shop manual 146-5[1]

CEBM016501

ShopManual

WB146-5

BACKHOE LOADER

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordancewith 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 oradd improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-mended that customers contact their distributor for information on the latest revision.

SERIAL NUMBERS WB146-5 A23001 and UP

August 2006 Copyright 2006 KomatsuPrinted in USA DataKom Publishing Division

00-1WB146-5

FOREWORD CONTENTS

12CONTENTS 00

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . Will be issued at a later time

90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 WB146-5

FOREWORD SAFETY

12SAFETY 00

SAFETY NOTICE 00 00

GENERAL PRECAUTIONS 00

Mistakes in operation are extremely dangerous. Read theOPERATION & MAINTENANCE MANUAL carefully be-fore operating the machine.

1. Before carrying out any greasing or repairs, read all theprecautions given on the decals which are fixed to themachine.

2. When carrying out any operation, always wear safetyshoes and helmet. Do not wear loose work clothes, orclothes with buttons missing.

● Always wear safety glasses when hitting parts with ahammer. or when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, ex-perienced welder carry out the work. When carrying outwelding work, always wear welding gloves, apron,glasses, cap and other clothes suited for welding work.

4. When carrying out any operation with two or moreworkers, always agree on the operating procedure be-fore starting. Always inform your fellow workers beforestarting any step of the operation. Before starting work,hang UNDER REPAIR signs on the controls in the oper-ator's compartment.

5. Keep all tools in good condition and learn the correctway to use them. Decide a place in the repair workshopto keep tools and removed parts. Always keep the toolsand parts in their correct places. Always keep the workarea clean and make sure that there is no dirt or oil onthe floor. Smoke only in the areas provided for smoking.Never smoke while working.

PREPARATIONS FOR WORK 00

1. Before adding oil or making repairs, park the machineon hard, level ground, and block the wheels or tracks toprevent the machine from moving.

2. Before starting work, lower blade, ripper, bucket or anyother work equipment to the ground. If this is not possi-ble, insert the safety pin or use blocks to prevent thework equipment from falling. In addition, be sure to

lock all the control levers and hang warning signs onthem.

3. When disassembling or assembling, support the ma-chine with blocks, jacks or stands before starting work.

4. Remove all mud and oil from the steps or other placesused to get on and off the machine. Always use thehandrails, ladders or steps when getting on or off themachine. Never jump on or off the machine. If it is im-possible to use the handrails, ladders or steps, use astand to provide safe footing.

PRECAUTIONS DURING WORK 00

1. When removing the oil filler cap, drain plug or hydrau-lic pressure measuring plugs, loosen them slowly to pre-vent the oil from spurting out. Before disconnecting orremoving components of the oil, water or air circuits,first remove the pressure completely from the circuit.

2. The water and oil in the circuits are hot when the engineis stopped, so be careful not to get burned. Wait for theoil and water to cool before carrying out any work onthe oil or water circuits.

3. Before starting work, remove the leads from the battery.ALWAYS remove the lead from the negative (-) termi-nal first.

4. When raising heavy components, use a hoist or crane.Check that the wire rope, chains and hooks are free fromdamage. Always use lifting equipment which has amplecapacity. Install the lifting equipment at the correct plac-es. Use a hoist or crane and operate slowly to preventthe component from hitting any other part. Do not workwith any part still raised by the hoist or crane.

5. When removing covers which are under internal pres-sure or under pressure from a spring, always leave twobolts in position on opposite sides. Slowly release thepressure, then slowly loosen the bolts to remove.

6. When removing components, be careful not to break ordamage the wiring, Damaged wiring may cause electri-cal fires.

IMPORTANT SAFETY NOTICEProper service and repair is extremely important for the safe operation of your machine. The service and repair techniquesrecommended and described in this manual are both effective and safe methods of operation. Some of these operations re-quire 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 ac-companying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, firstconsider safety, and take the necessary actions to deal with the situation.

WB146-5 00-3

FOREWORD SAFETY

7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.Fuel or oil on the floor can cause you to slip, or can even start fires.

8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.

9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.

● When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine isbeing operated.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, sobe extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly in-stalled.

10. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such asguards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed cor-rectly.

11. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

12. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-ments.

13. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separatessuddenly, 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 electricalgenerating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the ma-chine.

00-4 WB146-5

FOREWORD GENERAL

12GENERALGENERAL 00

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-stand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. Forease of understanding, the manual is divided into the following sections. These sections are further divided into each maingroup of components.

GENERALThis section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant andlubricant specification charts.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARDThis section explains the structure and function of each component. It serves not only to give an understanding of thestructure, but also serves as reference material for troubleshooting.

TESTING, ADJUSTING AND TROUBLESHOOTINGThis section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-tion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.

DISASSEMBLY AND ASSEMBLYThis 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.

NOTICEThe specifications contained in this shop manual are subject to change at any time and without any advance notice. Contactyour distributor for the latest information.

WB146-5 00-5

FOREWORD HOW TO READ THE SHOP MANUAL

12HOW TO READ THE SHOP MANUAL 00

VOLUMES 00

Shop manuals are issued as a guide to carrying out repairs.They are divided as follows:

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series

Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models

These various volumes are designed to avoid duplication ofinformation. Therefore to deal with all repairs for any model,it is necessary that chassis, engine, electrical and attachmentbe available.

DISTRIBUTION AND UPDATING 00

Any additions, amendments or other changes will be sent toyour distributors. Get the most up-to-date information beforeyou start any work.

FILING METHOD 00

1. See the page number on the bottom of the page. File thepages in correct order.

2. Following examples show how to read the page number:

Example:

10 - 3

Item number (10. Structure and Function)

Consecutive page number for each item

3. Additional pages: Additional pages are indicated by ahyphen (-) and numbered after the page number. File asin the example.

Example:

00

00

00

00

00

00

REVISED EDITION MARK 00

When a manual is revised, an edition mark ( …) is re-corded on the bottom outside corner of the pages.

REVISIONS 00

Revised pages are shown at the LIST OF REVISED PAGESbetween the title page and SAFETY page.

SYMBOLS 00

So that the shop manual can be of ample practical use, im-portant places for safety and quality are marked with the fol-lowing symbols.

10-410-4-1

Added pages10-4-2

10-5

Symbol Item Remarks

SafetySpecial safety precautions arenecessary when performing thework.

★ Caution

Special technical precautions orother precautions for preservingstandards are necessary when per-forming the work.

Weight

Weight of parts or systems. Cau-tion necessary when selectinghoisting wire or when workingposture is important, etc.

TorquePlaces that require special atten-tion for tightening torque duringassembly.

Coat Places to be coated with adhesivesand lubricants etc.

Oil, water Places where oil, water or fuelmust be added, and the capacity.

DrainPlaces where oil or water must bedrained, and quantity to bedrained.

00-6 WB146-5

FOREWORD HOISTING INSTRUCTIONS

12HOISTING INSTRUCTIONS 00

HOISTING 00

● If a part cannot be smoothly removed from the machineby hoisting, the following checks should be made:

1. Check for removal of all bolts fastening the part to therelative parts.

2. Check for existence of another part causing interfacewith the part to be removed.

WIRE ROPES 00

1. Use adequate ropes depending on the weight of parts tobe hoisted, referring to the table below:

★ The allowable load value is estimated to be 1/6 or 1/7 ofthe 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 toslip off the hook during hoisting, and a serious accidentcan result. Hooks have maximum strength at the middleportion.

3. Do not sling a heavy load with one rope alone, but slingwith two or more ropes symmetrically wound on to theload.

4. Do not sling a heavy load with ropes forming a widehanging angle from the hook. When hoisting a load withtwo or more ropes, the force subjected to each rope willincrease with the hanging angles. The table belowshows the variation of allowable load (kg) when hoist-ing is made with two ropes, each of which is allowed tosling up to 1000 kg vertically, at various hanging angles.When two ropes sling a load vertically, up to 2000 kg oftotal weight can be suspended. This weight becomes1000 kg when two ropes make a 120° hanging angle. Onthe other hand, two ropes are subject to an excessiveforce as large as 4000 kg if they sling a 2000 kg load at alifting angle of 150°

00

WARNING!Heavy parts (25kg or more) must belifted with a hoist etc. In the DISASSEMBLY ANDASSEMBLY section, every part weighing 25 kg ormore is indicated clearly with the symbol.

Wire ropes, standard “Z” or “S” twist ropes withoutgalvanizing

Rope diameter Allowable load

mm kN tons

10 9.8 1.0

11.2 13.7 1.4

12.5 15.7 1.6

14 21.6 2.2

16 27.5 2.8

18 35.3 3.6

20 43.1 4.4

22.4 54.9 5.6

30 98.1 10.0

40 176.5 18.0

50 274.6 28.0

60 392.2 40.0

WARNING!Slinging with one rope may cause turn-ing of the load during hoisting, untwisting of the rope,or slipping of the rope from its original winding posi-tion on the load, which can result in a dangerous acci-dent

WB146-5 00-7

FOREWORD QUICK DISCONNECT COUPLER

12QUICK DISCONNECT COUPLER 00

TYPE 1 00

DISCONNECTION 00

1. Release the residual pressure from the hydraulic tank. For details,see TESTING AND ADJUSTING, Releasing residual pressurefrom hydraulic tank.

2. Hold the adapter (1) and push the hose joint (2) into the matingadapter (3). The adapter can be pushed in about 3.5 mm. Do nothold the rubber cap portion (4).

3. After the hose joint (2) is pushed into the adapter (3), press the rub-ber cap portion (4) against the adapter until it clicks.

4. Hold the hose adapter (1) or hose (5) and pull it out. Since some hy-draulic oil flows out, prepare an oil receiving container.

CONNECTION 00

1. Hold the hose adapter (1) or hose (5) and insert it in the matingadapter (3), aligning them with each other. Do not hold the rubbercap portion (4).

2. After inserting the hose in the mating adapter, pull it back to checkits connecting condition. When the hose is pulled back, the rubbercap portion moves toward the hose about 3.5 mm. This does not in-dicate an abnormality.

WARNING!Before carrying out the following work, release theresidual pressure from the hydraulic tank. For details, seeTESTING AND ADJUSTING, Releasing residual pressure fromhydraulic tank.

WARNING!Even if the residual pressure is released from the hy-draulic tank, some hydraulic oil flows out when the hose is dis-connected. Accordingly, prepare an oil receiving container.

00-8 WB146-5


12TYPE 2 00

DISCONNECTION 00

1. Hold the mouthpiece of the tightening portion and push body (2) instraight until sliding prevention ring (1) contacts contact surface aof the hexagonal portion at the male end.

2. Hold in the condition in Step 1, and turn the lever (4) to the right,clockwise.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body(2) to disconnect it.

CONNECTION 00

1. Hold the mouthpiece of the tightening portion and push body (2) instraight until sliding prevention ring (1) contacts surface a of thehexagonal portion at the male end to connect it.

00-9 WB146-5


12TYPE 3 00

DISCONNECTION 00

1. Hold the mouthpiece of the tightening portion and push the body(2) in straight until sliding prevention ring (1) contacts surface a ofthe hexagonal portion at the male end.

2. Hold in the condition in Step 1, and push until the cover (3) con-tacts surface a of the hexagonal portion at the male end.

3. Hold in the condition in Steps 1 and 2, and pull out the whole body(2) to disconnect it.

CONNECTION 00

1. Hold the mouthpiece of the tightening portion and push the body(2) in straight until the slide prevention ring (1) contacts surface aof the hexagonal portion at the male end to connect it.

00

00-10 WB146-5

FOREWORD COATING MATERIALS

12COATING MATERIALS 00

★ The recommended coating materials prescribed in the shop manuals are listed below.

Category Code Part No. Quantity Container Main applications, features

Adh

esiv

es

LT-1A 790-129-9030 150 g Tube ● Used to prevent rubber gaskets, rubber cush-ions and cork plugs from coming out

LT-1B 790-129-9050 20 g(2 pes.)

Polyethylene container

● Used in places requiring an immediately ef-fective, strong adhesive.

● Used for plastics (except polyethylene,polypropylene, tetrafluoroethylene, and vi-nyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylene container

● Features: Resistance to heat, chemicals● Used for anti-loosening and sealant purposes

for bolts and plugs.

LT-3

790-129-9060(Set of adhe-sive and hard-ening agent)

Adh : 1 kgHardening

agent:500 g

Can ● Used as adhesive or sealant for metal, glassor plastic.

LT-4 790-129-9040 250 g Polyethylene container ● Used as sealant for machined holes.

HoltzMH 705 790-126-9120 75 g Tube ● Used as heat-resisting sealant for repairing

engine.

3 Bond 1735 179-129-9140 2 g Polyethylene

container

● Quick hardening type adhesive.● Cure time: within 5 sec. to 3 min.● Used mainly for adhesion of metals, rubbers,

plastics and woods.

Aron-al-pha201

790-129-9130 50 g Polyethylene container

● Quick hardening type adhesive.● Quick cure type (max. strength after 30 min-

utes).● Used mainly for adhesion of rubbers, plas-

tics and metals.

Loctite648-50 79A-129-9110 50 cc Polyethylene

container

● Features: Resistance to heat, chemicals● Used at joint portions subject to high temper-

ature.

Gasketsealant

LG-1 790-129-9010 200 g Tube ● Used as adhesive or sealant for gaskets andpacking of power train case, etc.

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 pre-vent seizure.

● Used as sealant for heat resistant gasket forat high temperature locations such as enginepre-combustion chamber, exhaust pipe.

00-11 WB146-5

FOREWORD COATING MATERIALS

Gasket seal-ant

LG-4 790-129-9020 200 g Tube

● Features: Resistance to water, oil● Used as sealant for flange surface, thread.

Also possible to use as sealant for flangeswith large clearance.

● Used as sealant for mating surfaces of finaldrive case, transmission case.

LG-5 790-129-9080 1 kg Polyethylene container

● Used as sealant for various threads, pipejoints, flanges. for tapered plugs, elbows,nipples of hydraulic piping.

LG-6 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 hardeningtype.

● Used as sealant for flywheel housing, intakemanifold, oil pan, thermostat housing, etc.

3 Bond 1211 790-129-9090 100 g Tube ● Used as heat-resisting sealant for repairing

engines.

Mol

ybde

num

disu

lphi

delu

bric

ant LM-G 09940-00051 60 g Can ● Used as lubricant for sliding parts (to prevent

squeaking).

LM-P 09940-00040 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.

Grease

G2-LI

SYG2-400LI

SYG2-350LI

SYG2-400LI-A

SYG2-160LI

SYGA160CNLI

Various Various ● General purpose type

G2-CA

SYG2-400CA

SYG2-350CA

SYG2-400CA-A

SYG2-160CA

SYG2-160CNCA

Various Various● Used for normal temperature, light load

bearing at places in contact with water orsteam.

Mol

ybde

num

disu

lphi

delu

bric

ant

SYG2-400M 400 g (10 per case) Belows type ● Used for places with heavy load.

Category Code Part No. Quantity Container Main applications, features

00-12 WB146-5

FOREWORD STANDARD TIGHTENING TORQUE

12STANDARD TIGHTENING TORQUE 00

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY ANDASSEMBLY.

Thread diameter of bolt Width across flats

mm mm N•m lbf ft

6 10 11.8 - 14.7 8.70 - 10.84

8 13 27 - 34 19.91 - 25.07

10 17 59 - 74 43.51 - 54.57

12 19 98 - 123 72.28 - 90.72

14 22 153 - 190 112.84 - 140.13

16 24 235 - 285 173.32 - 210.20

18 27 320 - 400 236.02 - 295.02

20 30 455 - 565 335.59 - 416.72

22 32 610 - 765 449.91 - 564.23

24 36 785 - 980 578.98 - 722.81

27 41 1150 - 1440 848.19 - 1062.09

30 46 1520 - 1910 1121.09 - 1408.74

33 50 1960 - 2450 1445.62 - 1807.02

36 55 2450 - 3040 1807.02 - 2242.19

39 60 2890 - 3630 2131.55 - 2677.35

Thread diameter of bolt Width across flats

mm mm N•m lbf ft

6 10 5.9 - 9.8 4.35 - 7.22

8 13 13.7 - 23.5 10.10 - 17.33

10 14 34.3 - 46.1 25.29 - 34.00

12 27 74.5 - 90.2 54.94 - 66.52

00-13 WB146-5


12TIGHTENING TORQUE OF HOSE NUTS 00

Use these torques for hose nuts.

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00

Use these torques for split flange bolts.

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Nominal No.Thread diameter Width across flat Tightening torque

mm mm N•m lbf ft

02 14 19 19.6 - 29.4 14.5 - 21.7

03 18 24 29.4 - 68.6 21.7 - 50.6

04 22 27 58.9 - 98.1 44.4 - 72.4

05 24 32 107.9 - 166.7 79.6 - 123.0

06 30 36 147.1 - 205.9 108.5 - 151.9

10 33 41 147.1 - 245.1 108.5 - 180.8

12 36 46 196.2 - 294.2 144.7 - 217.0

14 42 55 245.2 - 343.2 180.9 - 253.1

Thread diameter Width across flat Tightening torque

mm mm N•m kgm

10 14 59 - 74 43.51 - 54.57

12 17 98 - 123 72.28 - 90.72

16 22 235 - 285 173.32 - 210.20

Thread diameter Width across flat Tightening torque

mm mm N•m lbf ft

14 19 24.5 ± 4.9 18.0 ± 3.6

18 24 49 ± 19.6 36.1 ± 14.4

22 27 78.5 ± 19.6 57.8 ± 14.4

24 32 137.3 ± 29.4 101.2 ± 21.6

30 36 176.5 ± 29.4 130.1 ± 21.6

33 41 196.1 ± 49 144.6 ± 36.1

36 46 245.2 ± 49 180.8 ± 36.1

42 55 294.2 ± 49 216.9 ± 36.1

00-14 WB146-5


12TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 00

★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.

★ Apply the following torque when the threads are coated (wet) with engine oil.

Norminal No. Thread diameter Width across flat Tightening torque - N•m (lbf ft)mm mm Range Target

02 14

Varies depending on type of connector.

35 - 63 (25.81 - 46.46) 44 (32.45))03, 04 20 84 - 132 (61.95 - 97.35) 103 (75.96)05, 06 24 128 - 186 (94.40 - 137.18) 157 (115.79)10, 12 33 363 - 480 (267.73 - 354.02) 422 (311.25)

14 42 746 - 1010 (550.22 - 744.93) 883 (651.26)

Norminal No. Thread diameter Width across flat Tightening torque - N•m (lbf lb)mm mm Range Target

08 08 14 5.88 - 8.82 (4.33 - 6.50) 7.35 (5.42)10 10 17 9.8 - 12.74 (7.22 - 9.39) 11.27 (8.31)12 12 19 14.7 - 19.6 (10.84 - 14.45) 17.64 (13.01)14 14 22 19.6 - 24.5 (14.45 - 18.07) 22.54 (16.62)16 16 24 24.5 - 34.3 (18.07 - 25.29) 29.4 (21.68)18 18 27 34.3 - 44.1 (25.29 - 32.52) 39.2 (28.91)20 20 30 44.1 - 53.9 (32.52 - 39.75) 49.0 (36.14)24 24 32 58.8 - 78.4 (43.36 - 57.82) 68.6 (50.59)30 30 32 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50)33 33 _ 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75)36 36 36 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03)42 42 _ 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40)52 52 _ 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52)

Nominal hose size

Widthacross flats

Tightening torque - N•m (lbf ft) Taper seal Face seal

Range Target Thread size (mm)

Nominal thread size - TPI

Root diameter (mm) (Reference)

02 19 34 - 54 (25.0 - 39.8) 44 (32.4) - 9/16 - 18UN 14.334 - 63 (25.0 - 46.4) 44 (32.4) 14 - -

03 22 54 - 93 (39.8 - 68.5) 74 (54.5) - 11/16 -16UN 17.524 59 - 98 (43.5 - 72.2) 78 (57.5) 18 - -

04 27 84 - 132 (61.9 - 97.3) 103 (75.9) 22 13/16 - 16UN 20.605 32 128 - 186 (94.4 - 137.1) 157 (115.7) 24 1 - 14UNS 25.406 36 177 - 245 (130.5 - 180.7) 216 (159.3) 30 1 3/16 - 12UN 30.2

(10) 41 177 - 245 (130.5 - 180.7) 216 (159.3) 33 - -(12) 46 197 - 294 (145.3 - 216.8) 245 (180.7) 36 - -(14) 55 246 - 343 (181.4 - 252.9) 294 (216.8) 42 - -

00-15 WB146-5

FOREWORD ELECTRIC WIRE CODE

12ELECTRIC WIRE CODE 00

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table willhelp you understand WIRING DIAGRAMS.

Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS 00

CLASSIFICATION BY COLOR AND CODE 00

Nominalnumber

Copper wireCable O.D.

(mm)Current

rating (A) Applicable circuitNumber of strands

Dia. Of strand (mm)

Cross section (mm)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priority CircuitsClassification Charging Ground Starting Lighting Instrument Signal Other

1

Prim

ary Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Aux

iliar

y

Code WR — BW RW YR GW LW

Color White & Red — Black &

WhiteRed & White

Yellow & Red

Green & White

Blue & White

3Code WB — BY RB YB GR LR

Color White & Black — Black & Yel-

low Red & Black Yellow & Black

Green & Red Blue & Red

4Code WL — BR RY YG GY LY

Color White & Blue — Black & Red Red & Yel-

lowYellow &

GreenGreen & Yellow

Blue & Yel-low

5Code WG — — RG YL GB LB

Color White & Green — — Red &

GreenYellow &

BlueGreen &

BlackBlue & Black

6Code — — — RL YW GL —

Color — — — Red & Blue Yellow & White

Green & Blue —

00-16 WB146-5

FOREWORD CONVERSION TABLES

12CONVERSION TABLES 00

METHOD OF USING THE CONVERSION TABLE 00

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using theConversion Table, see the example given below.

EXAMPLE

● Method of using the Conversion Table to convert from millimeters to inches.

1. Convert 55 mm into inches.

A. Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from .

B. Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .

C. Take the point where the two lines cross as . This point gives the value when converting from millimeters toinches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to55 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 theright) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-17 WB146-5


12

Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748

20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142

30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536

40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717

70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110

80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504

90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89

20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93

30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98

40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07

60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12

70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17

80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21

90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-18 WB146-5


12

Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019

20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661

30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303

40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586

60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228

70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870

80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511

90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179

20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579

40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978

60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178

70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378

80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577

90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

WB146-5 00-19


12

N•m to lbf. ft. 1 N•m = 0.737 lbf. ft.

0 1 2 3 4 5 6 7 8 9

0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.63

10 7.37 8.107 8.884 9.581 10.318 11.055 11.792 12.259 13.266 14.003

20 14.74 15.477 16.214 16.951 17.688 18.425 19.126 19.899 20.636 21.373

30 22.11 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743

40 29.48 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113

50 36.85 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483

60 44.22 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853

70 51.59 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223

80 58.96 59.697 60.434 61.171 61.908 62.645 63.382 64.119 64.856 65.593

90 66.33 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963

100 73.7 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333

110 81.07 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703

120 88.44 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073

130 95.81 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443

140 103.18 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813

150 110.55 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183

160 117.92 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553

170 125.29 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923

180 132.66 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293

190 140.03 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663

00-20 WB146-5


12

N•m to lbf. inf 1 N•m = 8.85 lbf. inf

0 1 2 3 4 5 6 7 8 9

0 0 8.85 17.7 26.55 35.4 44.25 53.1 61.95 70.8 79.65

10 88.5 97.35 106.2 115.05 123.9 132.75 141.6 150.45 159.3 168.15

20 177 185.85 194.7 203.55 212.4 221.25 230.1 238.95 247.8 256.65

30 265.5 274.35 283.2 292.05 300.9 309.75 318.6 327.45 336.3 345.15

40 354 362.85 371.7 380.55 389.4 398.25 407.1 415.95 424.8 433.65

50 442.5 451.35 460.2 469.05 477.9 486.75 495.6 504.45 513.3 522.15

60 531 539.85 548.7 557.55 566.4 575.25 584.1 592.95 601.8 610.65

70 619.5 628.35 637.2 646.05 654.9 663.75 672.6 681.45 690.3 699.15

80 708 716.85 725.7 734.55 743.4 752.25 761.1 769.95 778.8 787.65

90 796.5 805.35 814.2 823.05 831.9 840.75 849.6 858.45 867.3 876.15

100 885 893.85 902.7 911.55 920.4 929.25 938.1 946.95 955.8 964.65

110 973.5 982.35 991.2 1000.05 1008.9 1017.75 1026.6 1035.45 1044.3 1053.15

120 1062 1070.85 1079.7 1088.55 1097.4 1106.25 1115.1 1123.95 1132.8 1141.65

130 1150.5 1159.35 1168.2 1177.05 1185.9 1194.75 1203.6 1212.45 1221.3 1230.15

140 1239 1247.85 1256.7 1265.55 1274.4 1283.25 1292.1 1300.95 1309.8 1318.65

150 1327.5 1336.35 1345.2 1354.05 1362.9 1371.75 1380.6 1389.45 1398.3 1407.15

160 1416 1424.85 1433.7 1442.55 1451.4 1460.25 1469.1 1477.95 1486.8 1495.65

170 1504.5 1513.35 1522.2 1531.05 1539.9 1548.75 1557.6 1566.45 1575.3 1584.15

180 1593 1601.85 1610.7 1619.55 1628.4 1637.25 1646.1 1654.95 1663.8 1672.65

190 1681.5 1690.35 1699.2 1708.05 1716.9 1725.75 1734.6 1743.45 1752.3 1761.15

WB146-5 00-21


12Temperature

Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperaturereading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to thetemperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the columnat the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigradevalues, and read the corresponding Fahrenheit temperature on the right.

°C °F °C °F °C °F °C °F-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

00-22 WB146-5

01 GENERAL

SPECIFICATIONS ................................................................................................................................................................ 01-2WEIGHT TABLE .................................................................................................................................................................. 01-3FUEL COOLANT AND LUBRICANTS .............................................................................................................................. 01-4

01-1WB146-5

GENERAL SPECIFICATIONS

12SPECIFICATIONS

ITEM UNIT WB146-5 A23001 and UP

Operating weightMinimum

kgMaximum

Bucket capacity

LoaderGP w/BOCE

m³

0.95

MP w/BOCE 0.99

Backhoe

305 mm Edge 0.07

457 mm Edge 0.12

609 mm Edge 0.18

762 mm Edge 0.23

915 mm Edge 0.29

Diesel engine

Model S4D102LE-2

Max power kW 69

Max torque N•m 407

Electrical system

Alternator V 12

Output A 95

Ground --- NEG

Battery Ah @ V 100

Starter kW 3.2

Travel speeds

Forward 1st

km/h

6.3

Forward 2nd 11.4

Forward 3rd 21.3

Forward 4th 37.8

Reverse 1st 6.3

Reverse 2nd 11.4

Reverse 3rd 21.3

Reverse 4th 37.8

Front tire pressureFront

kg/cm²3.26 - 3.36

Rear 1.83 - 1.93

01-2 WB146-5

GENERAL WEIGHT TABLE

12WEIGHT 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

12FUEL COOLANT AND LUBRICANTSIt is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for thequality of the fuel, coolant and lubricant must remain with the supplier.

When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recom-mended for this machine.

OPTION FOR VERY COLD AREAS:If the temperature is below 10°C, contact your distributor for advise on the type of oilto be used.

Reservoir Kind of fluid

Ambient Temperature - °C Capacity

-30 -20 -10 0 10 20 30 40 50 Specified Refill

Engine oil pan

Oil

API

CI-

4

SAE 5W-30

11 L 13 L

SAE 10W

SAE 20W-20

SAE 30

SAE 40

SAE 10W-30

SAE 15W-40

Hydraulic system

SAE 5W*

150 L 92 LSAE 10W

SAE 30

SAE 10W-30+

HEES 150 L 92 L

Front axle diff

Oil

API

CI-

4

See Note 1

6.5 L 6.5 L

Final gear 1 L each 1 L each

Rear axle diff 14.5 L 14.5 L

Final gear 1.5 L each 1.5 L each

TransmissionATF GM DEXRON® II D

20 L 17 L

Brakes 0.8 L 0.8 L

Fuel tank Diesel fuel

ASTM D975 No. 1 130 L -

ASTM D975 No. 2

Engine cool-ing system Coolant AF-NAC 14 L -

01-4 WB146-5

GENERAL FUEL COOLANT AND LUBRICANTS

12Note 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 -20°C. Consult your Komatsu distribu-tor for your specific needs.

NOTE Use only diesel fuel. The engine mounted in this machine employs electronic control and a high pres-sure fuel injection device to obtain good fuel consumption and good exhaust characteristics. For thisreason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lu-bricating ability is used, there will be a significant drop in durability.

WB146-5 01-5

GENERAL

12

MEMORANDA

01-6 WB146-5

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

WB14

12POWER TRAIN ...................................................................................................................................................... 10-3DESCRIPTION..................................................................................................................................................... 10-3POWER FLOW .................................................................................................................................................... 10-3

TRANSMISSION DIAGRAM................................................................................................................................ 10-5TRANSMISSION.................................................................................................................................................... 10-7

COMPLETE ASSEMBLY ................................................................................................................................... 10-7FORWARD REVERSE CLUTCH..................................................................................................................... 10-111ST THROUGH 4TH SPEED SHAFT .............................................................................................................. 10-114WD SHAFT ...................................................................................................................................................... 10-12

FRONT AXLE....................................................................................................................................................... 10-13COMPLETE ASSEMBLY ................................................................................................................................. 10-13

REAR AXLE ......................................................................................................................................................... 10-16COMPLETE ASSEMBLY ................................................................................................................................. 10-16DIFFERENTIAL ................................................................................................................................................ 10-17PLANETARY..................................................................................................................................................... 10-18WORK BRAKES................................................................................................................................................ 10-19DIFFERENTIAL LOCK .................................................................................................................................... 10-20

HYDRAULIC PUMP ............................................................................................................................................ 10-21MAIN PUMP ...................................................................................................................................................... 10-22DELIVERY CONTROL VALVE ...................................................................................................................... 10-26

MAIN CONTROL VALVE .................................................................................................................................. 10-32CLSS...................................................................................................................................................................... 10-39

DESCRIPTION................................................................................................................................................... 10-39OPERATING PRINCIPLES .............................................................................................................................. 10-40

STEERING UNIT.................................................................................................................................................. 10-55TECHNICAL DATA.......................................................................................................................................... 10-55OPERATION...................................................................................................................................................... 10-55

PPC VALVE.......................................................................................................................................................... 10-56LOADER ............................................................................................................................................................ 10-56OUTRIGGER ..................................................................................................................................................... 10-61BACKHOE ......................................................................................................................................................... 10-65

SOLENOID VALVE............................................................................................................................................. 10-67HYDRAULIC CONTROLS W/O MP BUCKET .............................................................................................. 10-67HYDRAULIC CONTROLS WITH MP BUCKET............................................................................................ 10-68

LOADER CYLINDERS........................................................................................................................................ 10-69BOOM................................................................................................................................................................. 10-69BUCKET............................................................................................................................................................. 10-70MP BUCKET...................................................................................................................................................... 10-71

10-16-5

10-2

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TABLE OF CONTENTS

BACKHOE CYLINDERS..................................................................................................................................... 10-72BOOM................................................................................................................................................................. 10-72ARM ................................................................................................................................................................... 10-73BUCKET............................................................................................................................................................. 10-74TELESCOPIC ARM CYLINDER ..................................................................................................................... 10-75SWING ............................................................................................................................................................... 10-76OUTRIGGER ..................................................................................................................................................... 10-77

WORK EQUIPMENT ........................................................................................................................................... 10-78LOADER ............................................................................................................................................................ 10-78BACKHOE ......................................................................................................................................................... 10-80

AIR CONDITIONING .......................................................................................................................................... 10-83

WB146-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

12POWER TRAIN

DESCRIPTION● The driving power for the engine b is transmitted through the flywheel to the converter c. The converter uses hydraulic oil

to convert the torque transmitted by the engine into driving power. The converter transmits motion to the drive shaft of thetransmission 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 hand i. The driving power transmitted to the front f and rear g axles is reduced by the differentials and then transmitted tothe planetary gear through the differential shafts.

POWER FLOW

B Engine F Front Axle

C Torque Converter G Rear AxleD Transmission H Front Drive ShaftE Hydraulic Pump I Rear Drive Shaft

Front AxleGear Transmission Differential Planet Total1st 5.533

2.462 6

81.7222nd 3.36 49.6273rd 1.532 22.6274th 0.81 11.963

Rear AxleGear Transmission Differential Planet Total1st 5.533

2.75 6.4

97.3382nd 3.36 59.1363rd 1.532 26.9634th 0.81 14.256

WB146-5 10-3

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

12

b Engine F Front Axle j Rear Tiresc Convert G Rear Axle 1) Front Tiresd Transmission H Front Drive Shafte Hydraulic Pump I Rear Drive Shaft

10-4 WB146-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION DIAGRAM

12TRANSMISSION DIAGRAM

b Engine E Transmission H Rear Axle Flangec Torque Converter F Reverse Clutch I 4WD Clutchd Forward Clutch G Hydraulic Pump J Front Axle Flange

WB146-5 10-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION DIAGRAM

12

B Converter Valve G Reverse Clutch 1! Control ValveC Converter H Max Pressure Valve 1@ Check ValveD Engine I Spin On Filter 1# Check ValveE Oil Cooler J Pump 1$ 4WD SolenoidF Forward Clutch 1) Suction Strainer 1% 4WD Clutch

10-6 WB146-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSMISSION

12TRANSMISSIONCOMPLETE ASSEMBLY

B Shift Lever F Suction Strainer J 4WD SolenoidC Torque Converter G 4th Gear Sensor a From Oil CoolerD Spin On Filter H Reverse Solenoid b To Oil CoolerE Oil Temperature Sender I Forward Solenoid

WB146-5 10-7


12

B Pump Drive Shaft H Rear Axle Flange 1# 4WD ClutchC Forward Reverse Shaft I 3rd Driven Gear 1$ 4WD Clutch ShaftD Reverse Gear Clutch J 4th Driven Gear 1% Front Axle FlangeE Forward Gear Clutch 1) 4WD Drive Gear 1^ 2nd Driven GearF Reverse Idler Gear Shaft 1! 1st Driven Gear 1& Rear Output ShaftG Drive Gears and Shaft 1@ 4WD Driven Gear 1* Torque Converter

10-8 WB146-5


12

B Gear Shift Lever H 3rd & 4th Selecting Rod 1# Spin On FilterC Centering Spring I 1st &2nd Selecting Fork 1$ Cold Oil Relief ValveD Return Spring J 4th Selecting Sensor 1% Return SpringE Check Ball 1) 3rd & 4th Selector 1^ Return SpringF 3rd & 4th Selecting Fork 1! 1st & 2nd Selector 1& Return SpringG 1st & 2nd Selecting Rod 1@ Suction Strainer

WB146-5 10-9


12

B Forward Reverse Solenoid H Valve 1# SpoolC 4WD Solenoid I Return Spring 1$ Forward SolenoidD Piston J Valve 1% Reverse SolenoidE Return Spring 1) Rod 1^ Check BallF Return Spring 1! Return Spring 1& Return SpringG Spring Guide Pin 1@ Spool Return Spring

10-10 WB146-5


12FORWARD REVERSE CLUTCH

1ST THROUGH 4TH SPEED SHAFT

B Reverse Gear E Reverse Clutch Piston a Reverse Clutch PortC Forward Gear F Thrust Ring b Forward Clutch PortD Forward Clutch Piston G Shaft c Lubrication Port

B 2nd Driver Gear E 4th Driven Gear H Thrust RingC 1st Driven Gear F 3rd Driven Gear I SynchronizerD 4WD Gear g Rear Output Shaft

WB146-5 10-11


124WD SHAFT

B Front Output Shaft E Cylinder a 4WD Pressure PortC 4WD Driven Gear F SpringD Thrust Ring G Disc

10-12 WB146-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FRONT AXLE

12FRONT AXLECOMPLETE ASSEMBLY

B Steering Cylinder E Tie Rod Nut h Mounting Pin BushingC Oil Refill Plug F Adjustment Screw a Left Cylinder PortD Oil Drain Plug G Lock Nut b Right Cylinder Port

Unit:mm

Check ItemCriteria

RemedyStandard Size

Tolerance Standard Clearance

Clearance LimitShaft Bushing

i Pin and Bushing Clearance 50 50 0-0.039 50.19 +0.04

0 --- --- Replace

WB146-5 10-13


12DIFFERENTIAL

B Side Gear F Adjustment Lock Nut J Bearing Spacer 1# Bearing Lock NutC Ring Gear G Axle Shaft 1) Outboard Bearing 1$ Inboard BearingD Dowel Pin H Dowel Pin 1! Lip Seal Ring 1% Pinion GearE Driven Gear I Differential Housing 1@ Lip Seal Ring Cover 1^ Oil Drain Plug

Unit : mm

Check ItemCriteria

RemedyStandard Clearance Clearance Limit

1& Axle Clearance --- ---

Adjust1* Ring and Pinion Gear Backlash 0.18 to 0.28 0.28

1( Pinion Preload - w/o lip seal 92 to 137 N•m

2) Ring and Pinion Gear Preload - w/o lip seal 129.5 to 194.5 N•m

10-14 WB146-5


12PLANETARY

B Planetary Carrier J Belleville Washer 1& Lip Ring SealC Planetary Gear 1) Upper King Pin Bushing 1* Tapered Roller BearingD Ring Gear 1! Lip Ring Seal 1( Retaining RingE Carrier Gear 1@ Axle Housing 2) Bolt BushingF Wheel Hub 1# Spherical Bearing 2! Stud BoltG Lip Ring Seal 1$ Lower King Pin Bushing 2@ Oil Drain PlugH Upper King Pin 1% Lower King PinI Adjustment Shim 1^ Belleville Washer

Unit:mm

2# Hub Rotation Torque ---Adjust

2$ Axle Shaft Clearance ---

WB146-5 10-15

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD REAR AXLE

12REAR AXLECOMPLETE ASSEMBLY

B Input Flange F Planetary Portion J Oil Drain PlugC Differential Portion G Parking Brake Levers 1) Axle Housing BreatherD Brake Portion H Brake Bleeder Screws a Brake Port .......................40.8 kg/cm²E Axle Housing I Oil Fill And Level Plugs b Diff Lock Port.............1295.4 kg/cm²

10-16 WB146-5


12DIFFERENTIAL

B Tapered Roller Bearing F Differential Housing J Bearing Lock Nut 1# Pinion GearC Side Gear G Bearing Lock Nut 1) Lip Oil Seal 1$ Differential HousingD Rotating Gear H Axle Shaft 1! Input FlangeE Ring Gear I Tapered Roller Bearing 1@ Bearing Spacer

Unit:mm

Check Item Criteria RemedyStandard Clearance Clearance Limit

1% Axle Clearance --- ---

Adjust1^ Ring And Pinion Gear Backlash 0.21 to 0.29 mm 0.29 mm1& Pinion Gear Preload - w/o seal ring 115 to 138 N•m1* Pinion Ring Gear Preload - w/o seal ring 148 to 188 N•m

WB146-5 10-17


12PLANETARY

B Stud Bolt F Axle Shaft J Tapered Roller BearingC Planet Gear G Pressure Plate 1) Oil SealD Wheel Hub H Retaining Ring 1! Wheel FlangeE Sun Gear I Ring Nut

Unit : mmCheck Item Criteria Remedy

1@ Hub Rotation Torque ---Adjust

1# Axle Shaft Clearance ---

10-18 WB146-5


12WORK BRAKES

B Bleed Screw E Middle Plate H BushingC Brake Piston F Outer Plate I Parking Brake Control CaliperD Friction Disc G Belleville Washer J Set Screw

Unit : mmCheck Item Criteria Remedy

1) Hub Rotation Torque --- Adjust

WB146-5 10-19


12DIFFERENTIAL LOCK

B Engagement Pin E Piston h ForkC Sleeve F Bushing i SpacerD Cover G Control Rod a Diff Lock Port

10-20 WB146-5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

12HYDRAULIC PUMP

COMPONENTS Ps From Hydraulic Tank Ps Oil Intakeb Hydraulic Pump P1L From Control Valve Pp P1L Pump Delivery Pressure Input

c Delivery Control Valve PLS From Control Valve LS P1C QD For Pump Delivery Pressure

d Oil Refil Plug PM From EV1 Solenoid Valve Pd2 Drain PlugPORT CONNECTIONS PORT FUNCTIONS Pen Delivery Control Pressure Check

P1 To Loader Valve P1 Pump Delivery PLS LS Signal InputPd To Hydraulic Tank Pd Drain PM Operarting Mode Control Signal

WB146-5 10-21


12MAIN PUMP

PORT FUNCTIONS Pe Delivery Control Signal Pd5 DrainPa Delivery Control Group Feed Pd4 Drain PM2 Operating Mode Signal

10-22 WB146-5


12

B Bearing G Piston 1! Control PistonC Input Shaft H Cylinder Block 1@ SpringD Pump Housing I Swash Plate 1# Seal RingE Swash Plate J Cover 1$ BallF Shoe 1) Shoe Guide

WB146-5 10-23


12FUNCTION

The rotation and torque transmitted to the pump shaft is converted intohydraulic energy and pressurized oil is delivered according to the loadrequirements.

