CEBM002201
SHOP MANUAL
WB156PS-5 BACKHOE LOADER
SERIAL NUMBERS
WB156PS-5 A73001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
June 2011 Printed in USA
Copyright 2011 Komatsu DataKom Publishing Division 00-1 b
FOREWORD
CONTENTS
12
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 b
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WB156PS-5
FOREWORD
SAFETY
12
SAFETY SAFETY NOTICE
00
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair procedures recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the procedure. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
and make sure there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
00
Mistakes in operation are extremely costly and dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1.
2.
3.
Before carrying out any greasing or repairs, read all the precautions given on the decals attached to the machine. When carrying out any operation, always wear proper safety equipment specified for the operation you are performing. Do not wear loose fitting work clothes, or clothes with buttons missing. • Always wear safety glasses when striking parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding operations, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation
4.
When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, lock and tag all controls in the operator's compartment.
5.
Keep all tools in good condition.
6.
Designate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean
WB156PS-5
PREPARATIONS FOR WORK
00
1.
Before adding oil or making repairs, park the machine on hard, level ground and block the wheels or tracks to prevent the machine from moving. Lower all work implements to the ground and remove starting key.
2.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.
Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, coolant or air circuits, first relieve the pressure completely from the circuit.
2.
The coolant and oil in the systems are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and coolant to cool before carrying out any work on the oil or coolant systems.
00-3 b
FOREWORD
SAFETY
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4.
When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting anything. Do not work with any part while it is still raised by the hoist or crane.
5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
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 even start fires.
8.
Never use flammable liquids to clean parts. Always use approved non-flammable solvents to clean parts.
9.
Be sure to assemble all parts in their original locations. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.
10. When installing high pressure hoses, be sure that they are not twisted. Damaged tubing is dangerous. Be extremely careful when installing tubes for high pressure circuits. Also make sure parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques and sequences. When installing protective parts such as guards, or parts that may vibrate or rotate at high speeds, be particularly careful to check their installation carefully. 12. When aligning two holes, never insert your fingers or hand. Use appropriate tools to align parts. 13. When measuring hydraulic pressure, be sure the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks on track-type machines. When removing the track, the track separates suddenly. Never let anyone stand at either end of the track. 15. When making repairs or adjustments on electronically-controlled engines, avoid any physical contact with the injection system’s wiring harness while the engine is running. Due to the high voltage and amperage in this system, serious injury may occur. 16. Never use a welder or machine with a higher voltage to jump-start or supply voltage to a machine with a lower voltage system. Damage to the machine’s electrical system, a fire or an explosion may result. Always stay within the same voltage range as the machine.
00-4 b
WB156PS-5
FOREWORD
GENERAL
12
GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. It explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING, ADJUSTING AND TROUBLESHOOTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. OTHER This section has the foldout drawings for the machine.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
WB156PS-5
00-5 b
FOREWORD
HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL VOLUMES
00
00
REVISIONS
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown on the LIST OF REVISED PAGES between the TITLE PAGE and SAFETY page.
Chassis volume: Engine volume:
SYMBOLS
Issued for every machine model 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 of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
DISTRIBUTION AND UPDATING
1. 2.
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Section number (10 is Structure, Function and Maintenance Standard)
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
★
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Places that require special attenTightening tion for tightening torque during torque assembly. Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
Consecutive page number for each item 3.
Remarks
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.
FILING METHOD
00
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
10-4 10-4-1 Added pages 10-4-2 10-5
REVISED EDITION MARK
00
When a manual is revised, an edition mark (b, c, d, etc.) is recorded on the bottom outside corner of the pages.
00-6 b
WB156PS-5
FOREWORD
HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS
00
HOISTING
can result. Hooks have maximum strength at the middle portion.
00
WARNING! Heavy parts (25 kg (55 lb) or more) must be lifted with a hoist, crane, etc. Every part weighing 25 kg (55 lb) or more is indicated clearly with this symbol.
●
1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1.
3.
WARNING! Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
00
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
Allowable load
mm (in)
kN
tons
10 (0.39)
9.8
1.0
11.2 (0.44)
13.7
1.4
12.5 (0.49)
15.7
1.6
14 (0.55)
21.6
2.2
16 (0.63)
27.5
2.8
18 (0.71)
35.3
3.6
20 (0.79)
43.1
4.4
22.4 (0.88)
54.9
5.6
30 (1.18)
98.1
10.0
40 (1.57)
176.5
18.0
50 (1.97)
274.6
28.0
60 (2.36)
392.2
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load when hoisting with two ropes, each of which is allowed to sling up to 1000 kg (2205 lb) vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg (4409 lb) of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg (8818 lb) if they sling a 2000 kg (4409 lb) load at a lifting angle of 150°.
★ The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident
WB156PS-5
00-7 b
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
00
The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1.
Standard size and tolerance • To be accurate, the finishing size of parts is a little different from one to another. • To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. • The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance." • The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size
Tolerance
120
-0.022 -0.126
★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example: 120 (–0.022/–0.126) ●
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
●
Indication of size of rotating shaft and hole and relationship drawing of them Standard size 60
Tolerance Shaft
Hole
-0.030 -0.076
+0.046 0
2.
Standard clearance and standard value • The clearance made when new parts are assembled is called the "standard clearance," which is indicated by the range from the minimum clearance to the maximum clearance. • When some parts are repaired, the clearance is generally adjusted to the standard clearance. • A value of performance and function of new products or equivalent is called the "standard value," which is indicated by a range or a target value. • When some parts are repaired, the value of performance/function is set to the standard value.
3.
Standard interference • When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference between these sizes is called the "interference." • The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference."
00-8 b
WB156PS-5
FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
•
4.
After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. Repair limit and allowable value • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the "repair limit." • If a part is worn to the repair limit must be replaced or repaired. • The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the "allowable value." • If a product is worn to the allowable value, it must be checked or repaired. The permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
5.
Clearance limit • Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit." • If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6.
Interference limit • The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit." • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
WB156PS-5
00-9 b
FOREWORD
COATING MATERIALS
12
COATING MATERIALS
00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Adhesives
Category
Code
Part No.
Quantity
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
179-129-9140
2g
Polyethylene container
Main applications, features ●
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out.
●
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and nonmetal.
●
● ●
●
Used as adhesive or sealant for metal, glass or plastic.
●
Used as sealant for machined holes.
●
Used as heat-resisting sealant for repairing engine.
●
Quick hardening type adhesive Cure time: within five seconds to three minutes Used mainly for adhesion of metals, rubbers, plastics and woods.
● ● ●
Aronalpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
50 g
Polyethylene container
● ● ● ●
LG-3
790-129-9070
1 kg
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature. Used as adhesive or sealant for gaskets and packing of power train case, etc.
●
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Can ●
00-10 b
Quick hardening type adhesive Quick cure type (maximum strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
●
●
Gasket sealant
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
WB156PS-5
FOREWORD Category
Code
COATING MATERIALS Part No.
Quantity
Container
Main applications, features ● ●
LG-4
790-129-9020
200 g
Tube
● ● ●
LG-5
790-129-9080
1 kg
Polyethylene container
Gasket sealant
● ●
LG-6
09940-00011
250 g
Tube
● ●
Molybdenum disulphide lubricant
●
LG-7
09920-00150
150 g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2160CNCA
Various
Various
400 g (10 per case)
Belows type
Molybdenum disulphide lubricant
Grease
WB156PS-5
SYG2-400M
●
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
●
Used as heat-resisting sealant for repairing engines.
●
Used as lubricant for sliding parts (to prevent squeaking).
● ●
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
●
General purpose type
●
Used for normal temperature, light load bearing at places in contact with water or steam.
●
Used for places with heavy load.
00-11 b
FOREWORD
STANDARD TIGHTENING TORQUE
12
STANDARD 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 AND ASSEMBLY. Thread diameter of bolt
Width across flats
mm
mm
N·m
lbf ft
6
10
13.2 ±1.4
9.7 ±1.0
8
13
31.4 ±2.9
23.2 ±2.1
10
17
65.7 ±6.8
48.5 ±5.0
12
19
112 ±9.8
82.6 ±7.2
14
22
177 ±19
130.5 ±14.0
16
24
279 ±29
205.8 ±23.4
18
27
383 ±39
282.5 ±28.8
20
30
549 ±58
404.9 ±42.8
22
32
745 ±78
549.5 ±57.5
24
36
927 ±98
683.7 ±72.3
27
41
1320 ±140
973.6 ±103.2
30
46
1720 ±190
1268.6 ±140.1
33
50
2210 ±240
1630.0 ±177.0
36
55
2750 ±290
2028.3 ±213.9
39
60
3280 ±340
2419.2 ±250.8
Thread diameter of bolt
Width across flats
mm
mm
N·m
lbf ft
6
10
7.85 ±1.95
5.75 ±1.4
8
13
18.6 ±4.9
13.7 ±3.6
10
14
40.2 ±5.9
29.6 ±4.4
12
27
82.35 ±7.85
60.7 ±5.8
00-12 b
WB156PS-5
FOREWORD
STANDARD TIGHTENING TORQUE
12 TIGHTENING TORQUE OF HOSE NUTS
00
Use these torques for hose nuts. Thread diameter
Width across flats
Tightening torque
mm
mm
N·m
lbf ft
02
14
19
24.5 ±4.9
18.1 ±3.6
03
18
24
49 ±19.6
36.1 ±14.4
04
22
27
78.5 ±19.6
57.9 ±14.4
05
24
32
137.3 ±29.4
101.3 ±21.7
06
30
36
176.5 ±29.4
130.2 ±21.7
10
33
41
196.1 ±49
144.6 ±36.1
12
36
46
245.2 ±49
180.9 ±36.1
14
42
55
294.2 ±49
217.0 ±36.1
Nominal No.
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
00
Use these torques for split flange bolts. Thread diameter
Width across flats
Tightening torque
mm
mm
N·m
lbf ft
10
14
65.7 ±6.8
48.5 ±5.0
12
17
112 ±9.8
82.6 ±7.2
16
22
279 ±29
205.8 ±21.4
TIGHTENING TORQUE FOR FLARED NUTS
00
Use these torques for flared part of nut.
Thread diameter
Width across flats
mm
mm
N·m
lbf ft
14
19
24.5 ±4.9
18.0 ±3.6
18
24
49 ±19.6
36.1 ±14.5
22
27
78.5 ±19.6
57.9 ±14.5
24
32
137.3 ±29.4
101.3 ±21.7
30
36
176.5 ±29.4
130.2 ±21.7
33
41
196.1 ±49
144.6 ±36.1
36
46
245.2 ±49
180.9 ±36.1
42
55
294.2 ±49
217.0 ±36.1
WB156PS-5
Tightening torque
00-13 b
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Thread diameter mm 14 20 24 33 42
Norminal No. 02 03, 04 05, 06 10, 12 14
Width across flat mm Varies depending on type of connector.
Tightening torque (Nm {lbf ft}) Range Target 35 - 63 {25.81 - 46.46} 44 {32.45} 84 - 132 {61.95 - 97.35} 103 {75.96} 128 - 186 {94.40 - 137.18} 157 {115.79} 363 - 480 {267.73 - 354.02} 422 {311.25} 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below. Thread diameter mm 08 10 12 14 16 18 20 24 30 33 36 42 52
Norminal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 36 -
Tightening torque (Nm {lbf lb}) Range Target 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42} 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31} 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01} 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62} 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68} 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91} 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14} 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59} 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50} 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75} 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03} 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40} 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
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. Tightening torque (Nm {lbf ft}) Nominal Width size of hose across flats
02 03 04 05 06 (10) (12) (14)
00-14 b
19 22 24 27 32 36 41 46 55
Range
Target
34 - 54 {25.0 - 39.8} 44 {32.4} 34 - 63 {25.0 - 46.4} 44 {32.4} 54 - 93 {39.8 - 68.5} 74 {54.5} 59 - 98 {43.5 - 72.2} 78 57.5} 84 - 132 {61.9 - 97.3} 103 {75.9} 128 - 186 {94.4 - 137.1} 157 {115.7} 177 - 245 {130.5 - 180.7} 216 {159.3} 177 - 245 {130.5 - 180.7} 216 {159.3} 197 - 294 {145.3 - 216.8} 245 {180.7} 246 - 343 {181.4 - 252.9} 294 {216.8}
Taper seal type
Face seal type
Nominal thread Thread size Root diameter (mm) size - Threads per (mm) (Reference) inch, Thread series 9/16 - 18UN 14.3 14 11/16 -16UN 17.5 18 22 13/16 - 16UN 20.6 24 1 - 14UNS 25.4 30 1 3/16 - 12UN 30.2 33 36 42 -
WB156PS-5
FOREWORD
ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE
00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
00
Copper wire Nominal numNumber of Dia. Of strand Cross section ber strands (mm) (mm)
Cable O.D. (mm)
Current rating (A)
Applicable circuit
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
CLASSIFICATION BY COLOR AND CODE
1
Circuits Classification Primary
Priority
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
—
BW
RW
YR
GW
LW
Color
White & Red
—
Black & White
Red & White
Yellow & Red
Green & White
Blue & White
Code
WB
—
BY
RB
YB
GR
LR
Color
White & Black
—
Black & Yellow
Red & Black
Yellow & Black
Green & Red
Blue & Red
Code
WL
—
BR
RY
YG
GY
LY
Color
White & Blue
—
Black & Red
Red & Yellow
Yellow & Green
Green & Yellow
Blue & Yellow
Code
WG
—
—
RG
YL
GB
LB
Color
White & Green
—
—
Red & Green
Yellow & Blue
Green & Black
Blue & Black
Code
—
—
—
RL
YW
GL
—
Color
—
—
—
Red & Blue
Yellow & White
Green & Blue
—
2
Auxiliary
3
4
00
5
6
WB156PS-5
00-15 b
FOREWORD
CONNECTING PUSH-PULL TYPE COUPLER
CONNECTING PUSH-PULL TYPE COUPLER
00
WARNING! Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare a container to catch oil. ★ Type 1 1.
Disconnection A. Hold adapter (1) and push hose joint (2) into mating adapter (3) (Fig. 1). •
The adapter can be pushed in about 3.5 mm (0.14 in). • Do not hold rubber cap portion (4). B. After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks (Fig. 2). C. Hold hose adapter (1) or hose (5) and pull it out (Fig. 3). •
2.
Since some hydraulic oil flows out, prepare a container to catch oil.
Connection A. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other (Fig. 4). • Do not hold rubber cap portion (4). B. After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition (Fig. 5). •
00-16 b
When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm (0.14 in). This does not indicate an abnormality, however.
WB156PS-5
FOREWORD
CONNECTING PUSH-PULL TYPE COUPLER
★ Type 2 1.
Disconnection A. Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end (Fig. 6). B. While holding the condition of Step A, turn lever (8) to the right (clockwise) (Fig. 7). C. While holding the condition of Steps A and B, pull out whole body (7) to disconnect it (Fig. 8).
2.
Connection • Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end (Fig. 9).
WB156PS-5
00-17 b
FOREWORD
CONNECTING PUSH-PULL TYPE COUPLER
★ Type 3 1.
Disconnection A. Hold the tightening portion and push body (9) straight until sliding prevention ring (8) touches contact surface (b) of the hexagonal portion at the male end (Fig. 10). B. While holding the condition of Step A, push cover (10) straight until it contacts surface (b) of the hexagonal portion at the male end (Fig. 11). C. While holding the condition of Steps A and B, pull out whole body (9) to disconnect it (Fig. 12).
2.
Connection • Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts surface (b) of the hexagonal portion at the male end (Fig. 13).
00-18 b
WB156PS-5
FOREWORD
CONVERSION TABLES
12
CONVERSION 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 the Conversion 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 b, then draw a horizontal line from b. B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c. C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to inches. 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 to 55 mm. B. Carry out the same procedure as above to convert 55 mm to 2.165 inches. C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
c 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
d b
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
WB156PS-5
00-19 b
FOREWORD
CONVERSION TABLES
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
00-20 b
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
WB156PS-5
FOREWORD
CONVERSION TABLES
12 1 l = 0.2642 U.S. Gal
Liter to U.S. Gallon 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
1 l = 0.21997 U.K. Gal
Liter to U.K. Gallon 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
WB156PS-5
00-21 b
FOREWORD
CONVERSION TABLES
12 kgm to ft lb
00-22 b
1 kgm = 7.233 ft lb 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.63 1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1439.4
1432.1
WB156PS-5
FOREWORD
CONVERSION TABLES
12 kg/cm2 to lb/in2
1 kg/cm2 = 14.2233lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
19324
1949
1963
1977
140
1991
2005
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
WB156PS-5
00-23 b
FOREWORD
CONVERSION TABLES
12 Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. °C °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 -27.8 -27.2 -26.7 -26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-24 b
WB156PS-5
01
GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 STANDARD ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 TELESCOPIC ARM (RETRACTED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 TELESCOPIC ARM (EXTENDED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5 MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 TOTAL MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 LIFTING POSITION MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9 LIFTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10 FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12 PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . 01-12 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13 FUEL AND ENGINE OIL REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-13 HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 01-14 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15 GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-15
WB156PS-5
01-1 b
GENERAL
SPECIFICATION DRAWING
SPECIFICATION DRAWING SPECIFICATIONS MACHINE DIMENSIONS AND WEIGHTS
A
Maximum height
4230 mm (13’11”)
B
Hinge pin height
3367 mm (11’1”)
C
Overall height, ROPS Cab
2935 mm (9’8”)
D
Maximum dumping height
2622 mm (8’7”)
E
Reach at maximum height and 45o dump angle
750 mm (2’5”)
F
Dumping angle
45o
G
Rollback angle
45o
H
Digging depth
138 mm (5’4”)
Maximum digging height
5525 mm (18’2”)
-with telescopic arm
6136 mm (20’2")
P
Digging depth (2’ level bottom) -with telescopic arm
4670 mm (15’4”) 5916 mm (19’5”)
Q
Reach at maximum height -with telescopic arm
3046 mm (10’0”) 4239 mm (13’11”)
Maximum reach from swing center
6034 mm (19’10”)
O
R
S
-with telescopic arm
7164 mm (23’6”)
Maximum digging depth
4725 mm (15’6”)
-with telescopic arm
5970 mm (19’7”)
I
Bucket reach (transport)
2023 mm (6’8”)
J
Ground clearance
430 mm (1’5”)
T
Digging reach
2320 mm (7’7”)
K
Wheel base
2175 mm (7’2”)
U
Rear tread
1800 mm (5’11”)
L
Backhoe swing center distance
1175 mm (3’10”)
V
Front tread
1874 mm (6’2”)
M
Transport length
7504 mm (24’7”)
W
Overall width (with bucket)
2356 mm (7’9”)
Dumping height (SAE)
3761 mm (12’4”)
Backhoe transport height
3676 mm (12’1”)
-arm retracted
3747 mm (12’4’’)
-with telescopic arm
3746 mm (12’4”)
-arm extended
4435 mm (14’7”)
N
01-2 1
X
WB156PS-5
GENERAL
BACKHOE ARM
BACKHOE ARM STANDARD ARM
WB156PS-5
01-3 1
GENERAL
BACKHOE ARM
TELESCOPIC ARM (RETRACTED)
01-4 1
WB156PS-5
GENERAL
BACKHOE ARM
TELESCOPIC ARM (EXTENDED)
WB156PS-5
01-5 1
GENERAL
MACHINE SYSTEMS SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS ENGINE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu S4D102LE-2 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical, 4-cycle water-cooler diesel engine Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharged Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 x 135 mm (4.49 x 5.31 in) Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 l (275 in3) Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18:1 Horsepower rating: Gross horsepower rating @ 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 kW 99 HP Net horsepower (SAE J 1349) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.8 kW 95 HP Max. torque @ 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 N·m (305 lbf ft) Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double elements and dust evacuator, condition indicator Lubrication system: Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator water cooled system Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric motor with air pre-heating system for cold climate
ELECTRICAL SYSTEM Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah (860 CCA) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 A Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 kW
SERVICE REFILL CAPACITIES Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 l (2.4 gal) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 l (3.7 gal) Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 l (39.6 gal) Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 l (10.8 gal) Hydraulic system capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 l (25.6 gal) Front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 l (2.0 gal) Rear axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 l (3.8 gal) Gearbox oil, Power Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 l (5.3 gal) Gearbox oil, Power Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0 l (7.4 gal)
01-6 1
WB156PS-5
GENERAL
MACHINE SYSTEMS SPECIFICATIONS
TRANSMISSION • • •
Electronically-controlled, four-wheel drive, full powershift transmission Twist Grip or EGM™ (Electronic Gear Management) gear controls for changing driving direction and gears at full power without disengaging the drive Twist Grip Controls in manual mode FORWARD
REVERSE
Gears
1st
2nd
3rd
4th
1st
2nd
3rd
4th
km/h
6.5
12.0
23.0
40.0
6.5
12.0
23.0
⎯
m/h
4.0
7.5
14.3
25.0
4.0
7.5
14.3
⎯
TOTAL MASS Maximum total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,498 - 8,518 kg (16,530 - 18,780 lb)
LOADER The design of the front loader allows for better tensile strength distribution and parallel movements when raising and lowering the bucket. Due to the linkage geometry, the number of greasing points has been dramatically reduced. Standard bucket width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,356 mm (7 ft 9 in) Standard bucket capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 m3 (1.25 yd3) Standard bucket weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 kg (1,000 lb) Lifting capacity at maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,900 kg (8,598 lb) Lifting capacity at ground level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,000 kg (11,020 lb) Breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,000 kg (13,224 lb)
BACKHOE The boom has a rounded profile and reinforced structure built with cast ends allowing for 180° rotation while maintaining high rotation torque. Bucket breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,126 kg (13,505 lb) Arm breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,915 kg (8,631 lb)
TIRE PRESSURE Front tire: 14 x 17.5 R4, 10 ply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 - 3.36 kg/cm2 (46 - 48 psi) Rear tire: 19.5 x 24 R4, 12 ply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.83 - 1.93 kg/cm2 (26 - 27 psi)
WB156PS-5
01-7 1
GENERAL
WEIGHT TABLE
12
WEIGHT TABLE ★ This Weight Table is for reference when handling components or when transporting the machine. Unit: kg (lb) Machine model
WB156PS-5
Engine assembly - Muffler and exhaust pipe
394 (869)
Radiator
37 (82)
Hydraulic oil tank (empty)
10 (22)
Fuel tank (empty)
68 (150)
Front counter weight
372 (820)
Engine hood
32 (71)
Canopy (without seat) Cab (without seat) Seat
580 (1,279) ⎯ 23 (51)
Engine - transmission - pump
682 (1,504)
Hydraulic pump
36.8 (81.1)
Transmission
254 (560)
Front axle
262 (578)
Rear axle
430 (948)
Front wheel (complete with rim)
⎯
Rear wheel (complete with rim)
⎯
Work equipment (front loader)
1,100 (2,425)
Boom
313 (690)
Bucket
436 (961)
Bucket cylinder
13x4
Fulcrum lever
32.5x2
Bucket tilt
46x2
Boom raise
35x2
Work equipment
⎯
•
With standard arm
850 (1,874)
•
With long arm
885 (1,951)
•
With telescopic arm
1,030 (2,271)
8-spool control valve
⎯
10-spool control valve
⎯
Backhoe boom cylinder
248 (547)
Backhoe arm cylinder
305 (672)
Backhoe swing frame
162.5 (358.3)
Outriggers
39x2
Boom cylinders
87.5 (193)
Arm cylinders
67 (148)
Bucket cylinders
52.5 (116)
Outrigger cylinders
27.5x2
Swing cylinders
34x2
01-8 1
WB156PS-5
GENERAL
LIFTING THE MACHINE
LIFTING THE MACHINE WARNING! Use a crane properly rated to handle the machine’s weight and size. The person operating the crane to lift the machine MUST be a qualified crane operator. • • • • •
Do not lift the machine with a person in the cab or on the machine. Use a wire rope that has ample strength for the weight of the machine being lifted. The operating weight of the WB156/ 156PS-5 is 7,498 kg (16,530 lb). Keep the machine horizontal when lifting it. Never enter the area under or around a raised machine. There is danger that the machine may lose its balance. Before lifting the machine, take the following steps to prevent the machine from unexpectedly moving. • Set the parking brake lever to the LOCK position. • If equipped with telescopic arm, lock the sliding arm to prevent accidental extension. • Engage the backhoe boom safety coupling. • Press the work equipment control switch to the LOCK position. • Insert the backhoe lock pin to lock the backhoe arm in position. • Connect outriggers safety cables.
WARNING! When lifting the machine, the wire rope must be fitted correctly or the machine may fall and cause serious injury or even death. Remark The lifting procedure applies to machines with standard specifications. The method of lifting may differ depending on the attachments and options installed. For details about lifting a machine that does not conform to standard specifications, contact your Komatsu distributor.
LIFTING POSITION MARKS
WB156PS-5
01-9 1
GENERAL
LIFTING THE MACHINE
LIFTING PROCEDURE ★ Machine must be on firm, level ground. 1.
Start the engine. Make sure the machine is horizontal; then set the work equipment to the travel posture (A). (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 50 cm (16 - 20 in)
2.
The telescopic arm is equipped with a safety element (6) that locks the sliding arm (2) when it is completely retracted and prevents any accidental extension. The safety element (6), held in its seat by the retainer (7), must be inserted to prevent the extension of the arm as shown in Figure A. For more details, see "Safety Devices" in the "OPTIONS, ATTACHMENTS" section.
3.
Raise and center the backhoe boom and engage the safety coupling.
4.
Press the work equipment control switch until the light on the switch is illuminated indicating the front and rear work equipment controls are locked.
01-10 1
WB156PS-5
GENERAL 5.
LIFTING THE MACHINE
Install the lock pin. WARNING! When installing the backhoe lock pin, be careful not to get caught between the backhoe frame and boom. Never reach over the backhoe controls to install the lock pin. There is the possibility that you may bump one of the control levers causing the backhoe work equipment to move; or you may lose your balance and fall into the work equipment. Always install the lock pin while standing on the ground.
