Komatsu WP142-5 Backhoe Loader Shop Manual CEBM018903

Description

• Model List:
  • WP142-5 Backhoe Loader

• 0.1. GENERAL
• 0.2. HOW TO READ THE SHOP MANUAL
• 0.2.1. VOLUMES
• 0.2.2. DISTRIBUTION AND UPDATING
• 0.2.3. FILING METHOD
• 0.2.4. REVISED EDITION MARK
• 0.2.5. REVISIONS
• 0.2.6. SYMBOLS
• 0.3. HOISTING INSTRUCTIONS
• 0.3.1. HOISTING
• 0.3.2. WIRE ROPES
• 0.4. EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
• 0.5. COATING MATERIALS
• 0.6. STANDARD TIGHTENING TORQUE
• 0.6.1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
• 0.6.2. TIGHTENING TORQUE OF HOSE NUTS
• 0.6.3. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
• 0.6.4. TIGHTENING TORQUE FOR FLARED NUTS
• 0.7. CONNECTING PUSHPULL TYPE COUPLER.
• 0.8. CONVERSION TABLES
• 0.8.1. METHOD OF USING THE CONVERSION TABLE
• 1. GENERAL
• 1.1. SPECIFICATION DRAWING
• 1.1.1. SPECIFICATIONS
• 1.1.2. BACKHOE ARM
• 1.2. MACHINE SYSTEMS SPECIFICATIONS
• 1.2.1. BACKHOE ARM
• 1.2.2. ENGINE
• 1.2.3. ELECTRICAL SYSTEM
• 1.2.4. SERVICE REFILL CAPACITIES
• 1.2.5. TRANSMISSION
• 1.2.6. TOTAL MASS
• 1.2.7. STANDARD BUCKET CAPACITY
• 1.2.8. LOADER
• 1.2.9. TIRE PRESSURE
• 1.3. WEIGHT TABLE
• 1.4. FUEL, COOLANT, AND LUBRICANTS
• 1.4.1. PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE
• 1.4.2. GREASE
• 1.4.3. FUEL AND ENGINE OIL REMARKS
• 1.5. HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS
• 1.6. LUBRICATION DIAGRAMS
• 1.6.1. GENERAL VIEW
• 2. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 2.1. POWER TRAIN
• 2.1.1. SYSTEM OVERVIEW
• 2.1.2. WHEEL DRIVE SYSTEM
• 2.1.3. TRANSMISSION COMPONENTS
• 2.1.4. CONVERTER AND TRANSMISSION CIRCUIT DIAGRAM
• 2.2. TRANSMISSION
• 2.2.1. CASE
• 2.2.2. TRANSMISSION INTERNAL VIEW
• 2.2.3. GEAR SHIFTER AND FILTERING SYSTEM
• 2.2.4. CLUTCH PACKS AND DRIVEN GEAR SET
• 2.2.5. WHEEL DRIVE SHAFT
• 2.2.6. CONTROL VALVE BLOCK
• 2.2.7. TRANSMISSION CASE SPECIFICATIONS
• 2.2.8. INTERNAL SPECIFICATIONS
• 2.2.9. GEAR SHIFTER AND COMPONENTS SPECIFICATIONS
• 2.3. FRONT AXLE ASSEMBLY
• 2.3.1. DIFFERENTIAL
• 2.3.2. FINAL DRIVE END
• 2.3.3. STEERING CYLINDER
• 2.3.4. AXLE CARRIER SPECIFICATIONS
• 2.3.5. AXLE END SPECIFICATIONS
• 2.3.6. STEERING UNIT CYLINDER SPECIFICATIONS
• 2.4. REAR AXLE ASSEMBLY
• 2.4.1. DIFFERENTIAL
• 2.4.2. AXLE END
• 2.4.3. AXLE CARRIER SPECIFICATIONS
• 2.4.4. AXLE END SPECIFICATIONS
• 2.5. REAR BRAKES
• 2.5.1. BRAKE SPECIFICATIONS
• 2.6. DIFFERENTIAL LOCK
• 2.6.1. LOCK SPECIFICATIONS
• 2.7. HYDRAULIC SYSTEM