The amount of oil delivered can be modified by changing the angle ofthe swash plate.

STRUCTURE

● Groove a supports and makes the cylinder block B an integral part ofthe 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 toform 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 theswash plate and slides in a circular movement. Pressurised oil isintroduced between the shoe and swash plate forming a staticbearing 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 thechambers of the block; pressure is adjusted by the valve plate 1). Thesurface of the swash plate is so designed that the oil pressure alwaysremains within acceptable limits. The oil in each chamber is drawn inand 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 hrotates on the ball j, and the angle a between the axis of the cylin-der block and the axis X of the swash plate changes. The angle a isknown as the swash plate angle.

10-24 WB146-5


122. When the axis X of the swash plate h retains the angle a in relationto the axis of the cylinder block B, flat surface A acts as a cam forthe shoe g. This is why the piston f slides inside the cylinderblock, creating a difference between volumes E and F and there-fore causing the suction and delivery of oil in a quantity that isequivalent to the difference between those volumes (F – E = deliv-ery). When the cylinder block rotates, chamber F decreases in vol-ume causing oil to be delivered to the circuits, while chamber Eincreases in volume causing oil to be suctioned. The illustrationshows the state of the pump when suction at chamber F and deliv-ery at chamber E are complete.

3. When the center line X of the swash plate h and the center line ofthe cylinder block B are perfectly aligned, the swash plate angle a= 0, the difference between the volumes E and F within the cylin-der block becomes 0 and the pump does not take in or deliver anyoil. The angle of the swash plate a is proportional to pump deliv-ery.

Control of Delivery

1. When angle a of the swash plate increases, the difference betweenvolumes E and F increases too, and this makes delivery Q increaseaccordingly. Angle a of the swash plate is varied by the servo pis-ton 1!.

2. The servo piston 1! moves in a reciprocating linear motion causedby pressure signals from the PC and LS valves. The linear motionis transmitted to the swash plate h. The swash plate is supported bythe pump body i through the ball j, and this is the reason why theswash plate moves in a semicircular alternate motion.

WB146-5 10-25


12DELIVERY CONTROL VALVE

PORT FUNCTIONS P1 Delivery Control Group Feed PE Delivery Control Signal OutputT Drain Pd4 Drain PM Operating Mode Signal Input

10-26 WB146-5


12

COMPONENTS i Gasket PORT FUNCTION

b Lever j Piston T Drain

c Spring 1) Spool PA Pump Delivery Pressure

d Retainer 1! Plug PM Operating Mode Signal Output

e Seal 1@ Seat PPL Delivery Control Signal Input

f Spool 1# Spring PE Delivery Control Signal

g Sleeve 1$ Nut PLS LS Signal Input

h Piston 1% Plug PPLS LS Pump Signal Input

WB146-5 10-27


12LS VALVE FUNCTION

● The LS valve controls the pump delivery according to the stroke ofthe control valve lever, the function of the delivery demands made bythe actuators.

● The LS valve detects the actuator’s delivery needs by means of thedifferential pressure PLS existing between pressure PPLS, con-trol valve input pressure, and pressure PLS, control valve outputpressure. The sensing of this differential pressure permits control ofthe main pump delivery Q. PPLS, PLS and PLS are, respec-tively, the pump pressure, the Load Sensing pressure, and the differ-ence in pressure between these two values.

● The LS valve detects the pressure difference PLS generated bythe passage of the oil flow through the surface freed by the controlvalve spool, and controls the pump delivery Q so as to keep the pres-sure drop constant. It can therefore be assumed that the pump deliv-ery is proportional to the demands made known by the control valve.

● Pump pressure PPLS, pump pressure at control valve input, andpressure PLS, Load Sensing pressure, are introduced into the LSvalve. The relation between differential pressure PLS and pumpdelivery varies as shown in the diagram on the right.

PC VALVE FUNCTION

● The PC, Power Control, valve performs an approximate powercheck, and ensures that the hydraulic horsepower absorbed by thepump does not exceed the horsepower delivered by the endothermalengine.

● This is achieved by limiting the pump delivery Q function of the de-livery pressure PPLS, even if the LS valve requests an increase indelivery 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 deliverypressure PPLS also increases simultaneously, the PC valve reducesthe 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 de-livery Q is switched in accordance with the force applied by pressurePC.

● When the force applied by pressure PC is added to the force appliedby the pump's delivery pressure against the spool f, the relation be-tween pump delivery pressure and delivery is switched from b to inaccordance with increment X.

10-28 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD HYDRAULIC PUMP

12PC VALVE OPERATION

Spring Operation

● PC valve spring loading d is defined by swash plate position.

● If control piston g moves to the right, spring d is compressed by thelever c and the spring load increases.

When Pump Pressure PA is Low

● The force applied by the pressure against the spool e decreases, andthe spool f shifts slightly to the right. At the same time, a connectionopens between ports C and D, and pressurised oil from valve LS issent for discharge, PT.

● Simultaneously, ports F and G on valve LS are interconnected, andpressure at port J is sent for relief, PT; the control piston c shifts tothe left. Pump delivery increases as a result.

● When the control piston c moves, the lever d moves to the left, andthe spring b expands, thereby reducing its load on the spool f. Con-sequently, the spool moves to the left and stops the oil flow betweenports C and D, and a passage opens between ports B and C. Thepressure at port C increases, and the control piston stops.

WB146-5 110-29


12When Pump Pressure PA Is High

● The force applied by the pressure against the spool e increases, andthe spool f shifts slightly to the left. At the same time, a connectionopens between ports C and B, and the pressure of the oil sent tovalve LS becomes equivalent to the pump's delivery pressure, PA.

● Simultaneously, ports F and G on valve LS are interconnected, andpressure at port J becomes equivalent to the pump's delivery pres-sure, PA, and the control piston c shifts to the right. Pump deliverydecreases 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 spoolf. Consequently, the spool moves to the right and stops the oil flowbetween 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


12When Equilibrium Has Been Reached

● The equilibrium between the force applied by pressure PA againstspool e and the force applied by spring b against spool f is whatdetermines the position at which the control piston c, pump stops.

WB146-5 110-31

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD MAIN CONTROL VALVE

12MAIN CONTROL VALVE

10-32 1 WB146-5


12

B5

A1 Arm Cylinder Rod B8 Loader Boom Cylinder Rod PA6 Solenoid Valve EV1, A1 PortA2 Swing Cylinder Head B9 Right Outrigger Cylinder Rod PA7 Solenoid Valve EV2, A2 PortA3 Loader Bucket Cylinder Head B10 Left Outrigger Cylinder Rod PA8 Loader PPC Valve, P3 PortA4 Backhoe Boom Cylinder Head LS Hydraulic Pump, PLS Port PA9 Outrigger PPC Valve, P1 PortA5 Backhoe Bucket Cylinder Rod P Hydraulic Pump, P1 Port PA10 Outrigger PPC Valve, P3 PortA6 Mp Bucket Cylinder Head D Steering Unit, P Port PB1 Left Backhoe PPC Valve Port 1A7 Jig Arm Cylinder Head DLS Steering Unit, LS Port PB2 Left Backhoe PPC Valve Port 2A8 Loader Boom Cylinder Head PP Hydraulic Pump, P1L Port PB3 Loader PPC Valve, P1 PortA9 Right Outrigger Cylinder Head T Drain PB4 Right Backhoe PPC Valve Port 1A10 Left Outrigger Cylinder Head TS Drain PB5 Right Backhoe PPC Valve Port 2B1 Arm Cylinder Head PPPC Solenoid Valve EV1, P Port PB6 Solenoid Valve EV1, B1 PortB2 Swing Cylinder Rod PA1 Left Backhoe PPC Valve Port 3 PB7 Solenoid Valve EV2, B2 PortB3 Loader Bucket Cylinder Rod PA2 Left Backhoe PPC Valve Port 4 PB8 Loader PPC Valve, P4 PortB4 Backhoe Boom Cylinder Rod PA3 Loader PPC Valve, P2 Port PB9 Outrigger PPC Valve, P1 PortB5 Backhoe Bucket Cylinder Head PA4 Right Backhoe PPC Valve Port 3 PB10 Outrigger PPC Valve, P4 PortB7 Mp Bucket Cylinder Rod PA5 Right Backhoe PPC Valve Port 4

WB146-5 110-33


12

B ACV - Jig Arm Extend 1) ASCV - Loader Bucket Curl 1( Backhoe Boom SpoolC ACV - Backhoe Bucket Curl 1! ACV - Backhoe Boom Lower 2) Loader Bucket Spoold ASCV - Backhoe Boom Raise 1@ ACV - Backhoe Bucket Dump 2! Backhoe Swing Spoole ACV - Loader Bucket Dump 1# ACV - Jig Arm Retract 2@ Backhoe Arm Spoolf ASCV - Backhoe Left Swing 1$ ACV - MP Loader Bucket Dump 2# Priority Valve Spoolg ACV - Backhoe Arm Out 1% Loader Boom Arm Spool 2$ Unloading Valveh Safety Valve 1^ Jig Arm Spool 2% LS By Pass Plugi ACV - Backhoe Arm In 1& MP Bucket Spoolj ASCV - Backhoe Right Swing 1* Backhoe Bucket SpoolACV - Anti-Cavitation Valve ASCV - Anti-Shock/Cavitation Valve

10-34 1 WB146-5


12

Unit : mm

Check Item

Spring CriteriaRemedyStandard Size Repair Limit

Free Length Installed Length Installed Load Free Length Installed Load

2^ Backhoe Arm In Spool Spring 24.2 23.7 30.4 N -- 24.3N

Replace

2& Backhoe Arm Out Spool Spring 27.2 26.7 30.38 N -- 24.3 N2* Prioroty Valve Spring 56.8 48.5 29.6 N -- 23.7 N2( Unloading Valve Spring 25.5 18.0 121.5 N -- 97.2 N3) Backhoe Swing Spool Spring 29.0 28.5 22.5 N -- 18.0 N3! Loader Bucket Spool Spring 42.3 40.5 54.9 N -- 43.9 N3@ Backhoe Boom Spool Spring 41.1 40.5 34.3 N -- 27.4 N3# Backhoe Bucket Spool Spring 41.1 40.5 34.3 N -- 27.4 N3$ MP Bucket Spool Spring 29.0 28.5 22.5 N -- 18.0 N3% Backhoe Jig Spool Spring 29.0 28.5 22.5 N -- 18.0 N3^ Loader Boom Raise Spool Spring 27.1 26.7 14.7 N -- 11.8 N3& Loader Boom Lower Spool Spring 38.7 27.6 355.7 N -- 284.5 N3* Loader Boom Float Spool Spring 19.4 19.0 14.7 N -- 11.8 N

Unit : mm

Check Item



2* PDV Tension Spring 15.4 8.0 7.44 N -- 5.96 N

Replace

2( PDV Tension Spring 31.4 21.8 63.7 N -- 51.0 N3) PDV Tension Spring 18.9 15.0 15.7 N -- 12.5 N3! PDV Tension Spring 37.1 24.0 34.3 N -- 27.4 N3@ PDV Tension Spring 20.0 15.0 4.32 N -- 3.45 N3# Check Valve Spring 27.2 21.0 4.7 N -- 3.76 N3$ Check Valve Spring 27.2 22.0 3.92 N -- 3.14 N3% Check Valve Spring 21.9 15.8 1.96 N -- 1.57 N

WB146-5 110-35


12

Pressure Reducing Valve Delivery Control Valve 1* Check ValveB Loader Boom j Backhoe Arm 1( Check ValveC Backhoe Jig Arm 1) Backhoe Swing 2) Check Valved MP Bucket 1! Loader Bucket 2! Check Valvee Backhoe Bucket 1@ Backhoe Boom 2@ Check Valvef Backhoe Boom 1# Backhoe Bucket 2# Check Valveg Loader Bucket 1$ MP Bucket 2$ Check Valveh Backhoe Swing 1% Backhoe Jig Arm 2% Check Valvei Backhoe Arm 1^ Loader Boom 2^ LS By Pass Plug

1& Main Relief Valve 2& LS, DLS Pressure Check Valve

10-36 1 WB146-5


12

b Backhoe Right Outrigger Spool e Backhoe Swing Spool H Backhoe Boom Spoolc Backhoe Left Outrigger Spool f Loader Boom Spoold Loader Bucket Spool g Backhoe Bucket Spool

Unit : mm

Check Item



i Outrigger Spool Outer Spring 18.0 17.5 39.2 N -- 31.4 NReplace

j Outrigger Spool Inner Spring 20.2 10.4 30.4 N -- 24.3 N

WB146-5 110-37


12

b PPC Maximum Pressure Valve e Blow Out Plug H Arm Spoolc Maximum Pressure Valve Spool f Unloading Valved Sequential Reducing Valve g LS By Pass Plug

Unit : mm

Check Item



i Outrigger Spool Outer Spring 18.0 17.5 39.2 N -- 31.4 N Replace

10-38 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD CLSS

12CLSSDESCRIPTIONCHARACTERISTICS

The term CLSS means Closed center Load Sensing System, whichhas the following characteristics:

● High precision control that is independent of the load applied to themovement;

● High precision control of digging action even during delicate ma-noeuvres.

● Ability to perform complex operations, guaranteed by control of oilflow 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 valveand the working equipment.

● The pump includes the main pump, the PC valve and the LS valve.

WB146-5 110-39


12OPERATING PRINCIPLESPUMPING PLATE CONTROL ANGLE

● The angle of the swash plate and the pump delivery, is controlled insuch a way that the differential pressure PLS between the deliverypressure PP of the pump and the pressure PLS at the outlet of the con-trol valve towards the actuator is maintained at a constant value. PLS= pump delivery pressure PP minus pressure PLS of delivery to the ac-tuator.

● If the differential pressure PLS becomes lower than the set pressureof the LS valve, the angle of the swash plate increases, delivery in-creasing.

● If the differential pressure PLS increases, the angle of the swash platedecreases.

10-40 1 WB146-5


12PRESSURE COMPENSATION CONTROL

● The pressure compensation valves are installed downstream from thecontrol valve in order to balance the differential pressure between theloads. When two or more movements, cylinders, are activated simulta-neously, the pressure differences P between the delivery at the con-trol valve inlet and outlets of the control valve are compensated bythese valves. This will obtain the distribution of the pump flow inproportion to the areas of passage S1 and S2 of each valve.

WB146-5 110-41



1. Unloading Valve Pressure ................................. LS + 28.02 kg/cm²

2. Main Pressure Relief Valve........................................222.14 kg/cm²

3. Safety Valve ...............................................................275.13 kg/cm²

4. Check Valve

5. Anti Shock/Cavitation Valve......................................219.08 kg/cm²



8. Pressure Compensation Valve

9. Priority Valve

10. PPC Reducing Vave

10-42 1 WB146-5


12UNLOADING VALVE

Neutral Position

FUNCTION

● When the control valve is in NEUTRAL position, pump delivery Q,resulting from the swash plate being at its min. angle, is sent into thetank circuit. When this happens, the pump's delivery pressure PP is reg-ulated at 28 kg/cm² by means of the spring c inside the valve. LS signalwith PLS pressure = 0 kg/cm² .

OPERATING

● Pump pressure PP acts on spool b on surface S1, and on surfaceS2, whereas PLS pressure acts on surface S2. Since no LS signalwith PLS pressure is generated when the control valve is in NEU-TRAL position, the only pressure acting on spool in this condition isthe pump's delivery pressure PP as regulated by spring compressionc.

● As the pump's delivery pressure PP increases and the resulting forceequals spring loading c, the spool b shifts to the right. The pump's de-livery circuit PP is then connected to the tank circuit T by means of theholes in spool. This ensures that the pump delivery pressure PP staysregulated at 28 kg/cm².

PP .................................................................................Pump circuit

PLS .................................................................Load Sensing circuit

T.....................................................................................Tank circuit

WB146-5 110-43


12Control Valve Fine Control

FUNCTION

● When the actuators' delivery needs during fine control are within thedelivery values related to the minimum angle of the swash plate, thepump's delivery pressure PP is regulated by pressure PLS at +28 kg/cm². Since the unloading valve opens when the differential pressurebetween the pump's delivery pressure PP and pressure PLS of theLS equals spring load c, 28 kg/cm², the differential pressure PLS be-comes 28 kg/cm².

OPERATING

● When fine controls are performed at the control valve, a PLS pres-sure is generated. This pressure acts on surface S3 on the right handside of the spool b. Since pressure PLS of LS is low, because thecontrol valve passage is small, the difference with the pump's deliv-ery pressure PP is great.

● When the differential pressure between the pump's delivery pressurePP and pressure PLS of the LS equals spring loading c 28 kg/cm²,the spool b shifts to the right and, in turn, the pump circuit PP con-nects to the tank circuit T.