6.
Connect the safety cables to prevent accidental lowering of the outriggers.
7.
Use wire ropes and slings that match the weight of the machine. The operating weight of the WB146/146PS-5 is 7,300 kg (16,090 lb). Wind the wire rope and fix it to the lifting points as shown in "Lifting Position Marks."
Remark Use protectors so that the wire ropes do not break at sharp edges or narrow places. Use threaders and bars having sufficient width so that the slings and wire ropes do not touch the machine. 8.
Clear the area of unwarranted personnel. Make sure enough ground guides are available to keep the area clear.
9.
Lift the machine about 100 - 200 mm (4 - 8 in) above the ground.
10. Make sure that the wire ropes are not slack and that the machine is level. If ropes require adjustment, lower the machine back to the ground first. 11. If the wire ropes are taut and the machine is level, continue to lift the machine slowly. Provide signals to the crane operator and observe areas the crane operator cannot see.
WB156PS-5
01-11 1
GENERAL
FUEL, COOLANT, AND LUBRICANTS
FUEL, COOLANT, AND LUBRICANTS PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE Ambient Temperature Reservoir
Type of fluid
-22°F -30° C
-4 -20
14 -10
32 0
50 10
68 20
Capacity 86 30
104 40
122 50
Specified
Refill
9 liter (2.4 gal)
9 liter (2.4 gal)
97 liter (25.6 gal)
41 liter (10.8 gal)
97 liter (25.6 gal)
41 liter (10.8 gal)
Front axle: Differential
6.5 liter (1.7 gal)
6.5 liter (1.7 gal)
Final reduction gear (ea.)
1 liter (0.26 gal)
1 liter (0.26 gal)
Rear axle: Differential
14.5 liter (3.8 gal)
14.5 liter (3.8 gal)
Final reduction gear (ea.)
1.5 liter (0.4 gal)
1.5 liter (0.4 gal)
20 liter (5.3 gal)
17 liter (4.5 gal)
0.8 liter (0.2 gal)
0.8 liter (0.2 gal)
150 liter (39.6 gal)
-
14 liter (3.7 gal)
-
SAE 5W-30 Engine oil pan
SAE 10W 30 SAE 15W-40 SAE 5W*
Hydraulic system
SAE 10W
Oil API CI-4
SAE 30 SAE 10W-30
Hydraulic system with biodegradable oil
Hydraulic transmission Brake system
Fuel tank
See page 3-12
(See Note 1)
GM DEXRON II D
Diesel fuel
ASTM D975 No. 1 ASTM D975 No. 2
Cooling system
Coolant
OPTION FOR VERY COLD AREAS:
01-12 1
Ethylene Glycol Base
If the temperature exceeds 10° C (50° F), contact your Komatsu distributor for advise on the type of oil to be used.
WB156PS-5
GENERAL
FUEL, COOLANT, AND LUBRICANTS
GREASE Lubrication Points
Consistency
Type
Articulations, grease fittings
NLGI 2
(See note 2)
Note 1: For axle oil, use only the recommended oil as follows. SHELL: DONAX TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TEXTRAN TDH OIL MOBIL: MOBILFLUID 422 or 424 Note 2: The recommended lubricating grease is No.2 multi-purpose lithium grease with 3% molybdenum disulfide (Lithio EP + MoS2).
FUEL AND ENGINE OIL REMARKS •
•
• • •
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur content
Change interval of oil in engine oil pan
0.5 to 1.0%
1/2 of regular interval
Above 1.0%
1/4 of regular interval
When starting the engine in an atmospheric temperature of lower than 0° C (32° F), be sure to use engine oil of SAE10W, SAE20W-20 and SAE10W-30, even though an atmospheric temperature goes up to 10° C (18° F) more or less in the day time. Use API classification CI-4. There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 10W-40), but be sure to add single grade oil that matches the temperature in the table. Use Komatsu genuine oil which has been specifically formulated and approved for use in the engine, hydraulic work equipment, transmission, axles, and brakes.
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: SAE: API:
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
WB156PS-5
01-13 3
GENERAL
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indicated in the following table is authorized and recommended: Supplier
HEES Synthetic Biodegradable Oil
KOMATSU
•
• •
---
AGIP
ARNICA S 46
ARAL
HEF 46 vitam
AVIA
SYNTOFLUID N 46
BP
BIOHYD SE-S 46
CONDAT
CONDAT D 46 K
ELF
HYDRELF BIO 46
ESSO
HYDRAULIKOIL HE 46
FINA
BIOYIDRAN TMP 46 SE 46
FUCHS
PLANTOHYD S 46
KENDALL
SYNTH NATURA 46 HV
KUWAIT PETROLEUM K8
HOLBEIN 46
MOBIL
EAL SYNDRAULIC
MOBIL (USA)
ENVIROSYN 46 H
PAKELO
GEOLUBE HYDRAULIC EP-46
PANOLIN
HLP SYNTH 46
SHELL
NATURELLE HFE-46
TAMOIL
GREEN HYDRO SAFETY 46
TEXACO
HYDRA 46
TOTAL
EQUIVIS BIO 46
VAVOLINE
UNISYN HLP 32/68
It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic motor, the transmissions, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at least 40° C (104° F), then start moving the equipment, so that all the parts of the system are filled with oil. Stop the engine and check the oil level.
01-14 3
WB156PS-5
GENERAL
LUBRICATION DIAGRAMS
12 LUBRICATION DIAGRAMS
GENERAL VIEW
Remark Use only recommended oil and grease.
WB156PS-5
01-15 3
GENERAL
LUBRICATION DIAGRAMS
MEMORANDUM
01-16 3
WB156PS-5
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 POWER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 CLUTCH PACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 FORWARD AND REVERSE PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 DRIVE SHAFT PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 DRIVEN GEAR SHAFT PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 4WD DRIVEN SHAFT PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 FINAL REDUCTION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 WHEEL BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 DELIVERY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25 LS VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 PC VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 PC VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 10-SPOOL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31 CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 PUMPING PLATE CONTROL ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 PRESSURE COMPENSATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39 WB156PS-5
10-1 1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41 LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 LS BYPASS PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 PRESSURE COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47 PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 PPC REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 PPC VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 STANDARD VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 PPC VALVE (FLOAT + RETURN TO DIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67 BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 LEFT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 RIGHT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE BUCKET . . . . . . . . . . . . 10-72 HYDRAULIC CONTROLS WITH MULTI-PURPOSE BUCKET . . . . . . . . . . . . . . . . 10-73 SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 BUCKET RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 BUCKET DUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77 LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79 MULTI-PURPOSE (MP) BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80 BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81 ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83 TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85 OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86 10-2 1
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TABLE OF CONTENTS
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88 LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88 BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
WB156PS-5
10-3 1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
12 POWER TRAIN
B C D E
F G H I
Engine Torque Converter Transmission Hydraulic Pump
Front Axle Rear Axle Front Drive Shaft Rear Drive Shaft
DESCRIPTION ●
The driving power for the engine b is transmitted through the flywheel to the converter c. The converter uses hydraulic oil to convert the torque transmitted by the engine into driving power. The converter transmits motion to the drive shaft of the transmission d and to the drive shaft of the hydraulic pump e.
●
The transmission d has two hydraulically-activated clutches that can be selected by an electrically-controlled gear selector. The same switch also controls the four-speed clutch packs.
●
The driving power is transmitted from the transmission flanges to the front f and rear g axles through the drive shafts h and i. The driving power transmitted to the front f and rear g axles is reduced by the differentials and then transmitted to the planetary gear through the differential shafts.
POWER FLOW
Gear 1st 2nd 3rd 4th
Transmission 5.533 3.360 1.532 0.810
Gear 1st 2nd 3rd 4th
Transmission 5.533 3.360 1.532 0.810
10-4 b
Front Axle Differential
2.462
Rear Axle Differential
2.750
Planet
6.000
Planet
6.400
Total 81.722 49.627 22.627 11.963 Total 97.338 59.136 26.963 14.256
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
12
b Engine c Torque Converter d Transmission e Hydraulic Pump
WB156PS-5
F Front Axle G Rear Axle H Front Drive Shaft I Rear Drive Shaft
j Rear Tires 1) Front Tires
10-5 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION DIAGRAM
12 TRANSMISSION DIAGRAM
b Suction Filter 1) FORWARD Engagement Test Port 1( 1st Gear Engagement c Pump 1! REVERSE Engagement Test Port 2) 2nd Gear Engagement d Oil Screen Drain Valve 1@ FORWARD Engagement 2! 3rd Gear Engagement E Spin-on Filter 1# REVERSE Engagement 2@ 4th Gear Engagement F Torque Converter 1$ 4WD Engagement/disengagement 2# Main Shaft Lubrication (B Shaft) G Cooler 1% Modulating Valve 2$ Output Shaft Lubrication (C/E Shaft) H Torque Converter Pressure Relief Valve 1^ Input Shaft Lubrication (A Pivot) Oil Temperature Thermostat Port 2% From Oil Cooler I Pressure Control/Flow Divider Valve 1& Backhoe Oil Feed Port J Vent 1* Drive Engagement Test Port 10-6 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12 TRANSMISSION
COMPLETE ASSEMBLY
a To Oil Cooler b From Oil Cooler
B Control Valve C Torque Converter D Spin-On Filter
WB156PS-5
E Oil Refill Port F Oil Drain Plug G Oil Temperature Sensor H Vent Plug I Speed Sensor
J Converter Input Pressure Check Port 1) Reverse Pressure Check Port 1! Forward Pressure Check Port 1@ PPC Valve Feed Pressure Check Port
10-7 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12
10-8 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12 VALVE BODY
Electrical Components
B 2nd Gear Solenoid Valve (ED6) C 4WD Solenoid Valve (ED5) D 4th Gear Solenoid Valve (ED2)
WB156PS-5
e Reverse Gear Solenoid Valve (ED4) F Forward Gear Solenoid Valve(ED3) G 3rd Gear Solenoid Valve (ED7)
H 1st Gear Solenoid Valve (ED1)
10-9 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12 CLUTCH PACKS FORWARD AND REVERSE PACK
a
Port Command Reverse Clutch
b
Port Command Forward Clutch
c
Lubrication Port
B Reverse Clutch C Forward Gear
D Reverse Clutch Piston E Forward Clutch Piston F Shoulder Ring G Driven Shaft
DRIVE SHAFT PACK
a
2nd Gear Port
B 3rd Drive Gear 10-10 b
C 2nd Drive Gear D 4th Drive Gear
E 1st Drive Gear F 2nd Gear Piston WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
TRANSMISSION
12 DRIVEN GEAR SHAFT PACK
a
4th Gear Port
b
3rd Gear Port
c
1st Gear Port
B 3rd Gear (Driven)
C 2nd Gear (Driven) D 4th Gear (Driven) E 4WD Drive Gear F 1st Gear (Driven)
G Rear Output Shaft H 1st Gear Piston I 4th Gear Piston J 3rd Gear Piston
4WD DRIVEN SHAFT PACK
a
4WD Disengagement Command Port
B Front Output Shaft
WB156PS-5
C 4WD Disengagement Piston D 4WD Drive Gear
E Piston F Spring
10-11 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 FRONT AXLE
COMPLETE ASSEMBLY
B Steering Cylinder C Oil Refill Plug D Oil Drain Plug
E Tie Rod Nut F Adjustment Screw G Lock Nut
h Mounting Pin Bushing a Left Cylinder Port b Right Cylinder Port Unit: mm Criteria
Check Item i Pin and Bushing Clearance
10-12 b
Standard Size 50
Tolerance Shaft 50
0 -0.039
Bushing 50.19
+0.04 0
Standard Clearance Clearance Limit ---
---
Remedy Replace
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 DIFFERENTIAL
B Side Gear C Ring Gear D Dowel Pin E Driven Gear
F Adjustment Lock Nut G Axle Shaft H Dowel Pin I Differential Housing
J Bearing Spacer 1) Outboard Bearing 1! Lip Seal Ring 1@ Lip Seal Ring Cover
1# Bearing Lock Nut 1$ Inboard Bearing 1% Pinion Gear 1^ Oil Drain Plug Unit: mm
Check Item
1& Axle Clearance 1* Ring and Pinion Gear Backlash 1( Pinion Preload - without lip seal 2) Ring and Pinion Gear Preload - without lip seal
WB156PS-5
Criteria Standard Clearance
Clearance Limit
---
---
0.18 - 0.28
0.28
92 - 137 N•m (3.6 - 5.4 lbf ft)
Remedy
Adjust
129.5 - 194.5 N•m (5.1 - 7.7 lbf ft)
10-13 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
FRONT AXLE
12 PLANETARY
B Planetary Carrier C Planetary Gear D Ring Gear E Carrier Gear F Wheel Hub G Lip Ring Seal H Upper King Pin I Adjustment Shim
J Belleville Washer 1) Upper King Pin Bushing 1! Lip Ring Seal 1@ Axle Housing 1# Spherical Bearing 1$ Lower King Pin Bushing 1% Lower King Pin 1^ Belleville Washer
1& Lip Ring Seal 1* Tapered Roller Bearing 1( Retaining Ring 2) Bolt Bushing 2! Stud Bolt 2@ Oil Drain Plug
Unit: mm
2# Hub Rotation Torque 2$ Axle Shaft Clearance
10-14 b
-----
Adjust
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 REAR AXLE
COMPLETE ASSEMBLY
B Input Flange C Differential Portion D Brake Portion
F Planetary Portion G Parking Brake Levers H Brake Bleeder Screws
a Brake Port ....... 40.8 kg/cm² (580 psi)
E Axle Housing
I Oil Fill and Level Plugs
b
WB156PS-5
J Oil Drain Plug 1) Axle Housing Breather Diff Lock Port.................................... ................1295.4 kg/cm² (18,425 psi)
10-15 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 DIFFERENTIAL
B Tapered Roller Bearing C Side Gear D Rotating Gear E Ring Gear
F Differential Housing G Bearing Lock Nut H Axle Shaft I Tapered Roller Bearing
J Bearing Lock Nut 1) Lip Oil Seal 1! Input Flange 1@ Bearing Spacer
1# Pinion Gear 1$ Differential Housing
Unit: mm Check Item
1% Axle Clearance 1^ Ring And Pinion Gear Backlash 1& Pinion Gear Preload - without seal ring 1* Pinion Ring Gear Preload - without seal ring 10-16 b
Criteria Standard Clearance Clearance Limit ----0.21 - 0.29 mm
0.29 mm
115 - 138 N•m (4.5 - 5.4 lbf ft)
Remedy
Adjust
148 - 188 N•m (5.8 - 7.4 lbf ft)
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 FINAL REDUCTION GEARS
F Axle Shaft G Pressure Plate H Retaining Ring I Ring Nut
B Stud Bolt C Planet Gear D Wheel Hub E Sun Gear
J Tapered Roller Bearing 1) Oil Seal 1! Wheel Flange Unit: mm
Check Item
1@ Hub Rotation Torque 1# Axle Shaft Clearance
WB156PS-5
Criteria -----
Remedy Adjust
10-17 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 WHEEL BRAKES
E Middle Plate F Outer Plate G Belleville Washer
B Bleed Screw C Brake Piston D Friction Disc
H Bushing I Parking Brake Control Caliper J Set Screw Unit: mm
Check Item
1) Hub Rotation Torque
10-18 b
Criteria
Remedy
---
Adjust
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
REAR AXLE
12 DIFFERENTIAL LOCK
B Engagement Pin C Sleeve D Cover
WB156PS-5
E Piston F Bushing G Control Rod
h Fork i Spacer a Diff Lock Port
10-19 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 HYDRAULIC PUMP
COMPONENTS
b Hydraulic Pump c Delivery Control Valve d Oil Refill Plug PORT CONNECTIONS
Ps From Hydraulic Tank
Ps
P1L From Control Valve Pp
P1L Pump Delivery Pressure Input
PLS From Control Valve LS
P1C QD For Pump Delivery Pressure
PM From EV1 Solenoid Valve
Pd2 Drain Plug
PORT FUNCTIONS
Oil Intake
Pen Delivery Control Pressure Check
P1 To Loader Valve
P1 Pump Delivery
PLS LS Signal Input
Pd To Hydraulic Tank
Pd Drain
PM Operating Mode Control Signal
10-20 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 MAIN PUMP
PORT FUNCTIONS Pa Delivery Control Group Feed
WB156PS-5
Pe Delivery Control Signal
Pd5 Drain
Pd4 Drain
PM2 Operating Mode Signal
10-21 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
B Bearing C Input Shaft D Pump Housing E Swash Plate F Shoe
10-22 b
G Piston H Cylinder Block I Swash Plate J Cover 1) Shoe Guide
1! Control Piston 1@ Spring 1# Seal Ring 1$ Ball
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 FUNCTION The rotation and torque transmitted to the pump shaft is converted into hydraulic energy and pressurized oil is delivered according to the load requirements. The amount of oil delivered can be modified by changing the angle of the swash plate. STRUCTURE ●
Groove a supports and makes cylinder block B an integral part of shaft c. The shaft is supported by front d and rear e bearings.
●
The end of piston f is a concave ball, and shoe g is staked to it to form one unit. The piston and shoe form a spherical bearing.
●
Swash plate h is supported by pump body i and ball j, and has a flat surface A. The shoe g remains in contact with the swash plate and slides in a circular movement. Pressurized oil is introduced between the shoe and swash plate forming a static bearing that allows the shoes to slip.
●
Pistons f perform their relative movements in an axial direction, inside the cylindrical chambers fashioned in cylinder block B.
●
The rotation of cylinder block B pressurizes the oil inside the chambers of the block; pressure is adjusted by valve plate 1). The surface of the swash plate is so designed that the oil pressure always remains within acceptable limits. The oil in each chamber is drawn in and discharged through holes in the valve plate.
OPERATION Pump Operation 1.
Cylinder block B rotates with shaft c, and shoe g slides on flat surface A. When this happens, swash plate h rotates on ball j, and angle a between the axis of the cylinder block and axis X of the swash plate changes. The angle a is known as the swash plate angle.
WB156PS-5
10-23 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 2. When axis X of swash plate h retains angle a in relation to the axis of cylinder block B, flat surface A acts as a cam for shoe g. This is why piston f slides inside the cylinder block, creating a difference between volumes E and F and therefore causing the suction and delivery of oil in a quantity that is equivalent to the difference between those volumes (F – E = delivery). When the cylinder block rotates, chamber F decreases in volume causing oil to be delivered to the circuits, while chamber E increases in volume causing oil to be suctioned. The illustration shows the state of the pump when suction at chamber F and delivery at chamber E are complete.
3.
When center line X of swash plate h and the center line of cylinder block B are perfectly aligned, the swash plate angle a = 0, the difference between the volumes E and F within the cylinder block becomes 0 and the pump does not take in or deliver any oil. The angle of the swash plate a is proportional to pump delivery.
Control of Delivery 1.
When angle a of the swash plate increases, the difference between volumes E and F increases too, and this makes delivery Q increase accordingly. Angle a of the swash plate is varied by servo piston 1!.
2.
Servo piston 1! moves in a reciprocating linear motion caused by pressure signals from the PC and LS valves. The linear motion is transmitted to swash plate h. The swash plate is supported by pump body i through ball j, and this is the reason why the swash plate moves in a semicircular alternate motion.
10-24 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 DELIVERY CONTROL VALVE
PORT FUNCTIONS T Drain
WB156PS-5
P1 Delivery Control Group Feed
PE
Pd4 Drain
PM Operating Mode Signal Input
Delivery Control Signal Output
10-25 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12
COMPONENTS
b Lever c Spring d Retainer e Seal f Spool g Sleeve h Piston
10-26 b
i Gasket j Piston 1) Spool 1! Plug 1@ Seat 1# Spring 1$ Nut 1% Plug
PORT FUNCTION T
Drain
PA
Pump Delivery Pressure
PM
Operating Mode Signal Output
PPL
Delivery Control Signal Input
PE
Delivery Control Signal
PLS
LS Signal Input
PPLS LS Pump Signal Input
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 LS VALVE FUNCTION ●
●
●
●
The LS valve controls the pump delivery according to the stroke of the control valve lever, the function of the delivery demands made by the actuators. The LS valve detects the actuator’s delivery needs by means of the differential pressure UPLS existing between pressure PPLS, control valve input pressure, and pressure PLS, control valve output pressure. The sensing of this differential pressure permits control of the main pump delivery Q. PPLS, PLS and UPLS are, respectively, the pump pressure, the Load Sensing pressure, and the difference in pressure between these two values. The LS valve detects the pressure difference UPLS generated by the passage of the oil flow through the surface freed by the control valve spool, and controls the pump delivery Q so as to keep the pressure drop constant. It can therefore be assumed that the pump delivery is proportional to the demands made known by the control valve. Pump pressure PPLS, pump pressure at control valve input, and pressure PLS, Load Sensing pressure, are introduced into the LS valve. The relation between differential pressure UPLS and pump delivery varies as shown in the diagram on the right.
PC VALVE FUNCTION ●
●
●
●
●
The PC, Power Control, valve performs an approximate power check, and ensures that the hydraulic horsepower absorbed by the pump does not exceed the horsepower delivered by the endothermal engine. This is achieved by limiting the pump delivery Q function of the delivery pressure PPLS, even if the LS valve requests an increase in delivery Q due to the larger section freed by the control valve spool, in the presence of high pressure pump delivery. When during operation the delivery Q increases and the delivery pressure PPLS also increases simultaneously, the PC valve reduces the pump delivery Q. When the delivery pressure PPLS decreases, the PC valve increases the pump flow. As pressure PC increases, the relation between pressure PA and delivery Q is switched in accordance with the force applied by pressure PC. When the force applied by pressure PC is added to the force applied by the pump's delivery pressure against the spool f, the relation between pump delivery pressure and delivery is switched from b to in accordance with increment X.
WB156PS-5
10-27 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 PC VALVE OPERATION Spring Operation ●
PC valve spring loading B is defined by swash plate position.
●
If control piston C moves to the right, spring B is compressed by lever D and the spring load increases.
When Pump Pressure PA is Low
●
●
●
The force applied by the pressure against spool e decreases, and spool f shifts slightly to the right. At the same time, a connection opens between ports C and D, and pressurized oil from valve LS is sent for discharge, PT. Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J is sent for relief, PT; control piston c shifts to the left. Pump delivery increases as a result. When control piston c moves, lever d moves to the left, and spring b expands, thereby reducing its load on spool f. Consequently, the spool moves to the left and stops the oil flow between ports C and D, and a passage opens between ports B and C. The pressure at port C increases, and the control piston stops.
10-28 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 When Pump Pressure PA is High
●
●
●
The force applied by the pressure against spool e increases, and spool f shifts slightly to the left. At the same time, a connection opens between ports C and B, and the pressure of the oil sent to valve LS becomes equivalent to the pump's delivery pressure, PA. Simultaneously, ports F and G on valve LS are interconnected, and pressure at port J becomes equivalent to the pump's delivery pressure, PA, and control piston c shifts to the right. Pump delivery decreases as a result. When control piston c moves, lever d moves to the right, and spring b compresses, thereby increasing its load on spool f. Consequently, the spool moves to the right and stops the oil flow between ports C and B, and a passage opens between ports D and C. The pressure at port C decreases, and control piston c stops.
WB156PS-5
10-29 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
HYDRAULIC PUMP
12 When Equilibrium has Been Reached
●
The equilibrium between the force applied by pressure PA against spool e and the force applied by spring b against spool f is what determines the position at which control piston c, pump stops.
