temperature of the evaporator above 0C, 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 therefore effectively purifies the air, and the droplets of condensate are discharged 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 constantly throughout the unit in nebulized form, lubricating the compressor, 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 electromagnetic clutch and hence the functioning of the air conditioning unit.
AIR CONDITIONING
WB146-5
110-84
20
TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE ................................................................................................. 20-3 ENGINE............................................................................................................................... 20-3 CHASSIS ............................................................................................................................. 20-4 SPECIAL TOOLS ................................................................................................................... 20-11 ENGINE SPEED ..................................................................................................................... 20-12 ENGINE WITHOUT LOAD ............................................................................................. 20-12 VALVE CLEARANCE ........................................................................................................... 20-14 AC COMPRESSOR BELT TENSION ................................................................................... 20-15 BLEED AIR FROM CIRCUITS ............................................................................................. 20-16 BLEED AIR FROM CYLINDERS ................................................................................... 20-16 BLEED AIR FROM BRAKING CIRCUIT ...................................................................... 20-16 RELEASING RESIDUAL PRESSURE............................................................................ 20-16 ACCELERATOR PEDAL AND LEVER ............................................................................... 20-17 ACCELERATOR PEDAL TRAVEL................................................................................ 20-17 ACCELERATOR LEVER TRAVEL................................................................................ 20-18 BRAKE SYSTEM ................................................................................................................... 20-19 CONTROL......................................................................................................................... 20-19 ADJUSTMENT ................................................................................................................. 20-19 CHECKS............................................................................................................................ 20-20 PARKING BRAKE ADJUSTMENT ...................................................................................... 20-23 HYDRAULIC CIRCUIT ......................................................................................................... 20-24 INTRODUCTION ............................................................................................................. 20-24 RELIEF VALVES ................................................................................................................... 20-26 TESTING ........................................................................................................................... 20-26 SETTING RELIEF VALVES ................................................................................................. 20-29 MAIN RELIEF VALVE.................................................................................................... 20-29 CIRCUIT RELIEF VALVES ............................................................................................ 20-29 LS DIFFERENTIAL PRESSURE ........................................................................................... 20-31 CONTROL......................................................................................................................... 20-31 ADJUSTMENT ................................................................................................................. 20-31 PPC SUPPLY PRESSURE...................................................................................................... 20-32 CHECK .............................................................................................................................. 20-32 ADJUSTMENT ................................................................................................................. 20-32 PC VALVE .............................................................................................................................. 20-33 ADJUSTMENT ................................................................................................................. 20-33 STEERING CONTROL SYSTEM ......................................................................................... 20-34 CONTROL......................................................................................................................... 20-34 SETTING ........................................................................................................................... 20-34 STEERING CYLINDER ......................................................................................................... 20-35 POWER TRAIN GROUP........................................................................................................ 20-36 WB146-5 20-1
TESTING AND ADJUSTING
TABLE OF CONTENTS
CONVERTER OIL PRESSURE ....................................................................................... 20-36 CLUTCH ENGAGEMENT PRESSURE .......................................................................... 20-36 SUPPLY PRESSURE ........................................................................................................ 20-37 TRANSMISSION CLUTCH FUNCTION.............................................................................. 20-38 MACHINE PREPARATION ............................................................................................ 20-38 CONTROL......................................................................................................................... 20-38 HYDRAULIC DRIFT ............................................................................................................. 20-39 LOADER ........................................................................................................................... 20-39 BACKHOE ........................................................................................................................ 20-40 AIR CONDITIONING ............................................................................................................ 20-44 WORK TEMPERATURE ................................................................................................. 20-44 UNIT CHECK ................................................................................................................... 20-45 EMPTYING THE AC UNIT ............................................................................................. 20-46 TROUBLESHOOTING GUIDE ............................................................................................. 20-47 FRONT AXLE................................................................................................................... 20-47 REAR AXLE ..................................................................................................................... 20-52 TRANSMISSION .............................................................................................................. 20-57
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
STANDARD VALUE TABLE

ENGINE
Machine Model Engine Model Item Measurement Conditions
High idle WB146-5 S4D102LE-2
Unit
Standard Value 2457
Service Limit Value 2407 - 2507 1000 - 1100 ---
Engine speeds
Low idle Rated speed At torque converter stall and full throttle At restriction indicator port
RPM
1050 --New element 381 635 0.7
Intake air restriction
mm H2O
Used element
Lubricating oil pressure with SAE Minimum at low idle 15W-40 oil and coolant temperature in operating Minimum at high idle range Fuel filter inlet restriction
Maximum restriction at high idle
kg/cm 2.1 New element mm Hg Used element 203 101
Blow by pressure
Coolant temperature in operating range Service Tool orifice size 5.613 mm H2O mm Full load at rated speed
Max 101.6
Max 431.8
Exhaust back pres- Maximum at converter stall and full throttle sure Coolant temperature Valve clearances with engine cold Fan Belt Tension
Maximum coolant operating temperature Intake valves Exhaust valves Deflection when pressed with finger force of approx. 10 kg
mm Hg C
76 105 0.254
mm 0.504 mm 10 10 - 15
WB146-5
20-3
TESTING AND ADJUSTING CHASSIS

Applicable Model Cat. Item Measurement Condition Engine coolant temperature: Within operation range Engine oil temperature: Within operation range Measurement taken on drive shaft pulley with tachometer. Engine coolant temperature: Within operation range Engine oil temperature: Within operation range Measurement taken on drive shaft pulley with tachometer.
WB146-5 Unit Standard Value Permissible Value 2407 - 2507
Max.
2457
Accelerator pedal Engine speed
Min. rpm Max.
1050 50
1000 - 1100
2200
2150 - 2250
Accelerator fuel
Min. l
1050 50 a b c
1000 - 1100 l a b c
Control valve
Bucket arm command only

mm 6 5.5 2 -
Raise
95 95 95 95 50 50 50 mm 50 50 50 50 50 35 35 40
80 - 110 80 - 110 80 - 110 80 - 110 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 40 - 60 25 - 45 25 - 45 30 - 50
Bucket arm control lever
Neutral J Lower Dump
Bucket control laver
Neutral J Curl Raise
Travel of levers and pedals
Boon backhoe control
Arm backhoe control lever
Bucket backhoe control lever
Engine stopped Lower Knob lever: at center and at Open 90 from the lever. Neutral J Value reading at end of workClose ing stroke plus half measured backlash Open Attachments on ground Neutral J Close Instrument metric divisions
Right Neutral J Left Up
Neutral J
Boom swing control lever
Outrigger control lever Fuel control lever
Neutral J Down Min J.Max
20-4
WB146-5

Applicable model Cat. Levers and pedals travel Item Measurement condition Engine stopped Accelerator pedal Knob lever: at center and at 90o from lever. Value reading at end of work stroke plus half measured backlash Attachments on ground Min J Max Right J Left

WB146-5 Unit Standard value Permissible value 65 - 95 3.1 - 3.9 3.1 - 3.9 1.0 - 2.0 1.0 - 2.0 1.3 - 2.3 1.3 - 2.3 0.8 - 1.8 0.8 - 1.8 1.0 - 2.0 5.0 - 7.0 2.5 - 5.5
mm
80 3.5
Wheel swing Bucket arm lever
rev Left J Right 3.5 1.5
Force for lever, pedal and steering wheel operation
Bucket lever Boom lever Arm lever Bucket lever Boom swing lever Outrigger lever Fuel lever Accelerator pedal
Engine speed: min. Oil temperature within operating range Tool connection at center of knob 80 mm away from handle base. Value reading at the 10 mm before end of work stroke. Instrument force gauge Ambient temperature 15 - 35oC
1.5 1.8 1.8 kg 1.3 1.3 1.5 6.0 4.0
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. Engine speed: 2200 rpm Oil temperature within operating range Move arm cylinder to end of stroke and measure pressure Instrument: 0 to 100 kg/cm pressure gauge mounted on adapter at port P1C Working mode switch: POWER Engine speed: 1500 50 rpm
Main valve pressure
Control valve
249 kg/cm
238 - 264
Steering unit
178
173 - 188
WB146-5
20-5