● The pump's delivery pressure PP is regulated by the combination ofthe pressure from the spring, 28 kg/cm², and the pressure PLS of theLS, when the differential pressure PLS reaches a value of 28 kg/cm².

10-44 1 WB146-5


12Control Valve Is In Use

FUNCTION

● When the request for oil flow from the actuators exceeds the mini-mum delivery of the pump during use of the control valve, the con-nection to the tank circuit is eliminated and the entire pump deliveryQ 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 sideof the spool b. Since the control valve passage is wide, the differencebetween the pressure PLS of the LS and the pump's delivery pres-sure PP is small.

● For this reason, since the differential pressure between the pump's de-livery pressure PP and the pressure PLS of the LS fails to reach thespring loading pressure value of spring c 28 kg/cm², the spool b ispushed to the left by the spring.

● The result is that the connection between the pump delivery circuitPP and the tank circuit T is excluded and the entire pump delivery Qis sent to the actuators.

WB146-5 110-45


12LS PRESSURE

Function

● LS pressure is the actuator's pressure at control valve output. Thispressure actually reduces the pump's PP pressure ñ via the pressurecompensation group reducing valve D to the same A pressure of theactuator circuit and then sends it into the PLS circuit of the LS. Inthe outriggers control valve, the actuator's pressure A is introduceddirectly 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 fromthe notch a via the duct b. At the same time, the pressure reducingvalve D moves to the right making the pump's pressure PP drop as itflows through the bottleneck c, and causing the pressure to flow intothe circuit PLS of the LS and into the chamber of spring PLSS. Atthis point, the PLS circuit of the LS is connected to the tank circuitT by means of the by pass plug E.

● The pressure acting on the left side of the reducing valve D is pres-sure PA of the actuator, and the pressure acting on the right hand sideis the reduced pressure PP of pump delivery. The reducing valve bal-ances out when pressure PA of the actuators and pressure PLSS ofthe spring chamber are balanced. This in turn allows the pressure PP,now reduced by the bottleneck c, to be introduced into the PLS cir-cuit of the LS at the same pressure A as the actuator's circuit.

10-46 1 WB146-5


Operation w/o Outriggers

● When the spool b is operated, pump pressure PP starts flowing intothe circuit of actuator A through the duct a.

● At the same time, pressurised oil is introduced into the PLS circuit ofthe LS through holes b.

★ The outriggers circuit differs from the working equipment cir-cuit in that the operating pressure of ctuator A is introduceddirectly into the PLS circuit of the LS.

WB146-5 110-47


12LS BY PASS PLUG

Description

● The LS by pass plug unloads residual pressure from the load sens-ing's PLS circuit.

● This makes the increment rate of load sensing's PLS pressuresmoother. By eliminating oil, through the bottleneck, a loss of pres-sure is generated in the flow that is controlled by the spool, and sta-bility is increased as a result, thereby reducing the actual differentialpressure LS.

Operation

● Pressurised oil in the Load Sensing PLS circuit flows through filtera, through orifice b and into the tank circuit T.

10-48 1 WB146-5


12PRESSURE COMPENSATION VALVES

Function

● Pressure compensation occurs during simultaneous operation of sev-eral movements, specifically when the pressure of an actuator be-comes lower than the pressure of the actuator on the opposite side,and pump delivery is on the verge of being increased. In this case, theright 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 PLSpressure of the LS for the right actuator acts on chamber PLS1 ofthe spring and pushes the pressure reducing valve b and the deliverycontrol valve c to the left. The delivery control valve produces a bot-tleneck between the pump's delivery PP circuit and the PPA circuitupstream of the control valve spool. This bottleneck generates a pres-sure loss between circuits PP and PPA.

● The delivery control valve c and the pressure reducing valve b arebalanced out at a point where the differential pressure between PAand PLS, these two acting on both surfaces of the pressure reducingvalve, equals the loss of pressure between PP and PPA, these twoacting on both surfaces of the delivery control valve.

● The differential pressure between the upstream pressure PPA andthe downstream pressure of both spools in the control valves con-cerned in the movement together are equalised, and pump delivery isdistributed proportionally to the sections a that are responsible foropening the notches of each spool.

WB146-5 110-49


12PRESSURE COMPENSATION VALVE

Function

● In order to equalize the characteristics of each actuator, the pressurecompensation valve will determine the compensation characteristicsby 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 up-stream of spool ≅ load sensing PLS pressure - actuator PA pressure(= A). Delivery is distributed proportionally to the opening surfacesof the spool.

● When the ratio is > 1.00: PP - PPA > PLS - PA (= A). Deliverydistribution is lower than the proportion of the opening surfaces ofthe spool.

● When the ratio is < 1.00: PP - PPA < PLS - PA (= A). Deliverydistribution is higher than the proportion of the opening surfaces ofthe spool.

10-50 1 WB146-5


12PRIORITY VALVE

Function

● The purpose of the priority valve is to feed pressurised oil to thesteering unit and to the other actuators.

● Oil distribution is determined by the position of the spool b of thepriority valve, which is in turn determined by LS signal, pump deliv-ery, steering circuit pressure, and hydraulic circuit pressure.

● The position of the spool b is determined in such a way as to ensurethat the oil delivered to the steering unit matches the delivery needsat any time.

WB146-5 110-51


12PPC REDUCING VALVE

Function

● This valve regulates the PPC feed pressure at 30 kg/cm². When ac-tuator pressure is low, the sequential valve closes to permit an in-crease in the pump's delivery pressure PP in order to supply pressureto the servocontrols.

Neutral Condition

● The spool b of the unloading valve moves, and delivery pressure isregulated at 30 kg/cm².

● The spool c and valve d reduce the pump's delivery pressure PP to 30kg/cm². Pressure is then sent to the controls via port PC.

10-52 1 WB146-5


12Control Valve Operated

● The spool b of the unloading valve moves to the left, and the pump'sdelivery pressure exceeds the pressure of the actuator circuit f by anamount equivalent to LS differential pressure.

● If the pump's delivery pressure PP exceeds 30 kg/cm², valves c and dreduce pressure PP to 30 kg/cm². The reduced pressure is then sent tothe controls via port PC.

● When this occurs, the sequential reducing valve e stays open.

WB146-5 110-53


12

● When the pump's delivery pressure PP is lower than 30 kg/cm², the se-quential reducing valve shifts to the right, thereby reducing the flow ofthe PP pressure to the actuator circuit f.

● This generates a pressure gap between PP pressure and actuatorpressure. PP pressure is incremented in excess of 30 kg/cm² and isthen reduced to 30 kg/cm² by valves c and d to guarantee pressurefeed to the controls.

10-54 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD STEERING UNIT

12STEERING UNIT

TECHNICAL DATASteering unit type ......................................................... OSPC200LS

Normal flow ............................................................................... 20 .

OPERATION● The steering unit consists of a control valve and a rotating oil dispens-

er, and is of the hydrostatic type. When the steering wheel is turned,the control valve sends oil from the pump P2, by means of the rotat-ing oil dispenser, to one side of the steering cylinder.

● The rotating dispenser ensures that the oil volume upplied to the cyl-inder is proportionate to the angle of rotation of the steering wheel. Inthe event of malfunction, the rotating oil dispenser will function au-tomatically as a hand pump, thus guaranteeing auxiliary steering.

a Port L - To Steering Cylinder c Port T - To Hydraulic Oil Tank e Port P - From Control Valveb Port R - To Steering Cylinder d Port P - To control valve

WB146-5 110-55

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD PPC VALVE

12PPC VALVELOADER

10-56 1 WB146-5


12

OPERATION

Neutral Position

BUCKET PORTION

● Control valve ports A and B and PPC valve ports P1 and P2 areconnected to discharge chamber D by means of the calibrated hole fin spool b.

PORTS B Spool - Ports P1, P2 & P4 I Protective BootP1 To Control Valve - PB3 Port C Spool - Port P3 J Electro Detent - Ports P2 & P3P2 To Control Valve - PA3 Port D Plunger - Ports P2 & P3 1) Lower Spring RetainerP3 To Control Valve - PA8 Port E Plunger - Ports P1 & P4 1! Center Spring RetainerP4 To Control Valve - PB8 Port F Adjusting Screw 1@ Upper Spring RetainerP From EV1 Solenoid Valve G Actuator Disc 1# Mounting PlateT To Hydraulic Tank H Handle Mount 1$ Valve Housing - Three Section

Unit : mm

Check Item



1% Bottom Outer Spring - Ports P1 30.6 41.2 N

Replace

1^ Bottom Outer Spring - Ports P2 31.6 39.1 N

1& Bottom Outer Spring - Ports P3 31.9 38.5 N1* Bottom Outer Spring - Ports P4 31.6 64.9 N1( Bottom Inner Spring - Ports P1 23.6 5.3 N

2) Bottom Inner Spring - Ports P2 24.6 5.3 N2! Bottom Inner Spring - Ports P3 25.3 5.3 N2@ Bottom Inner Spring - Ports P4 24.9 5.3 N

2# Center Spring - All Ports 21 12.3 N2$ Top Spring - Ports P1 & P4 11.4 28.4 N2% Top Spring - Ports P2 & P3 11 13.7 N

WB146-5 110-57


12BOOM PORTION

● Control valve ports A and B and PPC valve ports P3 and P4 areconnected to discharge chamber D by means of the calibrated hole fin spool b.

Fine Control, Neutral Actuator

● When the disk f starts pushing down on piston e and piston 1), theretainer j moves as a result. This movement will compress thespring c which will in turn act on the spool b and push it down-wards.

● As a result of this action, the calibrated hole f will be isolated fromthe drain chamber D and at almost at the same time it will be put inconnection with the PP chamber, which is directly connected to theloader control circuit.

● Pressure in the loader control circuit will flow through the calibratedhole f and into the circuit thereby increasing the pressure in port P1/B.

● When pressure P1 increases, spool b is pushed upwards, and cali-brated hole f is connected back to discharge chamber D thereby com-pressing the spring c.

● The floating of the spool b will continue until calibrated hole f ishalfway between discharge chamber D and pressure chamber PP,until the pressure in duct P1, the pressure acting on the section ofstem b, offsets the force applied by the spring c.

● The spring c is compressed proportionally to the movement of thedisk f and pressure at P1 increases in proportion to the travel of thedisk. The equilibrium position is then kept until the position of pistone 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, isenough to counteract the force of the spring c.

● This ensures proportionality between control lever position, B/P1circuit pressure, and main control valve stem displacement.

10-58 1 WB146-5


12Fine Control, Actuator Neutral

● When the disk f is released and moved to neutral position, the pistone is pushed upwards by the spring d acting on the retainer j, andspool b is thrusted upwards both by the force of spring c and by theforce that the pressure in section B/P1 applies against the stem. Thismovement moves the calibrated hole f of spool into the dischargechamber D, thereby allowing pressure in section B/P1 to be re-leased.

● If pressure P1 drops too quickly, spool b is pushed downwards byspring c and the calibrated hole f becomes cut off from the dischargechamber D; at almost the same time, the calibrated hole f is put inconnection with pressure chamber PP and starts supplying pressureto section P1 until the pressure corresponding to the control leverposition is balanced.

● When the spool of the control valve returns, oil flows back intochamber D, through calibrated hole f, and into chamber B of the con-trol valve spool opposite the operating one. Oil flows through ductP2 and into chamber B to ensure it is filled properly.

Fine Control, Neutral Full Stroke

● When the disk f pushes down on the piston e, and the retainer jpushes down on the spool b, calibrated hole f is put in direct connec-tion with chamber PP, which is in turn connected to a constantlypressurised loader control circuit.

● Oil is then allowed to flow directly into section B/P1 thereby push-ing the stem of the main control valve to the end of its travel. Thiscauses the main control valve to send the oil contained in chamberAB towards input P2, through calibrated hole f and into reliefchamber D.

WB146-5 110-59


12Control Lever To Float Position

● If piston e and piston 1) of the spool controlling the arm, port P4,are pushed downwards by disk f, the mechanism inside the PPCvalve will start locking the spool halfway along its travel.

● If piston e² is pushed upwards and the solenoid in the PPC valve isenergized, the force generated by the solenoid will retain the piston inplace and the arm float condition will be retained, even if the lever isreleased.

● At the same time, the control valve will also be activated and retainedin the arm float position.

Control Lever From Float Position

● The disk f can be moved back to neutral position by applying a forcethat exceeds the force applied by the solenoid.

● The floating state can also be cancelled, and the lever can move backto neutral position, denergizing the solenoid.

10-60 1 WB146-5


12OUTRIGGER

PORTS P From EV1 Solenoid Valve E BootP1 To Control Valve - PA9 Port T To Hydraulic Tank F Mounting PlateP2 To Control Valve - PB9 Port B Handle Knob G Left OutriggerP3 To Control Valve - PA10 Port C Stop H Right OutriggerP4 To Control Valve - PB10 Port D Handle

WB146-5 110-61


12OPERATION

Neutral Position

● Ports A and B of the main control valve and ports P1 and P2 of theoutrigger valve are connected to the tank circuit, the spool is in neu-tral position.

10-62 1 WB146-5


12Fine Control, Neutral Actuator

● When the lever b is moved in the direction shown by the arrow, thevalves c are rotated and a passage is opened between delivery duct aand port P1, while port P2 remains conected to the tank circuit.

● Pressure at port P1 increases as the travel of lever b increases. Con-sequently, the spool of the control valve moves to the left by a dis-tance that is proportional to the travel of the lever.

WB146-5 110-63


12Full Lever, Actuator Neutral

● When lever b is moved fully to the left, the valves c are fully rotat-ed.

● Port P1 is then connected directly to delivery duct a whereas portP2 is connected to tank circuit only, and the spool of the controlvalve performs its full travel.

10-64 1 WB146-5


12BACKHOELEFT VALVE

PORTS 4 To Swing Left Valve, PA2 Port 1 To Swing Right Valve, PB2 Port1 To Arm Out Valve, PB1 Port 3 To Arm In Valve, PA1 PortT To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port

WB146-5 110-65


12RIGHT VALVE

PORTS 4 To Bucket Dump Valve, PA5 Port 1 To Bucket Curl Valve, PB5 Port1 To Boom Raise Valve, PB4 Port 3 To Boom Lower Valve, PA4 PortT To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port

10-66 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD SOLENOID VALVE

12SOLENOID VALVEHYDRAULIC CONTROLS W/O MP BUCKET

PORTS VBH To Bakchoe PPC Valves, Port P C Boom Lock Solenoid, Y95ACC Accumulator VL To Loader PPC Valves, Port P D Backhoe PPC Solenoid, Y90P1 Pressure Tap PM To Hydraulic Pump, Port PM E Loader PPC Solenoid, Y93P2 To Outrigger PPC Valve, Port P P From Control Valve, Port PPPC F Ecopower Solenoid, Y91A2 To Boom Lock Cylinder T To Hydraulic TankB2 To Rear Axle B Differential Lock Solenoid, Y94

WB146-5 110-67

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD SOLENOID VALVE

12HYDRAULIC CONTROLS WITH MP BUCKET

PORTS VL To Loader PPC Valves, Port P C Boom Lock Solenoid, Y95ACC Accumulator A1 To Control Valve, Port PA6 D Backhoe PPC Solenoid, Y90P1 Pressure Tap B1 To Control Valve, Port PB6 E Loader PPC Solenoid, Y93P2 To Outrigger PPC Valve, Port P PM To Hydraulic Pump, Port PM f Bucket Open Solenoid, Y98A2 To Boom Lock Cylinder P From Control Valve, Port PPPC g Bucket Close Solenoid, Y99B2 To Rear Axle T To Hydraulic Tank h Ecopower Solenoid, Y91VBH To Bakchoe PPC Valves, Port P B Differential Lock Solenoid, Y94

10-68 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD LOADER CYLINDERS

12LOADER CYLINDERSBOOM

CHARACTERISTICS

A Piston Rod Bushing D Piston Retaining Nut G Cylinder RodB Barrel Bushing E Four Piece Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston i Piston Stop

Unit : mm

Check ItemCriteria

RemedyStandard Size


Clearance LimitOD ID

j Piston Rod to Head 36

Replace1) Bushing in Piston Rod 67 67.25 67.2 0.05

1! Bushing in Barrel 67 67.25 67.2 0.05

Unit : mmPiston Rod Diameter ............................................................................ 50Max Cylinder Length ....................................................................... 1740Min Cylinder Length........................................................................ 1170Cylinder Barrel Bore ............................................................................ 90Piston Stroke....................................................................................... 570Rod Thread for Piston Nut ................................................................M36

WB146-5 110-69


12BUCKET

CHARACTERISTICS

A Piston Rod Bushing D Piston Retaining Nut G Cylinder RodB Barrel Bushing E Four Piece Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston

Unit : mm

Check ItemCriteria

RemedyStandard Size



i Piston Rod to Head 33

Replacej Bushing in Piston Rod 52 52.25 52.2052.30

0.05-0.05

1) Bushing in Barrel 57 57.25 57.2057.30

0.05-0.05

Unit : mmPiston Rod Diameter ............................................................................ 45Max Cylinder Length ....................................................................... 2145Min Cylinder Length........................................................................ 1400Cylinder Barrel Bore ............................................................................ 70Piston Stroke....................................................................................... 745Rod Thread for Piston Nut ................................................................M33

10-70 1 WB146-5


12MP BUCKET

CHARACTERISTICS

A Piston Rod Bushing D Cylinder Piston G Cylinder BarrelB Cylinder Rod E Four Piece Piston SealC Cylinder Head F Retaining Nut

Unit : mm

Check ItemCriteria

RemedyStandard Size



h Piston Rod to Head 40 Replace

i Bushing in Piston Rod 50 51.8852.12

52.3952.39

0.510.27

Unit : mmPiston Rod Diameter ............................................................................ 40Max Cylinder Length ......................................................................... 705Min Cylinder Length.......................................................................... 475Cylinder Barrel Bore ............................................................................ 85Piston Stroke....................................................................................... 230Rod Thread for Piston Nut ................................................................M24

WB146-5 110-71

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD BACKHOE CYLINDERS

12BACKHOE CYLINDERSBOOM

CHARACTERISTICS

A Piston Rod Bushing E Four Piece Piston Seal i Set ScrewB Barrel Bushing F Cylinder Piston j Stop PinC Cylinder Barrel G Cylinder Rod 1) Check ValveD Stop Ball H Cylinder Head 1! Check Valve Spring

Unit : mm

Check ItemCriteria

RemedyStandard Size



1@ Piston Rod to Head 43

Replace1# Bushing in Piston Rod 75

1$ Bushing in Barrel 75

Unit : mm

Check ItemSpring Criteria

RemedyStandard Size Repair LimitFree Length Installed Length Installed Load Free Length Installed Load

1% Check Valve Spring 35 Replace

Unit : mmPiston Rod Diameter ............................................................................ 60Max Cylinder Length ....................................................................... 2160Min Cylinder Length........................................................................ 1310Cylinder Barrel Bore .......................................................................... 120Piston Stroke....................................................................................... 850Rod Thread for Piston Nut ................................................................M42

10-72 1 WB146-5


12ARM

CHARACTERISTICS

A Piston Rod Bushing D Piston Retaining Nut G Cylinder RodB Barrel Bushing E Four Piece Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston i Piston Spacer

Unit : mm

Check ItemCriteria

RemedyStandard Size



j Bushing in Piston Rod 60

Replace1) Bushing in Barrel 60

1! Piston Rod 60


WB146-5 110-73


12BUCKET

CHARACTERISTICS

A Piston Rod Bushing D Piston Retaining Nut G Cylinder RodB Barrel Bushing E Four Piece Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston

Unit : mm

Check ItemCriteria

RemedyStandard Size




Replacej Bushing in Piston Rod 55

1) Bushing in Barrel 55


10-74 1 WB146-5


12TELESCOPIC ARM CYLINDER

r

CHARACTERISTICS

A Piston Rod Bushing D Wear Rings G Cylinder RodB Barrel Bushing E Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston

Unit : mm

Check ItemCriteria

RemedyStandard Size




Replacej Bushing in Piston Rod 47 47.2 47.2147.3

0.010.1

1) Bushing in Barrel 47 47.15 47.2147.3

0.010.1

Unit : mmPiston Rod Diameter ............................................................................ 40Max Cylinder Length ....................................................................... 2590Min Cylinder Length........................................................................ 1450Cylinder Barrel Bore ............................................................................ 85Piston Stroke..................................................................................... 1140Piston Rod Thread.............................................................................M30

WB146-5 110-75


12SWING

CHARACTERISTICS

A Piston Rod Bushing D Cushion Valve G Retaining ScrewB Cylinder Rod E Piston Seal H Cylinder HeadC Cylinder Barrel F Cylinder Piston

Unit : mm

Check ItemCriteria

RemedyStandard Size




Replacej Piston Rod Bushing 68

1) Inner Pivot Bushing 50

1! Outer Pivot Bushing 60

Unit : mmPiston Rod Diameter ............................................................................ 50Max Cylinder Length ...................................................................... 514.5Min Cylinder Length............................................................................. --Cylinder Barrel Bore .......................................................................... 100Piston Stroke....................................................................................... 230Piston Rod Thread.............................................................................M42

10-76 1 WB146-5


12OUTRIGGER

CHARACTERISTICS

A Piston Rod Bushing E Piston Seal i Piston Retaining NutB Barrel Bushing F Cylinder Piston j Detent BallC Cylinder Barrel G Cylinder RodD Retarder Pin H Cylinder Head

Unit : mm

Check ItemCriteria

RemedyStandard Size



1) Piston Rod to Head 50

Replace1! Bushing in Piston Rod 55

1@ Bushing in Barrel 55

Unit : mmPiston Rod Diameter ............................................................................ 50Max Cylinder Length ....................................................................... 1365Min Cylinder Length.......................................................................... 850Cylinder Barrel Bore .......................................................................... 100Piston Stroke....................................................................................... 515Piston Rod Thread.............................................................................M39

WB146-5 110-77

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD WORK EQUIPMENT

12WORK EQUIPMENTLOADER

10-78 1 WB146-5


12 Unit : mm

Check ItemCriteria

RemedyStandard Size



b Bushing in Boom 52 52.10to 52.40

52.20to 52.30

-0.20to 0.20

Replace

c Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

d Bushing in Lever 52 52.10to 52.40

52.20to 52.30

-0.20to 0.20

e Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

f Bushing in Lever 55 54.85to 55.15

55.00to 55.046

-0.15to 0.196

g Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

h Bushing in Lever and Cylinder 75 75.046to 75.076

75.00to 75.046

-0.076to 0.0

i Pin to Bushing 60 59.894to 59.94

60.137to 60.197

0.197to 0.303

J Bushing in Cylinder 57 57.2to 57.3

57.25to 57.25

-0.05to 0.05

1) Pin to Bushing 50 49.911to 49.95

50.08to 50.24

0.13to 0.329

1! Bushing in Boom 57 57.2to 57.3

57.25to 57.25

-0.05to 0.05

1@ Pin to Bushing 50 49.911to 49.95

50.08to 50.24

0.13to 0.329

1# Bushing in Cylinder 67 67.10to 67.40

67.2to 67.2

-0.20to 0.10

1$ Pin to Bushing 60 59.894to 59.94

60.13to 60.29

0.19to 0.396

WB146-5 110-79


12BACKHOE

10-80 1 WB146-5


12 Unit : mm

Check ItemCriteria

RemedyStandard Size



b Top Bushing in Main Frame 80 80.059to 80.089

80.00to 80.054

-0.005to -0.089 Replace

c Pin to Bushing 65 64.894to 64.94

65.19to 65.264

0.25to 0.37

d Inner Bushing on Cylinder Stud 50 50.034to 50.05

50.0to 50.025

-0.009to -0.05

e Outer Bushing in Bracket 75 75.043to 75.062

75.0to 75.03

-0.013to -0.062

f Inner Bushing in Outer Bushing 60 59.894to 59.94

60.06to 60.09

0.12to 0.196

g Outer Bushing in Frame to to to

h Pin to Bushing 55 54.894to 54.94

55.137to 55.197

0.257to 0.303

i Bottom Bushing in Swing Frame 80 80.059to 80.089

80.0to 80.03

-0.029to -0.089

j Pin to Bushing 65 64.894to 64.94

65.19to 65.264

0.25to 0.37

1) Pin to Rod Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

1! Pin to Head Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

1@ Bushing in Stabilizer 55 54.985to 55.015

55.0to 55.03

-0.015to 0.045

1# Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

1$ Bushing in Boom 75 75.137to 75.197

75.0to 75.03

-0.107to -0.197

1% Pin to Bushing 60 59.894to 59.94

60.137to 60.197

0.197to 0.303

1^ Bushing in Boom 60 59.95to 60.15

60.0to 60.03

-0.08to -0.15

1& Pin to Bushing 50 49.911to 49.95

50.08to 50.024

0.13to 0.329

1* Bushing in Bucket Lever 52 52.10to 52.40

52.0to 52.03

-0.07to -0.40

1( Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

2) Pin to Cylinder Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

2! Lever Bushing in Arm 52 52.2to 52.23

52.10to 52.40

-0.13to -0.20

2@ Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

2# Bushing in Bucket Lever 52 52.10to 52.40

52.0to 52.03

-0.07to -0.40

2$ Pin to Bushing 45 44.911to 44.95

45.08to 45.24

0.13to 0.329

2% Bucket Bushing in Arm 57 56.45to 58.05

57.20to 57.23

-0.85to 0.78

2^ Pin to Bushing 50 49.911to 49.95

50.08to 50.24

0.13to 0.329

2& Pin to Boom Rod Bushing 60 59.894to 59.94

60.10to 60.174

0.16to 0.28

2* Pin to Boom & Arm Head Bushing 60 59.894to 59.94

60.10to 60.174

0.16to 0.28

2( Pin to Arm Rod Bushing 50 49.911to 49.95

50.08to 50.142

0.13to 0.231

3) Pin to Bucket Head Bushing 45 44.911to 44.95

45.08to 45.142

0.13to 0.231

3! Pin to Jig Head Bushing 40 39.911to 39.95

40.05to 40.10

0.10to 0.189

3@ Pin to Jig Rod Bushing 40 39.911to 39.95

40.05to 40.10

0.10to 0.189

WB146-5 110-81


12

10-82 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD AIR CONDITIONING

12AIR CONDITIONING

A Magnetic Clutch E Safety Pressure Switch I Cab Air Circulation FanB Compressor F Expansion Valve J Air ConveyorC Condenser G EvaporatorD Dryer Filter Tank H Clutch Control Sensor

10-83 1 WB146-5

STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD AIR CONDITIONING

12The compressor b is driven directly by the engine shaft by means of abelt, and made to rotate by a pulley fitted with an electromagneticallyengaged clutch a. A thermostatic sensor h controls the engagementand disengagement of the clutch. It disengages the clutch when theevaporator reaches the lower temperature limit and engages when theevaporator reaches the upper temperature limit.

The coolant fluid, in gaseous phase is drawn into the compressor whereit is subjected to compression and an intense heating process. In theseconditions the fluid is then sent into the condenser c where, due to theheat extracted by ambient temperature air flowing over fins, it reachescondensation temperature, and passes into a high pressure liquid state.Subsequently the coolant passes into the dryer filter group d which per-forms three functions: it filters out impurities, absorbs any moisturepresent in the circuit and, finally, also functions as a reserve tank. Thecoolant in its liquid state is then transferred to the evaporator G, firstpassing through an expansion valve F. The task of this valve is the con-stant metering of the quantity of fluid in order to maintain optimumevaporation. In the evaporator the coolant fluid is subjected to expan-sion, bringing it up to the critical evaporation point at a temperature ofapproximately -8°C.

The air flow generated by the centrifugal fan I which passes throughthe evaporator G at ambient temperature is considerably warmer than -8°C. For this reason it yields heat to the coolant fluid, bringing it up toboiling point and complete evaporation. On leaving the evaporator Gthe coolant is drawn once more into the compressor d and a new cyclecommences. The yielding of heat from the atmosphere in which theevaporator is positioned leads to the condensation of the water sus-pended in the air, and hence to dehumidification. The condensate isdeposited on the evaporator fins where, if a temperature higher than 0°Cis not maintained, it freezes and inhibits the functioning of the evapora-tor. The task of keeping the temperature of the evaporator above 0°C,and thus within the optimum limits for heat exchange, is entrusted to athermostatic sensor H.

The condensate that forms on the evaporator fins G also contains dust,pollens and particles suspended in the air. Continual condensation there-fore effectively purifies the air, and the droplets of condensate are dis-charged to the exterior. A fixed quantity of anti freeze oil is alsointroduced into the circuit, with the function of lubricating all themechanical parts of the unit. A percentage of this oil circulates con-stantly throughout the unit in nebulized form, lubricating the compres-sor, pistons and bearings and the expansion valve. A pressure switch Ehas been inserted in the electrical control circuit to protect the unit in thecase of a lack of coolant fluid or if the quantity becomes insufficient dueto leakages. This switch will inhibit the engagement of the electromag-netic clutch and hence the functioning of the air conditioning unit.

WB146-5 110-84

20 TESTING, ADJUSTING ANDTROUBLESHOOTING

WB14

STANDARD VALUE TABLE ................................................................................................. 20-3ENGINE............................................................................................................................... 20-3CHASSIS ............................................................................................................................. 20-4

SPECIAL TOOLS ................................................................................................................... 20-11ENGINE SPEED ..................................................................................................................... 20-12

ENGINE WITHOUT LOAD............................................................................................. 20-12VALVE CLEARANCE........................................................................................................... 20-14AC COMPRESSOR BELT TENSION ................................................................................... 20-15BLEED AIR FROM CIRCUITS ............................................................................................. 20-16

BLEED AIR FROM CYLINDERS................................................................................... 20-16BLEED AIR FROM BRAKING CIRCUIT ...................................................................... 20-16RELEASING RESIDUAL PRESSURE............................................................................ 20-16

ACCELERATOR PEDAL AND LEVER............................................................................... 20-17ACCELERATOR PEDAL TRAVEL................................................................................ 20-17ACCELERATOR LEVER TRAVEL................................................................................ 20-18

BRAKE SYSTEM ................................................................................................................... 20-19CONTROL......................................................................................................................... 20-19ADJUSTMENT ................................................................................................................. 20-19CHECKS............................................................................................................................ 20-20

PARKING BRAKE ADJUSTMENT...................................................................................... 20-23HYDRAULIC CIRCUIT......................................................................................................... 20-24

INTRODUCTION ............................................................................................................. 20-24RELIEF VALVES ................................................................................................................... 20-26

TESTING........................................................................................................................... 20-26SETTING RELIEF VALVES ................................................................................................. 20-29

MAIN RELIEF VALVE.................................................................................................... 20-29CIRCUIT RELIEF VALVES ............................................................................................ 20-29

LS DIFFERENTIAL PRESSURE........................................................................................... 20-31CONTROL......................................................................................................................... 20-31ADJUSTMENT ................................................................................................................. 20-31

PPC SUPPLY PRESSURE...................................................................................................... 20-32CHECK.............................................................................................................................. 20-32ADJUSTMENT ................................................................................................................. 20-32

PC VALVE .............................................................................................................................. 20-33ADJUSTMENT ................................................................................................................. 20-33

STEERING CONTROL SYSTEM ......................................................................................... 20-34CONTROL......................................................................................................................... 20-34SETTING........................................................................................................................... 20-34

STEERING CYLINDER......................................................................................................... 20-35POWER TRAIN GROUP........................................................................................................ 20-36

20-16-5

TESTING AND ADJUSTING TABLE OF CONTENTS

20-2

CONVERTER OIL PRESSURE ....................................................................................... 20-36CLUTCH ENGAGEMENT PRESSURE.......................................................................... 20-36SUPPLY PRESSURE........................................................................................................ 20-37

TRANSMISSION CLUTCH FUNCTION.............................................................................. 20-38MACHINE PREPARATION ............................................................................................ 20-38CONTROL......................................................................................................................... 20-38

HYDRAULIC DRIFT ............................................................................................................. 20-39LOADER ........................................................................................................................... 20-39BACKHOE ........................................................................................................................ 20-40

AIR CONDITIONING ............................................................................................................ 20-44WORK TEMPERATURE ................................................................................................. 20-44UNIT CHECK ................................................................................................................... 20-45EMPTYING THE AC UNIT............................................................................................. 20-46

TROUBLESHOOTING GUIDE ............................................................................................. 20-47FRONT AXLE................................................................................................................... 20-47REAR AXLE ..................................................................................................................... 20-52TRANSMISSION.............................................................................................................. 20-57

WARNING! When working with others, use agreed upon signals and do not let unauthorizedpersons near the machine.

WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is removedwhen the coolant is hot, the coolant will spurt our and cause burns. Be careful when workingclose to moving parts, fan, fan belt, etc. Entanglement with moving parts can cause seriousinjury.

WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked onfirm, level ground. Check that all machine safety devices are applied and that blocks are in placeto prevent the machine from moving.

WB146-5

TESTING AND ADJUSTING STANDARD VALUE TABLE

12STANDARD VALUE TABLEENGINE

Machine Model WB146-5

Engine Model S4D102LE-2

Item Measurement Conditions Unit Standard Value Service Limit Value

Engine speeds

• High idle

RPM

2457 2407 - 2507

• Low idle 1050 1000 - 1100

• Rated speed --- ---

Intake air restric-tion

• At torque converter stall and full throttle

• At restriction indicator portmm H2O

Newelement 381

Usedelement 635

Lubricating oil pressure with SAE 15W-40 oil and coolant tempera-ture in operating range

• Minimum at low idle

kg/cm²

0.7

• Minimum at high idle 2.1

Fuel filter inlet re-striction

• Maximum restriction at high idle mm Hg

Newelement 101

Usedelement 203

Blow by pressure

• Coolant temperature in operat-ing range

• Service Tool orifice size 5.613 mm

• Full load at rated speed

mm H2O Max 101.6 Max 431.8

Exhaust back pres-sure

• Maximum at converter stall and full throttle mm Hg 76

Coolant tempera-ture

• Maximum coolant operating temperature °C 105

Valve clearances with engine cold

• Intake valvesmm

0.254

• Exhaust valves 0.504

Fan Belt Tension • Deflection when pressed with finger force of approx. 10 kg mm 10 10 - 15

WB146-5 20-3


12CHASSIS

Applicable Model WB146-5

Cat. Item Measurement Condition Unit Standard Value Permissible Value

Engi

ne sp

eed

Accelerator pedal

• 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.

Max.

rpm

2457 2407 - 2507

Min. 1050 ±50 1000 - 1100

Accelerator fuel

Max. 2200 2150 - 2250

Min. 1050 ±50 1000 - 1100

Con

trol v

alve

Bucket arm command only

l a b c l a b c

mm - 6 5.5 2 - - - -

Trav

el o

f lev

ers a

nd p

edal

s

Bucket arm control lever

• Engine stopped• Knob lever: at center and at

90° from the lever.• Value reading at end of work-

ing stroke plus half measured backlash

• Attachments on ground• Instrument metric divisions

Neutral Raise

mm

95 80 - 110

Lower 95 80 - 110

Bucket control laver Neutral Dump 95 80 - 110

Curl 95 80 - 110

Boon backhoe control Neutral Raise 50 40 - 60

Lower 50 40 - 60

Arm backhoe control lever Neutral Open 50 40 - 60

Close 50 40 - 60

Bucket backhoe control lever Neutral Open 50 40 - 60

Close 50 40 - 60

Boom swing control lever Neutral Right 50 40 - 60

Left 50 40 - 60

Outrigger control lever Neutral Up 35 25 - 45

Down 35 25 - 45

Fuel control lever Min .Max 40 30 - 50

20-4 WB146-5


12Applicable model WB146-5

Cat. Item Measurement condition Unit Standard value Permissible value

Leve

rs a

nd p

edal

s tra

vel

Accelerator pedal• Engine stopped• Knob lever: at center and at 90o from

lever.• Value reading at end of work stroke

plus half measured backlash• Attachments on ground

Min Max mm 80 65 - 95

Wheel swingRight Left

Left Rightrev

3.5

3.5

3.1 - 3.9

3.1 - 3.9

Forc

e fo

r lev

er, p

edal

and

stee

ring

whe

el o

pera

tion

Bucket arm lever

• 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

kg

1.5 1.0 - 2.0

Bucket lever 1.5 1.0 - 2.0

Boom lever 1.8 1.3 - 2.3

Arm lever 1.8 1.3 - 2.3

Bucket lever 1.3 0.8 - 1.8

Boom swing lever 1.3 0.8 - 1.8

Outrigger lever 1.5 1.0 - 2.0

Fuel lever 6.0 5.0 - 7.0

Accelerator pedal 4.0 2.5 - 5.5

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.

−−− −−− −−−

Mai

n va

lve

pres

sure

Control valve

• Engine speed: 2200 rpm• Oil temperature within operating range• Move arm cylinder to end of stroke and measure pres-

sure• Instrument: 0 to 100 kg/cm² pressure gauge mounted

on adapter at port P1C• Working mode switch: POWER

kg/cm²249 238 - 264

Steering unit • Engine speed: 1500 ±50 rpm 178 173 - 188

WB146-5 20-5


12Applicable model WB146-5


Pres

sure

s of s

econ

dary

val

ves c

ircui

ts

Bucket curled

• Engine speed: 2200 rpm• Oil temperature within operating range• Move arm cylinder to end of stroke and measure pres-

sure• Instrument: 0 to 100 kg/cm² pressure gauge mounted on

adapter at port P1C• Working mode switch: POWER

kg/cm²

274 264 - 284

Bucket dump 244 234 - 259

Bucket open close 274 264 - 284

Boom raise 351 323 - 365

Boom lower 274 264 - 284

Arm close) 274 264 - 284

Arm out 274 264 - 284

Boom swing 234 223 - 249

Bucket curl 274 264 - 284

Bucket dump −−− −−−

Extenda arm out - in −−− −−−

Hammer delivery 193 183 - 213

Steering unit safety 228 228 - 249

Engi

ne sp

eed

with

load

- C

onve

rter

With converter

• Engine speed, w/o load: 2400 ±50 rpm• Oil temperature within operating range• Machine in 3rd gear• Work brakes: engaged• Work mode switch: POWER

rpm

2175 ±50 2125 - 2225

With converter and hydraulic circuit

• 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

2075 ±50 2025 - 2125

Hydraulic circuit at Low idle

• 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

600 Min. 600

20-6 WB146-5


Applicable model WB146-5


Hyd

raul

ic d

rift w

orki

ng e

quip

men

t

Work equipment

Load

er

• 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.

mm

150 300

Boom cylinder 12 20

Bucket cylinder 35 50

Working equip-ment

Bac

khoe

• 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 10 20

Arm cylinder 10 20

Bucket cylinder 8 15

WB146-5 20-7

.