10-30 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MAIN CONTROL VALVE
12 MAIN CONTROL VALVE
10-SPOOL CONTROL VALVE
WB156PS-5
10-31 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MAIN CONTROL VALVE
12
A1 Arm Cylinder (Head side) B8 Arm Raise Cylinder (Head side) PA6 From Solenoid Valve EV1 (A1 port) A2 Boom (LH-RH) swing (Bottom side) B9 RH Outrigger (Head side) PA7 From Solenoid Valve EV2 (A2 port) A3 Loader Bucket Cylinder (Bottom side)B10 LH Outrigger (Head side) PA8 From Bucket PPC Valve (P3 port) A4 Backhoe Boom (Bottom side) LS To Hydraulic Pump (PLS port) PA9 From Outriggers PPC Valve (P1 port) A5 Backhoe Bucket Cylinder (Head side) P From Hydraulic Pump (P1 port) PA10 From Outriggers PPC Valve (P3 port) A6 4 in1 Bucket Cylinder (Bottom side) D To Steering Unit (P port) PB1 From Backhoe LH PPC Valve (Port 1) A7 Telescopic Arm (Bottom side) DLS From Steering Unit (LS port) PB2 From Backhoe LH PPC Valve (Port 2) A8 Arm Raise Cylinder (Bottom side) PP To Hydraulic Pump, (P1L port) PB3 From Bucket PPC Valve (P1 port) A9 Right Outrigger (Bottom side) T To Hydraulic Tank PB4 From Backhoe RH PPC Valve (Port 1) A10 Left Outrigger (Bottom side) TS To Hydraulic Tank PB5 From Backhoe RH PPC Valve (Port 2) B1 To Arm Cylinder (Bottom side) PPPC To Solenoid Valve EV1 (P port) PB6 From Solenoid Valve EV1 (B1 port) B2 Boom (LH-RH) swing (Head side) SS Backhoe Plate Lock Cylinder PB7 From Solenoid Valve EV2 (B2 port) B3 Bucket Cylinders (Head side) PA1 From Backhoe LH PPC Valve (Port 3) PB8 From Bucket PPC Valve (P4 port) B4 Boom Cylinder (Head side) PA2 From Backhoe LH PPC Valve (Port 4) PB9 From Outriggers PPC Valve (P2 port) B5 Backhoe Bucket (Bottom side) PA3 From Bucket PPC Valve (P2 port) PB10 From Outriggers PPC Valve (P4 port) B6 4 in1 Bucket Cylinder (Head side) PA4 From Backhoe RH PPC Valve (Port 3) B7 Telescopic Arm (Head side) PA5 From Backhoe RH PPC Valve (Port 4)
10-32 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MAIN CONTROL VALVE
12
B Anti-cavitation Valve (Telescopic Arm Extend) C Anti-cavitation Valve (Backhoe Bucket Curl) d Anti-shock/Anti-cavitation Valve (Boom Raise) e Anti-cavitation Valve (Bucket Dump) f Anti-shock/Anti-cavitation Valve (LH Swing) g Anti-cavitation Valve (Arm Out) h Safety Valve i Anti-cavitation Valve (Arm In) j Anti-shock/Anti-cavitation Valve (RH Swing) 1) Anti-shock/Anti-cavitation Valve (Bucket Curl) 1! Anti-cavitation Valve (Boom Lower) 1@ Anti-cavitation Valve (Backhoe Bucket Dump) 1# Anti-cavitation Valve (Telescopic Arm Retract)
WB156PS-5
1$ Anti-cavitation Valve (4 in 1 Bucket Dump) 1% Spool (Backhoe Bucket Control) 1^ Spool (Telescopic Arm Control) 1& Spool (4 in 1 Bucket Control) 1* Spool (Backhoe Bucket Control) 1( Spool (Boom Control) 2) Spool (Front Bucket Control) 2! Spool (Boom Swing Control) 2@ Spool (Arm Control) 2# Spool (Priority Valve) 2$ Unloading Valve 2% LS Bypass Plug
10-33 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Pressure Reducing Valve
B Bucket Arm C Telescopic Arm d 4 in 1 Bucket e Backhoe Bucket f Boom g Front Bucket h Boom Swing i Arm
10-34 b
MAIN CONTROL VALVE
Delivery Control Valve
j Arm 1) Boom Swing 1! Front Bucket 1@ Boom 1# Backhoe Bucket 1$ 4 in 1 Bucket 1% Telescopic Arm 1^ Bucket Arm 1& Maximum Pressure Valve 1* Check Valve 1( Check Valve 2) Check Valve
2! Check Valve 2@ Check Valve 2# Check Valve 2$ Check Valve 2% Check Valve 2^ Check Valve 2& LS, DLS Pressure Check Valve 2* LS Bypass Plug
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
b Spool Right Outrigger Control e Backhoe Plate Lock Valve c Spool Left Outrigger Control f Spool Bucket Arm Control d Backhoe Plate Lock Solenoid Valve g Spool Backhoe Bucket Control
WB156PS-5
MAIN CONTROL VALVE
H Spool Boom Control i Spool Front Bucket Control j Spool Boom Swing Control
10-35 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
MAIN CONTROL VALVE
12
b Servo Control Maximum Pressure Valve c Maximum Pressure Valve Spool d Sequential Reducing Valve
10-36 b
e Blow Out Plug f Unloading Valve g LS Bypass Plug
H Arm Spool
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 CLSS
DESCRIPTION CHARACTERISTICS The term CLSS means Closed center Load Sensing System and has the following characteristics: ●
High precision control that is independent of the load applied to the movement.
●
High precision control of digging action even during delicate maneuvers.
●
Ability to perform complex operations, guaranteed by control of oil flow in function of the aperture surfaces of the shuttles.
●
Energy savings guaranteed by control of pump delivery.
STRUCTURE ●
●
The CLSS system includes the variable flow pump, the control valve and the working equipment. The pump includes the main pump, the PC valve and the LS valve.
WB156PS-5
10-37 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 OPERATING PRINCIPLES PUMPING PLATE CONTROL ANGLE ●
●
●
The angle of the swash plate and the pump delivery, is controlled in such a way that the differential pressure UPLS between the delivery pressure PP of the pump and the pressure PLS at the outlet of the control valve towards the actuator is maintained at a constant value. UPLS equals pump delivery pressure PP minus pressure PLS of delivery to the actuator.
If the differential pressure UPLS becomes lower than the set pressure of the LS valve, the angle of the swash plate increases and delivery increases. If the differential pressure UPLS increases, the angle of the swash plate decreases and delivery decreases.
10-38 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 PRESSURE COMPENSATION CONTROL ●
The pressure compensation valves are installed downstream from the control valve in order to balance the differential pressure between the loads. When two or more movements, cylinders, are activated simultaneously, the pressure differences UP between the delivery at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain the distribution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
WB156PS-5
10-39 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 MAIN CONTROL VALVE 10-Spool Control Valve 1.
Unloading Valve Pressure .............. LS + 27.05 kg/cm² (385 psi)
2.
Main Pressure Relief Valve....................... 218 kg/cm² (3,100 psi)
3.
Safety Valve .............................................. 270 kg/cm² (3,840 psi)
4.
Check Valve
5.
Anti Shock/Cavitation Valve..................... 215 kg/cm² (3,058 psi)
6.
Anti Shock/Cavitation Valve..................... 220 kg/cm² (3,129 psi)
7.
Anti Shock/Cavitation Valve..................... 350 kg/cm² (4,978 psi)
8.
Pressure Compensation Valve
9.
Priority Valve
10. Servo Controls Reducing Valve .................. 37.3 kg/cm² (540 psi) 11. Not Applicable
10-40 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 UNLOADING VALVE Neutral Position FUNCTION ●
When the control valve is in NEUTRAL position, pump delivery Q, resulting from the swash plate being at its minimum angle, is sent into the tank circuit. When this happens, the pump's delivery pressure PP is regulated at 28 kg/cm² (398 psi) by means of spring c inside the valve. LS signal with PLS pressure = 0 kg/cm² (0 psi).
OPERATING ●
●
Pump pressure PP acts on spool b on surface S1, and on surface S2, whereas PLS pressure acts on surface S2. Since no LS signal with PLS pressure is generated when the control valve is in NEUTRAL position, the only pressure acting on spool in this condition is the pump's delivery pressure PP as regulated by spring compression c. As the pump's delivery pressure PP increases and the resulting force equals spring loading c, spool b shifts to the right. The pump's delivery circuit PP is then connected to the tank circuit T by means of the holes in spool. This ensures that the pump delivery pressure PP stays regulated at 28 kg/cm² (398 psi). PP ................................................................................Pump Circuit PLS ................................................................ Load Sensing Circuit T.................................................................................... Tank Circuit
WB156PS-5
10-41 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
Control Valve Fine Control FUNCTION ●
When the actuators' delivery needs during fine control are within the delivery values related to the minimum angle of the swash plate, the pump's delivery pressure PP is regulated by pressure PLS at 28 kg/cm² (398 psi). Since the unloading valve opens when the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring load c, 28 kg/cm² (398 psi), the differential pressure UPLS becomes 28 kg/cm² (398 psi).
OPERATING ●
●
●
When fine controls are performed at the control valve, a PLS pressure is generated. This pressure acts on surface S3 on the right hand side of spool b. Since pressure PLS of LS is low, because the control valve passage is small, the difference with the pump's delivery pressure PP is great. When the differential pressure between the pump's delivery pressure PP and pressure PLS of the LS equals spring loading c 28 kg/cm² (398 psi), spool b shifts to the right and, in turn, the pump circuit PP connects to the tank circuit T. The pump's delivery pressure PP is regulated by the combination of the pressure from the spring, 28 kg/cm² (398 psi), and the pressure PLS of the LS, when the differential pressure UPLS reaches a value of 28 kg/cm² (398 psi).
10-42 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 Control Valve is in Use FUNCTION ●
When the request for oil flow from the actuators exceeds the minimum delivery of the pump during use of the control valve, the connection to the tank circuit is eliminated and the entire pump delivery Q is sent to the actuators.
OPERATING ●
●
●
When the control valve spool performs a longer travel, this generates a pressure PLS of the LS, which acts on the right side of spool b. Since the control valve passage is wide, the difference between the pressure PLS of the LS and the pump's delivery pressure PP is small. For this reason, since the differential pressure between the pump's delivery pressure PP and the pressure PLS of the LS fails to reach the spring loading pressure value of spring c 28 kg/cm² (398 psi), spool b is pushed to the left by the spring. The result is that the connection between the pump delivery circuit PP and the tank circuit T is excluded and the entire pump delivery Q is sent to the actuators.
WB156PS-5
10-43 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 LS PRESSURE Function ●
LS pressure is the actuator's pressure at control valve output. This pressure actually reduces the pump's PP pressure via the pressure compensation group reducing valve D to the same A pressure of the actuator circuit and then sends it into the PLS circuit of the LS. In the outriggers’ control valve, the actuator's pressure A is introduced directly into circuit PLS of the LS.
Operation Without Outriggers ●
●
When spool B is operated, pump pressure PP starts flowing into the circuit of actuator A from delivery control valve C and from the notch a via the duct b. At the same time, pressure reducing valve D moves to the right making the pump's pressure PP drop as it flows through the bottleneck c, and causing the pressure to flow into the circuit PLS of the LS and into the chamber of spring PLSS. At this point, the PLS circuit of the LS is connected to the tank circuit T by means of bypass plug E. The pressure acting on the left side of reducing valve D is pressure PA of the actuator, and the pressure acting on the right hand side is the reduced pressure PP of pump delivery. The reducing valve balances out when pressure PA of the actuators and pressure PLSS of the spring chamber are balanced. This in turn allows the pressure PP, now reduced by the bottleneck c, to be introduced into the PLS circuit of the LS at the same pressure A as the actuator's circuit.
10-44 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
●
When spool b is operated, pump pressure PP starts flowing into the circuit of actuator A through the duct a.
●
At the same time, pressurized oil is introduced into the PLS circuit of the LS through holes b.
CLSS
★ The outriggers’ circuit differs from the working equipment circuit in that the operating pressure of actuator A is introduced directly into the PLS circuit of the LS.
WB156PS-5
10-45 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 LS BYPASS PLUG Description ● ●
The LS bypass plug unloads residual pressure from the load sensing PLS circuit. This makes the increment rate of load sensing PLS pressure smoother. By eliminating oil through the bottleneck, a loss of pressure is generated in the flow that is controlled by the spool, and stability is increased as a result, thereby reducing the actual differential pressure LS.
Operation ●
Pressurized oil in the Load Sensing PLS circuit flows through filter a, through orifice b and into the tank circuit T.
10-46 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 PRESSURE COMPENSATION Function ●
Pressure compensation occurs during simultaneous operation of several movements, specifically when the pressure of an actuator becomes lower than the pressure of the actuator on the opposite side, and pump delivery is on the verge of being increased. In this case, the right actuator withstands a higher pressure than the left actuator.
Operation ●
●
●
During operation together, when right actuator pressure increases, delivery in circuit A of the left actuator tends to increase. The PLS pressure of the LS for the right actuator acts on chamber PLS1 of the spring and pushes pressure reducing valve b and delivery control valve c to the left. The delivery control valve produces a bottleneck between the pump's delivery PP circuit and the PPA circuit upstream of the control valve spool. This bottleneck generates a pressure loss between circuits PP and PPA. Delivery control valve c and pressure reducing valve b are balanced out at a point where the differential pressure between PA and PLS, these two acting on both surfaces of the pressure reducing valve, equals the loss of pressure between PP and PPA, these two acting on both surfaces of the delivery control valve. The differential pressure between the upstream pressure PPA and the downstream pressure of both spools in the control valves concerned in the movement together are equalized, and pump delivery is distributed proportionally to the sections a that are responsible for opening the notches of each spool.
WB156PS-5
10-47 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 PRESSURE COMPENSATION VALVE Function ●
In order to equalize the characteristics of each actuator, the pressure compensation valve will determine the compensation characteristics by performing a micrometer adjustment of the surface ratio S1/S2. This is the ratio of area S1, delivery control valve c end, to area S2, pressure reducing valve b end. S1 surface of delivery control valve c minus surface of piston d. S2 surface of pressure reducing valve b minus surface of piston d.
Compensation Characteristics ●
●
●
When the ratio is 1.00: Pump pressure PP minus pressure PPA upstream of spool ≅ load sensing PLS pressure - actuator PA pressure (= A). Delivery is distributed proportionally to the opening surfaces of the spool. When the ratio is > 1.00: PP - PPA > PLS - PA (= A). Delivery distribution is lower than the proportion of the opening surfaces of the spool. When the ratio is < 1.00: PP - PPA < PLS - PA (= A). Delivery distribution is higher than the proportion of the opening surfaces of the spool.
10-48 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 PRIORITY VALVE Function ● ●
●
The purpose of the priority valve is to feed pressurized oil to the steering unit and to the other actuators. Oil distribution is determined by the position of spool b of the priority valve, which is in turn determined by LS signal, pump delivery, steering circuit pressure, and hydraulic circuit pressure. The position of spool b is determined in such a way as to ensure that the oil delivered to the steering unit matches the delivery needs at any time.
WB156PS-5
10-49 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 PPC REDUCING VALVE Function ●
This valve regulates the PPC feed pressure at 30 kg/cm² (427 psi). When actuator pressure is low, the sequential valve closes to permit an increase in the pump's delivery pressure PP in order to supply pressure to the servo controls.
Neutral Condition ● ●
Spool b of the unloading valve moves, and delivery pressure is regulated at 30 kg/cm² (427 psi). Spool c and valve d reduce the pump's delivery pressure PP to 30 kg/cm² (427 psi). Pressure is then sent to the controls via port PC.
10-50 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12 Control Valve Operated
●
●
●
Spool b of the unloading valve moves to the left, and the pump's delivery pressure exceeds the pressure of the actuator circuit f by an amount equivalent to LS differential pressure. If the pump's delivery pressure PP exceeds 30 kg/cm² (427 psi), valves c and d reduce pressure PP to 30 kg/cm² (427 psi). The reduced pressure is then sent to the controls via port PC. When this occurs, sequential reducing valve e stays open.
WB156PS-5
10-51 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
CLSS
12
●
●
When the pump's delivery pressure PP is lower than 30 kg/cm² (427 psi), the sequential reducing valve shifts to the right, thereby reducing the flow of the PP pressure to actuator circuit f. This generates a pressure gap between PP pressure and actuator pressure. PP pressure is incremented in excess of 30 kg/cm² (427 psi) and is then reduced to 30 kg/cm² (427 psi) by valves c and d to guarantee pressure feed to the controls.
10-52 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
STEERING UNIT
12 STEERING UNIT
a Port L - To Steering Cylinder b Port R - To Steering Cylinder
c Port T - To Hydraulic Oil Tank d Port P - To Control Valve
e Port P - From Control Valve
TECHNICAL DATA Steering unit type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OSPC200LS Normal flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 l (5.3 gal)/min
OPERATION ●
The steering unit consists of a control valve and a rotating oil dispenser, and is of the hydrostatic type. When the steering wheel is turned, the control valve sends oil from the pump P2, by means of the rotating oil dispenser, to one side of the steering cylinder.
●
The rotating dispenser ensures that the oil volume applied to the cylinder is proportionate to the angle of rotation of the steering wheel. In the event of malfunction, the rotating oil dispenser will function automatically as a hand pump, thus guaranteeing auxiliary steering.
WB156PS-5
10-53 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 PPC VALVES
STANDARD VALVE
P1 To Control Valve - PB3 Port P2 To Control Valve - PA3 Port
10-54 b
P3 To Control Valve - PA8 Port P4 To Control Valve - PB8 Port
P From EV1 Solenoid Valve (VL Port) T To Hydraulic Tank
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12
B Spool C Adjusting Screw (Inner) d Adjusting Screw (Outer) e Piston f Disk
WB156PS-5
g Nut h Joint i Cover j Retainer 1) Body
10-55 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 OPERATION Neutral Position BUCKET PORTION ●
Control valve ports A and B and PPC valve ports P1 and P2 are connected to discharge chamber D by means of the calibrated hole f in spool b.
BOOM PORTION ●
Control valve ports A and B and PPC valve ports P3 and P4 are connected to discharge chamber D by means of the calibrated hole f in spool b.
10-56 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
Fine Control, Neutral J Actuator ●
●
●
●
●
●
When disk f starts pushing down on piston e and piston 1), retainer j moves as a result. This movement will compress spring c which will in turn acts on spool b and push it downwards. As a result of this action, the calibrated hole f will be isolated from the drain chamber D and at almost at the same time it will be put in connection with the PP chamber, which is directly connected to the loader control circuit. Pressure in the loader control circuit will flow through the calibrated hole f and into the circuit thereby increasing the pressure in port P1/ B. When pressure P1 increases, spool b is pushed upwards, and calibrated hole f is connected back to discharge chamber D thereby compressing spring c. The floating of spool b will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP, until the pressure in duct P1, the pressure acting on the section of stem b, offsets the force applied by spring c. Spring c is compressed proportionally to the movement of disk f and pressure at P1 increases in proportion to the travel of the disk. The equilibrium position is then kept until the position of piston e is changed: 1. As long as pressures at ports B and P1 are perfectly balanced; 2. Until pressure in section B/P1, the pressure acting on stem b, is enough to counteract the force of spring c.
●
This ensures proportionality between control lever position, B/P1 circuit pressure, and main control valve stem displacement.
WB156PS-5
10-57 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 Fine Control, Actuator J Neutral ●
●
●
When disk f is released and moved to neutral position, piston e is pushed upwards by spring d acting on retainer j, and spool b is thrust upwards both by the force of spring c and by the force that the pressure in section B/P1 applies against the stem. This movement moves the calibrated hole f of spool into the discharge chamber D, thereby allowing pressure in section B/P1 to be released. If pressure P1 drops too quickly, spool b is pushed downwards by spring c and the calibrated hole f becomes cut off from the discharge chamber D; at almost the same time, the calibrated hole f is put in connection with pressure chamber PP and starts supplying pressure to section P1 until the pressure corresponding to the control lever position is balanced. When the spool of the control valve returns, oil flows back into chamber D, through calibrated hole f, and into chamber B of the control valve spool opposite the operating one. Oil flows through duct P2 and into chamber B to ensure it is filled properly.
Fine Control, Neutral J Full Stroke ●
●
When disk f pushes down on piston e, and retainer j pushes down on spool b, calibrated hole f is put in direct connection with chamber PP, which is in turn connected to a constantly pressurized loader control circuit. Oil is then allowed to flow directly into section B/P1 thereby pushing the stem of the main control valve to the end of its travel. This causes the main control valve to send the oil contained in chamber AB towards input P2, through calibrated hole f and into relief chamber D.
10-58 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 Control Lever to Float Position ●
If piston e and piston 1) of the spool controlling the arm, port P4, are pushed downwards by disk f, the mechanism inside the PPC valve will start locking the spool halfway along its travel.
●
If piston e is pushed upwards and the solenoid in the PPC valve is energized, the force generated by the solenoid will retain the piston in place and the arm float condition will be retained, even if the lever is released.
●
At the same time, the control valve will also be activated and retained in the arm float position.
Control Lever from Float Position ●
Disk f can be moved back to neutral position by applying a force that exceeds the force applied by the solenoid.
●
The floating state can also be cancelled, and the lever can move back to neutral position by de-energizing the solenoid.
WB156PS-5
10-59 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 PPC VALVE (FLOAT + RETURN TO DIG)
P1 To Control Valve - PB3 Port P2 To Control Valve - PA3 Port
10-60 b
P3 To Control Valve - PA8 Port P4 To Control Valve - PB8 Port
P From EV1 Solenoid Valve (VL Port) T To Hydraulic Tank
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12
B Spool C Adjusting Screw (Inner) d Adjusting Screw (Outer) e Piston f Disc g Disc
WB156PS-5
h Joint i Cover j Retainer 1) Piston 1! Body
10-61 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 OPERATION Control Lever in Neutral Position BUCKET PPC VALVE ●
Control valve ducts A and B and PPC valve ducts P1 and P2 are connected to discharge chamber D by means of the calibrated hole f in spool B.
BUCKET RAISE PPC VALVE ●
Control valve ducts A and B and PPC valve ducts P3 and P4 are connected to discharge chamber D by means of the calibrated hole f in spool B.
10-62 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 Fine Control, Neutral J Actuator ●
●
●
When disk f starts pushing down on piston e and piston 1), retainer j moves as a result. This movement will compress spring C which will in turn act on spool B and push it downwards. As a result of this action, the calibrated hole f will be isolated from the drain chamber D and at almost at the same time it will be put in connection with the PP chamber, which is directly connected to the servo controls circuit. Pressure in the servo controls circuit will flow through the calibrated hole f and into the circuit thereby increasing the pressure in duct P1-B. When pressure P1 increases, spool B is pushed upwards, and calibrated hole f is connected back to discharge chamber D thereby compressing spring C. The floating of spool B will continue until calibrated hole f is halfway between discharge chamber D and pressure chamber PP, in other words until the pressure in duct P1 - the pressure acting on the section of stem B - offsets the force applied by spring C. Spring C is compressed proportionally to the movement of disk f and therefore, pressure at P1 increases in proportion to the travel of disk f. The equilibrium position is then kept until the position of piston e is changed, i.e.: a) as long as pressures at ports B and P1 are perfectly balanced; b) until pressure in section B-P1, (i.e. the pressure acting on stem B) is enough to counteract the force of spring C.
●
This ensures proportionality between control lever position, B-P1 circuit pressure, and main control valve stem displacement.
WB156PS-5
10-63 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
Fine Control, Actuator J Neutral ●
●
●
When disk f is released and moved to neutral position, piston e is pushed upwards by spring d acting on retainer j, and spool b is thrust upwards both by the force of spring c and by the force that the pressure in section B/P1 applies against the stem. This movement moves the calibrated hole f of spool into the discharge chamber D, thereby allowing pressure in section B/P1 to be released. If pressure P1 drops too quickly, spool b is pushed downwards by spring c and the calibrated hole f becomes cut off from the discharge chamber D; at almost the same time, the calibrated hole f is put in connection with pressure chamber PP and starts supplying pressure to section P1 until the pressure corresponding to the control lever position is balanced. When the spool of the control valve returns, oil flows back into chamber D, through calibrated hole f, and into chamber B of the control valve spool opposite the operating one. Oil flows through duct P2 and into chamber B to ensure it is filled properly.
Fine Control, Neutral J Full Stroke ●
●
When disk f pushes down on piston e, and retainer j pushes down on spool b, calibrated hole f is put in direct connection with chamber PP, which is in turn connected to a constantly pressurized loader control circuit. Oil is then allowed to flow directly into section B/P1 thereby pushing the stem of the main control valve to the end of its travel. This causes the main control valve to send the oil contained in chamber AB towards input P2, through calibrated hole f and into relief chamber D.
10-64 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
When Control Lever is Moved to Float Position ●
●
●
If piston e and piston 1) of the spool controlling the arm (port P4) are pushed downwards by disk f, the mechanism inside the PPC valve will start locking the spool halfway along its travel. If piston 42 is pushed upwards and the solenoid in the PPC valve is energized, the force generated by the solenoid will retain the piston 4 in place and the arm float condition will be retained, even if the lever is released. At the same time, the control valve will also be activated and retained in the arm float position.
When Control Lever is Moved from Float to Neutral Position ●
●
Disk f can be moved back to neutral position by applying a force that exceeds the force applied by the solenoid. The floating state can also be cancelled, and the lever can move back to neutral position by de-energizing the solenoid.
WB156PS-5
10-65 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 OUTRIGGER
PORTS
P From EV1 Solenoid Valve T To Hydraulic Tank
To Control Valve - PA7 Port (8 Spool) To Control Valve - PA9 Port (10 Spool) To Control Valve - PB7 Port (8 Spool) P2 B Handle Knob To Control Valve - PB9 Port (10 Spool) To Control Valve - PA8 Port (8 Spool) P3 C Stop To Control Valve - PA10 Port (10 Spool) To Control Valve - PB7 Port (8 Spool) P4 D Handle To Control Valve - PB10 Port (10 Spool) P1
10-66 b
E Boot F Mounting Plate G Left Outrigger H Right Outrigger
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 OPERATION Neutral Position ●
Ports A and B of the main control valve and ports P1 and P2 of the outrigger valve are connected to the tank circuit, the spool is in neutral position.
WB156PS-5
10-67 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 Fine Control, Neutral J Actuator ●
●
When lever b is moved in the direction shown by the arrow, valves c are rotated and a passage is opened between delivery duct a and port P1, while port P2 remains connected to the tank circuit. Pressure at port P1 increases as the travel of lever b increases. Consequently, the spool of the control valve moves to the left by a distance that is proportional to the travel of the lever.
10-68 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 Full Lever, Actuator J Neutral ● ●
When lever b is moved fully to the left, valves c are fully rotated. Port P1 is then connected directly to delivery duct a whereas port P2 is connected to tank circuit only, and the spool of the control valve performs its full travel.