Applicable model Cat. Item Bucket curled Bucket dump Bucket open close Pressures of secondary valves circuits Boom raise Boom lower Arm close) Arm out Boom swing Bucket curl Bucket dump Extenda arm out - in Hammer delivery Steering unit safety Engine speed, w/o load: 2400 50 rpm Oil temperature within operating range Machine in 3rd gear Work brakes: engaged Work mode switch: POWER Engine speed, w/o load: 2400 50 rpm Oil temperature within operating range Machine in 3rd gear Work brakes: engaged Bucket raised bottom of stroke Steering held at end of stroke Working mode switch: POWER Engine speed, w/o load: 1050 50 rpm Oil temperature within operating range Machine in Neutral Parking brake: applied Bucket dump bottom of stroke Working mode switch: POWER Engine speed: 2200 rpm Oil temperature within operating range Move arm cylinder to end of stroke and measure pressure Instrument: 0 to 100 kg/cm pressure gauge mounted on adapter at port P1C Working mode switch: POWER Measurement condition

WB146-5 Unit Standard value 274 244 274 351 274 274 kg/cm 274 234 274 193 228 Permissible value 264 - 284 234 - 259 264 - 284 323 - 365 264 - 284 264 - 284 264 - 284 223 - 249 264 - 284 183 - 213 228 - 249
With converter Engine speed with load - Converter
2175 50
2125 - 2225
With converter and hydraulic circuit
rpm
2075 50
2025 - 2125
Hydraulic circuit at Low idle
600
Min. 600
20-6
WB146-5

Applicable model Cat. Item Measurement condition In this position check in feedback of each cylinder and leakage with applied load on tip of bucket teeth. On level ground. GP Bucket: load 1800 kg MP Bucket: load 1550 kg Engine stopped Oil temperature: 45 - 55 C Check measures as soon as engine stops. Check changes every 5 min and total change in 15 min.

WB146-5 Permissible Standard value value
Unit
Work equipment
150
300
Boom cylinder
Loader
12
20
Hydraulic drift working equipment
Bucket cylinder
35
50
Working equipment
mm In this position check extension of each cylinder and 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 Engine stopped Oil temperature: 45 - 55 C Check measures as soon as engine stops. Check changes every 5 min and total change in 15 min. 200 350
Boom cylinders Backhoe
10
20
Arm cylinder
10
20
Bucket cylinder
15
WB146-5
20-7

.

WB146-5 Unit Standard value Permissible value
Applicable model Cat. Item Measurement condition Oil temperature: 45 - 55 C Backhoe balanced on guides bucket in Transport condition. Fully retract arm and bucket cylinder Lift bucket fulcrum pin 1 m off ground and swing boom to bottom of stroke in either direction. Move machine on a slope of 15 and apply parking brake. Stop engine and, after 1 minute, check inner cylinder feed back opposite to boom every 5 min for a total of 15 minutes.
Boom swing
15
15
Hydraulic drift work equipment
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 min. for a total of 15 minutes.
Outriggers
15
Loader
Boom Bucket Boom Arm Engine: Max speed Oil temperature: 45 - 55 C Leaking check: on cylinder opposite side to pressure one. Check 1 cylinder at a time. For loader bucket and boom and for swing, check the two cylinders separately.
2 each 1.6 each 3.3 3 cm/min 2.4 3.2 3.3 1.6
Max. 8 Max. 6 Max. 13.5 Max. 12 Max. 9.5 Max. 13 Max.13.5 Max 6
Cylinder Leakage
Backhoe
Bucket Boom swing Outriggers Jig arm
20-8
WB146-5

Applicable model Cat. Item Arm bucket Engine speed: max. Oil temperature: 45 - 55 C Bucket speed button: applied Lifting Measurement condition

WB146-5 Standard Permissible value value
Unit
3.6
3.1 - 4.1
Cylinders fully out Loader bucket
Lowering
Bucket at ground level Bucket Engine speed: max. Oil temperature: 45 - 55 C Bucket speed button: applied Cylinders fully out
2.6
2.2 - 3.0
Curl
2.3
2.0 - 2.6
Dump
2.8
2.4 - 3.2
Work equipment speed
Boom cylinder fully in
Bucket on ground
Lowering
Engine speed: 2200 rpm Oil temperature: 45 - 55 C Backhoe balanced Power mode ON
Lifting U
sec.
2.7
2.3 - 3.1
2.0
1.7-2.3
Backhoe
Arm cylinder fully out Bucket cylinder fully in
Opening
Arm cylinder fully in
2.9
2.5 - 3.4
Closing U
3.2
2.7 - 3.7
Bucket cylinder fully out
Curl
Dump
1.7 - 2.3
2.5
2.1 - 2.9
WB146-5
20-9

Applicable model Cat. Item Measurement condition

WB146-5 Unit Standard value Permissible value
Work equipment speed
Boom swing to tight end of travel Backhoe
Right U
Boom swing to left end of travel
3.2
2.7 - 3.7
Engine speed: 2200 rpm Oil temperature: 45 - 55 C Arm vertical Power mode ON
Left U
3.2
2.7 - 3.7
Engine speed: min. Oil temperature: 45 - 55 C Check item necessary to lift bucket from level ground Arm bucket 0 Max. 2
Boom
Engine speed: min. Oil temperature: 45 - 55 C With attachments fully extended, lower boom and check necessary time from beginning of lift until bucket is on level ground Engine speed: min. Oil temperature: 45 - 55 C Place boom at 45, open completely with bucket curled. Extend arm cylinder and check time passing between arm stop at dead center and restart movement. Engine speed: min. Oil temperature: 45 - 55 C Place arm in horizontal position. Tilt back bucket cylinder and then extend it. Check time passing between bucket stop at dead center and then restart movement Engine speed: min. Oil temperature: 45 - 55 C Boom arm and bucket retracted and centered on machine Check time necessary for outriggers to raise machine from when they lean on level ground. Check each outrigger at a time.
sec
Max 2
Work equipment
Time lag
Arm
Max 2
Bucket
Max.2
Outriggers
Max. 2
20-10
WB146-5
SPECIAL TOOLS
SPECIAL TOOLS
Measurement Point Engine speed Valve clearance Oil and coolant temp Symbol A B D Code Name Qty 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Note 20 to 4000 rpm -50 to 1200C Full scale 61 kg/cm Full scale 255 kg/cm Full scale 408 kg/cm Full scale 612 kg/cm 0 to1020 kg/cm Delivery 0 to 300 l/min. Pump air bleeding Full scale 20 kg For coolant R134a Sampling every 15 sec For coolant R134a
Available Locally Multi scale tachometer Available Locally Feeler gauge 1 Available Locally Digital thermometer 1 Available Locally Pressure gauge 2 Available Locally Pressure gauge
E Hydraulic pressure
3 Available Locally Pressure gauge 4 Available Locally Pressure gauge 5 6 Servo control kit ATR800200 Flow meter Pipe fitting kit ATR201490 Tank cap
F Air bleeding Hand brake G L
1 2
Available Locally Spring dynamometer 1 Available Locally Maintenance station
Air Conditioning unit
2 Available Locally Thermometer hygrometer 3 Available Locally Leak detector
WB146-5
20-11
ENGINE SPEED
ENGINE SPEED
WARNING! When checking the engine speed be careful. Do not touch high temperature parts or get caught in rotating parts.
Check the engine speed with a tachometer A under the following conditions:

Engine coolant temperature .........................................68 to 80 C Hydraulic oil temperature ............................................45 to 55 C
ENGINE WITHOUT LOAD

1. Start the engine and check: Low idle speed without load, accelerator pedal released. High idle speed without load, accelerator pedal at the travel end.