Cat. Item Measurement condition Unit Standard value Permissible valueH

ydra

ulic

drif

t wor

k eq

uipm

ent

Bac

khoe

Boom swing

• 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.

mm

15 15

Outriggers

• 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. 7 15

Cyl

inde

r Lea

kage

Load

er Boom

• 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.

cm³/min

2 each Max. 8

Bucket 1.6 each Max. 6

Bac

khoe

Boom 3.3 Max. 13.5

Arm 3 Max. 12

Bucket 2.4 Max. 9.5

Boom swing 3.2 Max. 13

Outriggers 3.3 Max.13.5

Jig arm 1.6 Max 6

20-8 WB146-5


12 Applicable model WB146-5

Cat. Item Measurement condition Unit Standard value

Permissible value

Wor

k eq

uipm

ent s

peed

Load

er b

ucke

tArm bucket

Cylinders fully out

↕

Bucket at ground level

• Engine speed: max.

• Oil tempera-ture: 45 - 55 °C

• Bucket speed button: applied

Lift

ing

sec.

3.6 3.1 - 4.1

Low

erin

g

2.6 2.2 - 3.0

Bucket

Cylinders fully out

• Engine speed: max.

• Oil tempera-ture: 45 - 55 °C

• Bucket speed button: applied

C

url

2.3 2.0 - 2.6

Dum

p

2.8 2.4 - 3.2

Bac

khoe

Boom cylinder fully in

↕

Bucket on ground

• Engine speed: 2200 rpm• Oil temperature: 45 - 55

°C• Backhoe balanced• Power mode ON

Lifti

ng

2.7 2.3 - 3.1

Low

erin

g

2.0 1.7-2.3

Arm cylinder fully in

↕

Arm cylinder fully out

• Engine speed: 2200 rpm• Oil temperature: 45 - 55 °C• Backhoe balanced• Power mode ON

Ope

ning

2.9 2.5 - 3.4

Clo

sing

3.2 2.7 - 3.7

Bucket cylinder fully in

↕

Bucket cylinder fully out

• Engine speed: 2200 rpm• Oil temperature: 45 - 55

°C• Backhoe balanced• Power mode ON

Dum

p

2 1.7 - 2.3

Cur

l

2.5 2.1 - 2.9

WB146-5 20-9



Cat. Item Measurement condition Unit Standard value

Permissi-ble value

Wor

k eq

uipm

ent s

peed

Bac

khoe

Boom swing to tight end of travel

↕

Boom swing to left end of travel

• Engine speed: 2200 rpm• Oil temperature: 45 - 55 °C• Arm vertical• Power mode ON

Rig

ht

sec

3.2 2.7 - 3.7

Left 3.2 2.7 - 3.7

Wor

k eq

uipm

ent

Tim

e la

g

Arm bucket

• Engine speed: min.• Oil temperature: 45 - 55 °C• Check item necessary to lift

bucket from level ground

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

0 Max 2

Arm

• 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.

0 Max 2

Bucket

• 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

0 Max.2

Outriggers

• 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.

0 Max. 2

20-10 WB146-5

TESTING AND ADJUSTING SPECIAL TOOLS

12SPECIAL TOOLS

Measurement Point Symbol Code Name Qty Note

Engine speed A Available Locally Multi scale tachometer 1 20 to 4000 rpm

Valve clearance B Available Locally Feeler gauge 1 –

Oil and coolant temp D 1 Available Locally Digital thermometer 1 -50 to 1200°C

Hydraulic pressure

E

1 Available Locally Pressure gauge 2 Full scale 61 kg/cm²




5

ATR800200

Servo control kit 1 0 to1020 kg/cm²6

F1 Flow meter 1 Delivery 0 to 300 l/min.

2 Pipe fitting kit 1 –

Air bleeding G ATR201490 Tank cap 1 Pump air bleeding

Hand brake Available Locally Spring dynamometer 1 Full scale 20 kgL

Air Conditioning unit M

1 Available Locally Maintenance station 1 For coolant R134a

2 Available Locally Thermometer hygrometer 1 Sampling every 15 sec

3 Available Locally Leak detector 1 For coolant R134a

WB146-5 20-11

TESTING AND ADJUSTING ENGINE SPEED

12ENGINE SPEED

★ Check the engine speed with a tachometer A under the followingconditions:

● Engine coolant temperature.........................................68 to 80 °C

● Hydraulic oil temperature............................................45 to 55 °C

ENGINE WITHOUT LOAD1. Start the engine and check:

Low idle speed without load, accelerator pedal released. High idlespeed 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 goingon with other operations.

MACHINE IN POWER MODE AT MIN

1. With the transmission in neutral, idle the engine.

2. Dump the loader bucket and hold the movement; let the engine sta-bilize and then read the engine speed.

● Normal speed....................................................................600 rpm

● Minimum speed ................................................................600 rpm

WITH CONVERTER STALLED

1. Increase speed to high idle and brake with the foot brakes.

2. Hold the brakes while simultaneously engaging 3rd gear; let the en-gine stabilize, and read the rpm value.

● Minimum speed ..............................................................2125 rpm

● Maximum speed .............................................................2225 rpm

3. Hold the machine stalled as long as necessary, in any case for notmore than 30 sec., and carry out the tests at least 15 sec one fromthe other.

CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD

1. Increase speed to high idle and brake with the working brakes.

2. While holding the brakes:

a. Engage 3rd FORWARD

b. Raise the loader and hold in this position;

c. Steer the wheels fully;

WARNING! When checking the engine speed be careful.Do not touch high temperature parts or get caught inrotating parts.

20-12 WB146-5

TESTING AND ADJUSTING ENGINE SPEED

123. In the above conditions, let the engine stabilize, then read the en-gine rpm.

● Minimum speed ..............................................................2025 rpm

● Maximum speed .............................................................2125 rpm

4. Hold the machine stalled as little as necessary, in any case for notmore than 30 sec., and carry out the tests at least 15 sec one fromthe other.

ANALYSIS

1. If readings are not within the required interval, check the ENGINESHOP MANUAL.

2. If the engine has no conditions, adjust the pump's power absorp-tion, PC valve.

WB146-5 20-13

TESTING AND ADJUSTING VALVE CLEARANCE

12VALVE CLEARANCE1. Park the machine on solid, level ground, apply the parking brake,

and remove the ignition key.

2. Remove the air filter and muffler. For details see Section 30.

3. Release the coolant temperature sensor the wiring harness.

4. Adjust the valve clearance according to the instructions provided inthe ENGINE SHOP MANUAL.

20-14 WB146-5

TESTING AND ADJUSTING AC COMPRESSOR BELT TENSION

12AC COMPRESSOR BELT TENSION1. Turn the screw B clockwise to tension the belt C.

2. Apply a 10 kg force halfway between compressor pulley E and en-gine pulley D.

3. Check the resulting arrow F.

● Normal tensioning .........................................................4 to 6 mm

● New belt................................................................................3 mm

WARNING! Check the belt tension again after 15 minutesof operation.

WB146-5 20-15

TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS

12BLEED AIR FROM CIRCUITSBLEED 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 onone cylinder at a time.

1. Start the engine and run at high idle for about 5 min. to heat the oil.

2. Reduce speed to low idle and extend and retract the 1st cylinder tobe bled several times.

★ Extend and retract pistons until about 100 mm from their endof stroke.

3. Stop the engine, check and top off the oil in the tank.

4. Bring again the engine at high idle and repeat Step 2; return the en-gine to low idle speed and make a complete travel of the cylinderuntil the pump reaches its maximum pressure.

5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oillevel in the tank.

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 intothe 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 dto catch oil.

2. Push the brake pedal to the bottom and, while keeping it pushed,loosen the bleed screw c of the braking unit that is being bled untilthe pedal reaches the end of its stroke. Keeping the pedal at the endof its stroke, tighten the bleed screw.

3. Release the brake pedal, wait for few seconds and repeat above op-erations 2 or 3 times until, oil flows out the bleeding screw withoutair bubbles.

4. Repeat the same steps for the opposite braking unit.

★ Frequently check the oil level in the tank and refill every timethe level approaches minimum.

5. After bleeding air, apply on screws c safety plugs e.

RELEASING RESIDUAL PRESSURE1. Put work attachments on level ground, stop the engine.

2. Move all control levers in all directions to fully release cylinder andPPC circuit residual pressure.

20-16 WB146-5

TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER

12ACCELERATOR 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 pedalB manually.

ACCELERATOR PEDAL TRAVEL1. Make sure that the accelerator pedal b is fully raised and the accel-

erator lever c is at minimum stroke.

2. Push the accelerator pedal until the accelerator lever f contacts theinjection pump high idle adjusting screw.

3. Adjust the end travel stopper g of the accelerator pedal b in thisposition and lock it with the nut h.

4. Release the accelerator pedal b.

WB146-5 20-17

TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER

12ACCELERATOR LEVER TRAVEL1. Remove the front mat.

2. Remove the metal sheet b closing the bottom of the cab and the up-right guard c.

3. Check that the hand accelerator d is at end of travel at MIN.

4. Loosen and unscrew the locking nut e.

5. 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 fwith the locking nut e.

8. Check the MAX speed once more by pushing the hand acceleratorto the end of travel.

20-18 WB146-5

TESTING AND ADJUSTING BRAKE SYSTEM

12BRAKE SYSTEM★ Working condition:

● Set the machine on level surface with attachments on groundlevel

● Apply the parking brake and remove the ignition key

● Pedal connection pin a inserted.

CONTROL1. Remove the floor mat.

2. Check the height A between the floor and pedal b lower edge.

3. Depress the pedals by hand and check height B to determine slackG.

★ Standard clearance .......................................................3 - 8 mm

ADJUSTMENT1. Remove the front cover c.

WB146-5 20-19


122. Loosen the nuts d and adjust the slack using the stoppers e.

3. When adjustment is complete, secure the stoppers e.

★ When the stoppers are secured, double check to ensure that slackG is within the range and that the pedals touch the stopperssimultaneously.

CHECKS★ Working condition:

● Engine stopped

● Place the vehicle on firm level ground with the equipment raisedand 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 forleaks.

LEAKAGE CHECKS

1. Disconnect the hose B from the tubes c connecting to the axlebraking groups. Plug the tube.

● Plug all open tubes and hoses to prevent contamination.

2. Connect a pressure gauge E2 to the hose B.

3. Apply the brake pedals until a pressure of 122.2 kg/cm² is reached.

★ Do not exceed the max permitted pressure .........152.8 ±5 kg/cm²

4. Hold the pressure on the pedal for at least 2 minutes and verify thatthe pressure and pedal position remain unchanged.

★ If the position of the pedal needs to be changed in order to holdthe pressure, then the loss of pressure is to be blamed on leaksinside either pump. To confirm whether this is the case, checkthe oil. If a leak condition exists, the oil will be stirred.

20-20 WB146-5


12INDIVIDUAL PUMP CHECK

1. Remove the front lining d.

2. Disconnect the pressure equalizer hose f from the brake circuitpump e that is being inspected.

3. Seal the hole of the equalizer plug A.

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 pressurizethe circuit to 122.2 kg/cm².

★ Do not exceed the max permitted pressure .........152.8 ±5 kg/cm²

WB146-5 20-21


127. Hold the pressure on the pedal for at least 2 minutes and verify thatpressure and pedal position remain unchanged.

★ If the position of the pedal needs to be changed in order to holdthe pressure, then the loss of pressure is to be blamed on leaksinside the pump, and in this case the pump needs to bechanged. To confirm whether this is the case, check the oil. If aleak condition exists, the oil will be stirred.

8. Repeat for the other pump.

BRAKE GROUP LEAKAGE

1. Disconnect the delivery hose b from the braking group that is be-ing inspected.

2. Connect a suitable tool between the delivery hose b and the brak-ing group.

★ Check to ensure that the pressure tap i is installed between thebraking group and the cut out valve j.

3. Connect a pressure gauge E2 to the tool pressure tap and open thecut out valve j.

4. Operate the brake pump and pressurize the circuit to 152.8 ±56 kg/cm² max.

5. Hold the pressure while simultaneously closing the valve j to keepthe braking circuit that is being inspected under pressure.

6. Release the brake pedal and monitor the pressure gauge E2 for twominutes.

★ If the pressure reading changes in the negative, then there is abrake piston seal failure.

7. Repeat the test for the other brake group using the same procedureas above.

8. Restore the brake circuit to operating condition.

WARNING! Further evidence of leak is an increase in thelevel of oil in the axle, and the fact that the oil is stirred asa result. Replace all sealing rings in the various axle sec-tions and completely change the lubricant.

WARNING! When checks and repair are complete, bleedthe air from the braking groups

20-22 WB146-5

TESTING AND ADJUSTING PARKING BRAKE ADJUSTMENT

12PARKING 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. Engage the parking brake.

3. Press and hold the microswitch d while engaging 2nd gear and se-lecting a direction of movement.

4. Accelerate engine gradually up to 1530 ±50 rpm.

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 whensitting in the driver’s seat.

6. Apply the parking brake and repeat the test.

★ If a normal braking condition is not achieved after 2 attemptsto adjust the lever, check control cable for slackness and brakedisc for wear and replace components as necessary.

WARNING! If machine moves, release the microswitch toreturn to N, Neutral.

WB146-5 20-23

TESTING AND ADJUSTING HYDRAULIC CIRCUIT

12HYDRAULIC CIRCUITINTRODUCTION

INTRODUCTION

1. The machine is equipped with a single control valve with hydrauli-cally controlled spools. The control valve is protected against overpressure by a main relief valve, referred to as the LS safety valve,with an adjustable pressure setting.

2. The full pump delivery supplies the control valve.

3. Pump delivery is shut by the priority valve, inside the control valve,when the steering unit is used for a steering manoeuvre.

b Engine D Hydraulic Pump f LS Safety Valvec Transmission E Steering Unit g Main Control Valve

20-24 WB146-5

TESTING AND ADJUSTING HYDRAULIC CIRCUIT


Cylinder and Movement Port kg/cm²

Hammer B0 191.02

Backhoe ArmOpen A1 275.13

Close B1 275.13

Backhoe SwingRight A2 234.37

Left B2 234.37

Loader BucketDump A3 244.56

Curl B3 275.13

Backhoe BoomLower A4 275.13

Raise A4 346.02

Backhoe BucketDump A5 ---

Curl B5 275.13

MP BucketClose A6 275.13

Open B6 275.13

Telescopic ArmOut A7 ---

In B7 ---

Loader ArmRaise A8 ---

Lower B8 ---

Right OutriggerDown A9 ---

Up B9 ---

Left OutriggerDown A10 ---

Up B10 ---

WB146-5 20-25

TESTING AND ADJUSTING RELIEF VALVES

12RELIEF VALVESTESTINGUNLOADING VALVE

1. Connect a pressure gauge E1 to the tap P1C on the pump. Startthe engine and run at low idle with all levers in neutral position.

2. In this condition, check the pressure in the hydraulic circuit.

★ Normal pressure ..............................................41.8 ±4.1 kg/cm²

★ 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 theengine, move the hand accelerator lever to full throttle and checksetting pressure for main relief valve by forcing the loader armraise movement the full travel span.

● Nominal pressure.............................................239.4 - 270 kg/cm²

★ If the main relief valve pressure does not correspond to the nominal pres-sure value, it must be reset.

SECONDARY VALVES

Boom Swing, Loader Bucket Dump and Hammer



● Hydraulic oil ................................................................. 45 - 55 °C


★ 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 theengine and bring the hand accelerator lever up to 2200 rpm.

20-26 WB146-5


122. Check pressure for each movement, with the control lever at theend of its travel and at stabilized pressure.

★ Move piston to the end of stroke to check the pressure.

Backhoe Boom Raise



● Hydraulic oil ................................................................. 45 - 55 °C


1. Set the machine with the arm in the vertical position and the bucketon level ground.

2. Stop the engine and release the residual hydraulic pressures

3. Disconnect the hose b and connect a tee c with an adapter. Con-nect a pressure gauge E3 to the adapter.

4. Start the engine, connect a 1500 kg weight to the bucket, and fullylower the outriggers.

Cylinder and movement Setting kg/cm²

Hammer 183.4 – 213.9

Boom swingRight 229.2 – 254.7

Left 229.2 – 254.7

Loader Dump 239.4 – 264.9

WB146-5 20-27


125. Slowly extend the arm and boom and take the pressure when theboom lowers.

★ Normal pressure ...........................................326 - 366.7 kg/cm²

Arm In, Loader Bucket, Backhoe Bucket, Boom Raise, And MP Bucket



● Hydraulic oil ................................................................. 45 - 55 °C


★ The pressure readings are to be operated from the same check point.

1. Connect a pressure gauge E3 to pressure tap P1C of the pump.

2. Start the engine and bring the hand accelerator lever up to 2200rpm.

3. Set the main relief valve b to a value 30.5 kg/cm² higher than themaximum pressure to be tested.

4. Check pressure for each movement, with the control lever at theend of its travel and at stabilized pressure.

★ Move piston to the end of stroke to check the pressure of theworking equipment.

★ If one movement fails to reach the setting pressure, then themalfunction is in the tested element.

★ If all movements fail to reach the setting pressure, then youneed to pressure set or replace the secondary valve.

Cylinder and movement Setting kg/cm²

Arm Close 264.9 – 285.3

Loader bucket Curl 264.9 – 285.3

Boom Left 264.9 – 285.3

Loader Dump 264.9 – 285.3

Close 264.9 – 285.3

Open 264.9 – 285.3

20-28 WB146-5

TESTING AND ADJUSTING SETTING RELIEF VALVES

12SETTING RELIEF VALVESMAIN RELIEF VALVE1. Loosen lock nut B.

2. Adjust the pressure using the screw C.

★ To increase pressure..........................................Turn Clockwise

★ To decrease pressure .............................Turn Counterclockwise

3. Lock the nut B.

★ When adjustment is complete, check the setting of the mainrelief valve using the procedures used for measurements.

CIRCUIT RELIEF VALVESARM 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.



3. Tighten the lock nut B while holding the adjusting nut c.

Lock nut ............................................................29.4 - 39.2 N•m

Lock nut B ..............................................................39 - 49 N•m

WB146-5 20-29

TESTING AND ADJUSTING SETTING RELIEF VALVES

12SWING, LOADER DUMP, HAMMER, AND BOOM RAISE

1. Loosen the lock nut B.

2. Adjust the pressure using the nut C.



3. Tighten the lock nut B while holding the adjusting nut c.

Lock nut B ..............................................................39 - 49 N•m

20-30 WB146-5

TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE

12LS DIFFERENTIAL PRESSURECONTROL★ Test conditions:

★ Engine ..............................Stopped but at working temperature.

★ Hydraulic oil ............................................................ 45 - 55 °C.

★ Machine: front equipment on the ground, parking brakeapplied and boom and arm fully extended.

★ Working mode.............................................................. POWER

1. Disconnect the hose b from the LS line, Install a tee with a pres-sure tap c and reconnect the hose b.

2. Connect a differential pressure gauge E4 to adaptor c and to tapP1C on the pump.

3. Start the engine and run it at low idle, 1050 ±50 rpm, and, withoutany lever movement, in neutral position, read the pressure.

★ Normal value......................................................41.7 ±4 kg/cm²

★ If PLS pressure is not within the permissible range, replacethe control valve unloading valve.

4. Simultaneously perform a boom raise and a backhoe bucket curlmovement to end of travel and then read the pressure.

★ Normal value......................................................28 ±1.5 kg/cm²

★ If the PLS value is not within the permissible range, set theunloading valve.

