PDF Shop Manual Komatsu WB150AWS-2 Backhoe Loader - 2 MB
This shop manual provides comprehensive service and repair information for the Komatsu WB150AWS-2 Backhoe Loader (SN 150F80001 and up).
It contains the detailed instructions, specifications, and schematics needed for major repairs and maintenance.
Professional technicians use this manual to perform everything from engine service to complex hydraulic system troubleshooting.
This is the ultimate guide for servicing your Komatsu backhoe.
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--- Page 1 ---
WEBM003301
September 2002 2002
--- Page 3 ---
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle por-
tion.
Heavy parts (25 kg or more) must be lifted
with a hoist etc. In the Disassembly and Assem-
bly section, every part weighing 25 kg or more is
clearly indicated with the symbol
1. If a part cannot be smoothly removed from the ma-
chine by hoisting, the following checks should be
made:
ā¢ Check for removal of all bolts fastening the part 3) Do not sling a heavy load with one rope alone, but
to the relative parts. sling with two or more ropes symmetrically wound
ā¢ Check for any part causing interference with on to the load.
the part to be removed. Slinging with one rope may cause turning of the load
during hoisting, untwisting of the rope, or slipping of
the rope from its original winding position on the
2. Wire ropes load, which can cause dangerous accidents.
1) Use adequate ropes depending on the weight of 4) Do not sling a heavy load with ropes forming a wide
parts to be hoisted, referring to the table below: hanging angle from the hook.
When hoisting a load with two or more ropes, the
WIRE ROPES force subjected to each rope will increase with the
(Standard Ā«SĀ» or Ā«ZĀ» twist ropes hanging angles.
without galvanizing) The table below shows the variation of allowable
load (kg) when hoisting is made with two ropes,
Rope diameter (mm) Allowable load (tons) each of which is allowed to sling up to 1000 kg ver-
tically, at various handing angles.
10.0 1.0
When two ropes sling a load vertically, up to 2000 kg
11.2 1.4 of total weight can be suspended.
This weight becomes 1000 kg when two ropes
12.5 1.6
make a 120Ā° hanging angle.
14.0 2.2 On the other hand, two ropes are subjected to an ex-
cessive force as large as 4000 kg if they sling a 2000
16.0 2.8
kg load at a lifting angle of 150Ā°.
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0
The allowable load value is estimated to be one-
sixth or one-seventh of the breaking strength of the
rope used.
2) Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the
rope to slip off the hook during hoisting, and a se-
rious accident can result.
WB150AWS-2 00-7
--- Page 4 ---
CONVERSION TABLE
From liter to U.S. Gall.
1 į = 0.2642 U.S. Gall.
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
From liter to U.K. Gall.
1 į = 0.21997 U.K. Gall.
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 7.969 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 12.257 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
WB150AWS-2 00-17
--- Page 5 ---
STRUCTURE AND FUNCTION POWER TRAIN
Gears Transmission Differential Planetary Total
1st gear 4.374 83.273
2nd gear 2.436 46.377
2.75 6.923
3rd gear 1.232 23.455
4th gear 0.651 12.394
6
4
9
3
8
2
7
1 10
5
RKZ04460
1. Diesel engine 5. Front axle 9. Rear wheels
2. Convertor 6. Rear axle 10. Front wheels
3. Transmission 7. Front Cardan drive shaft
4. Hydraulic pump 8. Rear Cardan drive shaft
WB150AWS-2 10-3
--- Page 6 ---
STRUCTURE AND FUNCTION FRONT AXLE
Final reduction - join
21 4 5
7
6 8
3 9
2 10
11
1
13
22 14
12
14
20 19 18 17 16
RKZ04300
1. Planetary carrier 12. Axle body
2. Planetary 13. Bearing
3. Ring gear 14. Joint
4. Ring gear carrier 15. Pin
5. Wheel hub 16. Protection
6. Seal 17. Seal
7. Pin 18. Bearing
8. Shim 19. Snap ring
9. Protection 20. Steady pin
10. Bushing 21. Stud bolt
11. Seal 22. Plug
WB150AWS-2 10-13
--- Page 7 ---
PAGE INTENTIONALLY
LEFT BLANK
--- Page 8 ---
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. When a control valve lever is activated
4
b
PP T PLS
c d e a 6
To the actuator
Control valve f
Min Max
PP
M 3 X
1
Y RKZ01161
2
ā¢ When the control valve lever is moved out of its Equilibrium is re-established in the system when the
NEUTRAL position, the opening f is determined, al- pressure ,PLS generates on the spool (4) the dif-
lowing an LS signal to be generated. ference in force exerted by the spring (6), and the
ā¢ Until the ,PLS generates a force less than the force passage between delivery lines c and d is re-
exerted by the spring (6) on the spool (4), the system opened.
will remain stable.
When the opening f is such as to provoke a reduc-
tion in ,PLS, the spool (4) moves to the left ( ) to
form a passage between delivery lines d and e. The
chamber X loses pressure and the servo-piston
causes the swash plate to move towards maximum
displacement.