Low idle speed....................................................... 1050 50 rpm High idle speed ...................................................... 2400 50 rpm
If the idle speeds are not within limits, without a load on the engine, check the accelerator pedal stop and wiring insulation before going on with other operations.
MACHINE IN POWER MODE AT MIN 1. 2. With the transmission in neutral, idle the engine. Dump the loader bucket and hold the movement; let the engine stabilize and then read the engine speed.

Normal speed ....................................................................600 rpm Minimum speed ................................................................600 rpm
WITH CONVERTER STALLED 1. 2. Increase speed to high idle and brake with the foot brakes. Hold the brakes while simultaneously engaging 3rd gear; let the engine 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.
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD 1. 2. Increase speed to high idle and brake with the working brakes. While holding the brakes: a. b. c. Engage 3rd FORWARD Raise the loader and hold in this position; Steer the wheels fully;
20-12
WB146-5

3. In the above conditions, let the engine stabilize, then read the engine rpm.

ENGINE SPEED
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. If the engine has no conditions, adjust the pump's power absorption, PC valve.
2.
WB146-5
20-13
VALVE CLEARANCE
VALVE CLEARANCE
1. Park the machine on solid, level ground, apply the parking brake, and remove the ignition key. Remove the air filter and muffler. For details see Section 30. Release the coolant temperature sensor the wiring harness. Adjust the valve clearance according to the instructions provided in the ENGINE SHOP MANUAL.
2. 3. 4.
20-14
WB146-5
AC COMPRESSOR BELT TENSION
AC COMPRESSOR BELT TENSION

1. Turn the screw B clockwise to tension the belt C.
2.
Apply a 10 kg force halfway between compressor pulley E and engine pulley D. Check the resulting arrow F.

3.
Normal tensioning ......................................................... 4 to 6 mm New belt................................................................................ 3 mm

WARNING! Check the belt tension again after 15 minutes of operation.
WB146-5
20-15
BLEED AIR FROM CIRCUITS
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. 2.
Start the engine and run at high idle for about 5 min. to heat the oil. 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. 4.
Stop the engine, check and top off the oil in the tank. Bring again the engine at high idle and repeat Step 2; return the engine to low idle speed and make a complete travel of the cylinder until the pump reaches its maximum pressure. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level in the tank.
5.
BLEED AIR FROM BRAKING CIRCUIT
This operation is to be carried out every time maintenance is made on the braking circuit to remove or replace a component, or when air entered into the circuit. Machine must be stopped with attachments on level ground.
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. 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. Release the brake pedal, wait for few seconds and repeat above operations 2 or 3 times until, oil flows out the bleeding screw without air bubbles. Repeat the same steps for the opposite braking unit. Frequently check the oil level in the tank and refill every time the level approaches minimum.
2.
3.
4.
5.
After bleeding air, apply on screws c safety plugs e.
RELEASING RESIDUAL PRESSURE

1. 2. Put work attachments on level ground, stop the engine. Move all control levers in all directions to fully release cylinder and PPC circuit residual pressure.
20-16
WB146-5
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.
ACCELERATOR PEDAL TRAVEL

1. Make sure that the accelerator pedal b is fully raised and the accelerator lever c is at minimum stroke.
2.
Push the accelerator pedal until the accelerator lever f contacts the injection pump high idle adjusting screw.
3.
Adjust the end travel stopper g of the accelerator pedal b in this position and lock it with the nut h. Release the accelerator pedal b.
4.
WB146-5
20-17
TESTING AND ADJUSTING ACCELERATOR LEVER TRAVEL

1. 2. Remove the front mat. Remove the metal sheet b closing the bottom of the cab and the upright guard c.
3. 4. 5.
Check that the hand accelerator d is at end of travel at MIN. Loosen and unscrew the locking nut e. Start the engine and move the hand accelerator d to MAX.
6.
Tighten the nut f to the required speed for hand accelerator.
Engine idle speed............................................................2200 rpm
7.
Return to engine low idle speed and retain the position of the nut f with the locking nut e. Check the MAX speed once more by pushing the hand accelerator to the end of travel.
8.
20-18
WB146-5
BRAKE SYSTEM
BRAKE SYSTEM
Working condition:
Set the machine on level surface with attachments on ground level Apply the parking brake and remove the ignition key
Pedal connection pin a inserted.
CONTROL
1. 2. 3. Remove the floor mat. Check the height A between the floor and pedal b lower edge. Depress the pedals by hand and check height B to determine slack G. Standard clearance .......................................................3 - 8 mm
ADJUSTMENT
1. Remove the front cover c.
WB146-5
20-19

2. 3. Loosen the nuts d and adjust the slack using the stoppers e. When adjustment is complete, secure the stoppers e.
When the stoppers are secured, double check to ensure that slack G is within the range and that the pedals touch the stoppers simultaneously.
BRAKE SYSTEM
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.
The brake system checking procedure consists of two steps:
Checking the brake pumps and checking the braking groups for leaks.
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.
2. 3.
Connect a pressure gauge E2 to the hose B. Apply the brake pedals until a pressure of 122.2 kg/cm is reached. Do not exceed the max permitted pressure .........152.8 5 kg/cm
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

INDIVIDUAL PUMP CHECK 1. Remove the front lining d.
BRAKE SYSTEM
2.
Disconnect the pressure equalizer hose f from the brake circuit pump e that is being inspected. Seal the hole of the equalizer plug A.
3.
4.
Remove the clamp g.
5.
Disconnect the delivery hoses h from the pump that is being tested.
Connect a pressure gauge E2 to the pump during the inspection.
6.
Apply the brake pedal corresponding to the pump and pressurize the circuit to 122.2 kg/cm. Do not exceed the max permitted pressure .........152.8 5 kg/cm
WB146-5
20-21

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.
BRAKE SYSTEM
8.
Repeat for the other pump.
BRAKE GROUP LEAKAGE 1. Disconnect the delivery hose b from the braking group that is being inspected. Connect a suitable tool between the delivery hose b and the braking group.
Check to ensure that the pressure tap i is installed between the braking group and the cut out valve j.
2.
3. 4. 5.
Connect a pressure gauge E2 to the tool pressure tap and open the cut out valve j. Operate the brake pump and pressurize the circuit to 152.8 56 kg/ cm max. Hold the pressure while simultaneously closing the valve j to keep the braking circuit that is being inspected under pressure. 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. WARNING! Further evidence of leak is an increase in the level of oil in the axle, and the fact that the oil is stirred as a result. Replace all sealing rings in the various axle sections and completely change the lubricant.
6.
7.
Repeat the test for the other brake group using the same procedure as above. Restore the brake circuit to operating condition.
WARNING! When checks and repair are complete, bleed the air from the braking groups
8.
20-22
WB146-5
PARKING BRAKE ADJUSTMENT
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
1.
Remove the screws b and parking brake housing c.
2. 3.
Engage the parking brake. Press and hold the microswitch d while engaging 2nd gear and selecting a direction of movement. Accelerate engine gradually up to 1530 50 rpm.
WARNING! If machine moves, release the microswitch to return to N, Neutral.
4.
5.
Rotate the end of the lever e by 2 or 3 turns counterclockwise. Direction of rotation is from the operator s point of view when sitting in the driver s seat.
6.
Apply the parking brake and repeat the test. If a normal braking condition is not achieved after 2 attempts to adjust the lever, check control cable for slackness and brake disc for wear and replace components as necessary.
WB146-5
20-23
HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT
INTRODUCTION
b Engine c Transmission
INTRODUCTION 1.
D Hydraulic Pump E Steering Unit
f LS Safety Valve g Main Control Valve
The machine is equipped with a single control valve with hydraulically 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. The full pump delivery supplies the control valve. Pump delivery is shut by the priority valve, inside the control valve, when the steering unit is used for a steering manoeuvre.
2. 3.
20-24
WB146-5