ADJUSTMENT★ If the PLS 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.



★ Each turn of the adjustment screw c will change the pressureby approx. 13.2 kg/cm².

2. Lock the nut b.

3. When adjustment is complete, check the setting of the LS valve us-ing the procedures used for checking.

Lock nut B ..............................................................39 - 49 N•m

WB146-5 20-31

TESTING AND ADJUSTING PPC SUPPLY PRESSURE

12PPC SUPPLY PRESSURECHECK★ Test conditions:

★ Engine ...............................................At operating temperature.

★ Hydraulic oil temperature ......................................... 45 - 55 °C

1. Connect a pressure gauge E1 to the pressure tap b of the solenoidvalve group c.

2. Start the engine and run the engine at low idle with all levers inneutral position.

3. Check the pressure.

★ Normal pressure ....................................................38 ±3 kg/cm²

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.



★ Each turn of the adjustment screw d will change the pressureby approx. kg/cm².

2. Lock the nut c.

Lock nut c .............................................................22 ±2.5 N•m

20-32 WB146-5

TESTING AND ADJUSTING PC VALVE

12PC VALVEADJUSTMENT★ If pump delivery and LS differential pressure are within permissible val-

ues, but you notice that the engine rpm drops as a result of a change in theload, or that working equipment is very slow, it is time to adjust the PCvalve b.

1. Loosen the nut c and turn the adjustment screw d.

★ To decrease the pump's torque absorption, turn the adjustmentscrew d counterclockwise

★ To increase the pump's torque absorption (i.e. to increase thespeed of working equipment) turn the adjustment screw d

clockwise.

★ Turn the adjustment screw by not more than 180° in relation tothe 0° line, in both directions

★ Adjustment screw position on first installation shown

2. Lock the nut c.

Lock nut c ........................................................27.4 - 34.4 N•m

WB146-5 20-33

TESTING AND ADJUSTING STEERING CONTROL SYSTEM

12STEERING CONTROL SYSTEM★ Test conditions:

● Engine........................................................Operating temperature

● Hydraulic oil ................................................................. 45 - 55 °C

CONTROL1. Connect a pressure gauge E3 to the tap P1C on the main control

valve.

2. Start the engine and bring it to idle speed 1500 ±50 rpm and carryout a total steering.

3. Force the steering wheel at the end of stroke, check pressure.

★ Normal pressure ........................................178.3 - 188.5 kg/cm²

4. Check the other steering direction.

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.



2. Stop the engine and replace the plug d; ensure that the seal f is inits proper position.

Plug c .....................................................................40 - 60 N•m

20-34 WB146-5

TESTING AND ADJUSTING STEERING CYLINDER

12STEERING 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, thenstop the engine.

2. Disconnect the supply hose c from the cylinder b on the sidewhere the rod is fully out d; plug the hose tightly.

3. Connect a provisional hose to the cylinder b to collect any leakingfluid.

4. Start the engine and operate the engine at high idle speed.

5. Force the steering wheel to the end of its travel and retain the posi-tion for 30 seconds; measure any leak during the following minute.

6. Release the steering wheel, run the engine at low idle, and then stopthe engine.

7. Check if leakage is normal.

★ Test cylinder on one side only, as there is only one gasket sepa-rating the two chambers.

8. Restore the hydraulic connection, steer the wheel several times inboth directions to remove any air from the circuit.

WB146-5 20-35

TESTING AND ADJUSTING POWER TRAIN GROUP

12POWER TRAIN GROUPThe power train group can be used to perform pressure tests on theinternal 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 raisedand safety devices engaged.

● Lower cab closeout........................................................Removed.

CONVERTER OIL PRESSURE1. Remove the plug P22 and connect the pressure gauge E6.

2. Start the engine and heat the engine and all the fluids up to workingtemperature. In particular make sure that the power train oil reachesa temperature of 80 ±5 °C.

3. With the engine at MIN, check the pressure on the pressure gaugeE6.

★ Idle pressure ............................................................3.05 kg/cm²

4. Gradually increase engine speed to 2200 rpm; take a new readingon pressure gauge E6.

★ Normal pressure ............................................3.05 - 9.17 kg/cm²

5. Bring the engine back to MIN and compare the pressure with thenormal value.

★ Min pressure ...........................................................3.05 kg/cm²

★ If the pressure value drops to below the permissible lowerlimit, the power train pump needs an replacement.

CLUTCH ENGAGEMENT PRESSURE1. Remove the plug P19 and connect the pressure gauge E6.


3. Bring the engine up to low idle and check the pressure on the pres-sure gauge E6.

★ Normal pressure ...............................................Max. 0.3 kg/cm²

Plug ................................................................................ 30 N•m

20-36 WB146-5

TESTING AND ADJUSTING POWER TRAIN GROUP

124. With the working brakes applied, select reverse gear and graduallyincrease rev speed up to MAX, then take a new reading from thepressure gauge E6.


5. Bring the engine back to MIN and the transmission in neutral posi-tion; compare the pressure with the normal value.

★ Normal pressure ...............................................Max. 0.3 kg/cm²

6. Remove the pressure adapter and replace the plug P19.

7. Repeat the same test for the FORWARD gear, reading the pressurefrom the orifice protected by the plug P18.

● If the pressures are different for the two travel directions, there isa loss of pressure on the clutch piston with lower pressure.

SUPPLY PRESSURE1. Remove the plug P21 and connect the pressure gauge E6.


3. Bring the engine up to low idle and check the pressure on the pres-sure gauge.


4. Gradually increase engine speed to 2200 rpm; take a new readingon pressure gauge.

★ Min. pressure ..........................................................14.2 kg/cm²

★ If reading drops below minimum, the transmission pump needsreplacing.

Plug ................................................................................ 30 N•m

Plug ................................................................................ 30 N•m

WB146-5 20-37

TESTING AND ADJUSTING TRANSMISSION CLUTCH FUNCTION

12TRANSMISSION CLUTCH FUNCTION★ Test conditions:

● Engine: stopped.

● Brake pedals: connected by a cotter pin.

● Machine: on solid and level ground with the equipment raisedand safety devices engaged.

★ This test must be performed after having checked the pressuresof the power train group.

MACHINE PREPARATION1. Prepare a tachometer to measure the engine rpm.

● Release the accelerator immediately and stop the engine.

● Check the wear on the brake disks and change them before com-pleting the tests.

CONTROL1. Start the engine and heat the engine and all the fluids up to working

temperature. In particular make sure that the power train oil reachesa temperature of 80 ±5 °C.

2. With the engine in idling condition, accelerate to MAX. and checkthat in this condition the revs remain within permissible limits.

3. Brake hard and bring the engine up to MAX.

4. Engage the 3rd gear while braking and accelerating as above; con-firm that engine speed decreases to the permissible range

5. Repeat this test in REVERSE gear.

★ If the revs are high than the permissible limits, the clutches areworn, and must be replaced.

WARNING! Make sure that the brake pedals are fastenedtogether by the cotter pin b. During the following tests,during the engine acceleration phase with the gearengaged, the condition of the brake disks can also bechecked If, while force is being exerted on the brake ped-als, the machine starts to travel, even slowly:

20-38 WB146-5

TESTING AND ADJUSTING HYDRAULIC DRIFT

12HYDRAULIC 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 pressure’s removed.

LOADERBOOM CIRCUIT

1. Put the machine with the bucket edge on blocks A of about 10 cmand in vertical position in relation to the ground.

2. Stop the engine and release the residual hydraulic pressures.

3. Disconnect the tubes b and c from the lift cylinders d and plugthem.

4. Plug the cylinders, base side, and apply a temporary tube, rod side,to catch any possible oil leakage.

5. Start the engine and curl the bucket until the teeth are in the tilt po-sition by 10°.

6. Stop the engine and check bucket link position for movement 5minutes.

● If the bucket link has no lowering movement, drift is due to thecontrol valve.

To test the individual cylinders, proceed as follows:

7. Move the bucket to let the edge lean on the ground in vertical posi-tion.

8. Remove from one of the cylinders the plug fitted on the cylinderbottom side in Step 4.

9. Start the engine and retract the bucket to bring the teeth in a tilt po-sition of about 10° upwards.

10. Stop the engine and check the loader position for 5 minutes.

● If the bucket link lowers, drift is due to seal leakage of theplugged cylinder.

11. Repeat Steps 8 to 10 to check the other cylinder.

WB146-5 20-39


12BUCKET CIRCUIT

1. Put the machine with the loader on level ground and bucket edgetilted 10°. Put a 1500 kg weight in the bucket.

2. Disconnect the tubes b and c from both bucket cylinders d andplug them to prevent contamination.

3. Plug the bucket cylinder, head side, and install a temporary tube onthe rod side to catch oil leakage.

4. Start the engine and raise the loader until the bucket hinge pin isaligned with boom hinge pin.

5. Stop the engine and check the position of the bucket edge for 5minutes.

● If the bucket has no movement, drift is due to the control valve.

To test the individual cylinders, proceed as follows:

6. Lower the loader to the ground.

7. Remove from one of the cylinders the plug fitted on the cylinderhead side in Step 3.

8. Start the engine and raise the loader as indicated in Step 4.

9. Stop the engine and check the position of the bucket edge for 5minutes.

● If the bucket edge turns, the drift is due to seal leakage of theplugged cylinder.

10. Repeat operation from Steps 6 to 9 to check the other cylinder.

BACKHOE★ Test condition:

★ Backhoe aligned

★ Lifted outriggers

20-40 WB146-5


12BOOM CIRCUIT

1. Set the machine with the boom in vertical position and with thebucket on level ground leaned on the side.


3. Disconnect the hoses b and c that feed cylinder d.

4. Plug the two hoses to avoid impurity inlet.

5. Plug the cylinder head side.

6. Apply a temporary tube to tube e base side to catch oil leakage.

7. Start the engine and extend the arm.

8. Stop the engine and check the boom position for 5 minutes.

● If boom has a lowering movement, drift is due to cylinder gas-kets.

● If boom has no lowering movement, drift is due to control valve.

ARM CIRCUIT

1. Set the machine with the arm fully extended and with the bucketteeth on ground.


WB146-5 20-41


123. Disconnect the tubes b and c the tubes from the arm cylinder dand 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 tubeon the base side to catch oil leakage.

5. Start the engine and raise the boom.

6. Stop the engine and check the arm position for 5 minutes.

● If the arm has a lowering movement, drift is due to the cylinderseals.

● 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 levelground on the side. Put a 450 kg weight in the bucket or fill it withdirt.


3. Disconnect the bucket cylinder d hoses b and c and plug them toavoid impurity inlet.

4. Plug the bucket cylinder port on the base side and fit a temporarytube on the rod side to catch oil leakage.

20-42 WB146-5


125. Start the engine and raise the boom.

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

● If the bucket has an movement, drift is due to the cylinder seals.

● If the bucket has no movement, drift is due to the control valve.

OUTRIGGERS CIRCUT - W/O LOCK VALVESI

1. Set the machine with the arm in vertical position and with the buck-et on level ground leaned to the side.

2. Put 20 cm blocks under the outriggers.

3. Without forcing them, lower the outriggers onto the blocks.


5. Disconnect from the cylinders b, the tubes c and d after the lockvalve e.

6. Plug the cylinders base head tube c. Add a temporary tubes to therod side d tube to catch oil leakage.

7. Start the engine, use the boom to raise the machine, and remove theblocks supporting the outriggers.

8. Lower the machine and stop the engine.

9. Check the outriggers position for 5 minutes.

● If one or both outriggers lower, drift is due to one or both cylin-ders.

● If there is no lowering, drift is due to control valve.

WB146-5 20-43

TESTING AND ADJUSTING AIR CONDITIONING

AIR CONDITIONING★ Test conditions:

● Machine on level ground with the working equipment raised andin safety conditions with the parking brake engaged

WORK TEMPERATURE1. Connect the maintenance station to the high pressure, HP, valve

and the low pressure, LP, valve.

2. Start the engine and bring it up to a speed of 1500 rpm.

3. Switch on the AC unit using the switch. Select an intermediate ven-tilation speed inside the cab.

4. Use the thermometer M2 to check that the temperature inside thecab is equal to or lower than the ambient temperature.

★ If the temperature of the cab is higher than the ambient temper-ature, open the doors and widows and wait until the cab tem-perature stabilizes at the outside value.

5. Close the doors and windows and let the AC unit operate in theseconditions for 5 to 10 minutes.

6. Use the thermometer M2 to check the temperature of the air at thecentral outlets.

★ Position the probe as close as possible to the air outlets.

7. Compare the average value of the measured temperatures using thefollowing table:

8. If the average value of the temperature measured does not fall with-in the values given in the table, it will be necessary to thoroughlycheck the unit.

Ambient temp °C 20 25 30 35

Outgoing air temp °C 6 - 8 8 - 10 8 - 12 9 - 14

20-44 WB146-5


12UNIT CHECKCheck 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 followingtable, the causes must be found by checking the high-pressure and lowpressure gauges.

The following conditions may be found:

Unit: kg/cm²

Outside Air Temp °CUnit with R134a.

Low Pressure High PressureMin Max Min Max

20 1.2 2.5 6.0 9.025 1.0 2.5 7.5 10.530 1.1 2.4 9.5 13.035 1.3 2.4 12.0 15.540 1.5 1.8 18.0 18.845 1.8 1.9 21.5 22.0

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

LP low to HP high or normal● 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.

LP normal to HP normal● 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

LP high to HP high

● 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

LP normal or low to HP low

● 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

LP roughly equal to HP● Compressor belt missing● Electromagnetic pulley that slips or does not engage● Compressor damaged

WB146-5 20-45


EMPTYING THE AC UNIT1. Connect the maintenance station M1 to service valves b and c

and follow the specific maintenance station instructions relative tothe drainage of the unit.

2. Disconnect the group to be substituted or reconditioned immediate-ly after switching off the maintenance station. Plug the removed ordisconnected connection tubes tightly and with a minimum of de-lay.

3. Carefully check the quantity of R134A recovered and contained inthe disassembled parts, since the same quantity must be replacedwhen the air conditioning unit is filled.

20-46 WB146-5

TESTING AND ADJUSTING TROUBLESHOOTING GUIDE

12TROUBLESHOOTING GUIDEFRONT AXLE

Wheel vibration; front tire resistance; half shaft breakage.CAUSES REMEDY

Incorrect installation Correct installation

Defective axle Replace the differential in case it does not survive any of the testphases

Overloading incorrect weight distribution Remove excessive weight and redistribute load following instructionsrelated to the vehicle

Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent half shaft Replace half shaft

No differential action; jamming while steering.CAUSES REMEDY



Overloading incorrect weight distribution Remove excessive weight and redistribute load following instructionsrelated to the vehicle

Steering is difficult; vehicle goes straight while trying to turn it.CAUSES REMEDY



Overloading/incorrect weight distribution Remove excessive weight and redistribute load following instructionsrelated to the vehicle

Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBroken half shaft Replace half shaft

Excess noiseCAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent or broken half shaft Replace half shaftIncorrect wheel adjustment Verify group integrity and wheel side bearingsContamination in the axle box or incorrect assemblyof parts

Look for foreign particles. Check for proper assembly of the variousparts of the axle.

WB146-5 20-47


12 Uneven wear of tiresCAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent or broken half shaft Replace half shaftBlocked 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 pneu-matic wear on sharp turns.

● Verify assembly of all components

● Reduce the steering angle to minimum and decelerate when thevehicle begins to kick.

Incorrect wheel adjustment Verify group integrity and wheel side bearings

Friction noiseCAUSES REMEDY



Bent or broken half shaft Replace half shaft

Damaged or worn out axle parts Check the condition of the ring gear, pinion gear, bearings, etc.Replace when necessary.

Contamination in the axle box or incorrect assemblyof parts


Incorrect adjustment of bevel gear set. Parts of thetrans worn out transmission gears, U joint, etc. Replace or adjust as required.

Vibration during forward drive, intermittent noiseCAUSES REMEDY




Bent half shaft Replace half shaftDifferent rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires

20-48 WB146-5


12 Noise while drivingCAUSES REMEDY

Excessive backlash between pinion and ring gear AdjustWorn out pinion and ring gear ReplaceWorn out pinion bearings ReplacePinion bearings loose AdjustExcessive axial pinion backlash AdjustWorn out differential bearings ReplaceDifferential bearings loose AdjustRing gear out of round ReplaceLow oil level Oil levelPoor or worn oil ReplaceBent half shaft Replace

Noise while driving in neutralCAUSES REMEDY

Noises coming from axle are usually heard but notloud when vehicle moves in neutral gear. Replace or adjust (see above)

Incorrect backlash between pinion and ring, soundheard while decelerating, disappears while increas-ing speed

Replace

Pinion or input flange worn out Adjust

Intermittent noiseCAUSES REMEDY

Ring gear damaged Replace bevel gear setDifferential box bolts loosened Tighten to torque

Constant noiseCAUSES REMEDY

Ring gear teeth or pinion damaged Replace bevel gear setWorn out bearings ReplacePinion spline worn out ReplaceBent half shaft Replace

Noise while steeringCAUSES REMEDY

Worn out differential gears ReplaceWorn out differential box or spider ReplaceDifferential thrust washers worn out ReplaceHalf shaft spline worn out Replace

WB146-5 20-49


12 Ring gear teeth broken at the outer sideCAUSES REMEDY

Excessive gear load compared to the one foreseenReplace bevel gear set. Carefully follow the recommended operationsfor the adjustment of the bevel gear set free backlash.Incorrect gear adjustment (excessive backlash)

Pinion nut loosened

Ring gear tooth brokenCAUSES REMEDY

Load bumpReplace bevel gear set. Adjust bevel gear set free backlashIncorrect gear adjustment insufficient backlash

Pinion nut loosened

Pinion or ring gear teeth wornCAUSES REMEDY

Insufficient lubrication; contaminated oil; improperlubrication

Replace bevel gear set. Carefully follow the recommended operationsfor the adjustment of the bevel gear set free play. Use correct lubri-cants, fill to proper levels and replace according to the recommendedschedule.Worn out pinion bearings

Overheated ring and pinion teethCAUSES REMEDY

Prolonged operation at high temperatureReplace bevel gear set. Use correct lubricants, fill to proper levels andreplace according to the recommended schedule.Insufficient lubrication; contaminated oil; improper

lubrication

Pinion teeth pittingCAUSES REMEDY

Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels andreplace according to the recommended schedule.Insufficient lubrication

Axle beam body bentCAUSES REMEDY

Vehicle overloadedReplace axle beam bodyVehicle accident

Load bump

Worn out or pitted bearingsCAUSES REMEDY

Insufficient lubrication; contaminated oil

Replace bearings, use correct lubricants, fill to proper levels andreplace according to the recommended schedule.

Excessive useNormal wear outPinion nut loosened

20-50 WB146-5


12 Oil leakage from gaskets and sealsCAUSES REMEDY

Prolonged operation at high temperatureReplace the gasket or seal and matching surface if damaged. Use cor-rect lubricants, fill to proper levels and replace according to the recom-mended schedule.