WB156PS-5
10-69 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 BACKHOE LEFT VALVE
PORTS 1 To Arm Out Valve, PB1 Port T To Hydraulic Tank
10-70 b
4 To Swing Left Valve, PA2 Port 3 To Arm in Valve, PA1 Port P To EV1 Solenoid Valve, VBH Port
2 To Swing Right Valve, PE2 Port
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PPC VALVES
12 RIGHT VALVE
PORTS 1 To Boom Raise Valve, PB4 Port T To Hydraulic Tank
WB156PS-5
4 To Bucket Dump Valve, PA5 Port 3 To Boom Lower Valve, PA4 Port P To EV1 Solenoid Valve, VBH Port
2 To Bucket Curl Valve, PB5 Port
10-71 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
12 SOLENOID VALVE
HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE BUCKET
PORTS ACC Accumulator P1
Pressure Tap
P2
To Outrigger PPC Valve, Port P
A2
To Boom Lock Cylinder
B2
To Rear Axle
10-72 b
VBH To Backhoe PPC Valves, Port P VL
To Loader PPC Valves, Port P PM To Hydraulic Pump, Port PM P From Control Valve, Port PPPC
T
C Boom Lock Solenoid, Y95 D Backhoe PPC Solenoid, Y90 E Loader PPC Solenoid, Y93 F Ecopower Solenoid, Y91
To Hydraulic Tank
B Differential Lock Solenoid, Y94
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SOLENOID VALVE
12 HYDRAULIC CONTROLS WITH MULTI-PURPOSE BUCKET
PORTS
VL
ACC Accumulator
A1
P1
Pressure Tap
B1
P2
To Outrigger PPC Valve, Port P
A2 B2
To Boom Lock Cylinder To Rear Axle
VBH To Backhoe PPC Valves, Port P
WB156PS-5
To Loader PPC Valves, Port P To Control Valve, Port PA6
To Control Valve, Port PB6 PM To Hydraulic Pump, Port PM P From Control Valve, Port PPPC T
To Hydraulic Tank
C Boom Lock Solenoid, Y95 D Backhoe PPC Solenoid, Y90 E Loader PPC Solenoid, Y93 f Bucket Open Solenoid, Y98 g Bucket Close Solenoid, Y99 h Ecopower Solenoid, Y91
B Differential Lock Solenoid, Y94
10-73 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SAFETY VALVES
12 SAFETY VALVES
BUCKET RAISE
a
To Raise Cylinders (Head Side) (Port PIL)
b
From Control Valve (8 Spool) (Port A6) From Control Valve (10 Spool) (Port A8)
C To Raise Cylinders (Bottom Side)
10-74 b
Components B Solenoid Valve
Characteristics Safety Valve Calibration 3,190 ±145 psi
C Adjusting Screw D Spring E Spool F Unlock Screw
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SAFETY VALVES
12 BUCKET DUMP
Characteristics a b
To Dump Cylinders (Bottom Side) (Port PIL) To Dump Cylinders (Head Side) (Port C2)
Safety Valve Calibration 3,191 ±145 psi
C From Control Valve (8 Spool) (B3 Port)
WB156PS-5
10-75 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SAFETY VALVES
12 BOOM
Characteristics a To Boom Cylinders (Bottom Side) (Port PIL) b From Control Valve (Port B4) C To Boom Cylinder (Head Side) (C2 Port)
10-76 b
Safety Valve Calibration 1: 3,626 ±218 psi Safety Valve Calibration 1: 2,901 ±290 psi
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
SAFETY VALVES
12 ARM
Characteristics
a To Arm Cylinders (Bottom Side) (Port PIL) b From Control Valve (Port A1) C To Arm Cylinder (Head Side) (C2 Port)
WB156PS-5
Safety Valve Calibration 1: 4,351 ±145 psi
10-77 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER CYLINDERS
12 LOADER CYLINDERS
BOOM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four-Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Gland i Piston Stop Unit: mm Criteria
Check Item
j Piston Rod to Head 1) Bushing in Piston Rod 1! Bushing in Barrel
Standard Size
Tolerance OD
ID
Standard Clearance
67
67.25
67.2
0.05
67
67.25
67.2
0.05
Clearance Limit
Remedy
36 Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 50 Maximum Cylinder Length.............................................................. 1740 Minimum Cylinder Length............................................................... 1170 Cylinder Barrel Bore ............................................................................ 90 Piston Stroke....................................................................................... 570 Rod Thread for Piston Nut ................................................................M36
10-78 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER CYLINDERS
12 BUCKET
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four-Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Gland Unit: mm Criteria
Check Item
Standard Size
Tolerance OD
ID
Standard Clearance
i Piston Rod to Head
33
j Bushing in Piston Rod
52
52.25
52.20 52.30
0.05 -0.05
1) Bushing in Barrel
57
57.25
57.20 57.30
0.05 -0.05
Clearance Limit
Remedy
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 45 Maximum Cylinder Length.............................................................. 2145 Minimum Cylinder Length............................................................... 1400 Cylinder Barrel Bore ............................................................................ 70 Piston Stroke....................................................................................... 745 Rod Thread for Piston Nut ................................................................M33
WB156PS-5
10-79 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
LOADER CYLINDERS
MULTI-PURPOSE (MP) BUCKET
A Cylinder Rod B Cylinder Rod End Bushing C Cylinder Gland
D Cylinder Piston E Four-Piece Piston Seal F Retaining Nut
G Cylinder Barrel
Unit: mm Criteria Check Item
Standard Size
h Piston Rod to Head
40
i Bushing in Piston Rod
50
Tolerance OD
ID
Standard Clearance
51.88 52.12
52.39 52.39
0.51 0.27
Clearance Limit
Remedy
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 40 Maximum Cylinder Length................................................................ 705 Minimum Cylinder Length................................................................. 475 Cylinder Barrel Bore ............................................................................ 85 Piston Stroke....................................................................................... 230 Rod Thread for Piston Nut ................................................................M24
10-80 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 BACKHOE CYLINDERS
BOOM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel D Stop Ball
E Four-Piece Piston Seal F Cylinder Piston G Cylinder Rod H Cylinder Gland
i Set Screw j Stop Pin 1) Check Valve 1! Check Valve Spring Unit: mm Criteria
Check Item
1@ Piston Rod to Head 1# Bushing in Piston Rod 1$ Bushing in Barrel
Standard Size
Tolerance OD
ID
Standard Clearance
Clearance Limit
Remedy
43 Replace
75 75
Unit: mm Spring Criteria Check Item
Standard Size Free Length
1% Check Valve Spring
Installed Length Installed Load
35
Repair Limit Free Length
Remedy
Installed Load
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 60 Maximum Cylinder Length.............................................................. 2160 Minimum Cylinder Length............................................................... 1310 Cylinder Barrel Bore .......................................................................... 120 Piston Stroke....................................................................................... 850 Rod Thread for Piston Nut ................................................................M42
WB156PS-5
10-81 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 ARM
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four-Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Gland i Piston Spacer Unit: mm Criteria
Check Item
j Bushing in Piston Rod 1) Bushing in Barrel 1! Piston Rod
Standard Size
Tolerance OD
ID
Standard Clearance
Clearance Limit
Remedy
60 Replace
60 60
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 60 Maximum Cylinder Length.............................................................. 1795 Minimum Cylinder Length............................................................... 1065 Cylinder Barrel Bore .......................................................................... 115 Piston Stroke....................................................................................... 700 Rod Thread for Piston Nut ................................................................M42
10-82 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 BUCKET
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Piston Retaining Nut E Four-Piece Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Gland Unit: mm Criteria
Check Item
i Piston Rod to Head j Bushing in Piston Rod 1) Bushing in Barrel
Standard Size
Tolerance OD
ID
Standard Clearance
Clearance Limit
Remedy
55 Replace
55 55
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 55 Maximum Cylinder Length.............................................................. 1850 Minimum Cylinder Length............................................................... 1085 Cylinder Barrel Bore .......................................................................... 110 Piston Stroke....................................................................................... 765 Rod Thread for Piston Nut ................................................................M36
WB156PS-5
10-83 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 TELESCOPIC ARM CYLINDER
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel
D Wear Rings E Piston Seal F Cylinder Piston
G Cylinder Rod H Cylinder Gland Unit: mm Criteria
Check Item
Standard Size
Tolerance OD
ID
Standard Clearance
i Piston Rod to Head
40
j Bushing in Piston Rod
47
47.2
47.21 47.3
0.01 0.1
1) Bushing in Barrel
47
47.15
47.21 47.3
0.01 0.1
Clearance Limit
Remedy
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 40 Maximum Cylinder Length.............................................................. 2590 Minimum Cylinder Length............................................................... 1450 Cylinder Barrel Bore ............................................................................ 85 Piston Stroke..................................................................................... 1140 Piston Rod Thread.............................................................................M30
10-84 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 SWING
A Piston Rod Bushing B Cylinder Rod C Cylinder Barrel
D Cushion Valve E Piston Seal F Cylinder Piston
G Retaining Screw H Cylinder Gland Unit: mm Criteria
Check Item
i j 1) 1!
Standard Size
Piston Rod to Head
50
Piston Rod Bushing
68
Inner Pivot Bushing
50
Outer Pivot Bushing
60
Tolerance OD
ID
Standard Clearance
Clearance Limit
Remedy
Replace
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 50 Maximum Cylinder Length............................................................. 514.5 Minimum Cylinder Length.................................................................. n/a Cylinder Barrel Bore .......................................................................... 100 Piston Stroke....................................................................................... 230 Piston Rod Thread.............................................................................M42
WB156PS-5
10-85 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
12 OUTRIGGER
A Piston Rod Bushing B Barrel Bushing C Cylinder Barrel D Retarder Pin
E Piston Seal F Cylinder Piston G Cylinder Rod H Cylinder Gland
i Piston Retaining Nut j Detent Ball
Unit: mm Criteria Check Item
1) Piston Rod to Head 1! Bushing in Piston Rod 1@ Bushing in Barrel
Standard Size
Tolerance OD
ID
Standard Clearance
Clearance Limit
Remedy
50 Replace
55 55
CHARACTERISTICS Unit: mm Piston Rod Diameter ............................................................................ 50 Maximum Cylinder Length.............................................................. 1365 Minimum Cylinder Length................................................................. 850 Cylinder Barrel Bore .......................................................................... 100 Piston Stroke....................................................................................... 515 Piston Rod Thread.............................................................................M39
10-86 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
BACKHOE CYLINDERS
MEMORANDUM
WB156PS-5
10-87 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
12 WORK EQUIPMENT
LOADER
10-88 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
12
Unit: mm (in) Criteria Check Item
Tolerance
Standard Size
OD
ID
Standard Clearance
b Bushing in Boom
52 (2.05)
52.10 - 52.40 (2.05 - 2.06)
52.20 - 52.30 (2.055 - 2.059)
-0.20 - 0.20 (-0.008 - 0.008)
c Pin to Bushing
45 (1.77)
44.91 - 44.95 (1.768 - 1.769)
45.08 - 45.24 (1.775 - 1.781)
0.13 - 0.329 (0.005 - 0.013)
d Bushing in Lever
52 (2.05)
52.10 - 52.40 (2.05 - 2.06)
52.20 - 52.30 (2.055 - 2.059)
-0.20 - 0.20 (-0.008 - 0.008)
e Pin to Bushing
45 (1.77)
44.91 - 44.95 (1.768 - 1.769)
45.08 - 45.24 (1.775 - 1.781)
0.13 - 0.329 (0.005 - 0.013)
f Bushing in Lever
55 (2.16)
54.85 - 55.15 (2.159 - 2.171)
55.00 - 55.046 (2.165 - 2.167)
-0.15 - 0.196 (-0.006 - 0.008)
g Pin to Bushing
45 (1.77)
44.91 - 44.95 (1.768 - 1.769)
45.08 - 45.24 (1.775 - 1.781)
0.13 - 0.329 (0.005 - 0.013)
75 (2.95)
75.05 - 75.08 (2.95 - 2.96)
75.00 - 75.046 (2.953 - 2.954)
-0.076 - 0.0 (0.003 - 0.0)
i Pin to Bushing
60 (2.36)
59.89 - 59.94 (2.36 - 2.36)
60.137 - 60.197 (2.367 - 2.370)
0.197 - 0.303 (0.008 - 0.012)
J Bushing in Cylinder
57 (2.24)
57.2 - 57.3 (2.25 - 2.26)
57.25 (2.254)
-0.05 - 0.05 (-0.002 - 0.002)
1) Pin to Bushing
50 (1.97)
49.91 - 49.95 (1.77 - 1.77)
50.08 - 50.24 (1.972 - 1.978)
0.13 - 0.329 (0.005 - 0.013)
1! Bushing in Boom
57 (2.24)
57.2 - 57.3 (2.25 - 2.26)
57.25 (2.254)
-0.05 - 0.05 (-0.002 - 0.002)
1@ Pin to Bushing
50 (1.97)
49.91 - 49.95 (1.77 - 1.77)
50.08 - 50.24 (1.972 - 1.978)
0.13 - 0.329 (0.005 - 0.013)
1# Bushing in Cylinder
67 (2.64)
67.10 - 67.40 (2.64 - 2.65)
67.2 (2.646)
-0.20 - 0.10 (0.008 - 0.004)
1$ Pin to Bushing
60 (2.36)
59.89 - 59.94 (2.36 - 2.36)
60.13 - 60.29 (2.367 - 2.374)
0.19 - 0.396 (0.007 - 0.015)
h
Bushing in Lever and Cylinder
WB156PS-5
Clearance Limit
Remedy
Replace
10-89 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
12 BACKHOE
10-90 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
12
Unit: mm (in) Criteria Check Item
Standard Size
Tolerance OD
ID
Standard Clearance
80.00 - 80.054 (3.149 - 3.152) 65.19 - 65.264 (2.566 - 2.569)
-0.005 - -0.089 (-0.0002 - -0.0035) 0.25 - 0.37 (0.0098 - 0.0146)
b Top Bushing in Main Frame
80 (3.15)
c Pin to Bushing
65 (2.56)
80.059 - 80.089 (3.152 - 3.153) 64.894 - 64.94 (2.555 - 2.557)
Inner Bushing on Cylinder Stud
50 (1.97)
50.034 - 50.05 (1.969 - 1.970)
50.0 - 50.025 (1.968 - 1.970)
-0.009 - -0.05 (-0.0003 - -0.002)
e Outer Bushing in Bracket
75 (2.95)
75.043 - 75.062 (2.954 - 2.955)
75.0 - 75.03 (2.953 - 2.954)
-0.013 - -0.062 (-0.0005 - -0.0024)
f
Inner Bushing in Outer Bush60 (2.36) ing g Outer Bushing in Frame -
59.894 - 59.94 (2.358 - 2.360)
60.06 - 60.09 (2.364 - 2.366)
0.12 - 0.196 (0.0047 - 0.0077)
-
-
-
h Pin to Bushing
55 (2.16)
54.894 - 54.94 (2.358 - 2.360)
55.137 - 55.197 (2.171 - 2.173)
0.257 - 0.303 (0.010 - 0.012)
80 (3.15)
80.059 - 80.089 (3.152 - 3.153)
80.0 - 80.03 (3.149 - 3.151)
-0.029 - -0.089 (-0.0011 - -0.0035)
j Pin to Bushing
65 (2.56)
1) Pin to Rod Bushing
45 (1.77)
1! Pin to Head Bushing
45 (1.77)
1@ Bushing in Stabilizer
55 (2.16)
1# Pin to Bushing
45 (1.77)
1$ Bushing in Boom
75 (2.95)
1% Pin to Bushing
60 (2.36)
1^ Bushing in Boom
60 (2.36)
1& Pin to Bushing
50 (1.97)
1* Bushing in Bucket Lever
52 (2.05)
1( Pin to Bushing
45 (1.77)
2) Pin to Cylinder Bushing
45 (1.77)
2! Lever Bushing in Arm
52 (2.05)
2@ Pin to Bushing
45 (1.77)
2# Bushing in Bucket Lever
52 (2.05)
2$ Pin to Bushing
45 (1.77)
2% Bucket Bushing in Arm
57 (2.24)
2^ Pin to Bushing
50 (1.97)
2& Pin to Boom Rod Bushing
60 (2.36)
64.894 - 64.94 (2.555 - 2.557) 44.911 - 44.95 (1.768 - 1.770) 44.911 - 44.95 (1.768 - 1.770) 54.985 - 55.015 (2.165 - 2.166) 44.911 - 44.95 (1.768 - 1.770) 75.137 - 75.197 (2.958 - 2.961) 59.894 - 59.94 (2.358 - 2.360) 59.95 - 60.15 (2.360 - 2.368) 49.911 - 49.95 (1.768 - 1.770) 52.10 - 52.40 (2.051 - 2.063) 44.911 - 44.95 (1.768 - 1.770) 44.911 - 44.95 (1.768 - 1.770) 52.2 - 52.23 (2.055 - 2.056) 44.911 - 44.95 (1.768 - 1.770) 52.10 - 52.40 (2.051 - 2.063) 44.911 - 44.95 (1.768 - 1.770) 56.45 - 58.05 (2.222 - 2.285) 49.911 - 49.95 (1.768 - 1.770) 59.894 - 59.94 (2.358 - 2.360)
65.19 - 65.264 (2.566 - 2.569) 45.08 - 45.24 (1.775 - 1.781) 45.08 - 45.24 (1.775 - 1.781) 55.0 - 55.03 (2.165 - 2.166) 45.08 - 45.24 (1.775 - 1.781) 75.0 - 75.03 (2.953 - 2.954) 60.137 - 60.197 (2.367 - 2.370) 60.0 - 60.03 (2.362 - 2.363) 50.08 - 50.024 (1.972 - 1.969) 52.0 - 52.03 (2.047 - 2.048) 45.08 - 45.24 (1.775 - 1.781) 45.08 - 45.24 (1.775 - 1.781) 52.10 - 52.40 (2.051 - 2.063) 45.08 - 45.24 (1.775 - 1.781) 52.0 - 52.03 (2.047 - 2.048) 45.08 - 45.24 (1.775 - 1.781) 57.20 - 57.23 (2.252 - 2.253) 50.08 - 50.24 (1.972 - 1.978) 60.10 - 60.174 (2.366 - 2.369)
0.25 - 0.37 (0.0098 - 0.0146) 0.13 - 0.329 (0.0051 - 0.0129) 0.13 - 0.329 (0.0051 - 0.0129) -0.015 - 0.045 (-0.0006 - 0.0018) 0.13 - 0.329 (0.0051 - 0.0129) -0.107 - -0.197 (-0.0042 - -0.0077) 0.197 - 0.303 (0.0077 - 0.0119) -0.08 - -0.15 (-0.0031 - -0.0059) 0.13 - 0.329 (0.0051 - 0.0129) -0.07 - -0.40 (-0.0027 - -0.0157) 0.13 - 0.329 (0.0051 - 0.0129) 0.13 - 0.329 (0.0051 - 0.0129) -0.13 - -0.20 (-0.0051 - -0.0079) 0.13 - 0.329 (0.0051 - 0.0129) -0.07 - -0.40 (-0.0027 - -0.0157) 0.13 - 0.329 (0.0051 - 0.0129) -0.85 - 0.78 (-0.0335 - 0.0307) 0.13 - 0.329 (0.0051 - 0.0129) 0.16 - 0.28 (0.0063 - 0.0110)
Pin to Boom & Arm Head Bushing
60 (2.36)
59.894 - 59.94 (2.358 - 2.360)
60.10 - 60.174 (2.366 - 2.369)
0.16 - 0.28 (0.0063 - 0.0110)
2( Pin to Arm Rod Bushing
50 (1.97)
3) Pin to Bucket Head Bushing
45 (1.77)
3! Pin to Jig Head Bushing
40 (1.57)
3@ Pin to Jig Rod Bushing
40 (1.57)
49.911 - 49.95 (1.768 - 1.770) 44.911 - 44.95 (1.768 - 1.770) 39.911 - 39.95 1.571 - 1.573) 39.911 - 39.95 1.571 - 1.573)
50.08 - 50.142 (1.972 - 1.974) 45.08 - 45.142 (1.775 - 1.781) 40.05 - 40.10 (1.577 - 1.579) 40.05 - 40.10 (1.577 - 1.579)
0.13 - 0.231 (0.0051 - 0.0091) 0.13 - 0.231 (0.0051 - 0.0091) 0.10 - 0.189 (0.0039 - 0.0074) 0.10 - 0.189 (0.0039 - 0.0074)
d
i
2*
Bottom Bushing in Swing Frame
WB156PS-5
Clearance Limit
Remedy
Replace
10-91 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT
12
10-92 b
WB156PS-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONING
12 AIR CONDITIONING
A Magnetic Clutch B Compressor C Condenser D Dryer Filter Tank
WB156PS-5
E Safety Pressure Switch F Expansion Valve G Evaporator H Clutch Control Sensor
I Cab Air Circulation Fan J Air Conveyor
10-93 b
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
AIR CONDITIONING
12 ● Compressor b is driven directly by the engine shaft by means of a belt, and made to rotate by a pulley fitted with an electromagnetically engaged clutch a. ●
Thermostatic sensor h controls the engagement and disengagement of the clutch. It disengages the clutch when the evaporator reaches the lower temperature limit and engages when the evaporator reaches the upper temperature limit.
●
The coolant fluid, in gaseous phase is drawn into the compressor where it is subjected to compression and an intense heating process. In these conditions the fluid is then sent into condenser c where, due to the heat extracted by ambient temperature air flowing over fins, it reaches condensation temperature, and passes into a high-pressure liquid state. Subsequently, the coolant passes into dryer filter group d which performs three functions: it filters out impurities, absorbs any moisture present in the circuit and, finally, also functions as a reserve tank.
●
The coolant, in its liquid state, is then transferred to evaporator G, first passing through expansion valve F. The task of this valve is the constant metering of the quantity of fluid in order to maintain optimum evaporation. In the evaporator the coolant fluid is subjected to expansion, bringing it up to the critical evaporation point at a temperature of approximately -8° C (17.6° F).
●
The air flow generated by the centrifugal fan I, which passes through evaporator G at ambient temperature is considerably warmer than -8° C (17.6° F). For this reason, it yields heat to the coolant fluid bringing it up to boiling point and complete evaporation.
●
On leaving evaporator G, the coolant is drawn once more into compressor d and a new cycle commences. The yielding of heat from the atmosphere in which the evaporator is positioned leads to the condensation of the water suspended in the air, and hence to dehumidification.
●
The condensate is deposited on the evaporator fins where, if a temperature higher than 0° C is not maintained, it freezes and inhibits the functioning of the evaporator. The task of keeping the temperature of the evaporator above 0° C, and thus within the optimum limits for heat exchange, is entrusted to thermostatic sensor H.
●
The condensate that forms on evaporator fins G also contains dust, pollens and particles suspended in the air. Continual condensation therefore, effectively purifies the air and the droplets of condensate are discharged to the exterior. A fixed quantity of antifreeze oil is also introduced into the circuit, with the function of lubricating all the mechanical parts of the unit. A percentage of this oil circulates constantly throughout the unit in nebulized form, lubricating the compressor, pistons and bearings and the expansion valve.
●
Pressure switch E has been inserted in the electrical control circuit to protect the unit in the case of a lack of coolant fluid or if the quantity becomes insufficient due to leakages. This switch will inhibit the engagement of the electromagnetic clutch and hence, the functioning of the air conditioning unit.
10-94 b
WB156PS-5
20
TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11 ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12 ENGINE WITH LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12 MACHINE IN POWER MODE AT MIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12 WITH CONVERTER STALLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12 CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . 20-12 ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13 AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14 BLEED AIR FROM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 BLEED AIR FROM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 BLEED AIR FROM BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15 ACCELERATOR PEDAL AND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16 ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16 ACCELERATOR LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18 CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19 LEAKAGE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19 INDIVIDUAL PUMP CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20 BRAKE GROUP LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22 HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23 MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24 RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 SECONDARY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25 SETTING RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28 SWING, LOADER DUMP, HAMMER, AND BOOM RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29 LS DIFFERENTIAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30 PPC SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
WB156PS-5
20-1 b
TESTING AND ADJUSTING
TABLE OF CONTENTS
PC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32 STEERING CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33 STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34 POWER TRAIN GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35 CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35 CLUTCH ENGAGEMENT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35 SUPPLY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36 TRANSMISSION CLUTCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 MACHINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37 HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38 LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38 BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38 BUCKET CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39 BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39 BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 ARM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40 BUCKET CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41 OUTRIGGERS CIRCUIT - WITHOUT LOCK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43 WORK TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43 UNIT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43 EMPTYING THE AIR CONDITIONING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55 FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58 FUSE AND RELAY PANEL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58 FUSE AND RELAY PANEL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61 HEATING AND AIR CONDITIONING FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62 WARNING! When working with others, use agreed upon signals and do not let unauthorized persons near the machine. WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is removed when the coolant is hot, the coolant will spurt out and cause burns. Be careful when working close to moving parts, fan, fan belt, etc. Entanglement with moving parts can cause serious injury. WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked on firm, level ground. Check that all machine safety devices are applied and that blocks are in place to prevent the machine from moving.
20-2 1
WB156PS-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE
12 STANDARD VALUE TABLE
ENGINE
Item
Machine Model
WB156PS-5
Engine Model
S4D102LE-2
Measurement Conditions
Unit
Standard Value
Service Limit Value
2,457 ±50
2,370 - 2,507
1,050 ±50
1,000 - 1,100
---
---
• High idle (no load)
Engine speeds
• Low idle (no load)
RPM
• Rated speed (no load)
Intake air restriction
• At torque converter stall and full throttle • At restriction indicator port
Lubricating oil pressure with SAE • Minimum at low idle 15W-40 oil and coolant temperature in operating • Minimum at high idle range Fuel filter inlet restriction
Blow by pressure
• Maximum restriction at high idle
mm H2O
New element
381
Used element
635 0.7 (10)
kg/cm² (psi) 2.1 (30) New element
101
Used element
203
mm Hg
• Coolant temperature in operating range • Service Tool orifice size 5.613 mm H2O mm • Full load at rated speed
Max 101.6
Exhaust back pres- • Maximum at converter stall and full throttle sure
mm Hg
76
Coolant temperature
• Maximum coolant operating temperature
° C (° F)
105 (221)
Valve clearances with engine cold
• Intake valves
mm (in)
0.254 (0.0099) 0.504 (0.0198)
mm (in)
10 (0.394)
Fan Belt Tension
WB156PS-5
• Exhaust valves • Deflection when pressed with finger force of approximately 10 kgf (22 lbf)
Max 431.8
10 - 15 (0.394 - 0.5905)
20-3 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE
12 CHASSIS Applicable Model Cat.
Item
Engine speed
Accelerator pedal
Accelerator fuel
WB156PS-5 Standard Value
Permissible Value
Max.
2,457
2,407 - 2,507
Min.
1,050 ±50
1,000 - 1,100
Max.
2,200
2,150 - 2,250
Min.