MAIN CONTROL VALVE Cylinder and Movement Hammer Backhoe Arm Backhoe Swing Open Close Right Left Dump Curl Lower Raise Dump Curl Close Open Out In Raise Lower Down Up Down Up Port B0 A1 B1 A2 B2 A3 B3 A4 A4 A5 B5 A6 B6 A7 B7 A8 B8 A9 B9 A10 B10 kg/cm 191.02 275.13 275.13 234.37 234.37 244.56 275.13 275.13 346.02 --275.13 275.13 275.13 -----------------
HYDRAULIC CIRCUIT
Loader Bucket
Backhoe Boom
Backhoe Bucket
MP Bucket
Telescopic Arm
Loader Arm
Right Outrigger
Left Outrigger
WB146-5
20-25
RELIEF VALVES
RELIEF VALVES
TESTING
UNLOADING VALVE 1. 2. 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. In this condition, check the pressure in the hydraulic circuit. Normal pressure ..............................................41.8 4.1 kg/cm The unloading valve cannot be reset; replace if necessary. MAIN RELIEF VALVE Test conditions:

Engine.................................................. At Operating Temperature Hydraulic oil ................................................................. 45 - 55 C Working brakes ................................................................. Applied
1.
Connect a pressure gauge E3 to the tap P1C of the pump. Start the engine, move the hand accelerator lever to full throttle and check setting pressure for main relief valve by forcing the loader arm raise movement the full travel span.
Nominal pressure.............................................239.4 - 270 kg/cm
If the main relief valve pressure does not correspond to the nominal pressure value, it must be reset.
SECONDARY VALVES Boom Swing, Loader Bucket Dump and Hammer Test conditions:

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

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. Cylinder and movement Hammer Boom swing Loader Backhoe Boom Raise Test conditions:

RELIEF VALVES
Setting kg/cm 183.4 213.9 Right Left Dump 229.2 254.7 229.2 254.7 239.4 264.9
1.
Set the machine with the arm in the vertical position and the bucket on level ground. Stop the engine and release the residual hydraulic pressures Disconnect the hose b and connect a tee c with an adapter. Connect a pressure gauge E3 to the adapter.
2. 3.
4.
Start the engine, connect a 1500 kg weight to the bucket, and fully lower the outriggers.
WB146-5
20-27

5. Slowly extend the arm and boom and take the pressure when the boom lowers. Normal pressure ...........................................326 - 366.7 kg/cm
RELIEF VALVES
Arm In, Loader Bucket, Backhoe Bucket, Boom Raise, And MP Bucket Test conditions:

The pressure readings are to be operated from the same check point. 1. 2. Connect a pressure gauge E3 to pressure tap P1C of the pump. Start the engine and bring the hand accelerator lever up to 2200 rpm. Set the main relief valve b to a value 30.5 kg/cm higher than the maximum pressure to be tested. 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.
Cylinder and movement Setting kg/cm
3.
4.
Arm Loader bucket Boom Loader
Close Curl Left Dump Close Open
264.9 285.3 264.9 285.3 264.9 285.3 264.9 285.3 264.9 285.3 264.9 285.3
If one movement fails to reach the setting pressure, then the malfunction is in the tested element. If all movements fail to reach the setting pressure, then you need to pressure set or replace the secondary valve.
20-28
WB146-5
SETTING RELIEF VALVES

MAIN RELIEF VALVE
1. 2. Loosen lock nut B. Adjust the pressure using the screw C. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise 3. Lock the nut B. Lock nut ............................................................29.4 - 39.2 Nm When adjustment is complete, check the setting of the main relief valve using the procedures used for measurements.
CIRCUIT RELIEF VALVES

ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET 1. Loosen the lock nut B. A Circuit Relief Valve.......................................... Hammer Circuit B Circuit Relief Valve...................................................Swing Left C Circuit Relief Valve.............................................. Loader Dump D Circuit Relief Valve................................................ Swing Right E Circuit Relief Valve ...........................................................Boom 2. Adjust the pressure using the nut C. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise 3. Tighten the lock nut B while holding the adjusting nut c. Lock nut B ..............................................................39 - 49 Nm
WB146-5
20-29

SWING, LOADER DUMP, HAMMER, AND BOOM RAISE 1. Loosen the lock nut B.
2.
Adjust the pressure using the nut C. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise
3.
Tighten the lock nut B while holding the adjusting nut c. Lock nut B ..............................................................39 - 49 Nm
20-30
WB146-5
LS DIFFERENTIAL PRESSURE
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 pressure tap c and reconnect the hose b. Connect a differential pressure gauge E4 to adaptor c and to tap P1C on the pump. 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/cm If UPLS pressure is not within the permissible range, replace the control valve unloading valve. 4. Simultaneously perform a boom raise and a backhoe bucket curl movement to end of travel and then read the U pressure. Normal value......................................................28 1.5 kg/cm If the UPLS value is not within the permissible range, set the unloading valve.
2. 3.
ADJUSTMENT
If the UPLS value is not within the specified range, adjust the LS valve
as follows:
1.
Loosen the retaining nut b and turn the adjustment screw c. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise Each turn of the adjustment screw c will change the pressure by approx. 13.2 kg/cm.
2.
Lock the nut b. Lock nut B ..............................................................39 - 49 Nm
3.
When adjustment is complete, check the setting of the LS valve using the procedures used for checking.
WB146-5
20-31
PPC SUPPLY PRESSURE
PPC SUPPLY PRESSURE

CHECK
Test conditions: Engine ............................................... At operating temperature. Hydraulic oil temperature ......................................... 45 - 55 C 1. 2. Connect a pressure gauge E1 to the pressure tap b of the solenoid valve group c. Start the engine and run the engine at low idle with all levers in neutral position. Check the pressure. Normal pressure ....................................................38 3 kg/cm
3.
ADJUSTMENT
If the pressure value is not within the tolerance range, adjust the valve b as
follows:
1.
Loosen the retaining nut c and turn the adjustment screw d. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise Each turn of the adjustment screw d will change the pressure by approx. kg/cm.
2.
Lock the nut c. Lock nut c ............................................................. 22 2.5 Nm
20-32
WB146-5
PC VALVE
PC VALVE
ADJUSTMENT
If pump delivery and LS differential pressure are within permissible values, 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.
1.
Loosen the nut c and turn the adjustment screw d. To decrease the pump's torque absorption, turn the adjustment screw d counterclockwise To increase the pump's torque absorption (i.e. to increase the speed of working equipment) turn the adjustment screw d clockwise. Turn the adjustment screw by not more than 180 in relation to the 0 line, in both directions
Adjustment screw position on first installation shown
2.
Lock the nut c. Lock nut c ........................................................27.4 - 34.4 Nm
WB146-5
20-33
STEERING CONTROL SYSTEM
STEERING CONTROL SYSTEM

Test conditions:

Engine........................................................ Operating temperature Hydraulic oil ................................................................. 45 - 55 C
CONTROL
1. 2. Connect a pressure gauge E3 to the tap P1C on the main control valve. Start the engine and bring it to idle speed 1500 50 rpm and carry out a total steering. Force the steering wheel at the end of stroke, check pressure. Normal pressure ........................................178.3 - 188.5 kg/cm 4. Check the other steering direction.
3.
SETTING
If pressure is not within permissible value, set the upper valve b of the
steering unit c.
1.
Remove the plug d. Insert a wrench and loosen the screw e. To increase pressure ..........................................Turn Clockwise To decrease pressure .............................Turn Counterclockwise
2.
Stop the engine and replace the plug d; ensure that the seal f is in its proper position. Plug c .....................................................................40 - 60 Nm
20-34
WB146-5
STEERING CYLINDER
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. Disconnect the supply hose c from the cylinder b on the side where the rod is fully out d; plug the hose tightly. Connect a provisional hose to the cylinder b to collect any leaking fluid. Start the engine and operate the engine at high idle speed. Force the steering wheel to the end of its travel and retain the position for 30 seconds; measure any leak during the following minute. Release the steering wheel, run the engine at low idle, and then stop the engine. Check if leakage is normal. Test cylinder on one side only, as there is only one gasket separating the two chambers.
2.
3.
4. 5.
6.
7.
8.
Restore the hydraulic connection, steer the wheel several times in both directions to remove any air from the circuit.
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20-35
POWER TRAIN GROUP
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.
CONVERTER OIL PRESSURE