Oil gasket assembled incorrectlySeal lip damagedContaminated oil

Excessive wearing out of input flange splineCAUSES REMEDY

Exhaustive useReplace the flange. Check that the pinion spline is not excessivelyworn. Replace bevel gear set if requiredPinion nut loosened

Pinion axle backlash

Fatigue failure of pinion teethCAUSES REMEDY

Exhaustive useReplace bevel gear set

Continuous overload

Pinion and ring teeth breakageCAUSES REMEDY

Crash load of differential components Check and/or replace other differential components

Side gear spline worn outCAUSES REMEDY

Excessive use Replace differential gear group. Replace half shaft if required

Thrust washer surface worn out or scratchedCAUSES REMEDY

Insufficient lubrication; contaminated oil, improperlubrication

Use correct lubricants, fill to proper levels and replace according to therecommended schedule. Replace all scratched washers and those with0.1 mm smaller thickness than the new ones

Inner diameter of tapered roller bearing worn outCAUSES REMEDY

Excessive use axial pinion Replace bearing. Check pinion axial backlash Use correct lubricants,fill to proper levels and replace according to the recommended sched-ule.

Excessive pinion axial backlashInsufficient lubrication; contaminated oil

Bent or broken half shaft or half shaft broken at wheel sideCAUSES REMEDY

Vehicle intensively operated or overloadedReplace. Check that wheel support is not worn out or incorrectlyadjusted.Wheel support loosened

Beam body bent

WB146-5 20-51


12REAR AXLE

Wheel vibration; front tire resistance; half shaft breakage.CAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent half shaft Replace half shaft

Steering is difficult; vehicle goes straight while trying to turn it.CAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBroken half shaft Replace half shaft

No differential action; jamming while steering.CAUSES REMEDY



Broken half shaft Replace half shaftBent half shaft Replace half shaft

Excess noiseCAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent or broken half shaft Replace half shaftIncorrect wheel adjustment Verify group integrity and wheel side bearingsContamination in the axle box or incorrect assemblyof parts


20-52 WB146-5


12 Uneven wear of tiresCAUSES REMEDY




Different rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tiresBent or broken half shaft Replace half shaftBlocked half shaft:● Abnormal functioning of the differential or break-

age/blockage of control device.● Vehicles with wide steering angle may proceed

with kicks, have steering difficulty or cause pneu-matic wear on sharp turns.

● Verify assembly of all components

● Reduce the steering angle to minimum and decelerate when thevehicle begins to kick.

Incorrect wheel adjustment Verify group integrity and wheel side bearings

Friction noiseCAUSES REMEDY



Bent or broken half shaft Replace half shaft

Damaged or worn out axle parts Check the condition of the ring gear, pinion gear, bearings, etc.Replace when necessary.

Contamination in the axle box or incorrect assemblyof parts


Incorrect adjustment of bevel gear set. Parts of thetrans worn out transmission gears, U joint, etc. Replace or adjust as required.

Vibration during forward drive, intermittent noiseCAUSES REMEDY




Bent half shaft Replace half shaftDifferent rotation radius of the tires Replace the tire or adjust pressure to have the same radius on both tires

WB146-5 20-53


12 Noise while drivingCAUSES REMEDY

Excessive backlash between pinion and ring gear AdjustWorn out pinion and ring gear ReplaceWorn out pinion bearings ReplacePinion bearings loose AdjustExcessive axial pinion backlash AdjustWorn out differential bearings ReplaceDifferential bearings loose AdjustRing gear out of round ReplaceLow oil level Oil levelPoor or worn oil ReplaceBent half shaft Replace

Noise while driving in neutralCAUSES REMEDY

Noises coming from axle are usually heard but notloud when vehicle moves in neutral gear. Replace or adjust (see above)

Incorrect backlash between pinion and ring soundheard while decelerating, disappears while increas-ing speed

Replace

Pinion or input flange worn out Adjust

Intermittent noiseCAUSES REMEDY

Ring gear damaged Replace bevel gear setDifferential box bolts loosened Tighten to torque

Constant noiseCAUSES REMEDY

Ring gear teeth or pinion damaged Replace bevel gear setWorn out bearings ReplacePinion spline worn out ReplaceBent half shaft Replace

Noise while steeringCAUSES REMEDY

Worn out differential gears ReplaceWorn out differential box or spider ReplaceDifferential thrust washers worn out ReplaceHalf shaft spline worn out Replace

20-54 WB146-5


12 Ring gear teeth broken at the outer sideCAUSES REMEDY

Excessive gear load compared to the one foreseenReplace bevel gear set. Carefully follow the recommended operationsfor the adjustment of the bevel gear set free backlash.Incorrect gear adjustment, excessive backlash

Pinion nut loosened

Ring gear tooth brokenCAUSES REMEDY

Load bumpReplace bevel gear set. Adjust bevel gear set free backlash.Incorrect gear adjustment, insufficient backlash

Pinion nut loosened

Pinion or ring gear teeth wornCAUSES REMEDY

Insufficient lubrication; contaminated oil; improperlubrication

Replace bevel gear set. Carefully follow the recommended operationsfor the adjustment of the bevel gear set free play. Use correct lubri-cants, fill to proper levels and replace according to the recommendedschedule.Worn out pinion bearings

Overheated ring and pinion teethCAUSES REMEDY

Prolonged operation at high temperatureReplace bevel gear set. Use correct lubricants, fill to proper levels andreplace according to the recommended schedule.Insufficient lubrication; contaminated oil; improper

lubrication

Pinion teeth pittingCAUSES REMEDY

Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels andreplace according to the recommended schedule.Insufficient lubrication

Axle beam body bentCAUSES REMEDY

Vehicle overloadedReplace axle beam bodyVehicle accident

Load bump

Worn out or pitted bearingsCAUSES REMEDY

Insufficient lubrication; contaminated oil

Replace bearings. Use correct lubricants, fill to proper levels andreplace according to the recommended schedule.

Excessive useNormal wear outPinion nut loosened

WB146-5 20-55


12 Oil leakage from gaskets and sealsCAUSES REMEDY

Prolonged operation at high temperatureReplace the gasket or seal and matching surface if damaged. Use cor-rect lubricants, fill to proper levels and replace according to the recom-mended schedule.

Oil gasket assembled incorrectlySeal lip damagedContaminated oil

Excessive wearing out of input flange splineCAUSES REMEDY

Exhaustive useReplace the flange. Check that the pinion spline is not excessivelyworn. Replace bevel gear set if requiredPinion nut loosened

Pinion axle backlash

Fatigue failure of pinion teethCAUSES REMEDY

Exhaustive useReplace bevel gear set

Continuous overload

Pinion and ring teeth breakageCAUSES REMEDY

Crash load of differential components Check and/or replace other differential components

Side gear spline worn outCAUSES REMEDY

Excessive use Replace differential gear group. Replace half shaft if required

Thrust washer surface worn out or scratchedCAUSES REMEDY

Lack of lubrication; contaminated oil, improperlubrication

Use correct lubricants, fill to proper levels and replace according to therecommended schedule. Replace all scratched washers and those with0.1 mm smaller thickness than the new ones

Inner diameter of tapered roller bearing worn outCAUSES REMEDY

Excessive use axial pinion Replace bearing. Check pinion axial backlash. Use correct lubricants,fill to proper levels and replace according to the recommended sched-ule.

Excessive pinion axial backlashInsufficient lubrication; contaminated oil

Bent or broken half shaft or half shaft broken at wheel sideCAUSES REMEDY

Vehicle intensively operated or overloadedReplace. Check that wheel support is not worn out or incorrectlyadjusted.Wheel support loosened

Beam body bent

20-56 WB146-5


12TRANSMISSION

Vehicle does not moveCAUSES REMEDY

Faulty supply to solenoid valves Check/ReplaceDamaged wiring connections between transmissionand vehicle Repair/Replace

Oxidized contacts in electrical wiring CleanBreak in electrical cable ReplaceDamaged solenoids ReplaceDamaged sensors ReplaceShort circuits or open connections Check/replace fusesIncorrect oil level Fill oil to proper levelCheck for leaks RepairBlocked intake filter CleanDamaged oil pump ReplaceDamaged oil pump relief valve Replace oil pumpBlocked/damaged transmission filter ReplaceDamaged/jammed control valve ReplaceDamaged converter ReplaceOil temperature below 0°C Wait for oil to reach operating temperature (stall test)Damaged rotary seals ReplaceDamaged synchronizers ReplaceBlocked reverse lever RepairWorn clutch Replace/repair clutchNo drive transmission, broken gears, shafts, bear-ings, etc. Check/Repair/Replace

Vehicle has reduced power transmissionCAUSES REMEDY

Incorrect oil temperature Wait for oil to reach operating temperature (stall test)Transmission oil overheating See “Overheating” Incorrect operating pressure Check hydraulic circuit and replace, oil pump, filters, control valveDamaged converter ReplaceIncorrect oil level Fill oil to proper levelWorn clutch Replace/Repair4WD clutch failure Repair/Replace 4WD shaft groupOverheating solenoids ReplaceDamaged transmission and vehicle wiring connec-tions Repair/Replace

Damaged sensors Replace

WB146-5 20-57


12 OverheatingCAUSES REMEDY

Damaged hydraulic cooling system RepairDirty heat exchanger CleanParking brake inadvertently activated ReleaseExcessive dirt on axle wheel hubs CleanSeizing, broken gears, shafts, bearings, etc. Check/Repair/ReplaceBraking force outside transmission: irregular axleoperation Check/Repair axle

Clutch plate drag Repair/ReplaceDamaged converter ReplaceDamaged oil thermostat ReplaceIncorrect oil level Add oilWorn oil pump Replace

Wheels rotate when vehicle is raisedCAUSES REMEDY

Clutch plate drag Repair/ReplaceLow oil temperature (high oil viscosity) Wail for oil to reach operating temperature (stall test)Incorrect oil specifications Replace oil and filtersDamaged control valve ReplaceFaulty reverser locking Repair/Replace

NoiseCAUSES REMEDY

Damaged converter ReplaceDamaged oil pump ReplaceAeration/Cavitation Check oil levelSeizing (broken gears, shafts, bearings, etc.) Check/Repair/ReplaceWorn clutch plates Replace

Irregular actuationCAUSES REMEDY

Damaged control valve ReplaceElectrical system fault Repair/ReplaceWorn clutch plates ReplaceDamaged converter ReplaceLow oil temperature (high oil viscosity) Wait for oil to reach operating temperature (stall test)Overheating See “Overheating”Damaged hydraulic system Repair/Replace

20-58 WB146-5


12 Gear remains engagedCAUSES REMEDY

Damaged/jammed shuttle shaft lever Repair/ReplaceElectrical system fault Repair/ReplaceDamaged control valve ReplaceDamaged hydraulic system Repair/ReplaceDamaged clutch Repair/ReplaceDamaged gear lever rod ReplaceDamaged synchronizer Replace

No 4WD power transmissionCAUSES REMEDY

Damaged 4WD clutch ReplaceHydraulic system fault Repair/ReplaceDamaged control valve ReplaceFaulty brake sensor Check/ReplaceElectrical system fault Repair/Replace

Gear shift will not engageCAUSES REMEDY

Damaged shifter ReplaceDamaged synchronizer Replace

WB146-5 20-59


12

20-60 WB146-5

90 OTHERS

WB14

HYDRAULIC CIRCUIT.......................................................................................................... 90-31 OF 4 .................................................................................................................................... 90-32 OF 4 .................................................................................................................................... 90-53 OF 4 .................................................................................................................................... 90-74 OF 4 .................................................................................................................................... 90-9

ELECTRICAL SCHEMATIC................................................................................................ 90-11WIRING - 1 OF 7 ................................................................................................................ 90-11WIRING - 2 OF 7 ................................................................................................................ 90-13WIRING - 3 OF 7 ................................................................................................................ 90-15WIRING - 4 OF 7 ................................................................................................................ 90-17WIRING - 5 OF 7 ................................................................................................................ 90-19WIRING - 6 OF 7 ................................................................................................................ 90-21WIRING - 7 OF 7 ................................................................................................................ 90-23LEGEND FOR WIRING SCHEMATIC............................................................................. 90-25FUSE AND RELAY PANEL.............................................................................................. 90-27

90-16-5

OTHERS

12

90-2 WB146-5

OTHERS HYDRAULIC CIRCUIT

90-3
WB146-5
12HYDRAULIC CIRCUIT1 OF 4


WB146-5
90-4
12


90-5
WB146-5
122 OF 4


WB146-5
90-6
12


90-7
WB146-5
123 OF 4


WB146-5
90-8
12


90-9
WB146-5
124 OF 4


WB146-5
90-10
12

OTHERS ELECTRICAL SCHEMATIC

90-11
WB146-5
12ELECTRICAL SCHEMATICWIRING - 1 OF 7


WB146-5
90-12
12


90-13
WB146-5
12WIRING - 2 OF 7


WB146-5
90-14
12


90-15
WB146-5
12WIRING - 3 OF 7


WB146-5
90-16
12


90-17
WB146-5
12WIRING - 4 OF 7


WB146-5
90-18
12


90-19
WB146-5
12WIRING - 5 OF 7


WB146-5
90-20
12


90-21
WB146-5
12WIRING - 6 OF 7


WB146-5
90-22
12


90-23
WB146-5
12WIRING - 7 OF 7


WB146-5
90-24
12


90-25

DESCRIPTION ITEM DESCRIPTIONAC Harness ConnectorHeater ConnectorCab Harness ConnectorDriver Site Harness ConnectorMotor Harness Connector

s Driver Site Harness ConnectorCab Harness ConnectorCab Harness Connector

p Switch Harness Connectors Cab Harness Connectors Work Light Harness Connector

Cigar LighterFloat SolenoidReturn To Dig SolenoidEMPI SolenoidRear PPC SolenoidEC Power SolenoidBack Up AlarmPPC SolenoidDifferential Lock SolenoidBoom Unlock SolenoidSolenoidMP Bucket Close SolenoidMP Bucket Open Solenoid4WD SolenoidForward Speed Solenoid

WB146-5

12LEGEND FOR WIRING SCHEMATIC

ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEMA6 Machine Function Unit F19 Low Beam Light 15A Fuse S24 Starting Switch X27.sB13 Return To Dig Sensor F20 Main Beam Light 15A Fuse S40 Seat Switch X28.sB59 Brake Oil Low Level Switch F21 Return To Dig Sensor 10A Fuse S41 Rear Horn Switch X44.pB97 Rear Horn Switch F22 EC Power 7.5A Fuse S46 Parking Brake Switch X44.sB105 Transmission Oil Temperature Sender F23 Steering Unit 10A Fuse S53 Stop Light Switch X65.pB111 Fuel Level Sender F24 Flasher 7.5A Fuse S54 Stop 4WD Switch X128.B112 Thermistor F25 Reverse Buzzer Switch 10A Fuse S57 Steering Column Gear Shift X140B113 Air Filter Switch F27 General 175A Fuse S60 Steering Column Light Switch X142B115 Engine Oil Pressure Switch S80 Ride Control Switch X166.B121 Horn G1 Battery S81 Boom Unlock Switch X166.

G118 Starter Motor S83 EC Power Switch X177.E136 Right Rear Wok Light G119 Alternator S84 EMPI Solenoid Valve SwitchE138 Left Rear Work Light S85 Rear Horn Switch X30E143 Right Front Wok Light H17 Buzzer S86 General Light Switch Y48E146 Left Front Work Light S87 4WD Switch Y49E147 Left Indicator K1 Starter Lock Out Unit S88 PPC Switch Y60E148 Beacon Lamp K2 Flasher S89 Warning Switch Y90E151 Right Indicator K3 Low Beam Light Relay S97 Rear Horn Switch Y91E152 Cab Light K4 Main Beam Light Relay S104 4th Speed Switch Y92E154 Rear Left Light K5 Front Horn Relay S107 Declutch Switch Y93E155 Left Indicator Light K6 Return To Dig Solenoid Relay S167 Beacon Light Switch Y94E155 Right Indicator Light K7 Stop Light Relay S168 Front Working Light Switch Y95E156 Rear Right Light K8 Starter Relay S169 Rear Working Light Switch Y96E400 Right Front Work Light K9 Forward Speed Relay Y98E401 Left Front Work Light K10 Reverse Speed Relay X1.s Unit Connector Y99E402 Left Rear Work Light K11 Declutch Relay X2.s Unit Connector Y106E403 Right Rear Work Light K45 Reheating Relay X3.s Unit Connector Y108

K56 Safety Start Relay X4.s Unit ConnectorF1 Front Work Light 15A Fuse K61 Services Relay X5.s Unit ConnectorF2 Rear Work Light 15A Fuse K111 X7.p Motor Harness ConnectorF3 Right Position Light 3a Fuse X7.s Driver Site Harness ConnectorF4 Left Position Light 3a Fuse M42 Rear Window Wiper X8.p Gear Harness ConnectorF5 Horn 10A Fuse M55 Window Washer Pump X8.s Driver Site Harness ConnectorF6 Rear Work Light 15A Fuse M58 Front Window Wiper X9.p Front Dashboard Harness ConnectorF7 Front Window Washer 7.5A Fuse M116 AC Compressor Clutch X9.s Driver Site Harness ConnectorF8 Stop Light Switch 7.5A Fuse X10.p Front Dashboard Harness ConnectorF9 Front Work Light 15A Fuse P43 Instrument Panel X10.s Driver Site Harness ConnectorF10 Front Wiper 10A Fuse P63 Front Control Panel X11.p Solenoid Valve Harness ConnectorF11 Optional 7.5A Fuse X11.s Driver Site Harness ConnectorF12 Instruments And Buzzer 5A Fuse R114 Preheater X12.p Chassis Harness ConnectorF13 Lever Grip 10A Fuse X12.s Driver Site Harness ConnectorF14 Light And Optional Switch 10A Fuse S2 EC Power Switch Solenoid Valve X15.p Optional Harness ConnectorF15 Safety Starter 10A Fuse S3 MP Bucket Close Switch X25.p Switch Panel Harness ConnectorF16 Beacon Light 10A Fuse S4 Declutch Switch X25.s Driver Site Harness ConnectorF17 Warning Switch 10A Fuse S5 MP Bucket Open Switch X26.p Switch Panel Harness ConnectorF18 Cab Light And Cigar Lighter 10A Fuse S6 Differential Locking Switch X26.s Driver Site Harness Connector


WB146-5
90-26
12


90-27

TIER I ENGINEPosition DescriptionF1 A 15A Light Blue for Low BeamF1 B 3A Violet for Parking LightsF1 C 3A Violet for Parking LightsF2 A 10A Red for LighterF2 B 7.5A Brown for Dome Light RadioF2 C 10A Red for Emergency Power SupplyF3 A 7.5A Brown for Start EnableF3 B 7.5A Brown for Instruments Switch LightsF3 C 7.5A Brown for OPT SolenoidF4 A 7.5A Brown for Diff Lock Solenoid ValveF4 B 10A Red for Direction SelectorF4 C 15A Light Blue for High BeamF5 A 15A Light Blue for HeaterF5 B 15A Light Blue for Rear Work LightF5 C 15A Light Blue for Front Work LightF6 A 15A Light Blue for Wiper and BeaconF6 B 7.5A Brown for Dimmer Switch Horn RelayF6 C 10A Red for Directional IndicatorsF7 A 7.5A Brown for MonitorF7 B 10A Red for HornF7 C 7.5A Brown for Alt Excitation Stop Solenoid

K1 Forward Gear RelayK2 Reverse Gear RelayK3 Four Wheel Drive RelayK4 ···K5 Low Beam RelayK6 High Beam RelayK7 Direction Selector Power Supply RelayK8 Horn RelayK9 Turn Indicator RelayK10 Flasher RelayK11 4th Gear Signaling Relay

WB146-5

12FUSE AND RELAY PANEL


WB146-5
90-28
12

shop manual 146-5[1]

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