1,050 ±50
1,000 - 1,100
Measurement Condition
Unit
• 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.
rpm
Control valve
l
c
l
a
b
c
6 5.5 2
-
-
-
-
Raise
95 (3.74)
80-110 (3.1-4.3)
Lower
95 (3.74)
80-110 (3.1-4.3)
Dump
95 (3.74)
80-110 (3.1-4.3)
Curl
95 (3.74)
80-110 (3.1-4.3)
Raise
50 (1.97)
40-60 (1.6-2.4)
• Engine stopped Lower • Knob lever: at center and at Open 90° from the lever. Neutral J • Value reading at end of workClose ing stroke plus half measured backlash Open Neutral J • Attachments on ground Close • Instrument metric divisions
50 (1.97)
40-60 (1.6-2.4)
50 (1.97)
40-60 (1.6-2.4)
50 (1.97)
40-60 (1.6-2.4)
50 (1.97)
40-60 (1.6-2.4)
50 (1.97)
40-60 (1.6-2.4)
Right
50 (1.97)
40-60 (1.6-2.4)
Left
50 (1.97)
40-60 (1.6-2.4)
Up
35 (1.38)
25-45 (1.0-1.87)
Down
35 (1.38)
25-45 (1.0-1.8)
Min J Max
40 (1.57)
30-50 (1.2-2.0)
mm
Bucket control laver
Travel of levers and pedals
b
Bucket arm command only
Bucket arm control lever
Boon backhoe control
Arm backhoe control lever
Bucket backhoe control lever
Boom swing control lever
Outrigger control lever Fuel control lever
20-4 1
a
Neutral J
Neutral J
Neutral J
Neutral J
Neutral J
-
mm (in)
WB156PS-5
TESTING AND ADJUSTING 12
STANDARD VALUE TABLE
Applicable model Unit
Standard value
Permissible value
mm (in)
80 (3.15)
65-95 (2.6-3.7)
3.5
3.1 - 3.9
3.5
3.1 - 3.9
Bucket arm lever
1.5 (3.3)
1.0 - 2.0 (2.2 - 4.4)
Bucket lever
1.5 (3.3)
1.0 - 2.0 (2.2 - 4.4)
1.8 (3.97)
1.3 - 2.3 (2.9 - 5.1)
1.8 (3.97)
1.3 - 2.3 (2.9 - 5.1)
1.3 (2.87)
0.8 - 1.8 (1.8 - 4.0)
1.3 (2.87)
0.8 - 1.8 (1.8 - 4.0)
1.5 (3.3)
1.0 - 2.0 (2.2 - 4.4)
Fuel lever
6.0 (13.2)
5.0 - 7.0 (11.0 - 15.4)
Accelerator pedal
4.0 (8.82)
2.5 - 5.5 (5.5 - 12.1)
−−−
−−−
Force for lever, pedal and steering wheel operation
Levers and pedals travel
Cat.
Item
Measurement condition • Engine stopped
Accelerator pedal
Wheel swing
Boom lever Arm lever Bucket lever Boom swing lever Outrigger lever
Steering wheel
Main valve pressure
WB156PS-5
Control valve
• Knob lever: at center and at 90o from lever. • Value reading at end of work stroke plus half measured backlash • Attachments on ground
Min J Max Right J Left
rev Left J Right
• Engine speed: min. • Oil temperature within operating range • Tool connection at center of knob 80 mm (3.15 in) away from handle base. • Value reading at the 10 mm (0.4 in) before end of work stroke. • Instrument force gauge
kgf (lbf)
• Ambient temperature 15 - 35o C (59 - 95° F)
• Force measured on steering wheel knob at min. RPM for approximately half a rev under steady motion at a speed of 2.5 per rev. • Engine speed: 2,200 rpm • Oil temperature within operating range • Move arm cylinder to end of stroke and measure pressure • Instrument: 0 to 100 kg/cm² (0 to 1,422 psi) pressure gauge mounted on adapter at port P1C • Working mode switch: POWER
−−−
238 - 264 249 (3,542) kg/cm²
(3,385 - 3,755)
(psi) 173 - 188
Steering unit
• Engine speed: 1,500 ±50 rpm
178 (2,532) (2,461 - 2,674)
WB156PS-5
20-5 1
TESTING AND ADJUSTING 12
STANDARD VALUE TABLE
Applicable model
Engine speed with load - Converter
Pressures of secondary valves circuits
Cat.
20-6 1
WB156PS-5 Standard value
Permissible value
Bucket curled
274 (3,897)
264 - 284 (3,755 - 4,039)
Bucket dump
244 (3,470)
234 - 259 (3,328 - 3,684)
Bucket open close
274 (3,897)
264 - 284 (3,755 - 4,039)
Boom raise
351 (4,992)
323 - 365 (4,594 - 5,191)
Boom lower
274 (3,897)
264 - 284 (3,755 - 4,039)
274 (3,897)
264 - 284 (3,755 - 4,039)
274 (3,897)
264 - 284 (3,755 - 4,039)
234 (3,328)
223 - 249 (3,172 - 3,542)
Bucket curl
274 (3,897)
264 - 284 (3,755 - 4,039)
Bucket dump
−−−
−−−
Telescopic arm out - in
−−−
−−−
Hammer delivery
193 (2,745)
183 - 213 (2,603 - 2,029)
Steering unit safety
228 (3,243)
228 - 249 (3,243 - 3,542)
2,175 ±50
2,125 - 2,225
2,075 ±50
2,025 - 2,125
600
Min. 600
Item
Arm close Arm out Boom swing
Measurement condition
• Engine speed: 2,200 rpm • Oil temperature within operating range • Move arm cylinder to end of stroke and measure pressure • Instrument: 0 - 100 kg/cm² (0 - 1,422 psi) pressure gauge mounted on adapter at port P1C • Working mode switch: POWER
With converter
• Engine speed, without load: 2,400 ±50 rpm • Oil temperature within operating range • Machine in 3rd gear • Work brakes: engaged • Work mode switch: POWER
With converter and hydraulic circuit
• Engine speed, without load: 2,400 ±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
Hydraulic circuit at Low idle
• Engine speed, without load: 1,050 ±50 rpm • Oil temperature within operating range • Machine in Neutral • Parking brake: applied • Bucket dump bottom of stroke • Working mode switch: POWER
Unit
kg/cm² (psi)
rpm
WB156PS-5
TESTING AND ADJUSTING
STANDARD VALUE TABLE
Applicable model Cat.
Item
Measurement condition • In this position check in feedback of each cylinder and leakage with applied load on tip of bucket teeth. • On level ground • General Purpose (GP) Bucket: load 1800 kg (3,968 lb) Multi-purpose (MP) Bucket: load 1550 kg (3,417 lb) • Engine stopped • Oil temperature: 45 - 55° C (113 - 131° F) • Check measures as soon as engine stops. • Check changes every five minutes and total change in 15 minutes.
150 (5.9)
300 (11.81)
12 (0.47)
20 (0.79)
35 (1.38)
50 (1.97)
200 (7,087)
350 (13.78)
10 (0.39)
20 (0.79)
Arm cylinder
10 (0.39)
20 (0.79)
Bucket cylinder
8 (0.31)
15 (0.59)
Boom cylinder
Loader
Work equipment
Bucket cylinder
mm Working equipment
Boom cylinders Backhoe
Hydraulic drift working equipment
Unit
WB156PS-5 Permissible Standard value value
WB156PS-5
• 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 (750 lb) • Bucket load with telescopic arm: 0 kg Fully extend arm • Engine stopped • Oil temperature: 45 - 55 °C (113 - 131° F) • Check measures as soon as engine stops. • Check changes every five minutes and total change in 15 minutes.
(in)
20-7 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE
.
Applicable model Cat.
Item
Loader
15 (0.59)
15 (0.59)
7 (0.275)
15 (0.59)
2 each
Max. 8
(in) • Oil temperature: 45 - 55° C (113 - 131° F) • Backhoe balanced • Boom and arm cylinders in, bucket cylinder out • Outriggers at maximum extension. • Engine stopped • Check frame lowering for each side every five minutes for a total of 15 minutes.
Boom Bucket Boom Arm
Backhoe
Cylinder Leakage
Standard value Permissible value
mm
Outriggers
Bucket Boom swing Outriggers Jig arm
20-8 1
Unit
• Oil temperature: 45 - 55° C (113 - 131° F) • Backhoe balanced on guides bucket in • Transport condition • Fully retract arm and bucket cylinder Lift bucket fulcrum pin 1 m (39.37 in) 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 one minute, check inner cylinder feed back opposite to boom every five minutes for a total of 15 minutes.
Backhoe
Hydraulic drift work equipment
Boom swing
Measurement condition
WB156PS-5
• Engine: Max speed • Oil temperature: 45 - 55° C (113 - 131° F) • Leaking check: on cylinder opposite side to pressure one. • Check one cylinder at a time. • For loader bucket and boom and for swing, check the two cylinders separately.
cm³/min
1.6 each
Max. 6
3.3
Max. 13.5
3
Max. 12
2.4
Max. 9.5
3.2
Max. 13
3.3
Max.13.5
1.6
Max 6
WB156PS-5
TESTING AND ADJUSTING 12
STANDARD VALUE TABLE Applicable model
Cat.
Item
Measurement condition
Unit
WB156PS-5 Standard Permissible value value
Arm cylinder fully out Bucket cylinder fully in
↕ Bucket cylinder fully out
WB156PS-5
• Engine speed: 2,200 rpm • Oil temp: 45 - 55 °C (113 - 131° F) • Backhoe balanced • Power mode ON
2.8
2.4 - 3.2
2.7
2.3 - 3.1
2.0
1.7-2.3
2.9
2.5 - 3.4
3.2
2.7 - 3.7
2
1.7 - 2.3
2.5
2.1 - 2.9
Lifting U
Lowering
↕
• Engine speed: 2,200 rpm • Oil temperature: 45 - 55° C (113 - 131° F) • Backhoe balanced • Power mode ON
Curl
Backhoe
Arm cylinder fully in
2.0 - 2.6
Dump
Bucket on ground
2.3
Lowering
↕
• Engine speed: 2,200 rpm • Oil temp: 45 - 55° C (113 - 131° F) • Backhoe balanced • Power mode ON
2.2 - 3.0
Opening
Boom cylinder fully in
2.6
Closing U
Bucket at ground level Bucket • Engine speed: max. • Oil temperature: 45 - 55° C (113 - 131° F) • Bucket speed Cylinders fully button: applied out
3.1 - 4.1
Dump
↕
3.6
Curl
Work equipment speed
Loader bucket
Cylinders fully out
• Engine speed: max. • Oil temp: 45 - 55° C (113 - 131° F) • Bucket speed button: applied
Lifting
Arm bucket
sec.
20-9 1
TESTING AND ADJUSTING
STANDARD VALUE TABLE
Permissible value
Right U
3.2
2.7 - 3.7
3.2
2.7 - 3.7
0
Max. 2
0
Max. 2
Arm
• Engine speed: min. • Oil temperature: 45 - 55° C (113 - 131° F) • 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 (113 - 131° F) • 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 (113 - 131° F) • 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
Boom swing to tight end of travel Backhoe
Item
Work equipment speed
Standard value
Cat.
↕ Boom swing to left end of travel
Arm bucket
Time lag
Work equipment
Boom
20-10 1
WB156PS-5
Left U
Applicable model Measurement condition
• Engine speed: 2,200 rpm • Oil temperature: 45 - 55° C (113 - 131° F) • Arm vertical • Power mode ON
Unit
• Engine speed: min. • Oil temperature: 45 - 55° C (113 - 131° F) • Check item necessary to lift bucket from level ground
• Engine speed: min. • Oil temperature: 45 - 55° C (113 - 131° F) • With attachments fully extended, lower boom and check necessary time from beginning of lift until bucket is on level ground
sec
WB156PS-5
TESTING AND ADJUSTING
SPECIAL TOOLS
12 SPECIAL TOOLS Measurement Point
Symbol
Code
Name
Qty
Note
Engine speed
A
Available Locally Multi scale tachometer
1
20 to 4,000 rpm
Valve clearance
B
Available Locally Feeler gauge
1
–
Oil and coolant temp
D
1 Available Locally Digital thermometer
1
-50 to 1200° C (-58 to 2,192° F)
1 Available Locally Pressure gauge
2
Full scale 61 kg/cm² (868 psi)
2 Available Locally Pressure gauge
1
Full scale 255 kg/cm² (3,627 psi)
3 Available Locally Pressure gauge
1
Full scale 408 kg/cm² (5,803 psi)
4 Available Locally Pressure gauge
1
Full scale 612 kg/cm² (8,705 psi)
Servo control kit
1
0 to 1,020 kg/cm² (0 to 14,508 psi)
Flow meter
1
Delivery 0 to 300 l/min. (0 to 79.25 gal/min.)
Pipe fitting kit
1
–
Tank cap
1
Pump air bleeding
E Hydraulic pressure
5 6 F
1
ATR800200
2 Air bleeding
G
ATR201490
Hand brake
L
Available Locally Spring dynamometer
1
Full scale 20 kg (44 lb)
1 Available Locally Maintenance station
1
For coolant R134a
2 Available Locally Thermometer hygrometer
1
Sampling every 15 seconds
3 Available Locally Leak detector
1
For coolant R134a
Air Conditioning unit
WB156PS-5
M
20-11 1
TESTING AND ADJUSTING
ENGINE SPEED
ENGINE SPEED WARNING! When checking the engine speed be careful. Do not touch high temperature parts or get caught in rotating parts.
★ Check the engine speed with a tachometer A under the following conditions: ●
Engine coolant temperature............... 68 - 80° C (154 - 176° F)
●
Hydraulic oil temperature...................45 - 55° C (113 - 131° F)
ENGINE WITH LOAD 1.
Start the engine and check: Low idle speed without load, accelerator pedal released High idle speed without load, accelerator pedal at the travel end ●
Low idle speed.................................................... 1,050 ±50 rpm
●
High idle speed ................................................... 2,400 ±50 rpm
★ If the idle speeds are not within limits, without a load on the engine, check the accelerator pedal stop and wiring insulation before going on with other operations. MACHINE IN POWER MODE AT MIN 1.
With the transmission in neutral, idle the engine.
2.
Dump the loader bucket and hold the movement; let the engine stabilize and then read the engine speed. ●
Normal speed....................................................................600 rpm
●
Minimum speed ................................................................600 rpm
WITH CONVERTER STALLED 1.
Increase speed to high idle and brake with the foot brakes.
2.
Hold the brakes while simultaneously engaging 3rd gear; let the engine stabilize, and read the rpm value.
3.
●
Minimum speed .............................................................2,125 rpm
●
Maximum speed ............................................................2,225 rpm
Hold the machine stalled as long as necessary, in any case for not more than 30 seconds, and carry out the tests at least 15 seconds apart.
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
20-12 1
WB156PS-5
TESTING AND ADJUSTING
VALVE CLEARANCE
12 3. In the above conditions, let the engine stabilize, then read the engine rpm.
4.
●
Minimum speed .............................................................2,025 rpm
●
Maximum speed ............................................................2,125 rpm
Hold the machine stalled as little as necessary, in any case for not more than 30 seconds, and carry out the tests at least 15 seconds apart.
ANALYSIS 1.
If readings are not within the required interval, check the ENGINE SHOP MANUAL.
2.
If the engine has no abnormal conditions, adjust the pump's power absorption, PC valve.
VALVE CLEARANCE 1.
Park the machine on solid, level ground, apply the parking brake, and remove the starting 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 in the ENGINE SHOP MANUAL.
WB156PS-5
20-13 1
TESTING AND ADJUSTING
AIR CONDITIONER COMPRESSOR BELT TENSION
12 AIR CONDITIONER COMPRESSOR BELT
TENSION 1.
Turn screw B clockwise to tension belt C.
2.
Apply a 10 kgf (22 lbf) force halfway between compressor pulley E and engine pulley D.
3.
Check the resulting arrow F. ●
Normal tensioning .............................. 4 - 6 mm (0.16 - 0.24 in)
●
New belt..............................................................3 mm (0.12 in) WARNING! Check the belt tension again after 15 minutes of operation.
20-14 1
WB156PS-5
TESTING AND ADJUSTING
BLEED AIR FROM CIRCUITS
12 BLEED AIR FROM CIRCUITS
BLEED AIR FROM CYLINDERS ★ When the hydraulic cylinders or associated tubes have been removed, it is necessary to bleed air before using the machine again. Bleed one cylinder at a time. 1.
Start the engine and run at high idle for about five minutes to heat the oil.
2.
Reduce speed to low idle and extend and retract the 1st cylinder to be bled several times. ★ Extend and retract pistons until about 100 mm (3.94 in) from their end of stroke.
3.
Stop the engine, check and top off the oil in the tank.
4.
Bring the engine to high idle again and repeat Step 2; return the engine to low idle speed and make a complete travel of the cylinder until the pump reaches its maximum pressure.
5.
Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level 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 into the circuit. Machine must be stopped with attachments on level ground. 1.
Make sure that oil in brake system tank b is at maximum level. Remove safety plugs on bleed screws c. Attach a vinyl hose d to catch oil.
2.
Push the brake pedal to the bottom and, while keeping it pushed, loosen bleed screw c of the braking unit that is being bled until the pedal reaches the end of its stroke. Keeping the pedal at the end of its stroke, tighten the bleed screw.
3.
Release the brake pedal, wait for few seconds and repeat above operations two or three times until oil flows out the bleeding screw without air bubbles.
4.
Repeat the same steps for the opposite braking unit. ★ Frequently check the oil level in the tank and refill every time the level approaches minimum.
5.
After bleeding air, apply on screws c safety plugs e.
RELEASING RESIDUAL PRESSURE 1.
Put work attachments on level ground, stop the engine.
2.
Move all control levers in all directions to fully release cylinder and PPC circuit residual pressure.
WB156PS-5
20-15 1
TESTING AND ADJUSTING
ACCELERATOR PEDAL AND LEVER
ACCELERATOR PEDAL AND LEVER ★ Measurement conditions: ●
Machine ......................Shut down with safety features engaged
●
Engine.............................Stopped and at operating temperature
●
Idle speeds ...............................................Within standard value
★ In order to check high speed engine idle, push the accelerator pedal B manually.
ACCELERATOR PEDAL TRAVEL 1.
Make sure that accelerator pedal b is fully raised and accelerator lever c is at minimum stroke.
2.
Push the accelerator pedal until accelerator lever f contacts the injection pump high idle adjusting screw.
3.
Adjust end travel stopper g of accelerator pedal b in this position and lock it with nut h.
4.
Release accelerator pedal b.
20-16 1
WB156PS-5
TESTING AND ADJUSTING
ACCELERATOR PEDAL AND LEVER
12 ACCELERATOR LEVER TRAVEL 1.
Remove the front mat.
2.
Remove metal sheet b closing the bottom of the cab and upright guard c.
3.
Check that hand accelerator d is at end of travel at MIN.
4.
Loosen and unscrew locking nut e.
5.
Start the engine and move hand accelerator d to MAX.
6.
Tighten nut f to the required speed for hand accelerator. ●
Engine idle speed....................................................... 2,200 rpm
7.
Return to engine low idle speed and retain the position of nut f with locking nut e.
8.
Check the maximum speed once more by pushing the hand accelerator to the end of travel.
WB156PS-5
20-17 1
TESTING AND ADJUSTING
BRAKE SYSTEM
12 BRAKE SYSTEM ★ Working condition: ●
Set the machine on firm, level surface with the attachments secure on the ground.
●
Apply the parking brake and remove the starting key.
●
Insert pedal connection pin a.
CONTROL 1.
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 slack G. ★ Standard clearance .......................... 3 - 8 mm (0.12 - 0.31 in)
ADJUSTMENT 1.
Remove front cover c.
20-18 1
WB156PS-5
TESTING AND ADJUSTING
BRAKE SYSTEM
12 2. Loosen nuts d and adjust the slack using stoppers e. 3.
When adjustment is complete, secure stoppers e. ★ When the stoppers are secured, double check to ensure that slack G is within the range and that the pedals touch the stoppers simultaneously.
CHECKS ★ Working condition: ●
Engine stopped
●
Place the vehicle on firm, level ground with the equipment raised and the safety devices activated.
●
Independent brake pedals and oil pan at maximum level.
★ The brake system checking procedure consists of two steps: ●
Checking the brake pumps and checking the braking groups for leaks.
LEAKAGE CHECKS 1.
Disconnect hose B from tubes c connecting to the axle braking groups. Plug the tube. ●
Plug all open tubes and hoses to prevent contamination.
2.
Connect pressure gauge E2 to the hose B.
3.
Apply the brake pedals until a pressure of 122.2 kg/cm² (1,738 psi) is reached. ★ Do not exceed the maximum permitted pressure.................... ............................................152.8 ±5 kg/cm² (2,173 ±71 psi)
4.
Hold the pressure on the pedal for at least two minutes and verify that the pressure and pedal position remain unchanged. ★ If the position of the pedal needs to be changed in order to hold the pressure, then pressure loss is due to leaks inside either pump. To confirm whether this is the case, check the oil. If a leak condition exists, the oil will be stirred.
WB156PS-5
20-19 1
TESTING AND ADJUSTING
BRAKE SYSTEM
12 INDIVIDUAL PUMP CHECK 1.
Remove front cover d.
2.
Disconnect pressure equalizer hose f from brake circuit pump e that is being inspected.
3.
Seal the hole of equalizer plug A.
4.
Remove clamp g.
5.
Disconnect delivery hoses h from the pump that is being tested. Connect a pressure gauge E2 to the pump during the inspection.
6.
Apply the brake pedal corresponding to the pump and pressurize the circuit to 122.2 kg/cm² (1,738 psi). ★ Do not exceed the maximum permitted pressure.................... ............................................152.8 ±5 kg/cm² (2,173 ±71 psi)
20-20 1
WB156PS-5
TESTING AND ADJUSTING
BRAKE SYSTEM
12 7. Hold the pressure on the pedal for at least two minutes and verify that pressure and pedal position remain unchanged. ★ If the position of the pedal needs to be changed in order to hold the pressure, then pressure loss is due to leaks inside the pump, and the pump needs to be changed. To confirm if this is the case, check the oil. If a leak condition exists, the oil will be stirred. 8.
Repeat for the other pump.
BRAKE GROUP LEAKAGE 1.
Disconnect delivery hose b from the braking group that is being inspected.
2.
Connect a suitable tool between delivery hose b and the braking group. ★ Check to ensure that pressure tap i is installed between the braking group and cut-out valve j.
3.
4.
Connect a pressure gauge E2 to the tool pressure tap and open cutout valve j. Operate the brake pump and pressurize the circuit to 152.8 ±56 kg/ cm² (2,173 ±796 psi) maximum.
5.
Hold the pressure while simultaneously closing valve j to keep the braking circuit that is being inspected under pressure.
6.
Release the brake pedal and monitor pressure gauge E2 for two minutes. ★ If the pressure reading changes in the negative, then there is a brake piston seal failure. WARNING! Further evidence of leak is an increase in the level of oil in the axle, and the fact that the oil is stirred as a result. Replace all sealing rings in the various axle sections and completely change the lubricant.
7.
Repeat the test for the other brake group using the same procedure as above.
8.
Restore the brake circuit to operating condition. WARNING! When checks and repair are complete, bleed the air from the braking groups.
WB156PS-5
20-21 1
TESTING AND ADJUSTING
PARKING BRAKE ADJUSTMENT
12 PARKING BRAKE ADJUSTMENT ★ Test conditions: ●
Tire pressure .................................. Within the prescribed range
●
Machine in operating conditions ...... Without load and on level ground
●
Working brake pedals ........................Connected by a cotter pin
1.
Remove screws b and parking brake housing c.
2.
Engage the parking brake.
3.
Press and hold microswitch d while engaging 2nd gear and selecting a direction of movement.
4.
Accelerate engine gradually up to 1530 ±50 rpm. WARNING! If machine moves, release the microswitch to return to N (Neutral).
5.
Rotate the end of lever e by two or three turns counterclockwise. ★ Direction of rotation is from the operator’s point of view when sitting in the driver’s seat.
6.
Apply the parking brake and repeat the test. ★ If a normal braking condition is not achieved after two attempts to adjust the lever, check control cable for slackness and brake disc for wear and replace components as necessary.
20-22 1
WB156PS-5
TESTING AND ADJUSTING
HYDRAULIC CIRCUIT
12 HYDRAULIC CIRCUIT
INTRODUCTION
b Engine c Transmission
D Hydraulic Pump E Steering Unit
f LS Safety Valve g Main Control Valve
1.
The machine is equipped with a single control valve with hydraulically-controlled spools. The control valve is protected against over pressure by a main relief valve, referred to as the LS safety valve, with an adjustable pressure setting.
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 maneuver.
WB156PS-5
20-23 1
TESTING AND ADJUSTING
HYDRAULIC CIRCUIT
12 MAIN CONTROL VALVE 10-Spool Cylinder and Movement
Backhoe Swing Loader Bucket Backhoe Boom Backhoe Bucket
4 in 1 bucket Telescopic arm Arm Right Outrigger Left Outrigger
20-24 1
Set (psi)
B0
2,756
Open
A1
3,916
Close
B1
3,916
Right
A2
3,336
Hammer Backhoe Arm
Port
Left
B2
3,336
Dump
A3
3,481
Curl
B3
3,916
Lower
A4
3,916
Raise
B4
5,004
Dump
A5
---
Curl
B5
---
Closed
A6
3,916
Open
B6
3,916
Out
A7
---
In
B7
---
Up
A6
---
Down
B6
3,990
Down
A7
---
Up
B7
---
Down
A8
---
Up
B8
---
WB156PS-5
TESTING AND ADJUSTING
RELIEF VALVES
12 RELIEF VALVES
TESTING UNLOADING VALVE 1.
Connect a pressure gauge E1 to the tap P1C on the pump. Start the engine and run at low idle with all levers in neutral position.
2.
In this condition, check the pressure in the hydraulic circuit. ★ Normal pressure ....................41.8 ±4.1 kg/cm² (594 ±58 psi) ★ The unloading valve cannot be reset; replace if necessary.
MAIN RELIEF VALVE ★ Test conditions:
1.