1. 2. Remove the plug P22 and connect the pressure gauge E6. 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. With the engine at MIN, check the pressure on the pressure gauge E6. Idle pressure ............................................................ 3.05 kg/cm 4. Gradually increase engine speed to 2200 rpm; take a new reading on pressure gauge E6. Normal pressure ............................................3.05 - 9.17 kg/cm 5. Bring the engine back to MIN and compare the pressure with the normal value. Min pressure ........................................................... 3.05 kg/cm If the pressure value drops to below the permissible lower limit, the power train pump needs an replacement. Plug ................................................................................ 30 Nm
3.
CLUTCH ENGAGEMENT PRESSURE

1. 2. Remove the plug P19 and connect the pressure gauge E6. 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. Bring the engine up to low idle and check the pressure on the pressure gauge E6. Normal pressure ...............................................Max. 0.3 kg/cm
3.
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WB146-5

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/cm 5. Bring the engine back to MIN and the transmission in neutral position; compare the pressure with the normal value. Normal pressure ...............................................Max. 0.3 kg/cm 6. Remove the pressure adapter and replace the plug P19. Plug ................................................................................ 30 Nm 7. Repeat the same test for the FORWARD gear, reading the pressure from the orifice protected by the plug P18.
POWER TRAIN GROUP
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. 2. Remove the plug P21 and connect the pressure gauge E6. 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. Bring the engine up to low idle and check the pressure on the pressure gauge. Normal pressure ............................................14.2 - 17.3 kg/cm 4. Gradually increase engine speed to 2200 rpm; take a new reading on pressure gauge. Min. pressure .......................................................... 14.2 kg/cm If reading drops below minimum, the transmission pump needs replacing. Plug ................................................................................ 30 Nm
3.
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20-37
TRANSMISSION CLUTCH FUNCTION
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.
WARNING! Make sure that the brake pedals are fastened together by the cotter pin b. During the following tests, during the engine acceleration phase with the gear engaged, the condition of the brake disks can also be checked If, while force is being exerted on the brake pedals, the machine starts to travel, even slowly:

Release the accelerator immediately and stop the engine. Check the wear on the brake disks and change them before completing the tests.
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. With the engine in idling condition, accelerate to MAX. and check that in this condition the revs remain within permissible limits. Brake hard and bring the engine up to MAX. Engage the 3rd gear while braking and accelerating as above; confirm that engine speed decreases to the permissible range Repeat this test in REVERSE gear. If the revs are high than the permissible limits, the clutches are worn, and must be replaced.
2.
3. 4. 5.
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WB146-5
HYDRAULIC DRIFT
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.
All testing conditions:

Engine.................................................... At operating temperature Hydraulic oil ................................................................. 45 - 55 C Removal and install tubes only after residual pressures removed.
LOADER
BOOM CIRCUIT 1. 2. 3. Put the machine with the bucket edge on blocks A of about 10 cm and in vertical position in relation to the ground. Stop the engine and release the residual hydraulic pressures. Disconnect the tubes b and c from the lift cylinders d and plug them. Plug the cylinders, base side, and apply a temporary tube, rod side, to catch any possible oil leakage. Start the engine and curl the bucket until the teeth are in the tilt position by 10. Stop the engine and check bucket link position for movement 5 minutes.
4.
5.
6.
If the bucket link has no lowering movement, drift is due to the control valve.
To test the individual cylinders, proceed as follows: 7. Move the bucket to let the edge lean on the ground in vertical position. Remove from one of the cylinders the plug fitted on the cylinder bottom side in Step 4. Start the engine and retract the bucket to bring the teeth in a tilt position of about 10 upwards.
8.
9.
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.
11. Repeat Steps 8 to 10 to check the other cylinder.
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20-39

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. Disconnect the tubes b and c from both bucket cylinders d and plug them to prevent contamination. Plug the bucket cylinder, head side, and install a temporary tube on the rod side to catch oil leakage. Start the engine and raise the loader until the bucket hinge pin is aligned with boom hinge pin. Stop the engine and check the position of the bucket edge for 5 minutes.
HYDRAULIC DRIFT
2. 3.
4.
5.
If the bucket has no movement, drift is due to the control valve.
To test the individual cylinders, proceed as follows: 6. 7. Lower the loader to the ground. Remove from one of the cylinders the plug fitted on the cylinder head side in Step 3. Start the engine and raise the loader as indicated in Step 4. Stop the engine and check the position of the bucket edge for 5 minutes.
8. 9.
If the bucket edge turns, the drift is due to seal leakage of the plugged cylinder.
10. Repeat operation from Steps 6 to 9 to check the other cylinder.
BACKHOE
Test condition: Backhoe aligned Lifted outriggers
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WB146-5

BOOM CIRCUIT 1. 2. Set the machine with the boom in vertical position and with the bucket on level ground leaned on the side. Stop the engine and release the residual hydraulic pressures.
HYDRAULIC DRIFT
3. 4. 5. 6.
Disconnect the hoses b and c that feed cylinder d. Plug the two hoses to avoid impurity inlet. Plug the cylinder head side. Apply a temporary tube to tube e base side to catch oil leakage.
7. 8.
Start the engine and extend the arm. Stop the engine and check the boom position for 5 minutes.
If boom has a lowering movement, drift is due to cylinder gaskets. 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. Stop the engine and release the residual hydraulic pressures.
2.
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20-41

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.
HYDRAULIC DRIFT
5. 6.
Start the engine and raise the boom. 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. Stop the engine and release the residual hydraulic pressures.
2.
3.
Disconnect the bucket cylinder d hoses b and c and plug them to avoid impurity inlet. Plug the bucket cylinder port on the base side and fit a temporary tube on the rod side to catch oil leakage.
4.
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WB146-5

5. 6. Start the engine and raise the boom. Stop the engine and check the bucket position for 5 minutes.

HYDRAULIC DRIFT
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.
OUTRIGGERS CIRCUT - W/O LOCK VALVESI 1. Set the machine with the arm in vertical position and with the bucket on level ground leaned to the side. Put 20 cm blocks under the outriggers. Without forcing them, lower the outriggers onto the blocks. Stop the engine and release the residual hydraulic pressures.
2. 3. 4.
5.
Disconnect from the cylinders b, the tubes c and d after the lock valve e. Plug the cylinders base head tube c. Add a temporary tubes to the rod side d tube to catch oil leakage. Start the engine, use the boom to raise the machine, and remove the blocks supporting the outriggers.
6.
7.
8. 9.
Lower the machine and stop the engine. Check the outriggers position for 5 minutes.
If one or both outriggers lower, drift is due to one or both cylinders. If there is no lowering, drift is due to control valve.
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20-43
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. Start the engine and bring it up to a speed of 1500 rpm. Switch on the AC unit using the switch. Select an intermediate ventilation speed inside the cab. Use the thermometer M2 to check that the temperature inside the cab is equal to or lower than the ambient temperature. If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab temperature stabilizes at the outside value.
2. 3.
4.
5.
Close the doors and windows and let the AC unit operate in these conditions for 5 to 10 minutes. Use the thermometer M2 to check the temperature of the air at the central outlets. Position the probe as close as possible to the air outlets.
6.
7.
Compare the average value of the measured temperatures using the following table:
20 6 -8 25 8 - 10 30 8 - 12 35 9 -14
Ambient temp C Outgoing air temp C
8.
If the average value of the temperature measured does not fall within the values given in the table, it will be necessary to thoroughly check the unit.
20-44
WB146-5
TESTING AND ADJUSTING 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/cm Unit with R134a. Outside Air Temp C 20 25 30 35 40 45 Low Pressure Min 1.2 1.0 1.1 1.3 1.5 1.8 Max 2.5 2.5 2.4 2.4 1.8 1.9 High Pressure Min 6.0 7.5 9.5 12.0 18.0 21.5 Max 9.0 10.5 13.0 15.5 18.8 22.0
AIR CONDITIONING
The following conditions may be found: CONDITIONS
CAUSES - FAULTS