• 2.7.1. HYDRAULIC CIRCUIT DIAGRAM
• 2.7.2. HYDRAULIC PUMP
• 2.7.3. LOADER 3 SPOOL VALVE
• 2.7.4. LOADER SPOOL VIEW
• 2.7.5. BACKHOE CONTROL VALVE
• 2.7.6. BACKHOE SPOOL VIEW
• 2.8. SOLENOID VALVE
• 2.8.1. (ST1 VALVE LOCK DIFFERENTIAL LOCK BACKHOE BOOM LOCK)
• 2.9. MASTER CYLINDER (BRAKES)
• 2.9.1. SPECIFICATIONS
• 2.10. LOADER CYLINDERS
• 2.10.1. ARM CYLINDERS
• 2.10.2. BUCKET CYLINDER
• 2.10.3. ARM CYLINDER TOLERANCE
• 2.10.4. BUCKET CYLINDER TOLERANCE
• 2.11. BACKHOE CYLINDERS
• 2.11.1. BOOM cylinder
• 2.11.2. ARM cylinder
• 2.11.3. BUCKET SPECIFICATIONS
• 2.11.4. OUTRIGGER SPECIFICATIONS
• 2.11.5. BOOM SWING SPECIFICATIONS
• 2.11.6. BOOM CYLINDER TOLERANCE
• 2.11.7. ARM CYLINDER TOLERANCE
• 2.11.8. BUCKET CYLINDER TOLERANCE
• 2.11.9. BOOM SWING CYLINDER TOLERANCE
• 2.11.10. OUTRIGGERS TOLERANCE
• 2.12. PIN AND BUSHING CLEARANCES
• 2.12.1. LOADER WORK EQUIPMENT
• 2.12.2. BACKHOE WORK EQUIPMENT
• 3. STANDARD VALUE TABLES
• 3.1. STANDARD VALUE TABLE FOR ENGINE
• 3.2. STANDARD VALUE TABLE FOR CHASSIS
• 4. TESTING AND ADJUSTING
• 4.1. BLEED AIR FROM CIRCUITS
• 4.1.1. BLEED AIR FROM BRAKING CIRCUIT
• 4.1.2. RELEASING RESIDUAL PRESSURE
• 4.2. ACCELERATOR PEDAL AND THROTTLE LEVER
• 4.2.1. ACCELERATOR PEDAL TRAVEL
• 4.2.2. THROTTLE LEVER TRAVEL
• 4.3. PARKING BRAKE ADJUSTMENT
• 4.4. HYDRAULIC CIRCUIT
• 4.4.1. INTRODUCTION
• 4.4.2. MAIN RELIEF VALVE
• 4.4.3. CHECKING LOAD SENSING SIGNAL (LS VALVE)
• 4.4.4. CHECKING COMPENSATED FLOW VALVE
• 4.4.5. OPERATION OF THE PRIORITY VALVE
• 4.4.6. TESTING AND SETTING STEERING SYSTEM PRESSURE
• 4.4.7. CHECKING FOR LEAKS IN THE STEERING CYLINDERS
• 4.5. POWER TRAIN
• 4.5.1. CONVERTER OIL PRESSURE
• 4.5.2. CLUTCH ENGAGEMENT PRESSURE
• 4.5.3. CLUTCH FUNCTION
• 4.6. HYDRAULIC DRIFT
• 5. TROUBLESHOOTING
• 5.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.3.1. PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT
• 5.3.2. HANDLING ELECTRONIC CONTROL UNIT
• 5.3.3. POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS
• 5.3.4. HOW TO READ ELECTRIC WIRE CODE
• 5.3.5. CLASSIFICATION BY COLOR AND CODE
• 5.3.6. POINTS TO REMEMBER WHEN LHANDLING HUYDRAULIC EQUIPMENT
• 5.4. CHECKS BEFORE TROUBLESHOOTING
• 5.5. TROUBLESHOOTING GUIDE
• 5.5.1. FRONT AXLE
• 5.5.2. REAR AXLE
• 5.5.3. TRANSMISSION
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. HOW TO USE THIS MANUAL
• 6.1.1. REMOVAL AND INSTALLATION OF COMPONENTS
• 6.1.2. OVERHAUL OF COMPONENTS
• 6.2. PRECAUTIONS WHEN CARRYING OUT AN OPERATION
• 6.3. SPECIAL TOOL LIST.