●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Working brakes..............................................................Applied
Connect a pressure gauge E3 to the tap P1C of the pump. Start the engine, move the hand accelerator lever to full throttle and check setting pressure for main relief valve by forcing the loader arm raise movement the full travel span. ●
Nominal pressure...........239.4 - 270 kg/cm² (3,405 - 3,840 psi)
★ If the main relief valve pressure does not correspond to the nominal pressure value, it must be reset. SECONDARY VALVES Boom Swing, Loader Bucket Dump and Hammer ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Working brakes..............................................................Applied
★ The pressure readings are to be operated from the same check point. 1.
Connect a pressure gauge E3 to the tap P1C of the pump. Start the engine and bring the hand accelerator lever up to 2,200 rpm.
2.
Check pressure for each movement, with the control lever at the end of its travel and at stabilized pressure. ★ Move piston to the end of stroke to check the pressure.
Cylinder and movement
Setting kg/cm² (psi)
Hammer Boom swing Loader
WB156PS-5
183.4 - 213.9 (2,608 - 3,042) Right
229.2 -254.7 (3,260 - 3,623)
Left
229.2 - 254.7 (3,260 - 3,623)
Dump
239.4 - 264.9 (3,405 - 3,768)
20-25 1
TESTING AND ADJUSTING
RELIEF VALVES
Backhoe Boom Raise ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Working brakes..............................................................Applied
1.
Set the machine with the arm in the vertical position and the bucket on level ground.
2.
Stop the engine and release the residual hydraulic pressures.
3.
Disconnect hose b and connect tee c with an adapter. Connect a pressure gauge E3 to the adapter.
4.
Start the engine. Connect a 1,500 kg (3,307 lb) weight to the bucket, and fully lower the outriggers.
5.
Slowly extend the arm and boom and take the pressure when the boom lowers. ★ Normal pressure .........326 - 366.7 kg/cm² (4,637 - 5,216 psi)
20-26 1
WB156PS-5
TESTING AND ADJUSTING
RELIEF VALVES
Arm In, Loader Bucket, Backhoe Bucket, Boom Raise, and Multi-Purpose (MP) Bucket ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Working brakes..............................................................Applied
★ The pressure readings are to be operated from the same check point.
1.
Connect pressure gauge E3 to pressure tap P1C of the pump.
2.
Start the engine and bring the hand accelerator lever up to 2,200 rpm.
3.
Set main relief valve b to a value 30.5 kg/cm² (434 psi) higher than the maximum pressure to be tested.
4.
Check pressure for each movement, with the control lever at the end of its travel and at stabilized pressure. ★ Move piston to the end of stroke to check the pressure of the working equipment.
Cylinder and movement
Setting kg/cm² (psi)
Arm
Close
264.9 – 285.3 (3,405 - 5,480)
Loader bucket
Curl
264.9 – 285.3 (3,405 - 5,480)
Boom
Left
264.9 – 285.3 (3,405 - 5,480)
Loader
Dump
264.9 – 285.3 (3,405 - 5,480)
Close
264.9 – 285.3 (3,405 - 5,480)
Open
264.9 – 285.3 (3,405 - 5,480)
★ If one movement fails to reach the setting pressure, then the malfunction is in the tested element. ★ If all movements fail to reach the setting pressure, then you need to pressure set or replace the secondary valve.
WB156PS-5
20-27 1
TESTING AND ADJUSTING
SETTING RELIEF VALVES
12 SETTING RELIEF VALVES
MAIN RELIEF VALVE 1.
Loosen lock nut B.
2.
Adjust the pressure using the screw C. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise
3.
Lock nut B. Lock nut ..............................29.4 - 39.2 N•m (21.7 - 28.9 lbf ft) ★ When adjustment is complete, check the setting of the main relief valve using the procedures used for measurements.
CIRCUIT RELIEF VALVES ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET 1.
Loosen 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 nut C. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise
3.
Tighten lock nut B while holding adjusting nut c. Lock nut B ...................................39 - 49 N•m (28.8 - 36 lbf ft)
20-28 1
WB156PS-5
TESTING AND ADJUSTING
SETTING RELIEF VALVES
12 SWING, LOADER DUMP, HAMMER, AND BOOM RAISE 1.
Loosen lock nut B.
2.
Adjust the pressure using nut C. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise
3.
Tighten lock nut B while holding adjusting nut c. Lock nut B ...................................39 - 49 N•m (28.8 - 36 lbf ft)
WB156PS-5
20-29 1
TESTING AND ADJUSTING
LS DIFFERENTIAL PRESSURE
12 LS DIFFERENTIAL PRESSURE
CONTROL ★ Test conditions: ●
Engine.............................. Stopped, but at working temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Machine: ..................... front equipment on the ground, parking brake applied and boom and arm fully extended.
●
Working mode ..............................................................POWER
1.
Disconnect hose b from the LS line and install a tee with pressure tap c and reconnect hose b.
2.
Connect differential pressure gauge E4 to adaptor c and to tap P1C on the pump.
3.
Start the engine and run it at low idle (1,050 ±50 rpm) in neutral position without any lever movement, and read the U pressure. ★ Normal value............................41.7 ±4 kg/cm² (593 ±57 psi) ★ If UPLS pressure is not within the permissible range, replace the control valve unloading valve.
4.
Simultaneously perform a boom raise and a backhoe bucket curl movement to end of travel and then read the U pressure. ★ Normal value............................28 ±1.5 kg/cm² (398 ±21 psi) ★ If the UPLS value is not within the permissible range, set the unloading valve.
ADJUSTMENT ★ If the UPLS value is not within the specified range, adjust the LS valve as follows: 1.
Loosen retaining nut b and turn adjustment screw c. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise ★ Each turn of adjustment screw c will change the pressure by approximately 13.2 kg/cm² (188 psi).
2.
Lock nut b. Lock nut B ...................................39 - 49 N•m (28.8 - 36 lbf ft)
3.
When adjustment is complete, check the setting of the LS valve using the procedures used for checking.
20-30 1
WB156PS-5
TESTING AND ADJUSTING
PPC SUPPLY PRESSURE
12 PPC SUPPLY PRESSURE
CHECK ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil temperature...................45 - 55° C (113 - 131° F)
1.
Connect pressure gauge E1 to pressure tap b of solenoid valve group c.
2.
Start the engine and run the engine at low idle with all levers in neutral position.
3.
Check the pressure. ★ Normal pressure ..........................38 ±3 kg/cm² (540 ±43 psi)
ADJUSTMENT ★ If the pressure value is not within the tolerance range, adjust valve b as follows: 1.
Loosen retaining nut c and turn adjustment screw d. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise
2.
Lock nut c. Lock nut c .................................... 22 ±2.5 N•m (16 ±1.8 lbf ft)
WB156PS-5
20-31 1
TESTING AND ADJUSTING
PC VALVE
12 PC VALVE
ADJUSTMENT ★ If pump delivery and LS differential pressure are within permissible values, but you notice that the engine rpm drops as a result of a change in the load, or that working equipment is very slow, it is time to adjust PC valve b.
1.
Loosen nut c and turn adjustment screw d. ★ To decrease the pump's torque absorption, turn adjustment screw d counterclockwise. ★ To increase the pump's torque absorption (i.e. to increase the speed of working equipment) turn adjustment screw d clockwise. ★ Turn the adjustment screw by not more than 180° in relation to the 0° line, in both directions. ★ Adjustment screw position on first installation shown.
2.
Lock nut c. Lock nut c ...........................27.4 - 34.4 N•m (20.2 -25.4 lbf ft)
20-32 1
WB156PS-5
TESTING AND ADJUSTING
STEERING CONTROL SYSTEM
12 STEERING CONTROL SYSTEM ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
CONTROL 1.
Connect pressure gauge E3 to tap P1C on the main control valve.
2.
Start the engine and bring it to idle speed 1,500 ±50 rpm and carry out steering in both directions.
3.
Turn the steering wheel to the end of stroke, check pressure. ★ Normal pressure ......178.3 - 188.5 kg/cm² (2,536 - 2,681 psi)
4.
Check the other steering direction.
SETTING ★ If pressure is not within permissible value, set upper valve b of steering unit c. 1.
Remove plug d. Insert a wrench and loosen screw e. ★ To increase pressure....................................... Turn clockwise ★ To decrease pressure .......................... Turn counterclockwise
2.
Stop the engine and replace plug d. Make sure that seal f is in the proper position. Plug c .......................................40 - 60 N•m (29.5 - 44.2 lbf ft)
WB156PS-5
20-33 1
TESTING AND ADJUSTING
STEERING CYLINDER
12 STEERING CYLINDER ★ Test conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Working brakes.............................................................Engaged
●
Maximum steering pressure .............. Within permissible limits
1.
Start the engine. Steer the wheels fully in either direction, then stop the engine.
2.
Disconnect supply hose c from cylinder b on the side where the rod is fully out d; plug the hose tightly.
3.
Connect a provisional hose to cylinder b to collect any leaking fluid.
4.
Start the engine and operate the engine at high idle speed.
5.
Turn the steering wheel to the end of its travel and retain the position for 30 seconds; measure any leak during the following minute.
6.
Release the steering wheel, run the engine at low idle, and then stop the engine.
7.
Check if leakage is normal. ★ Test cylinder on one side only, as there is only one gasket separating the two chambers.
8.
Restore the hydraulic connection. Steer the wheel several times in both directions to remove any air from the circuit.
20-34 1
WB156PS-5
TESTING AND ADJUSTING
POWER TRAIN GROUP
12 POWER TRAIN GROUP The power train group can be used to perform pressure tests on the internal hydraulic circuit. These are useful for identifying malfunctions. Specifically, the tests involve: Converter Oil Pressure Clutch Engagement Pressure (both directions of travel) ★ Test condition: ●
Engine............................................................................Stopped
●
Brake pedals ......................................Connected by a cotter pin
●
Machine: ................. on solid, level ground with the equipment raised and safety devices engaged.
●
Lower cab closeout..................................................... Removed
CONVERTER OIL PRESSURE 1.
Remove plug P3 and connect pressure gauge E6.
2.
Start the engine and heat the engine and all the fluids up to working temperature. In particular, make sure that the power train oil reaches a temperature of 80 ±5° C (176 ±41° F).
3.
With the engine at MIN, check the pressure on the pressure gauge E6. ★ Idle pressure ........................................ 3.05 kg/cm² (43.4 psi)
4.
Gradually increase engine speed to 2,200 rpm; take a new reading on pressure gauge E6. ★ Normal pressure ............3.05 - 9.17 kg/cm² (43.4 - 130.4 psi)
5.
Bring the engine back to MIN and compare the pressure with the normal value. ★ Minimum pressure .............................. 3.05 kg/cm² (43.4 psi) ★ If the pressure value drops to below the permissible lower limit, the power train pump needs a replacement. Plug ............................................................ 30 N•m (22.1 lbf ft)
CLUTCH ENGAGEMENT PRESSURE 1.
Remove plug P18 and connect pressure gauge E6.
2.
Start the engine and heat the engine and all the fluids up to working temperature. In particular, make sure that the power train oil reaches a temperature of 80 ±5 °C (176 ±41° F).
3.
Bring the engine up to low idle and check the pressure on pressure gauge E6. ★ Normal pressure ...................Maximum 0.3 kg/cm² (43.4 psi)
WB156PS-5
20-35 1
TESTING AND ADJUSTING
POWER TRAIN GROUP
12 4. With the working brakes applied, select reverse gear and gradually increase engine speed up to MAX, then take a new reading from pressure gauge E6. ★ Normal pressure ................13.7 - 16.8 kg/cm² (195 - 239 psi) 5.
Bring the engine back to MIN and the transmission in neutral position; compare the pressure with the normal value. ★ Normal pressure ...................Maximum 0.3 kg/cm² (43.4 psi)
6.
Remove the pressure adapter and replace plug P18. Plug ............................................................... 30 N•m (22 lbf ft)
7.
Repeat the same test for the FORWARD gear, reading the pressure from the orifice protected by plug P17. ●
If the pressures are different for the two travel directions, there is a loss of pressure on the clutch piston with lower pressure.
SUPPLY PRESSURE 1.
Remove plug P21 and connect pressure gauge E6.
2.
Start the engine and heat the engine and all the fluids up to working temperature. In particular, make sure that the power train oil reaches a temperature of 80 ±5° C (176 ±41° F).
3.
Bring the engine up to low idle and check the pressure on the pressure gauge. ★ Normal pressure ................14.2 - 17.3 kg/cm² (202 - 246 psi)
4.
Gradually increase engine speed to 2200 rpm; take a new reading on pressure gauge. ★ Minimum pressure ............................... 14.2 kg/cm² (202 psi) ★ If reading drops below minimum, the transmission pump needs replacing. Plug ............................................................... 30 N•m (22 lbf ft)
20-36 1
WB156PS-5
TESTING AND ADJUSTING
TRANSMISSION CLUTCH FUNCTION
12 TRANSMISSION CLUTCH FUNCTION ★ Test conditions: ●
Engine: .......................................................................... stopped
●
Brake pedals: .....................................connected by a cotter pin
●
Machine: ........... on solid and level ground with the equipment raised and safety devices engaged.
★ This test must be performed after having checked the pressures of the power train group.
MACHINE PREPARATION 1.
Prepare a tachometer to measure the engine rpm. WARNING! Make sure that the brake pedals are fastened together by cotter pin b. During the following tests, during the engine acceleration phase with the gear engaged, the condition of the brake disks can also be checked. ●
If machine starts to travel, even slowly, while force is being exerted on the brake pedals, release the accelerator immediately and stop
the engine. ●
Check the wear on the brake disks and change them before completing the tests.
CONTROL 1.
Start the engine and heat the engine and all the fluids up to working temperature. In particular make sure that the power train oil reaches a temperature of 80 ±5° C (176 ±41° F).
2.
With the engine in idling condition, accelerate to maximum and check that in this condition the rpms remain within permissible limits.
3.
Brake hard and bring the engine up to maximum.
4.
Engage the 3rd gear while braking and accelerating as above; confirm that engine speed decreases to the permissible range.
5.
Repeat this test in REVERSE gear. ★ If the rpms are higher than the permissible limits, the clutches are worn, and must be replaced.
WB156PS-5
20-37 1
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 HYDRAULIC DRIFT ★ If working attachments have a hydraulic drift, it is necessary to check if reason is due to cylinders gaskets or to control valve. ★ All testing conditions: ●
Engine.................................................At operating temperature
●
Hydraulic oil.......................................45 - 55° C (113 - 131° F)
●
Remove and install tubes only after residual pressure is removed.
LOADER BOOM CIRCUIT 1.
Put the machine with the bucket edge on blocks A of about 10 cm (3.9 in) and in vertical position in relation to the ground.
2.
Stop the engine and release the residual hydraulic pressures.
3.
Disconnect tubes b and c from lift cylinders d and plug them.
4.
Plug the cylinders, base side, and apply a temporary tube, rod side, to catch any possible oil leakage.
5.
Start the engine and curl the bucket until the teeth are in the tilt position by 10°.
6.
Stop the engine and check bucket link position for movement five minutes. ●
If the bucket link has no lowering movement, drift is due to the control valve.
To test the individual cylinders, proceed as follows: 7.
Move the bucket to let the edge lean on the ground in vertical position.
8.
Remove from one of the cylinders the plug fitted on the cylinder bottom side in Step 4.
9.
Start the engine and retract the bucket to bring the teeth in a tilt position of about 10° upwards.
10. Stop the engine and check the loader position for five minutes. ●
If the bucket link lowers, drift is due to seal leakage of the plugged cylinder.
11. Repeat Steps 8 to 10 to check the other cylinder.
20-38 1
WB156PS-5
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 BUCKET CIRCUIT 1.
Put the machine with the loader on level ground and bucket edge tilted 10°. Put a 1,500 kg (3,307 lb) weight in the bucket.
2.
Disconnect tubes b and c from both bucket cylinders d and plug them to prevent contamination.
3.
Plug the bucket cylinder, head side, and install a temporary tube on the rod side to catch oil leakage.
4.
Start the engine and raise the loader until the bucket hinge pin is aligned with boom hinge pin.
5.
Stop the engine and check the position of the bucket edge for five minutes. ●
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 cylinder head 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 five minutes. ●
If the bucket edge turns, the drift is due to seal leakage of the plugged cylinder.
10. Repeat operation from Steps 6 to 9 to check the other cylinder.
BACKHOE ★ Test condition: ●
Backhoe aligned
●
Lifted outriggers
WB156PS-5
20-39 1
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 BOOM CIRCUIT 1.
Set the machine with the boom in vertical position and with the bucket on level ground, leaning on the side.
2.
Stop the engine and release the residual hydraulic pressure.
3.
Disconnect hoses b and c that feed cylinder d.
4.
Plug the two hoses to avoid contamination.
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 five minutes. ●
If boom has a lowering movement, drift is due to cylinder gaskets.
●
If boom has no lowering movement, drift is due to control valve.
ARM CIRCUIT 1.
Set the machine with the arm fully extended and with the bucket teeth on ground.
2.
Stop the engine and release the residual hydraulic pressures.
20-40 1
WB156PS-5
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 3. Disconnect tubes b, c and tubes from arm cylinder d. Plug them to avoid contamination. ★ If a safety valve is fitted, remove it. 4.
Plug the arm cylinder hole on the head side and fit a temporary tube on the base side to catch oil leakage.
5.
Start the engine and raise the boom.
6.
Stop the engine and check the arm position for five minutes. ●
If the arm has a lowering movement, drift is due to the cylinder seals.
●
If the arm has no movement, drift is due to the control valve.
BUCKET CIRCUIT 1.
Set the machine with the arm vertical and the bucket at level ground on the side. Put a 450 kg (992 lb) weight in the bucket or fill it with dirt.
2.
Stop the engine and release the residual hydraulic pressures.
3.
Disconnect from bucket cylinder d, hoses b and c. Plug them to avoid contamination.
4.
Plug the bucket cylinder port on the base side and fit a temporary tube on the rod side to catch oil leakage.
WB156PS-5
20-41 1
TESTING AND ADJUSTING
HYDRAULIC DRIFT
12 5. Start the engine and raise the boom. 6.
Stop the engine and check the bucket position for five minutes. ●
If the bucket moves, drift is due to the cylinder seals.
●
If the bucket does not move, drift is due to the control valve.
OUTRIGGERS CIRCUIT - WITHOUT LOCK VALVES 1.
Set the machine with the arm in vertical position and with the bucket on level ground leaned to the side.
2.
Put 20 cm (7.9 in) blocks under the outriggers.
3.
Without forcing them, lower the outriggers onto the blocks.
4.
Stop the engine and release the residual hydraulic pressures.
5.
Disconnect from cylinders b, tubes c and d after lock valve e.
6.
Plug the cylinders base head tube c. Add temporary tubes to rod side d tube to catch oil leakage.
7.
Start the engine, use the boom to raise the machine, and remove the blocks supporting the outriggers.
8.
Lower the machine and stop the engine.
9.
Check the outriggers position for five minutes. ●
If one or both outriggers lower, drift is due to one or both cylinders.
●
If there is no lowering, drift is due to control valve.
20-42 1
WB156PS-5
TESTING AND ADJUSTING
AIR CONDITIONING
AIR CONDITIONING ★ Test conditions: ●
Machine on level ground with the working equipment raised and in safety conditions with the parking brake engaged
WORK TEMPERATURE 1.
Connect the maintenance station to the high pressure (HP) valve and the low pressure (LP) valve.
2.
Start the engine and bring it up to a speed of 1,500 rpm.
3.
Switch on the air conditioning unit using the switch. Select an intermediate ventilation speed inside the cab.
4.
Use thermometer M2 to check that the temperature inside the cab is equal to or lower than the ambient temperature. ★ If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab temperature stabilizes at the outside value.
5.
Close the doors and windows and let the air conditioning unit operate in these conditions for five to ten minutes.
6.
Use thermometer M2 to check the temperature of the air at the central outlets. ★ Position the probe as close as possible to the air outlets.
7.
Compare the average value of the measured temperatures using the following table:
Ambient temp ° C (° F)
20 (68)
25 (77)
30 (86)
35 (95)
Outgoing air temp ° C (° F)
6 - 8 (43 - 46)
8 - 10 (46 - 50)
8 - 12 (46 - 54)
9 - 14 (48 - 57)
8.
If the average value of the temperature measured does not fall within the values given in the table, it will be necessary to thoroughly check the unit.
UNIT CHECK Check the unit after the Steps 1, 2, 3 and 5 of the preceding paragraph. A diagnosis of faults in the unit is based upon the working pressures. When the pressures do not fall within the values given in the following table, the causes must be found by checking the highpressure and low pressure gauges. Unit: kg/cm² (psi) Unit with R134a Outside Air Temp ° C (° F)
Low Pressure
High Pressure
Min.
Max.
Min.
Max.
20 (68)
1.2 (17)
2.5 (35.6)
6.0 (85)
9.0 (128)
25 (77)
1.0 (14)
2.5 (35.6)
7.5 (108)
10.5 (149)
30 (86)
1.1 (15.6)
2.4 (34)
9.5 (135)
13.0 (185)
35 (95)
1.3 (18.5)
2.4 (34)
12.0 (171)
15.5 (220)
40 (104)
1.5 (21.3)
1.8 (25.6)
18.0 (256)
18.8 (267)
45 (113)
1.8 (25.6)
1.9 (27)
21.5 (306)
22.0 (313)
WB156PS-5
20-43 1
TESTING AND ADJUSTING
AIR CONDITIONING
The following conditions may be found: CONDITIONS
CAUSES - FAULTS Electromagnetic pulley that slips or does not engage correctly ● Expansion valve blocked in open position ● Compressor damaged ●
LP high to HP normal or low
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 low to HP high or 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 normal to HP normal
Normal condition with very high ambient temperature, higher than 43° C (109° F) ● Excess coolant, 30 - 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 high to HP high
Normal condition with very low temperature, lower than 5° C (41° F) ● Lack of coolant, 70 - 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 normal or low to HP low
Compressor belt missing Electromagnetic pulley that slips or does not engage ● Compressor damaged ●
LP roughly equal to HP
●
EMPTYING THE AIR CONDITIONING UNIT 1.
Connect maintenance station M1 to service valves b and c and follow the specific maintenance station instructions relative to the drainage of the unit.
2.
Disconnect the group to be substituted or reconditioned immediately after switching off the maintenance station. Plug the removed or disconnected connection tubes tightly and with a minimum of delay.
3.
Carefully check the quantity of coolant recovered and contained in the disassembled parts, since the same quantity must be replaced when the air conditioning unit is filled.
20-44 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 TROUBLESHOOTING GUIDE
FRONT AXLE Wheel vibration; front tire resistance; half shaft breakage CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent half shaft
Replace half shaft.
No differential action; jamming while steering CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Steering is difficult; vehicle goes straight while trying to turn it CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Broken half shaft
Replace half shaft.
Excess noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent or broken half shaft
Replace half shaft.
Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle.
WB156PS-5
20-45 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Uneven wear of tires CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent or broken half shaft
Replace half shaft.
Blocked half shaft: ● Abnormal functioning of the differential or ● Verify assembly of all components. breakage/blockage of control device ● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the with kicks, have steering difficulty or cause pneuvehicle begins to kick. matic wear on sharp turns. Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Friction noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
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 assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle. Incorrect adjustment of bevel gear set. Parts of the Replace or adjust as required. trans worn out transmission gears, U joint, etc. Vibration during forward drive, intermittent noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Bent half shaft
Replace half shaft.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
20-46 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Noise while driving CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust.
Worn out pinion and ring gear
Replace.
Worn out pinion bearings
Replace.
Pinion bearings loose
Adjust.
Excessive axial pinion backlash
Adjust.
Worn out differential bearings
Replace.
Differential bearings loose
Adjust.
Ring gear out of round
Replace.
Low oil level
Add oil.
Poor or worn oil
Replace.
Bent half shaft
Replace.
Noise while driving in neutral CAUSES
REMEDY
Noises coming from axle are usually heard but not Replace or adjust (see above). loud when vehicle moves in neutral gear. Incorrect backlash between pinion and ring, sound heard while decelerating, disappears while increas- Replace. ing speed Pinion or input flange worn out
Adjust.
Intermittent noise CAUSES
REMEDY
Ring gear damaged
Replace bevel gear set.
Differential box bolts loosened
Tighten to torque.
Constant noise CAUSES
REMEDY
Ring gear teeth or pinion damaged
Replace bevel gear set.
Worn out bearings
Replace.
Pinion spline worn out
Replace.
Bent half shaft
Replace.
Noise while steering CAUSES
REMEDY
Worn out differential gears
Replace.
Worn out differential box or spider
Replace.
Differential thrust washers worn out
Replace.
Half shaft spline worn out
Replace.
WB156PS-5
20-47 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Ring gear teeth broken at the outer side CAUSES
REMEDY
Excessive gear load compared to the one foreseen Incorrect gear adjustment (excessive backlash)
Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
Pinion nut loosened Ring gear tooth broken CAUSES
REMEDY
Load bump Incorrect gear adjustment insufficient backlash
Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations lubrication for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES
REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule. lubrication Pinion teeth pitting CAUSES Excessive use Insufficient lubrication
REMEDY Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Axle beam body bent CAUSES
REMEDY
Vehicle overloaded Vehicle accident
Replace axle beam body.
Load bump Worn out or pitted bearings CAUSES
REMEDY
Insufficient lubrication; contaminated oil Excessive use Normal wear out
Replace bearings, use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Pinion nut loosened
20-48 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Oil leakage from gaskets and seals CAUSES
REMEDY
Prolonged operation at high temperature Oil gasket assembled incorrectly Seal lip damaged
Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Contaminated oil Excessive wearing out of input flange spline CAUSES
REMEDY
Exhaustive use Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required.
Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES Exhaustive use
REMEDY Replace bevel gear set.
Continuous overload Pinion and ring teeth breakage CAUSES Crash load of differential components
REMEDY Check and/or replace other differential components.
Side gear spline worn out CAUSES Excessive use
REMEDY Replace differential gear group. Replace half shaft if required.