LP high to HP normal or low
Electromagnetic pulley that slips or does not engage correctly Expansion valve blocked in open position Compressor damaged Expansion valve blocked in closed position or obstructed Filter saturated with moisture Obstruction in the LP line or in the HP line between the filter and the evaporator. Infiltration of hot air into the evaporator group, the pipes or the cab Hot air circulating in the heating group Formation of ice on the evaporator Normal condition with very high ambient temperature, higher than 43 C Excess coolant, 30 to 35% more Overheating of condenser Air present in the unit Obstruction in the HP line between the compressor and the condenser filler tube behind the measurement point of the HP Normal condition with very low temperature, lower than 5 C Lack of coolant, 70 to 75% less, probable leakages Obstruction in the HP line between the compressor and the condenser filler tube before the measurement point of the HP Compressor damaged Compressor belt missing Electromagnetic pulley that slips or does not engage Compressor damaged
LP low to HP high or normal
LP normal to HP normal
LP high to HP high
LP normal or low to HP low
LP roughly equal to HP
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20-45
TESTING AND ADJUSTING EMPTYING THE AC UNIT

1. Connect the maintenance station M1 to service valves b and c and follow the specific maintenance station instructions relative to the drainage of the unit. Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station. Plug the removed or disconnected connection tubes tightly and with a minimum of delay. Carefully check the quantity of R134A recovered and contained in the disassembled parts, since the same quantity must be replaced when the air conditioning unit is filled.
AIR CONDITIONING
2.
3.
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WB146-5
TROUBLESHOOTING GUIDE
FRONT AXLE
Wheel vibration; front tire resistance; half shaft breakage. CAUSES Incorrect installation Defective axle Overloading incorrect weight distribution Different rotation radius of the tires Bent half shaft Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft No differential action; jamming while steering. CAUSES Incorrect installation Defective axle Overloading incorrect weight distribution Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle REMEDY REMEDY
Steering is difficult; vehicle goes straight while trying to turn it. CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Broken half shaft Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft Excess noise CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Bent or broken half shaft Incorrect wheel adjustment Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft Verify group integrity and wheel side bearings REMEDY REMEDY
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.
WB146-5
20-47

Uneven wear of tires CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Bent or broken half shaft Blocked half shaft: Abnormal functioning of the differential or breakage/blockage of control device Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wear on sharp turns. Incorrect wheel adjustment Correct installation
REMEDY Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft
Verify assembly of all components Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
Verify group integrity and wheel side bearings Friction noise
CAUSES Incorrect installation Defective axle Bent or broken half shaft Damaged or worn out axle parts Correct installation
REMEDY Replace the differential in case it does not survive any of the test phases Replace half shaft Check the condition of the ring gear, pinion gear, bearings, etc. 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 Incorrect installation Defective axle Overloading/incorrect weight distribution Bent half shaft Different rotation radius of the tires Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace half shaft Replace the tire or adjust pressure to have the same radius on both tires REMEDY
20-48
WB146-5

Noise while driving CAUSES Excessive backlash between pinion and ring gear Worn out pinion and ring gear Worn out pinion bearings Pinion bearings loose Excessive axial pinion backlash Worn out differential bearings Differential bearings loose Ring gear out of round Low oil level Poor or worn oil Bent half shaft Adjust Replace Replace Adjust Adjust Replace Adjust Replace Oil level Replace Replace Noise while driving in neutral CAUSES 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 Ring gear damaged Differential box bolts loosened Replace bevel gear set Tighten to torque Constant noise CAUSES Ring gear teeth or pinion damaged Worn out bearings Pinion spline worn out Bent half shaft Replace bevel gear set Replace Replace Replace Noise while steering CAUSES Worn out differential gears Worn out differential box or spider Differential thrust washers worn out Half shaft spline worn out Replace Replace Replace Replace
REMEDY
REMEDY
REMEDY
REMEDY
REMEDY
WB146-5
20-49

Ring gear teeth broken at the outer side CAUSES Excessive gear load compared to the one foreseen Incorrect gear adjustment (excessive backlash) Pinion nut loosened Ring gear tooth broken CAUSES Load bump Incorrect gear adjustment insufficient backlash Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
REMEDY Replace bevel gear set. Adjust bevel gear set free backlash
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 lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES Prolonged operation at high temperature REMEDY
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 Excessive use Insufficient lubrication REMEDY Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Axle beam body bent CAUSES Vehicle overloaded Vehicle accident Load bump Worn out or pitted bearings CAUSES Insufficient lubrication; contaminated oil Excessive use Normal wear out Pinion nut loosened Replace bearings, use correct lubricants, fill to proper levels and replace according to the recommended schedule. REMEDY Replace axle beam body REMEDY
20-50
WB146-5

Oil leakage from gaskets and seals CAUSES Prolonged operation at high temperature Oil gasket assembled incorrectly Seal lip damaged Contaminated oil
REMEDY Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Excessive wearing out of input flange spline
CAUSES Exhaustive use Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES Exhaustive use Continuous overload Replace bevel gear set Pinion and ring teeth breakage CAUSES Crash load of differential components
REMEDY Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required
REMEDY
REMEDY Check and/or replace other differential components Side gear spline worn out
CAUSES Excessive use
REMEDY 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 Excessive use axial pinion Excessive pinion axial backlash Insufficient lubrication; contaminated oil REMEDY Replace bearing. Check pinion axial backlash Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Bent or broken half shaft or half shaft broken at wheel side CAUSES Vehicle intensively operated or overloaded Wheel support loosened Beam body bent Replace. Check that wheel support is not worn out or incorrectly adjusted. REMEDY
WB146-5
20-51
TESTING AND ADJUSTING REAR AXLE
Wheel vibration; front tire resistance; half shaft breakage. CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Bent half shaft Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft Steering is difficult; vehicle goes straight while trying to turn it. CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Broken half shaft Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft No differential action; jamming while steering. CAUSES Incorrect installation Defective axle Broken half shaft Bent half shaft Correct installation Replace the differential in case it does not survive any of the test phases Replace half shaft Replace half shaft Excess noise CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Bent or broken half shaft Incorrect wheel adjustment Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft Verify group integrity and wheel side bearings REMEDY REMEDY REMEDY REMEDY
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.
20-52
WB146-5

Uneven wear of tires CAUSES Incorrect installation Defective axle Overloading/incorrect weight distribution Different rotation radius of the tires Bent or broken half shaft Blocked half shaft: Abnormal functioning of the differential or breakage/blockage of control device. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wear on sharp turns. Incorrect wheel adjustment Correct installation
REMEDY Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace the tire or adjust pressure to have the same radius on both tires Replace half shaft
Verify assembly of all components Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
Verify group integrity and wheel side bearings Friction noise
CAUSES Incorrect installation Defective axle Bent or broken half shaft Damaged or worn out axle parts Correct installation
REMEDY Replace the differential in case it does not survive any of the test phases Replace half shaft Check the condition of the ring gear, pinion gear, bearings, etc. 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 Incorrect installation Defective axle Overloading/incorrect weight distribution Bent half shaft Different rotation radius of the tires Correct installation Replace the differential in case it does not survive any of the test phases Remove excessive weight and redistribute load following instructions related to the vehicle Replace half shaft Replace the tire or adjust pressure to have the same radius on both tires REMEDY
WB146-5
20-53