• 6.4. CONNECTOR REPAIR PROCEDURES
• 6.4.1. CONTACT TERMINAL REMOVAL (HD30 TYPE)
• 6.4.2. CRIMPING CONTACT TERMINAL (HD30 TYPE)
• 6.4.3. INSERTION OF CONTACT TERMINAL (HD30 TYPE)
• 6.4.4. CONTACT TERMINAL REMOVAL (DT TYPE)
• 6.4.5. CRIMPING CONTACT TERMINAL (DT TYPE)
• 6.4.6. INSERTION OF CONTACT TERMINAL (DT TYPE)
• 6.4.7. STRIPPING INSULATION
• 6.5. SIDE PANEL AND INSTRUMENT GROUP
• 6.5.1. LOWER ELECTRICAL GROUP
• 6.5.2. DASH BEZEL AND COVER
• 6.6. STEERING AND FRONT DASH ASSEMBLY
• 6.6.1. STEERING WHEEL
• 6.6.2. FRONT DASH ASSEMBLY
• 6.6.3. BLEED AIR FROM BRAKING CIRCUIT
• 6.7. HYDRAULIC OIL TANK
• 6.8. TRANSMISSION OVERHAUL PROCEDURES
• 6.8.1. TORQUE CONVERTER
• 6.8.2. PLUGS AND FILTERS
• 6.8.3. WHEEL DRIVE SOLENOID VALVE
• 6.8.4. TRANSMISSION HOUSING
• 6.8.5. CLUTCH PACK (A) AND GEAR SHAFT (D)
• 6.8.6. GEAR SHAFTS (B) AND (C)
• 6.8.7. GEAR SHAFT (E)
• 6.8.8. SHIFTER TOWER AND FORKS
• 6.9. BACKHOE CONTROL VALVE
• 6.9.1. REMOVAL
• 6.9.2. INSTALLATION
• 6.10. FRONT AXLE ASSEMBLY
• 6.10.1. REMOVAL
• 6.10.2. INSTALLATION
• 6.11. FRONT AXLE OVERHAUL PROCEDURES
• 6.11.1. STEERING CYLINDER ASSEMBLY
• 6.11.2. FRONT AXLE END PLANETARY ASSEMBLY
• 6.11.3. AXLE END HUB ASSEMBLY
• 6.12. REAR AXLE ASSEMBLY
• 6.12.1. REMOVAL
• 6.12.2. INSTALLATION
• 6.13. REAR AXLE OVERHAUL PROCEDURES
• 6.13.1. PARKING BRAKE ASSEMBLY
• 6.13.2. SERVICE BRAKE ASSEMBLY
• 6.13.3. REAR AXLE END PLANETARY ASSEMBLY
• 6.13.4. DIFFERENTIAL
• 6.13.5. DIFFERENTIAL LOCK
• 6.14. FRONT LOADER CONTROL VALVE ASSEMBLY
• 6.14.1. REMOVAL
• 6.14.2. INSTALLATION
• 6.15. SOLENOID VALVE ASSEMBLY
• 6.15.1. REMOVAL
• 6.15.2. INSTALLATION
• 6.16. FRONTEND LOADER ASSEMBLY
• 6.16.1. LOADER BOOM CYLINDERS
• 6.16.2. BUCKET CYLINDER AND MONOLINK
• 6.16.3. LOADER BUCKET
• 6.16.4. LOADER BOOM ASSEMBLY
• 6.17. BACKHOE ASSEMBLY
• 6.17.1. BUCKET CYLINDER
• 6.17.2. SWING CYLINDERS
• 6.17.3. BOOM LOCK CYLINDER
• 6.17.4. BACKHOE SWING FRAME
• 6.17.5. OUTRIGGER CYLINDERS
• 6.17.6. OUTRIGGER ARMS
• 6.18. WORK EQUIPMENT CYLINDER OVERHAUL PROCEDURES
• 6.18.1. LOADER AND BACKHOE CYLINDERS
• 6.18.2. SWING CYLINDERS
• 7. OTHERS
• 7.1. ELECTRICAL SCHEMATIC
• 7.1.1. CONNECTOR DESCRIPTION
• 7.1.2. SIDE INSTRUMENT PANEL
• 7.1.3. FRONT INSTRUMENT PANEL
• 7.1.4. FUSES, SWITCHES AND RELAYS
• 7.1.5. WIRE HARNESS
• 7.1.6. SWITCHES (1)
• 7.1.7. SWITCHES (2)
• 7.1.8. TRANSMISSION HARNESS