Thrust washer surface worn out or scratched CAUSES
REMEDY
Use correct lubricants, fill to proper levels and replace according to the Insufficient lubrication; contaminated oil, improper recommended schedule. Replace all scratched washers and those with lubrication 0.1 mm smaller thickness than the new ones. Inner diameter of tapered roller bearing worn out CAUSES Excessive use axial pinion Excessive pinion axial backlash Insufficient lubrication; contaminated oil
REMEDY Replace bearing. Check pinion axial backlash Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Bent or broken half shaft or half shaft broken at wheel side CAUSES
REMEDY
Vehicle intensively operated or overloaded Wheel support loosened
Replace. Check that wheel support is not worn out or incorrectly adjusted.
Beam body bent
WB156PS-5
20-49 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 REAR AXLE Wheel vibration; front tire resistance; half shaft breakage CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent half shaft
Replace half shaft.
Steering is difficult; vehicle goes straight while trying to turn it CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Broken half shaft
Replace half shaft.
No differential action; jamming while steering CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Broken half shaft
Replace half shaft.
Bent half shaft
Replace half shaft.
Excess noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent or broken half shaft
Replace half shaft.
Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Contamination in the axle box or incorrect assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle.
20-50 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Uneven wear of tires CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
Bent or broken half shaft
Replace half shaft.
Blocked half shaft: ● Abnormal functioning of the differential or break- ● Verify assembly of all components. age/blockage of control device. ● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the with kicks, have steering difficulty or cause pneuvehicle begins to kick. matic wear on sharp turns. Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Friction noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
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 assembly Look for foreign particles. Check for proper assembly of the various of parts parts of the axle. Incorrect adjustment of bevel gear set. Parts of the Replace or adjust as required. trans worn out transmission gears, U joint, etc. Vibration during forward drive, intermittent noise CAUSES
REMEDY
Incorrect installation
Correct installation.
Defective axle
Replace the differential if it fails any of the test phases.
Overloading/incorrect weight distribution
Remove excessive weight and redistribute load following instructions related to the vehicle.
Bent half shaft
Replace half shaft.
Different rotation radius of the tires
Replace the tire or adjust pressure to have the same radius on both tires.
WB156PS-5
20-51 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Noise while driving CAUSES
REMEDY
Excessive backlash between pinion and ring gear
Adjust.
Worn out pinion and ring gear
Replace.
Worn out pinion bearings
Replace.
Pinion bearings loose
Adjust.
Excessive axial pinion backlash
Adjust.
Worn out differential bearings
Replace.
Differential bearings loose
Adjust.
Ring gear out of round
Replace.
Low oil level
Add oil.
Poor or worn oil
Replace.
Bent half shaft
Replace.
Noise while driving in neutral CAUSES
REMEDY
Noises coming from axle are usually heard but not Replace or adjust (see above). loud when vehicle moves in neutral gear. Incorrect backlash between pinion and ring sound heard while decelerating, disappears while increas- Replace. ing speed Pinion or input flange worn out
Adjust.
Intermittent noise CAUSES
REMEDY
Ring gear damaged
Replace bevel gear set.
Differential box bolts loosened
Tighten to torque.
Constant noise CAUSES
REMEDY
Ring gear teeth or pinion damaged
Replace bevel gear set.
Worn out bearings
Replace.
Pinion spline worn out
Replace.
Bent half shaft
Replace.
Noise while steering CAUSES
REMEDY
Worn out differential gears
Replace.
Worn out differential box or spider
Replace.
Differential thrust washers worn out
Replace.
Half shaft spline worn out
Replace.
20-52 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Ring gear teeth broken at the outer side CAUSES
REMEDY
Excessive gear load compared to the one foreseen Incorrect gear adjustment, excessive backlash
Replace bevel gear set. Carefully follow the recommended operations for the adjustment of the bevel gear set free backlash.
Pinion nut loosened Ring gear tooth broken CAUSES
REMEDY
Load bump Incorrect gear adjustment, insufficient backlash
Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened Pinion or ring gear teeth worn CAUSES
REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations lubrication for the adjustment of the bevel gear set free play. Use correct lubricants, fill to proper levels and replace according to the recommended Worn out pinion bearings schedule. Overheated ring and pinion teeth CAUSES
REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule. lubrication Pinion teeth pitting CAUSES Excessive use Insufficient lubrication
REMEDY Replace bevel gear set. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Axle beam body bent CAUSES
REMEDY
Vehicle overloaded Vehicle accident
Replace axle beam body.
Load bump Worn out or pitted bearings CAUSES
REMEDY
Insufficient lubrication; contaminated oil Excessive use Normal wear out
Replace bearings. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Pinion nut loosened
WB156PS-5
20-53 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Oil leakage from gaskets and seals CAUSES
REMEDY
Prolonged operation at high temperature Oil gasket assembled incorrectly Seal lip damaged
Replace the gasket or seal and matching surface if damaged. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Contaminated oil Excessive wearing out of input flange spline CAUSES
REMEDY
Exhaustive use Replace the flange. Check that the pinion spline is not excessively worn. Replace bevel gear set if required.
Pinion nut loosened Pinion axle backlash Fatigue failure of pinion teeth CAUSES Exhaustive use
REMEDY Replace bevel gear set.
Continuous overload Pinion and ring teeth breakage CAUSES Crash load of differential components
REMEDY Check and/or replace other differential components.
Side gear spline worn out CAUSES Excessive use
REMEDY Replace differential gear group. Replace half shaft if required.
Thrust washer surface worn out or scratched CAUSES
REMEDY
Use correct lubricants, fill to proper levels and replace according to the Lack of lubrication; contaminated oil, improper recommended schedule. Replace all scratched washers and those with lubrication 0.1 mm (0.0039 in) smaller thickness than the new ones. Inner diameter of tapered roller bearing worn out CAUSES Excessive use axial pinion Excessive pinion axial backlash Insufficient lubrication; contaminated oil
REMEDY Replace bearing. Check pinion axial backlash. Use correct lubricants, fill to proper levels and replace according to the recommended schedule.
Bent or broken half shaft or half shaft broken at wheel side CAUSES
REMEDY
Vehicle intensively operated or overloaded Wheel support loosened
Replace. Check that wheel support is not worn out or incorrectly adjusted.
Beam body bent
20-54 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 TRANSMISSION Vehicle does not move CAUSES Faulty supply to solenoid valves
REMEDY Check/Replace.
Damaged wiring connections between transmission Repair/Replace. and vehicle Oxidized contacts in electrical wiring
Clean.
Break in electrical cable
Replace.
Damaged solenoids
Replace.
Damaged sensors
Replace.
Short circuits or open connections
Check/replace fuses.
Gear selector and direction of movement selector Replace selector. malfunction Shift electronic control unit malfunction
Replace.
Incorrect oil level
Fill oil to proper level.
Check for leaks
Repair.
Blocked intake filter
Clean.
Damaged oil pump
Replace.
Damaged oil pump relief valve
Replace oil pump.
Blocked/damaged transmission filter
Replace.
Damaged/jammed control valve
Replace.
Damaged converter
Replace.
Oil temperature below 0°C
Wait for oil to reach operating temperature (stall test).
Damaged rotary seals
Replace.
Damaged seals
Replace.
Blocked reverse lever
Repair.
Worn clutch
Replace/repair clutch.
No drive transmission, broken gears, shafts, bearCheck/Repair/Replace. ings, etc. Vehicle has reduced power transmission CAUSES
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 valve.
Damaged converter
Replace.
Incorrect oil level
Fill oil to proper level.
Worn clutch
Replace/Repair.
4WD clutch failure
Repair/Replace 4WD shaft group.
Overheating solenoids
Replace.
Damaged transmission and vehicle wiring connecRepair/Replace. tions Damage to shift electronic control logic
Replace.
Damaged sensors
Replace.
WB156PS-5
20-55 1
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Overheating CAUSES
REMEDY
Damaged hydraulic cooling system
Repair.
Dirty heat exchanger
Clean.
Parking brake inadvertently activated
Release.
Excessive dirt on axle wheel hubs
Clean.
Seizing, broken gears, shafts, bearings, etc.
Check/Repair/Replace.
Braking force outside transmission: irregular axle Check/Repair axle. operation Clutch plate drag
Repair/Replace.
Damaged converter
Replace.
Damaged oil thermostat
Replace.
Incorrect oil level
Check and adjust to proper oil level.
Worn oil pump
Replace.
Wheels rotate when vehicle is raised CAUSES
REMEDY
Clutch plate drag
Repair/Replace.
Low oil temperature (high oil viscosity)
Wait for oil to reach operating temperature (stall test).
Incorrect oil specifications
Replace oil and filters.
Damaged control valve
Replace.
Faulty reverser locking
Repair/Replace.
Noise CAUSES
REMEDY
Damaged converter
Replace.
Damaged oil pump
Replace.
Aeration/Cavitation
Check oil level.
Seizing (broken gears, shafts, bearings, etc.)
Check/Repair/Replace.
Worn clutch plates
Replace.
Irregular actuation CAUSES
REMEDY
Damaged control valve
Replace.
Electrical system fault
Repair/Replace.
Worn clutch plates
Replace.
Damaged converter
Replace.
Low oil temperature (high oil viscosity)
Wait for oil to reach operating temperature (stall test).
Overheating
See "Overheating."
Gear selector or direction of movement selector Replace. malfunction Control module unit malfunction
Replace.
Shift electronic control malfunction
Replace.
Damaged hydraulic system
Repair/Replace.
20-56 1
WB156PS-5
TESTING AND ADJUSTING
TROUBLESHOOTING GUIDE
12 Gear remains engaged CAUSES
REMEDY
Damaged/jammed shuttle shaft lever
Repair/Replace.
Electrical system fault
Repair/Replace.
Damaged control valve
Replace.
Damaged hydraulic system
Repair/Replace.
Damaged clutch
Repair/Replace.
Selector malfunction
Replace.
Control module malfunction
Replace.
Shift electronic control malfunction
Replace.
No 4WD power transmission CAUSES
REMEDY
Damaged 4WD clutch
Replace.
Hydraulic system fault
Repair/Replace.
Damaged control valve
Replace.
Faulty brake sensor
Check/Replace.
Electrical system fault
Repair/Replace.
Selector malfunction
Replace.
Control module malfunction
Replace.
Shift electronic control malfunction
Replace.
Gear shift will not engage CAUSES
REMEDY
Damage to clutch engagement assembly
Repair/Replace.
Damage to hydraulic system
Repair/Replace.
Damaged control valve
Replace.
Damage to pressure sensors
Check/Replace.
Electrical system fault
Repair/Replace.
Selector malfunction
Replace.
Control module malfunction
Replace.
Shift electronic control malfunction
Replace.
WB156PS-5
20-57 1
TESTING AND ADJUSTING
FUSES AND RELAYS
FUSES AND RELAYS WARNING! When replacing fuses or relays, always check the condition of the contacts for corrosion. Never replace a fuse with a fuse of higher or lower amp rating. Damage to the electrical system may result.
FUSE AND RELAY PANEL LOCATION • The fuses and relays are grounded on a single board positioned on the right side of the cab. Removing cover (1) exposes the fuses and relays, if it is necessary to service them. • If an electrical system fails during operation, it is important to check the fuses or relays first.
• Once cover (1) is removed, the fuses and relays are easily accessible. • With the starter key in the “ON” position, check each fuse with a test light. This will indicate which bank of fuses or relays has failed. • To replace a fuse or relay, the starter switch must be in the “OFF” position.
20-58 1
WB156PS-5
TESTING AND ADJUSTING
FUSES AND RELAYS
FUSE AND RELAY PANEL LAYOUT FUSES
Position
Color
Amps
F1
Light blue
15
Front work lamps
F2
Light blue
15
Rear work lamps
F3
Violet
3
Parking lights front left and rear right, warning lamps and dash lamps
F4
Violet
3
Parking lights front right and rear left, cigarette lighter
F5
Red
10
Front horn
F6
Light blue
15
Lateral rear work lights
F7
Brown
7.5
Rear windshield wiper and rear horn
F8
Brown
7.5
Stop lights and stop light relay
F9
Light blue
15
Lateral front work lights
F10
Red
10
Front windshield wiper, windshield washer pump
F11
Brown
7.5
Boom lock solenoid valve
F12
Orange
5
Buzzer power supply, general alarm and warning lamps supply
F13
Red
10
Optional equipment, differential and 4-wheel drive solenoid power supply
WB156PS-5
Circuit
20-59 1
TESTING AND ADJUSTING
Fuse Position
FUSES AND RELAYS
Description
F14
High/low beam, horn and safety solenoid valve
F15
Engine stop solenoid, A/C relay and functions relay
F16
Rotating beacon
F17
Hour meter memory, hazard warning light
F18
Cigarette lighter and cab lamp
F19
Left and right low beam
F20
Left and right high beam
F21
Return-to-dig sensor, LSS solenoid valve, loader arm float solenoid, return-to-dig solenoid valve and direction indicator
F22
Joystick control lock solenoid, EC power solenoid valve, PPC power supply
F23
Steering unit
F24
Direction indicator power supply
F25
Declutching relay, forward gear solenoid valve, reverse gear solenoid valve and reverse alarm
F27
General system fuse, starter key, start relay, and preheat power supply
20-60 1
WB156PS-5
TESTING AND ADJUSTING
FUSES AND RELAYS
RELAYS
Relay Position
Description
K1
Safety unit (against repeated start)
K2
Turn signal and/or flasher
K3
Low beam relay
K4
High beam relay
K5
Front horn relay
K6
Return-to-dig relay
K7
Stop light relay
K8
Start enabling relay
K9
Forward gear relay
K10
Reverse relay
K11
Directional indicator power supply relay (declutch)
K12
Machine function relay
K13
Start relay
K14
Preheating relay
K15
Multifunction unit
WB156PS-5
20-61 1
TESTING AND ADJUSTING
FUSES AND RELAYS
HEATING AND AIR CONDITIONING FUSES AND RELAYS • The fuses and relays are grouped on a single board positioned under the storage compartment and can be reached after opening the door (1) and removing the container (2).
• The following tables indicate the characteristics and the functions of the single fuses and relays.
FUSES Fuse Position
Color
Amps
1
Yellow
20
1 and 2 fan speed power supply
2
Orange
40
3rd fan speed power supply
3
Brown
7.5
Air conditioner compressor
Circuit
RELAYS Relay Position
Description
4
3rd fan speed relay
5
General heating relay
6
Air conditioner compressor relay
20-62 1
WB156PS-5
30
DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 REMOVAL AND INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 30-7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 OVERHAUL OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 ASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 PRECAUTIONS FOR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9 SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11 CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . 30-16 CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 FRONT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27 AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30 AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34 AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35 WB156PS-5
30-1 1
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37 AIR CONDITIONER COMPRESSOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38 EXHAUST STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40 CAB HEATING AND COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51 STEERING AND FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53 FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55 STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60 BLEED AIR FROM BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-68 HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-78 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-82 BLEED AIR FROM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-83 TRANSMISSION OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84 30-2 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84 PLUGS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-89 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99 HYDRAULIC SUPPLY LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103 TRANSMISSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111 CLUTCH PACK (A) AND GEAR SHAFT (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 CLUTCHES AND DISC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-126 CHECKING CLUTCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135 SHAFT (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-136 CLUTCHES AND DISC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144 SHAFT (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-151 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-151 CLUTCHES AND DISC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165 1st GEAR CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 3rd GEAR CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 4th GEAR CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-167 SHAFT (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183 CLUTCHES AND DISC INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-196 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205 STEERING SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 WB156PS-5
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INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 FRONT AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210 FRONT AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-215 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217 AXLE END HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222 AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230 PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-234 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237 CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242 REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-244 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246 REAR AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247 PARKING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-247 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-249 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-251 SERVICE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-254 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-259 REAR AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-270 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-274 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-276 DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-281 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-281 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-284 CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-287 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-287 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-291 PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-295 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-295 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-297 30-4 1
WB156PS-5
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FRONT LOADER PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-301 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-301 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-302 FRONT-END LOADER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-303 LOADER BOOM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-303 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304 BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-305 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-305 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306 FRONT LOADER BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-307 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-307 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-307 LOADER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-308 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-308 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-309 BACKHOE PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-311 PPC VALVE SUPPORT RELEASE CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-312 INSTALLATION AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-314 PPC VALVE GAS STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-315 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-315 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-317 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318 BACKHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319 BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320 TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-321 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-321 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-321 ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-322 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-322 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-323 BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-324 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-324 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-325 SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-326 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-326 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328 BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-329 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-329 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330 BACKHOE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330 WB156PS-5
30-5 1
DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-331 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-331 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-333 TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-334 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-334 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-334 TELESCOPIC ARM GIBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-335 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-335 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-335 BACKHOE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337 BACKHOE SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-338 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-338 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-338 OUTRIGGER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-339 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-339 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-340 OUTRIGGER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-341 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-341 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-341 WORK EQUIPMENT CYLINDER OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-342 LOADER AND BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-342 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-342 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-344 SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-347 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-347 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-349
30-6 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL
12 HOW TO USE THIS MANUAL
REMOVAL AND INSTALLATION OF COMPONENTS REMOVAL • •
The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the REMOVAL Section are explained and listed below. WARNING! This mark indicates safety-related precautions which must be followed when doing the work. Remark This mark gives guidance or precautions when doing the procedure. This mark shows the amount of fuel, oil or water to be drained. This mark indicates the weight of a part or component.
INSTALLATION •
Except where otherwise instructed, install parts is the reverse order of removal.
•
Marks shown in the INSTALLATION Section stand for the following. WARNING! This mark indicates safety-related precautions which must be followed when doing the work. ★
This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used. This mark indicates the specified torque.
This mark indicates the amount of fuel, oil or coolant to be added.
WB156PS-5
30-7 1
DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL
12 OVERHAUL OF COMPONENTS
DISASSEMBLY PROCEDURES • •
The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained. Various symbols used in the DISASSEMBLY Section are explained and listed below. WARNING! This mark indicates safety-related precautions which must be followed when doing the work. Remark This mark gives guidance or precautions when doing the procedure. This mark shows the amount of fuel, oil or coolant to be drained.
ASSEMBLY PROCEDURES • •
Section titled ASSEMBLY contains procedures, precautions and the expertise for the work, as well as the amount of oil or water to be added. Various symbols used in the ASSEMBLY Section are explained and listed below. WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
★
This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used. This mark indicates the specified torque.
This mark indicates the amount of fuel, oil or coolant to be added.
30-8 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR WORK
12 PRECAUTIONS FOR WORK When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation. 1.
Precautions when carrying out removal work: ● If draining a system always dispose of the fluids correctly. ● After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt and/or dust from entering. ● Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. ● To prevent any excessive force from being applied to the wiring, always hold the connectors when unplugging the connectors. Do not pull the wires. ● Install wires and hoses with tags to show their installation position to prevent any mistake when installing. ● Record the of thickness of the shims, and keep in a safe place. ● When raising components, be sure to use lifting equipment of ample strength and always stand clear of what you are lifting. ● When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. ● Before removing any unit, clean the surrounding area and install a cover to prevent any dust and/or dirt from entering after removal. ★ Precautions when handling piping during disassembly: ● Install the following blind plugs into the piping after disconnecting it during disassembly operations. A. Face seal type hoses and tubes Nominal number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
B. Split flange type hoses and tubes Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-30400
05
07379-00500
07378-10500
07371-30500
C. If the part is not under hydraulic pressure, the following plugs can be used. Nominal number
Part Number
06
Dimensions (mm) (in) D
d
L
07049-00608
6
5
8 (0.31)
08
07049-00811
8
6.5
11 (0.43)
10
07049-01012
10
8.5
12 (0.47)
12
07049-01215
12
10
15 (0.59)
14
07049-01418
14
11.5
18 (0.71)
16
07049-01620
16
13.5
20 (0.79)
18
07049-01822
18
15
22 (0.87)
20
07049-02025
20
17
25 (0.98)
22
07049-02228
22
18.5
28 (0.10)
24
07049-02430
24
20
30 (1.18)
27
07049-02734
27
22.5
34 (1.34)
WB156PS-5
30-9 1
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR WORK
2.
Precautions when carrying out installation work: ● Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. ● Install the hoses without twisting or interference. ● Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. ● Bend the cotter pins and lock plates securely. ● When coating with adhesive, clean the part and remove all oil and grease. Then coat the threaded portion with two to three drops of adhesive. ● When coating with gasket sealant, clean the surface and remove all oil and grease. Check that there is no dirt or damage, then coat uniformly with gasket sealant. ● Clean all parts, and correct any damage, dents, burrs, or rust. ● Coat rotating parts and sliding parts with engine oil. ● When press fitting parts, coat the surface with anti-friction compound (LM-P). ● After fitting snap rings, check to be sure snap ring is fitted securely in the ring groove. ● When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. ● When using eyebolts, check to be sure there is no deformation or deterioration, screw them in fully, and align the direction of the hook. ● When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. ★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: A. Start the engine and run at low idling. B. Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping the cylinder 100 mm (4.0 in) from the end of its stroke. C. Next, operate the hydraulic cylinder three to four times to the end of its stroke. ★ When using the machine for the first time after repair or long storage, follow the same procedure.
30-10 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
Component Removal of piston pump Removal of transmission
Disassembly and assembly of front axle
Disassembly and assembly of rear axle
WB156PS-5
Symbol B
D
E
Part Number
Part Name
Qty
12 SPECIAL TOOL LIST
1
⎯
Pump support tool
1
2
⎯
Transmission support tool
1
1
CA119099
Closed end wrench
1
2
CA119143
Plunger
1
3
CA119200
False differential box
1
4
CA119202
False pinion
1
5
CA119225
Plunger
1
6
CA119226
Plunger
1
7
CA119228
False differential box
1
8
CA715004
Plunger
1
9
CA715022
Key
1
10
CA715026
Plunger
1
11
CA715027
Plunger
1
12
CA715039
Plunger
1
13
CA715042
Plunger
1
14
CA715064
Plunger
1
15
CA715108
Plunger
1
16
CA715265
Key
1
17
CA715505
Plunger
1
18
CA715506
Plunger
1
19
CA715543
Plunger
1
20
CA715742
Plunger
1
21
CA722521
Sensor test system
1
1
CA119099
Key
1
2
CA119143
Bushing
1
3
CA119226
Plunger
1
4
CA715004
Plunger
1
5
CA715022
Key
1
6
CA715026
Plunger
1
7
CA715027
Plunger
1
8
CA715033
Plunger
1
9
CA715039
Plunger
1
10
CA715042
Plunger
1
11
CA715056
Plunger
1
12
CA715108
Plunger
1
13
CA715128
False pinion
1
30-11 1
Component
Disassembly and assembly of rear axle
Disassembly and assembly of transmission
E
F
SPECIAL TOOL LIST
Symbol
Part Number
14
CA715172
Plunger
1
15
CA715265
Key
1
16
CA715380
Bearing assembly kit
1
17
CA715388
False differential box
1
18
CA715391
Plunger
1
19
CA715456
Backlash tool
1
20
CA715505
Plunger
1
21
CA715506
Plunger
1
22
CA715541
Plunger
1
23
CA715706
Preload tool
1
24
CA715742
Plunger
1
25
CA715521
Sensor system test
1
1
CA714095
Plunger
1
2
CA715004
Plunger
1
3
CA715623
Plunger
1
4
CA715354
Plunger
1
5
CA715495
Protection and shims
1
6
CA715497
Plunger
1
7
CA715356
Calibrator
1
8
CA715501
Plunger
1
9
CA715358
Clutch installation tool
1
10
CA715499
Protection
1
11
CA715046
Plunger
1
12
CA715743
Protector and shims
1
13
CA715746
Plunger
1
14
CA715745
Calibrator
1
15
CA715496
Latch for B and C shafts
1
16
CA715149
Plunger
1
17
CA715493
Stop ring removal and installation tool
1
18
CA715257
Protection
1
19
CA715263
Protection
1
790-502-1003
Equipment
1
790-101-1102
Pump
1
790-102-3802
Key
1
790-302-1310
Key 65 mm (2.56 in)
1
790-302-1280
Key 55 mm (2.16 in)
1
790-302-1270
Key 50 mm (1.97 in)
1
790-302-1390
Key 46 mm (1.81 in)
1
1 2 Disassembly and assembly of cylinders
U 3
30-12 1
Qty
DISASSEMBLY AND ASSEMBLY
Part Name
WB156PS-5
Component
SPECIAL TOOL LIST Part Name
Symbol
Part Number
4
790-102-4300
Expander
1
796-720-1670
Calibrator for boom cylinder
1
07281-01279 796-720-1660 5
1 Calibrator for arm and swing cylinder
07281-01159 796-720-1650
796-720-1640
Calibrator for bucket and arm cylinder
U
7
8
WB156PS-5
1 1
Calibrator for outriggers and bucket cylinders
1
790-201-1702
Driver kit
1
790-101-5021
· Handle
1
01010-50816
· Screw
1
790-201-1781
· Driver for boom cylinder
1
790-201-1771
· Driver for bucket cylinder
1
790-201-1761
· Driver for bucket and arm cylinder
1
790-201-1751
· Driver for bucket cylinder
1
790-201-1741
· Driver for outrigger cylinder
1
790-201-1500
Driver kit
1
790-101-5021
· Handle
1
01010-50816
· Screw
1
790-201-1590
· Driver for boom cylinder
1
790-201-1580
· Driver for bucket cylinder
1
790-201-1570
· Driver for swing and bucket cylinder
1
790-201-1560
· Driver for bucket cylinder
1
790-201-1550
· Driver for outriggers cylinder
1
790-102-4300
Key
1
790-102-4310
Pin
2
07281-00909
6
1 1
07281-01029
Disassembly and assembly of cylinders
Qty
DISASSEMBLY AND ASSEMBLY
1
30-13 1
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE) 1.
Obtain the correct removal tool according to the wire size used in the connector.
2.
With the rear insert part of the connector facing you, snap the removal tool over the wire of the contact terminal you will be removing.
Remark Using a removal tool that is too large or too small will hinder wire removal and may damage the connector or removal tool. Always use the correct removal tool size for the wire gauge you are servicing. 3.