Noise while driving CAUSES Excessive backlash between pinion and ring gear Worn out pinion and ring gear Worn out pinion bearings Pinion bearings loose Excessive axial pinion backlash Worn out differential bearings Differential bearings loose Ring gear out of round Low oil level Poor or worn oil Bent half shaft Adjust Replace Replace Adjust Adjust Replace Adjust Replace Oil level Replace Replace Noise while driving in neutral CAUSES 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 Ring gear damaged Differential box bolts loosened Replace bevel gear set Tighten to torque Constant noise CAUSES Ring gear teeth or pinion damaged Worn out bearings Pinion spline worn out Bent half shaft Replace bevel gear set Replace Replace Replace Noise while steering CAUSES Worn out differential gears Worn out differential box or spider Differential thrust washers worn out Half shaft spline worn out Replace Replace Replace Replace
REMEDY
REMEDY
REMEDY
REMEDY
REMEDY
20-54
WB146-5

Ring gear teeth broken at the outer side CAUSES Excessive gear load compared to the one foreseen Incorrect gear adjustment, excessive backlash Pinion nut loosened Ring gear tooth broken CAUSES Load bump Incorrect gear adjustment, insufficient backlash Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
REMEDY Replace bevel gear set. Adjust bevel gear set free backlash.
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 lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES Prolonged operation at high temperature REMEDY
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 Excessive use Insufficient lubrication REMEDY Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Axle beam body bent CAUSES Vehicle overloaded Vehicle accident Load bump Worn out or pitted bearings CAUSES Insufficient lubrication; contaminated oil Excessive use Normal wear out Pinion nut loosened Replace bearings. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. REMEDY Replace axle beam body REMEDY
WB146-5
20-55

Oil leakage from gaskets and seals CAUSES Prolonged operation at high temperature Oil gasket assembled incorrectly Seal lip damaged Contaminated oil
REMEDY Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule. Excessive wearing out of input flange spline
CAUSES Exhaustive use Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES Exhaustive use Continuous overload Replace bevel gear set Pinion and ring teeth breakage CAUSES Crash load of differential components
REMEDY Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required
REMEDY
REMEDY Check and/or replace other differential components Side gear spline worn out
CAUSES Excessive use
REMEDY 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 Excessive use axial pinion Excessive pinion axial backlash Insufficient lubrication; contaminated oil REMEDY Replace bearing. Check pinion axial backlash. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Bent or broken half shaft or half shaft broken at wheel side CAUSES Vehicle intensively operated or overloaded Wheel support loosened Beam body bent Replace. Check that wheel support is not worn out or incorrectly adjusted. REMEDY
20-56
WB146-5
TESTING AND ADJUSTING TRANSMISSION

Vehicle does not move CAUSES Faulty supply to solenoid valves Check/Replace Damaged wiring connections between transmission Repair/Replace and vehicle Oxidized contacts in electrical wiring Break in electrical cable Damaged solenoids Damaged sensors Short circuits or open connections Incorrect oil level Check for leaks Blocked intake filter Damaged oil pump Damaged oil pump relief valve Blocked/damaged transmission filter Damaged/jammed control valve Damaged converter Oil temperature below 0C Damaged rotary seals Damaged synchronizers Blocked reverse lever Worn clutch Clean Replace Replace Replace Check/replace fuses Fill oil to proper level Repair Clean Replace Replace oil pump Replace Replace Replace
REMEDY
Wait for oil to reach operating temperature (stall test) Replace Replace Repair Replace/repair clutch
No drive transmission, broken gears, shafts, bearCheck/Repair/Replace ings, etc. Vehicle has reduced power transmission CAUSES Incorrect oil temperature Transmission oil overheating Incorrect operating pressure Damaged converter Incorrect oil level Worn clutch 4WD clutch failure Overheating solenoids See Overheating Check hydraulic circuit and replace, oil pump, filters, control valve Replace Fill oil to proper level Replace/Repair Repair/Replace 4WD shaft group Replace REMEDY Wait for oil to reach operating temperature (stall test)
Damaged transmission and vehicle wiring connecRepair/Replace tions Damaged sensors Replace
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20-57

Overheating CAUSES Damaged hydraulic cooling system Dirty heat exchanger Parking brake inadvertently activated Excessive dirt on axle wheel hubs Seizing, broken gears, shafts, bearings, etc. Repair Clean Release Clean Check/Repair/Replace
REMEDY
Braking force outside transmission: irregular axle Check/Repair axle operation Clutch plate drag Damaged converter Damaged oil thermostat Incorrect oil level Worn oil pump Repair/Replace Replace Replace Add oil Replace Wheels rotate when vehicle is raised CAUSES Clutch plate drag Low oil temperature (high oil viscosity) Incorrect oil specifications Damaged control valve Faulty reverser locking Repair/Replace Wail for oil to reach operating temperature (stall test) Replace oil and filters Replace Repair/Replace Noise CAUSES Damaged converter Damaged oil pump Aeration/Cavitation Seizing (broken gears, shafts, bearings, etc.) Worn clutch plates Replace Replace Check oil level Check/Repair/Replace Replace Irregular actuation CAUSES Damaged control valve Electrical system fault Worn clutch plates Damaged converter Low oil temperature (high oil viscosity) Overheating Damaged hydraulic system Replace Repair/Replace Replace Replace Wait for oil to reach operating temperature (stall test) See Overheating Repair/Replace REMEDY REMEDY REMEDY
20-58
WB146-5

Gear remains engaged CAUSES Damaged/jammed shuttle shaft lever Electrical system fault Damaged control valve Damaged hydraulic system Damaged clutch Damaged gear lever rod Damaged synchronizer Repair/Replace Repair/Replace Replace Repair/Replace Repair/Replace Replace Replace No 4WD power transmission CAUSES Damaged 4WD clutch Hydraulic system fault Damaged control valve Faulty brake sensor Electrical system fault Replace Repair/Replace Replace Check/Replace Repair/Replace Gear shift will not engage CAUSES Damaged shifter Damaged synchronizer Replace Replace
REMEDY
REMEDY
REMEDY
WB146-5
20-59
20-60
WB146-5
90
OTHERS
HYDRAULIC CIRCUIT .......................................................................................................... 90-3 1 OF 4 .................................................................................................................................... 90-3 2 OF 4 .................................................................................................................................... 90-5 3 OF 4 .................................................................................................................................... 90-7 4 OF 4 .................................................................................................................................... 90-9 ELECTRICAL SCHEMATIC ................................................................................................ 90-11 WIRING - 1 OF 7 ................................................................................................................ 90-11 WIRING - 2 OF 7 ................................................................................................................ 90-13 WIRING - 3 OF 7 ................................................................................................................ 90-15 WIRING - 4 OF 7 ................................................................................................................ 90-17 WIRING - 5 OF 7 ................................................................................................................ 90-19 WIRING - 6 OF 7 ................................................................................................................ 90-21 WIRING - 7 OF 7 ................................................................................................................ 90-23 LEGEND FOR WIRING SCHEMATIC............................................................................. 90-25 FUSE AND RELAY PANEL .............................................................................................. 90-27
WB146-5
90-1
OTHERS
90-2
WB146-5
OTHERS
HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT
1 OF 4
WB146-5
90-3
OTHERS
HYDRAULIC CIRCUIT
90-4
WB146-5
OTHERS 2 OF 4
HYDRAULIC CIRCUIT
WB146-5
90-5
OTHERS
HYDRAULIC CIRCUIT
90-6
WB146-5
OTHERS 3 OF 4
HYDRAULIC CIRCUIT
WB146-5
90-7
OTHERS
HYDRAULIC CIRCUIT
90-8
WB146-5
OTHERS 4 OF 4
HYDRAULIC CIRCUIT
WB146-5
90-9
OTHERS
HYDRAULIC CIRCUIT
90-10
WB146-5
OTHERS
ELECTRICAL SCHEMATIC
WIRING - 1 OF 7
WB146-5
90-11
OTHERS
90-12
WB146-5
OTHERS WIRING - 2 OF 7
WB146-5
90-13
OTHERS
90-14
WB146-5
WB146-5
90-15
OTHERS
90-16
WB146-5
WB146-5
90-17
OTHERS
90-18
WB146-5
WB146-5
90-19
OTHERS
90-20
WB146-5
WB146-5
90-21
OTHERS
90-22
WB146-5
WB146-5
90-23
OTHERS
90-24
WB146-5
OTHERS LEGEND FOR WIRING SCHEMATIC