WB150AWS-2 10-33
--- Page 9 ---
STRUCTURE AND FUNCTION HYDRAULIC PUMP
WORKING MODE SOLENOID VALVE
FUNCTION
ā¢ Calibration of the pump absorption torque is nor-
Pump discharge amount Q
mally performed for the working mode E.
Working mode P
When the solenoid valve of the working mode is
commutated the absorbed power of the pump is in- Working mode E
creased, as indicated by the working mode curve.
Pump discharge pressure Pp
RKZ01251
OPERATION
1. WORKING MODE E
3
2 ā P1
4
a
5
1
6
12V
DC
RKZ04940
ā¢ During normal operation (Working mode E), the PC ā¢ The ,P1 is generated by the calibrated hole (3) in
valve intervenes when a ,P1 is generated equal to the spool of the PC valve (2) when, at a determined
the loading on the spring (4). pump delivery pressure P1, the valve (1) puts the
delivery line a into discharge, thus generating a flow
F1 in the delivery line a.
WB150AWS-2 10-43
--- Page 10 ---
STRUCTURE AND FUNCTION BACKHOE CONTROL VALVE
G G G
2 2
6 8 9 10
5
5 5
8 2
7 G 4 4
G 4 G
Section
Sezione C
C -- C
C Section
Sezione D
D -- D
D Section
Sezione E - E
G
8
11
12 13
12 13
5
Section
Sezione G
G -- G
G
2 G 4
RKZ01380
Section
Sezione F
F -- F
F
1. Ball 8. Plug
2. Antishock/anticavitation valve 9. Outrigger command spool
3. Boom command spool 10. Boom swing command spool
4. Spool return spring 11. Arm command spool
5. Compensator 12. Spring
6. Bucket command spool 13. Check valve
7. Anticavitation valve
WB150AWS-2 10-53
--- Page 11 ---
STRUCTURE AND FUNCTION CLSS (Closed Center Load Sensing System)
2. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than
the delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by
the pressure PLS+24 bar.
Because the unloading valve opens when the differential pressure between the pump delivery pressure PP and the
PLS LS pressure becomes equivalent to the loading of the spring (2) (24 bar), the differential LS pressure ,PLS del
LS becomes 24 bar
2 1 PP
PLS T RKZ01750
OPERATION
Final control of control valve
ā¢ When final control are performed with the control Consequently the exceeding pump delivery Q, rela-
valve, a pressure PLS is generated that pressurizing tive to the actuator request, is sent to the tank circuit.
the spring chamber, acts on the left-hand extremity of ā¢ The pump delivery pressure PP is regulated by the
the valve (1). combination of the pressure provided by the spring
The actuator pressure is introduced into the LS circuit (24 bar) and by the LS pressure PLS, i.e. when the
and then into the spring chamber. pressure differential ,PLS reaches the value of 24
As a result, the pump pressure PP tends to increase. bar.
ā¢ When the differential pressure between the pump de-
livery pressure PP and the LS pressure PLS has the
same value as the loading on the spring (2) (24 bar),
the shuttle (1) moves to the left ( ) and the pump
circuit PP puts itself into communication with the tank
circuit T.
WB150AWS-2 10-63
--- Page 12 ---
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE
Solenoid valve group ST1 - Backhoe boom locking.
a c
b
1
RKZ04640
1. EV4 - Backhoe boom locking
a. Port 3 - To the transmission
b. Port 2 - From the transmission
c. Port 1 - Boom-locking cylinder
WB150AWS-2 10-73
--- Page 13 ---
STRUCTURE AND FUNCTION AIR-CONDITIONING UNIT
HOW THE AIR-CONDITIONING UNIT FUNCTIONS
The compressor (1) is driven directly by the engine shaft On leaving the evaporator (6) the coolant is drawn once
by means of a belt, and made to rotat by a pulley fitted more into the compressor (1) and a new cycle commenc-
with an electromagnetically-engaged clutch (1a). es.
A thermostatic sensor (7) controls the engagement and The yielding of heat from the atmosphere in which the
disengagement of the clutch. It disengages the clutch evaporator is positioned leads to the condensation of the
when the evaporator reaches the lower temperature limit water suspended in the air, and hence to dehumidifica-
and engages the clutch when the evaporator reaches tion. The condensate is deposited on the evaporator fins
the upper temperature limit. where, if a temperature higher than 0Ā°C is not main-
The coolant fluid (in gaseous phase) is drawn into the tained, it freezes and inhibits the functioning of the eva-
compressor where it is subjected to compression and an porator.
intense heating process. In these conditions the fluid is The task of keeping the temperature of the evaporator
then sent into the condenser (2) where, due to the heat above 0Ā°C (and thus within the optimum limits for heat
extracted by ambient temperature air flowing over fins, it exchange) is entrusted to a thermostatic sensor (7).