ITEM A6 B13 B59 B97 B105 B111 B112 B113 B115 B121 E136 E138 E143 E146 E147 E148 E151 E152 E154 E155 E155 E156 E400 E401 E402 E403 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 DESCRIPTION Machine Function Unit Return To Dig Sensor Brake Oil Low Level Switch Rear Horn Switch Transmission Oil Temperature Sender Fuel Level Sender Thermistor Air Filter Switch Engine Oil Pressure Switch Horn Right Rear Wok Light Left Rear Work Light Right Front Wok Light Left Front Work Light Left Indicator Beacon Lamp Right Indicator Cab Light Rear Left Light Left Indicator Light Right Indicator Light Rear Right Light Right Front Work Light Left Front Work Light Left Rear Work Light Right Rear Work Light Front Work Light 15A Fuse Rear Work Light 15A Fuse Right Position Light 3a Fuse Left Position Light 3a Fuse Horn 10A Fuse Rear Work Light 15A Fuse Front Window Washer 7.5A Fuse Stop Light Switch 7.5A Fuse Front Work Light 15A Fuse Front Wiper 10A Fuse Optional 7.5A Fuse Instruments And Buzzer 5A Fuse Lever Grip 10A Fuse Light And Optional Switch 10A Fuse Safety Starter 10A Fuse Beacon Light 10A Fuse Warning Switch 10A Fuse Cab Light And Cigar Lighter 10A Fuse ITEM F19 F20 F21 F22 F23 F24 F25 F27 G1 G118 G119 H17 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K45 K56 K61 K111 M42 M55 M58 M116 P43 P63 R114 S2 S3 S4 S5 S6 DESCRIPTION Low Beam Light 15A Fuse Main Beam Light 15A Fuse Return To Dig Sensor 10A Fuse EC Power 7.5A Fuse Steering Unit 10A Fuse Flasher 7.5A Fuse Reverse Buzzer Switch 10A Fuse General 175A Fuse Battery Starter Motor Alternator Buzzer Starter Lock Out Unit Flasher Low Beam Light Relay Main Beam Light Relay Front Horn Relay Return To Dig Solenoid Relay Stop Light Relay Starter Relay Forward Speed Relay Reverse Speed Relay Declutch Relay Reheating Relay Safety Start Relay Services Relay ITEM S24 S40 S41 S46 S53 S54 S57 S60 S80 S81 S83 S84 S85 S86 S87 S88 S89 S97 S104 S107 S167 S168 S169 X1.s X2.s X3.s X4.s X5.s X7.p X7.s X8.p X8.s X9.p X9.s X10.p X10.s X11.p X11.s X12.p X12.s X15.p X25.p X25.s X26.p X26.s DESCRIPTION Starting Switch Seat Switch Rear Horn Switch Parking Brake Switch Stop Light Switch Stop 4WD Switch Steering Column Gear Shift Steering Column Light Switch Ride Control Switch Boom Unlock Switch EC Power Switch EMPI Solenoid Valve Switch Rear Horn Switch General Light Switch 4WD Switch PPC Switch Warning Switch Rear Horn Switch 4th Speed Switch Declutch Switch Beacon Light Switch Front Working Light Switch Rear Working Light Switch Unit Connector Unit Connector Unit Connector Unit Connector Unit Connector Motor Harness Connector Driver Site Harness Connector Gear Harness Connector Driver Site Harness Connector Front Dashboard Harness Connector Driver Site Harness Connector Front Dashboard Harness Connector Driver Site Harness Connector Solenoid Valve Harness Connector Driver Site Harness Connector Chassis Harness Connector Driver Site Harness Connector Optional Harness Connector Switch Panel Harness Connector Driver Site Harness Connector Switch Panel Harness Connector Driver Site Harness Connector ITEM X27.s X28.s X44.p X44.s X65.p X128.s X140 X142 X166.p X166.s X177.s X30 Y48 Y49 Y60 Y90 Y91 Y92 Y93 Y94 Y95 Y96 Y98 Y99 Y106 Y108 DESCRIPTION AC Harness Connector Heater Connector Cab Harness Connector Driver Site Harness Connector Motor Harness Connector Driver Site Harness Connector Cab Harness Connector Cab Harness Connector Switch Harness Connector Cab Harness Connector Work Light Harness Connector Cigar Lighter Float Solenoid Return To Dig Solenoid EMPI Solenoid Rear PPC Solenoid EC Power Solenoid Back Up Alarm PPC Solenoid Differential Lock Solenoid Boom Unlock Solenoid Solenoid MP Bucket Close Solenoid MP Bucket Open Solenoid 4WD Solenoid Forward Speed Solenoid ITEM
DESCRIPTION
Rear Window Wiper Window Washer Pump Front Window Wiper AC Compressor Clutch Instrument Panel Front Control Panel Preheater EC Power Switch Solenoid Valve MP Bucket Close Switch Declutch Switch MP Bucket Open Switch Differential Locking Switch
WB146-5
90-25
OTHERS
90-26
WB146-5
OTHERS 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 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 Forward Gear Relay Reverse Gear Relay Four Wheel Drive Relay Low Beam Relay High Beam Relay Direction Selector Power Supply Relay Horn Relay Turn Indicator Relay Flasher Relay 4th Gear Signaling Relay
WB146-5
90-27
OTHERS
90-28
WB146-5

Shop Manual WB146 5

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Shop Manual WB146 5

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CEBM016501

August 2006 Printed in USA

Copyright 2006 Komatsu DataKom Publishing Division 00-1

PRECAUTIONS DURING WORK

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

DISTRIBUTION AND UPDATING

Coat Oil, water

10-4 10-4-1 Added pages 10-4-2 10-5

QUICK DISCONNECT COUPLER

QUICK DISCONNECT COUPLER

QUICK DISCONNECT COUPLER

QUICK DISCONNECT COUPLER

09940-00030 790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

50 g Adh : 1 kg Hardening agent: 500 g 250 g 75 g

Used as adhesive or sealant for metal, glass or plastic.

LT-4 Holtz MH 705 3 Bond 1735

Polyethylene container Tube

Loctite 648-50 LG-1

Polyethylene container Tube

Gasket sealant LG-3 790-129-9070 1 kg Can

LG-5 Gasket sealant LG-6

3 Bond 1211 Molybdenum disulphide lubricant LM-G

09940-00040 SYG2-400LI SYG2-350LI

General purpose type

SYG2-400CA Grease G2-CA SYG2-350CA

Molybdenum disulphide lubricant

400 g (10 per case)

Used for places with heavy load.

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm

Thread diameter of bolt mm 6 8 10 12

Width across flats mm 10 13 14 27 Nm

FOREWORD TIGHTENING TORQUE OF HOSE NUTS

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Tightening torque kgm

TIGHTENING TORQUE FOR FLARED NUTS

Width across flat mm 19 24 27 32 36 41 46 55 Nm

Tightening torque lbf ft

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Nominal hose size 02 03 04 05 06 (10) (12) (14)

Width across flats 19 22 24 27 32 36 41 46 55

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Starting B Black BW Black & White BY

Lighting R Red RW Red & White RB

Code Color Code

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740