reaches condensation temperature, and passes into a The condensate that forms on the evaporator fins (6)
high-pressure liquid state. also contains dust, pollens and particles suspended in
Subsequently the coolant passes into the drying-filter the air. Continual condensation therefore effectively pu-
group (3) which performs three functions: it filters out im- rifies the air, and the droplets of condensate are dis-
purities, absorbs any moisture present in the circuit and, charged to the exterior.
finally, also functions as a reserve tank. A fixed quantity of anti-freeze oil is also introduced into
The coolant in its liquid state is then transferred to the the circuit, with the function of lubricating all the mechan-
evaporator (6), first passing through an expansion valve ical parts of the unit. A percentage of this oil circulates
(5). The task of this valve is the constant metering of the constantly throughout the unit in nebulized form, lubri-
quantity of fluid in order to maintain optimum evapora- cating the compressor (pistons and bearings) and the
tion. expansion valve.
In the evaporator the coolant fluid is subjected to expan- A pressure switch (4) has been inserted in the electrical
sion, bringing it up to the critical evaporation point at a control circuit to protect the unit in the case of a lack of co-
temperature of approximately ā 8Ā°C. olant fluid or if the quantity becomes insufficient due to
The flow of air generated by centrifugal fan (8) which leakages. This switch will inhibit the engagement of the
passes through the evaporator (6) at ambient tempera- electromagnetic clutch and hence the functioning of the
ture is considerably warmer than ā 8Ā°C. For this reason air-conditioning unit.
it yields heat to the coolant fluid, bringing it up to boiling
point and complete evaporation.
WB150AWS-2 10-83
--- Page 14 ---
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
FOR MACHINE
Machine model WB150AWS-2
Classifi- Standard Permissible
cation
Check item Test condition Unit
value value
ā¢ Hydraulic oil temperature:
45 ā 55 Ā°C Max. 2375Ā±50 2325ā2425
ā¢ Converter oil temperature:
Accelerator pedal 80 Ā°C
ā¢ Engine oil temperature
Engine speed
cooling circuit: Min. 1050Ā±50 1000ā1100
in the limits
rpm
ā¢ Hydraulic oil temperature:
45 ā 55 Ā°C Max. 1950Ā±50 1900ā2000
ā¢ Converter oil temperature:
Accelerator lever 80 Ā°C
ā¢ Engine oil temperature
cooling circuit: Min. 1050Ā±50 1000ā1100
in the limits
All controls į į a b c į a b c
(front bucket and
Control valve
a b c
backhoe) 41.5 8 8 -- -- -- -- --
mm
For front shovel arm
command only 41.5 8 8 5 -- -- -- --
(with floating arm) RKZ02580
Front bucket tilt lever Raise
Neutral 50 60ā110
control Lower
Front bucket control Dump
Neutral 115 90ā140
lever Curled
Boom backhoe control Raise
Neutral 100 80ā120
lever Lower
Travel of levers and pedals
Arm backhoe control Opening
ā¢ Engine stopped Neutral 100 80ā120
lever Closing
ā¢ At the centre
Bucket backhoe control of knob lever Opening
ā¢ Valve reading Neutral 100 80ā120
lever Closing mm
at the end of
Boom swing working stroke Right
Neutral 100 80ā120
backhoe control lever ā¢ Attachments Left
on the ground
Outriggers control Up
Neutral 50 30ā65
lever Down
Fuel control lever Min. Max. 70 50ā90
Telescopic arm Out 15 10ā20
Neutral
control pedal In 30 20ā40
Right 15 10ā20
Breaker control pedal Neutral
Left 30 20ā40
WB150AWS-2 20-3
--- Page 15 ---
TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA
ā
The technical data of follow table are refered to a machine with max 500 kg shovel bucket, 600 mm (max. 160 kg)
backhoe bucket and standard arm (or telescopic arm) closed.
FOR MACHINE
Machine model WB150AWS-2
Classifi- Standard Permissible
cation
Check item Test condition Unit
value value
Measuring posture
Bucket 0 Max. 2
RKZ01630
ā¢ Engine speed: Min.
ā¢ Oil temperature: 45 ā 55Ā°C
ā¢ Put arm in horizontal position. Tilt back bucket
cylinder an then extend it.
Check the time passing between bucket stop at
Work equipment
dead centre and the restart movement.
Time lags
Measuring posture sec.
Outriggers 0 Max. 2
RKZ02700
ā¢ Engine speed: Min.
ā¢ Oil temperature: 45 ā 55Ā°C
ā¢ Boom, arm and bucket fully retracted and putted in
machine centre position.
ā¢ Check the time necessary for outriggers to raise
the machine from when they lean on level ground.
ā¢ Check each outrigger at a time.
WB150AWS-2 20-13
--- Page 16 ---
MEASURING ACCELERATOR PEDAL OPERATING
TESTING AND ADJUSTMENTS TRAVEL AND ACCELERATOR LEVER
2. Accelerator lever travel adjusting
1 - Remove mat and lateral cover (1).
1
RKZA9350
2 - Loosen nut (2) and tight the end lever travel bolt (3) of
some turns.