In a straight line, carefully slid the removal tool along the wire and into the grommet until a contact resistance is felt.
Remark Do not pull on the wire or twist the tool when inserting removal tool into the grommet. Damage to the tool or connector may result.
4.
Once tool is fully inserted into the connector, carefully pull the removal tool and contact terminal wire out of the connector.
5.
If contact terminal wire will not come out, remove tool and reinsert removal tool again.
30-14 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 CRIMPING CONTACT TERMINAL (HD30 TYPE) 1.
After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool number HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal, inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
WB156PS-5
30-15 1
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 INSERTION OF CONTACT TERMINAL (HD30 TYPE) 1.
Grasp contact terminal approximately 25.2 mm (1 in) behind the crimped barrel.
2.
Hold connector with rear grommet facing you.
3.
Insert completed contact terminal straight into connector grommet until a positive stop is felt.
4.
Once contact terminal is in connector, a slight tug will confirm that the contact terminal is properly locked in place.
5.
For unused wire cavities, insert sealing plugs for full environmental sealing.
30-16 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 CONTACT TERMINAL REMOVAL (DT TYPE) 1.
Remove the wedge lock using needle nose pliers or a hooked shaped wire.
2.
Pull the wedge lock straight out and save for reinstallation.
3.
To remove the contact terminal, gently pull the wire backwards while at the same time releasing the locking finger by pushing it away from the terminal with a small screwdriver.
4.
Hold the rear seal grommet in place and pull the contact terminal out of the connector.
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DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 CRIMPING CONTACT TERMINAL (DT TYPE) 1.
After insulation has been stripped from the wire and contact terminal is ready for crimping, raise selector knob on Crimp Tool number HDT48-00 and rotate until arrow is aligned with wire size to be crimped.
2.
Loosen locknut, turn adjusting screw in until it stops.
3.
Insert contact terminal with barrel up. Turn adjusting screw counterclockwise until contact terminal surface is flush with indenter cover. Tighten locknut.
4.
Insert wire into contact terminal. Be sure contact terminal is centered between indicators.
5.
Close crimp tool handle until crimp cycle is completed.
6.
Release the tool handle and remove the crimped contact terminal.
7.
Using the inspection hole in the contact terminal, inspect the crimped contact terminal to ensure that all strands are in the crimped barrel.
Remark The tool must be readjusted for each type/size of contact. Use Crimp tool HDT04-08 for size 8 and 4 contacts.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 INSERTION OF CONTACT TERMINAL (DT TYPE) 1.
Grasp the crimped contact terminal approximately 25.2 mm (1 in) behind the crimped barrel.
2.
Hold the connector with the rear grommet facing you and insert the completed wire into the connector.
3.
Push the contact terminal straight into the connector until a “click” is felt. A slight tug will confirm that the contact terminal is properly locked in place.
4.
Once all contact terminals are in place, insert the wedge lock with the arrow pointing toward exterior locking mechanism. The wedge lock will snap into place. Rectangular wedges are not oriented and may fit either way.
Remark As the connector receptacle is shown - use the same procedures for a plug.
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DISASSEMBLY AND ASSEMBLY
CONNECTOR REPAIR PROCEDURES
12 STRIPPING INSULATION After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or corroded sections of the wire being repaired referring to the Deutsch Table below. Deutsch Table Deutsch Terminal Part Number
Wire Gauge Range
Strip Length: mm (in)
0460 - 202 - 20141 0462 - 201 - 20141
20 AWG 20 AWG
3.96 - 5.53 (0.156 - 0.218) 3.96 - 5.53 (0.156 - 0.218)
0460 - 202 - 16141 0462 - 201 - 16141
16, 18 and 20 AWG 16, 18 and 20 AWG
6.35 - 7.92 (0.250 - 0.312) 6.35 - 7.92 (0.250 - 0.312)
0460 - 215 - 16141 0462 - 209 - 16141
14 AWG 14 AWG
6.35 - 7.92 (0.250 - 0.312) 6.35 - 7.92 (0.250 - 0.312)
0460 - 204 - 12141 0462 - 203 - 12141
12 and 14 AWG 12 and 14 AWG
5.64 - 7.21 (0.222 - 0.284) 5.64 - 7.21 (0.222 - 0.284)
0460 - 204 - 08141 0462 - 203 - 08141
8 and 10 AWG 8 and 10 AWG
10.92 - 12.47 (0.430 - 0.492) 10.92 - 12.47 (0.430 - 0.492)
0460 - 204 - 0490 0462 - 203 - 04141
6 AWG 6 AWG
10.92 - 12.47 (0.430 - 0.492) 10.92 - 12.47 (0.430 - 0.492)
Using wire insulation strippers, remove only the measured amount of insulation from the wire according to the size contact terminal listed in the “Strip Length” above.
Wire Inspection After stripping insulation from wire, inspect wire strands for: ● Corrosion, straightness and uniformity ● Broken or nicked wire strands are unacceptable and may cause high resistance in the circuit. ● Do not twist or wrap the wire strands as this may cause wire strand breakage during the crimping process.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
ENGINE HOOD
12 ENGINE HOOD
REMOVAL WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a firm, smooth and level surface. Lower all work equipment to the ground, set the parking brake, chock the wheels and disconnect the battery. 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove the cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower lock unit (1) down from its storage position onto the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on loader lock (1).
2.
Remove four grille mounting screws (1) and front grille assembly (2).
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DISASSEMBLY AND ASSEMBLY 3.
Fully raise engine hood (3) and remove safety pins (4) then disconnect gas struts (5) from the chassis.
4.
Remove snap rings (6) and retaining washers (7) from the pivot pins (8).
5.
Remove pivot pins (8) and have two people carefully lift hood assembly (3) off of the machine.
ENGINE HOOD
Engine hood: 32 kg (71 lb)
INSTALLATION ★ Installation is done in the reverse order. ★ After installing hood (3) be sure to line up hood latch bracket (9) when closing the hood.
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DISASSEMBLY AND ASSEMBLY
FRONT GUARD
12 FRONT GUARD
REMOVAL WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a firm, smooth and level surface. Lower all work equipment to the ground, set the parking brake, chock the wheels and disconnect the battery. ★ Before removing the front guard, the grille and hood assembly must be removed first. See “ENGINE HOOD” on page 30-21. 1.
After the grille and hood are removed, sling front guard (4) as shown in the illustration. Lift up slightly to relieve tension on mounting bolts (3) before removing them. Front guard: 110 kg (242 lb)
2.
Carefully remove four mounting bolts (3) that hold guard (4) in place. WARNING! When doing this procedure be sure to keep upward tension on guard frame (4). When removing four mounting bolts (3) be sure to stand clear of guard frame (4).
3.
Once four mounting bolts (3) are removed, move guard frame (4) forward then lift up on frame to remove from the machine.
INSTALLATION ★ Installation is done in the reverse order. Mounting bolts (3): Locktite 242
Bolts (3) torque: 300 N·m (221 lbf ft)
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DISASSEMBLY AND ASSEMBLY
RADIATOR
12
RADIATOR REMOVAL ★ Before removing the radiator, first the grille, hood and front guard assembly must be removed. See “ENGINE HOOD” on page 30-21 and “FRONT GUARD” on page 30-23. 1.
Open drain valve (3) and drain the engine coolant at the front of the radiator. WARNING! Slowly loosen the radiator cap to release the pressure inside the cooling system. A. Set a suitable size container under the engine coolant drain to catch the coolant that is drained from the cooling system.
B. Place the drain hose into the container and open the drain valve two to three turns to drain the engine coolant. Remark Do not drain coolant on the ground, in rivers or lakes or in a city sewer system. Coolant must be captured and recycled. Engine coolant: Approximately 15 l (4 gal)
2.
Disconnect connector (4) and remove horn (5).
3.
Disconnect hose (7) from radiator (6) and remove surge tank (8).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Remove four bolts and fan guard (10).
5.
Partially loosen fittings (11) and (12) to drain hydraulic oil from the oil cooler. Once it is drained, remove hoses (13) and (14). ★ Plug all hoses, lines and connections to prevent contamination.
RADIATOR
Hydraulic oil: Approximately 40 l (10.5 gal)
6.
Disconnect transmission oil cooler oil hoses (15) and (16) from the oil cooler and plug them to prevent contamination. ★ Mark the hoses and their respective positions for reconnecting.
Machines Equipped with Air Conditioning Remark Do not release refrigerants into the atmosphere. All refrigerants must be captured and recycled. 7.
After capturing refrigerant, remove hoses (17) and (18). ★ Plug all hoses, lines and connections to prevent contamination.
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DISASSEMBLY AND ASSEMBLY 8.
Disconnect upper (19) and lower (20) radiator hoses.
9.
Remove self-locking nuts (21), washers (22) and anti-vibration dampers (23).
RADIATOR
10. Remove bolts (24) retaining brackets (25).
11. Move radiator (6) to the front of the machine to disengage it from the cooling fan and lift it off of the machine frame. Radiator : 37 kg (82 lb)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
RADIATOR
12 INSTALLATION ★ To install, reverse removal procedure. ★ Refill the cooling system. Coolant: 15 l (4 gal)
★ Fill the tank with hydraulic oil up to maximum level. Hydraulic oil: 40 l (10.5 gal)
★ Ensure that the level of transmission oil is at maximum. ★ Start the engine at low idle to circulate all the fluids and to fill up the systems. ★ Accelerate gradually to 1,700 rpm; after about one minute, stop the engine and check or top off the level. Top off all oil levels. ★ Align radiator (6) with fan, making sure the fan protrudes from fan shroud by "a" 25 ±2 mm (1.0 ±0.1).
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DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER CONDENSER
12
AIR CONDITIONER CONDENSER WARNING! Do not release refrigerants into the atmosphere. All refrigerants must be captured and recycled.
REMOVAL 1.
Remove the front grille and the front guard. For details see “FRONT GUARD” on page 30-23.
2.
After capturing refrigerant, remove hoses (1) and (2). ★ Plug all hoses, lines and connections to prevent contamination.
3.
Disconnect the connector (3) and remove the horn (4).
4.
Remove four bolts (5) and washers then remove condenser (6) together with receiver-dryer.
INSTALLATION ★ To install, reverse removal procedure. ★ Refill the air conditioning unit.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
MUFFLER
12 MUFFLER WARNING! Be sure the engine and exhaust system have fully cooled down before removing any exhaust components. Failure to do so may result in a burn injury.
REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower lock unit (1) down from its storage position on to the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on the loader lock (1).
2.
Loosen nuts (1) on clamp (2) retaining muffler pipe (3) to the exhaust stack.
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30-29 1
DISASSEMBLY AND ASSEMBLY 3.
Remove clamp (4), disconnect pipe (3) from muffler (5) and remove pipe (3).
4.
Loosen tie strap (6) retaining the muffler pipe to the turbocharger.
5.
Remove four bolts (7) and washers.
6.
Sling and remove the muffler (5).
MUFFLER
Muffler: 30 kg (66 lb)
INSTALLATION ★ To install, reverse removal procedure.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
AIR FILTER
12 AIR FILTER
REMOVAL 1.
Park the machine on hard, level ground. Apply the parking brake, stop the engine and remove the starting key.
2.
Fully open engine hood, loosen straps (1) and (2), and disconnect pipes (3) and (4).
3.
Disconnect connector (6) from filter clogging sensor (5).
4.
Remove bolts (7) and remove the filter (8) together with the filter housing.
INSTALLATION ★ To install, reverse removal procedure.
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30-31 1
DISASSEMBLY AND ASSEMBLY
TURBOCHARGER
12
TURBOCHARGER WARNING! Be sure the engine and exhaust system have fully cooled down before removing any exhaust components. Failure to do so may result in a burn injury.
REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove the cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower lock unit (1) down from its storage position on to the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on the loader lock (1).
2.
Disconnect the coolant tube (2) from around suction pipe (1).
3.
Disconnect the suction pipe (1) from the turbocharger (3).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Disconnect connector (4) from the filter clogging lamp.
5.
Remove bolts (5) and the air filter (6).
6.
Remove bolts (7) and wastegate (8), then remove exhaust flange (9).
7.
Remove muffler (10). For details see “MUFFLER” on page 30-29.
WB156PS-5
TURBOCHARGER
30-33 1
DISASSEMBLY AND ASSEMBLY 8.
TURBOCHARGER
Remove turbocharger (3) according to the instructions provided in the engine manual.
INSTALLATION ★ To install, reverse removal procedure.
30-34 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER COMPRESSOR
12 AIR CONDITIONER COMPRESSOR WARNING! Do not release refrigerants into the atmosphere. All refrigerants must be captured and recycled.
REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove the cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower the lock unit (1) down from its storage position onto the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on loader lock (1).
2.
Recover refrigerant at ports (1) and (2) using the proper recovery equipment.
3.
Disconnect supply and return lines (5) and (6) from compressor (4). ★ Collect the O-rings and discard them.
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30-35 1
DISASSEMBLY AND ASSEMBLY 4.
Remove air filter (8).
5.
Remove fan guard (7).
6.
Loosen bolt (9) retaining tensioner (10).
7.
Loosen nut (11) and rotate screw (12) to loosen the belt tension.
8.
Disengage belt (13) from pulley (14).
9.
Remove bolt and nut (15).
30-36 1
AIR CONDITIONER COMPRESSOR
WB156PS-5
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER COMPRESSOR
10. Remove bolts (15) and remove compressor (4).
INSTALLATION ★ To install, reverse removal procedure. 1.
Replace O-rings with new ones.
2.
Adjust the compressor belt.
3.
Recharge the system.
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30-37 1
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER COMPRESSOR BELT
12
AIR CONDITIONER COMPRESSOR BELT REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove the cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower lock unit (1) down from its storage position onto the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on the loader lock (1).
2.
Remove fan guard (7).
3.
Loosen bolt (9) retaining tensioner bracket (10).
4.
Loosen nut (11) and adjust belt (13) tension by rotating bolt (12).
INSTALLATION ★ To install, reverse removal procedure. Bracket lock nut: 117.6 N·m (86.7 lbf ft) Fan fastening nuts: 42 N·m (31 lbf ft)
30-38 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
EXHAUST STACK
12 EXHAUST STACK
REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove the cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower lock unit (1) down from its storage position onto the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on loader lock (1).
2.
Remove exhaust clamp nuts (1) and clamp (2) from pipe (3).
3.
Loosen bolts (4) on the stack flange and remove one bolt only (for safety) to hold stack in place.
WB156PS-5
30-39 1
DISASSEMBLY AND ASSEMBLY 4.
OPERATOR’S SEAT
Remove bolt (5) and lift stack (6) off of the machine after removing last bolt (4) from flange.
INSTALLATION ★ To install, reverse removal procedure.
OPERATOR’S SEAT ★ This job requires two people to perform the removal and installation tasks.
REMOVAL ★ Before proceeding with any removal procedures, be sure the seat is locked in position. 1.
Unplug connector (1) and remove seat mounting bolts (3).
2.
With two people, lift the seat (2) off the machine.
Seat: 62 kg (137 lb)
INSTALLATION ★ To install, reverse removal procedure.
30-40 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
12 CAB HEATING AND COOLING SYSTEM WARNING! Do not release refrigerants into the atmosphere. All refrigerants must be captured and recycled. WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a firm, smooth and level surface. Lower all work equipment to the ground, set the parking brake, chock the wheels and disconnect the battery. WARNING! Do not drain coolant on the ground, in rivers or lakes or in a city sewer system. Coolant must be captured and recycled.
REMOVAL ★ If the machine does not have an air conditioning system installed, perform only those operations relating to the heating system. 1.
Drain the engine coolant. Coolant liquid: 15 l (4 gal)
2.
Evacuate the refrigerant from the air conditioning system.
3.
Remove floor mat (1); unplug connector (2), remove mounting bolts, remove seat (3).
4.
Remove screws (4) and remove control unit panel (5).
5.
Remove four screws (6) and remove the PPC valve and parking brake cover (7).
WB156PS-5
30-41 1
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
6.
Remove four screw covers and screws (8).
7.
Remove lower side instrument panel (9). ★ Cut the wiring harness strap and position instrument panel (9) inside R.H. case (10).
★ To install, reverse removal procedures.
8.
Remove four screw covers and screws (11).
9.
Remove upper side instrument panel (12).
10. Disconnect connector (13) from instrument panel (12). 11. Disconnect connectors (14) and (15) from the lighter.
12. Extract screws (16) and remove throttle lever handle (17). 13. Remove screws (18) from the throttle lever assembly.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
14. Remove screws (19) and (20).
15. Remove knobs (21) from outrigger PPC valves. 16. Remove PPC valve mounting plate (22).
17. Extract screws (23) and remove contact carrier plate (24) for rear wiper.
18. Extract lower screws (25) retaining right hand cover (10).
WB156PS-5
30-43 1
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
19. Extract three screw covers (26) and screws retaining the right hand cover (10) at the rear.
20. Extract two screw covers (27) and screws; extract lower screw (28) and washer.
21. Extract upper screw (29) retaining right hand cover (10) and its washer.
22. Move rear of the right hand cover (10) towards the middle of the cab, remove pin (30), and disconnect hand throttle cable (31). 23. Loosen nut and disconnect sheath (32).
30-44 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
24. Disconnect contact carrier cover connector (33).
25. Engage the parking brake. 26. Raise right hand cover (10) until PPC valve control and parking brake lever are disengaged; fully remove the cover.
FAN 1.
Unplug connector (34).
2.
Remove screw (35), then rotate fan group (36) counterclockwise.
3.
Extract fan group (36).
WB156PS-5
30-45 1
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
4.
Remove clamp (37).
5.
Unplug connectors (38) and (39). Slide them off and move to one side of the fuse and relay group (40).
6.
Disconnect the heating system inlet and outlet lines (42) from heater core (41).
Only for machines with air conditioning A. Unplug the pressure switch connector (43). B. Remove screw (44) and washer and plate (45). Disconnect delivery and return lines (46) and (47). C. Collect the O-rings and discard them.
HEATER CORE 1.
Remove four screws (48) and remove unit (41).
30-46 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CAB HEATING AND COOLING SYSTEM
12 INSTALLATION ★ To install, reverse removal procedure. Screw: 6 N·m (53 lbf in) ★ Refill the coolant liquid. Coolant liquid: 15 l (4 gal) ★ Recharge the air conditioning unit. Quantity of refrigerant (R134a): 2,250 ±150 g ★ Quantity of oil: see the amount recovered. ★ Start the engine and use a leak detector to check the air conditioning unit.
WB156PS-5
30-47 1
DISASSEMBLY AND ASSEMBLY
BATTERY
12
BATTERY WARNING! Be careful when working around batteries. • • • •
Keep metal tools away from battery, if possible. Do not set tools or parts on battery tops. The battery generates flammable gas and there is the danger of an explosion. Keep fire and/or sparks away from the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with lots of water and consult a doctor.
REMOVAL 1.
Lift door (1) and disconnect catch lever (2).
2.
Remove lower right-hand guard (3) off the cab.
3.
Remove protection shield (4).
4.
Remove platform (5) and the door.
30-48 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY 5.
Disconnect battery (8) negative (-) terminal (6). Then disconnect the positive (+) battery terminal (7).
6.
Loosen wing nut (9) and remove tie rod (10) and hold down bracket (11).
7.
Remove battery (8).
BATTERY
INSTALLATION ★ To install, reverse removal procedure. ★ Connect the battery positive (+) cable first, and then the negative (-) last.
WB156PS-5
30-49 1
DISASSEMBLY AND ASSEMBLY
FUEL TANK
12
FUEL TANK WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL 1.
Remove fuel cap (1) off fuel tank (2) and remove plug (3) in order to drain the fuel. WARNING! Do not remove or install fuel tank with fuel in it. Tank may become unstable causing fuel to spill. Fuel tank: Approximately 150 l (40 gal)
2.
Reinstall fill plug (3) and fuel cap (1).
3.
Remove the screws and lower left trim panel (4) from the cab.
4.
Disconnect connector (5) from fuel level gauge (6). ★ Mark, then disconnect, the fuel inlet and return hoses (8) and (7). ★ Plug all pipes and hoses to prevent contamination.
30-50 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY 5.
FUEL TANK
Place a lift under the fuel tank (2). Remove four retaining bolts (10) and washers, then remove the tank. Fuel tank: 62 kg (137 lb)
INSTALLATION ★ To install, reverse removal procedure. Tank retaining bolts: 120 N·m (89 lbf ft) 1.
Refill the fuel tank. Fuel fill: 150 l (40 gal)
2.
Bleed the air from the fuel circuit.
3.
Start the engine.
WB156PS-5
30-51 1
DISASSEMBLY AND ASSEMBLY
STEERING AND FRONT DASH ASSEMBLY
12
STEERING AND FRONT DASH ASSEMBLY WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
STEERING WHEEL REMOVAL ★ Before proceeding with any steering wheel or dash removal, the operator’s seat must be removed. See “OPERATOR’S SEAT” on page 30-40. 1.
Use a thin bladed screwdriver placed under each spoke of the steering wheel to pry away cover (1).
2.
Remove retaining nut (2) and remove steering wheel (3).
3.
Remove four screw covers (4) and loosen four screws (5) retaining the instrument panel.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
STEERING AND FRONT DASH ASSEMBLY
4.
Lift instrument panel (6) from steering column. Unplug connectors (7) and (8), and remove instrument panel.
5.
Remove screws (9) and (10) and release direction indicator group (11) and transmission control group (12).
6.
Unplug connectors (13) and (14) and remove (11) and (12).
INSTALLATION ★ To install, reverse removal procedure. ★ Before attempting to tighten the screws, check the anti-rotation stake (15) for proper engagement into the steering column (16).
WB156PS-5
30-53 1
DISASSEMBLY AND ASSEMBLY
STEERING AND FRONT DASH ASSEMBLY
12 FRONT DASH ASSEMBLY
REMOVAL 1.
Remove upper screws (4) retaining instrument panel (5).
2.
Remove covers (6) and extract screws (7) at the front trim cover (8).
3.
Remove screws (9) retaining front trim cover (8).
4.
Lower the steering column and remove knob (10).
5.
Slide front trim cover (8) up to remove it.
30-54 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY 6.
STEERING AND FRONT DASH ASSEMBLY
Take out the screws (11) and remove the instrument panel holder (5).
INSTALLATION ★ To install, reverse removal procedure.
WB156PS-5
30-55 1
DISASSEMBLY AND ASSEMBLY
STEERING AND FRONT DASH ASSEMBLY
12 STEERING UNIT
REMOVAL WARNING! Eliminate residual pressure from all circuits by moving all control levers in all directions.
1.
Remove the steering wheel with the direction indicator and transmission reverse/forward control groups. For details, see “STEERING AND FRONT DASH ASSEMBLY” on page 30-52.
2.
Loosen and remove upper screws (4) retaining instrument panel holder (5).
3.
Remove screws (6) retaining the side of the instrument panel holder.
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DISASSEMBLY AND ASSEMBLY
STEERING AND FRONT DASH ASSEMBLY
4.
Slide instrument panel holder (5) up to remove it.
5.
Loosen screw (7) and remove two screws (8); remove front guard (9).
6.
Mark the respective positions of connectors and disconnect five pipes (10) from steering unit (13). ★ Plug all pipes to prevent contamination.
7.
Loosen screws (11) fastening column (12) and steering unit (13); remove the steering unit.
INSTALLATION ★ To install, reverse removal procedure. ★ Start the engine and perform several complete steering maneuvers in both directions to bleed the air out of the steering system.
WB156PS-5
30-57 1
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
BRAKE SYSTEM REMOVAL WARNING! Eliminate residual pressure from all circuits by moving all control levers in all directions.
1.
Remove the steering wheel with the direction indicator and transmission reverse/forward control groups along with the operator’s seat, connectors and floor mat. For details, see “STEERING AND FRONT DASH ASSEMBLY” on page 30-52.
2.
Loosen and remove upper screws (4) retaining instrument panel holder (5).
3.
Remove the guards (6) and extract the upper screws (7) retaining the front trim cover.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Remove the lower screws (9) retaining the front trim cover (8).
5.
Slide the front trim cover (8) to remove it.
6.
Remove the lower screws (11) and remove the instrument panel holder (5).
7.
Remove cap (12) and draw the brake fluid from tank (13).
8.
Reinstall the cap and unplug connectors (14) and pressure switch connectors (15) and (16). ★ Connector (15) left (X54) ★ Connector (16) right (X53)
9.
Remove tank (13).
WB156PS-5
BRAKE SYSTEM
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DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
10. Disconnect delivery pipes (18) from master cylinder (17). ★ Plug all pipes and hoses to prevent contamination. 11. Take off four nuts (19) and remove the master cylinders. ★ If only one pump is to be removed, disconnect the pressure equalizing pipe (20) and remove master cylinders individually.
INSTALLATION ★ To install, reverse removal procedure.
Nuts (19): 20 N·m (14.75 lbf ft)
★ Bleed the air from the braking circuit. For details, see “BLEED AIR FROM BRAKING CIRCUIT” on page 30-61. ★ Make sure that the push-rods (21) center the seating of the pistons. ★ When installation is complete, inspect for proper brake pedal pretravel and alignment. See “BRAKE SYSTEM” on page 18 in Section 20.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BRAKE SYSTEM
BLEED AIR FROM BRAKING CIRCUIT ★ This operation is to be carried out every time maintenance is made on the braking circuit to remove or replace a component, or when air entered into the circuit. Machine must be stopped with attachments on level ground. 1.
Make sure that brake fluid in brake system tank (1) is at maximum level. Remove safety plugs on bleed screws (2). Attach a vinyl hose (3) to catch oil.
2.
Push the brake pedal to the bottom and, while keeping it pushed, loosen bleed screw (2) of the braking unit that is being bled until the pedal reaches the end of its stroke. Keeping the pedal at the end of its stroke, tighten the bleed screw.
3.
Release the brake pedal, wait for few seconds and repeat above operations two or three times until oil flows out the bleeding screw without air bubbles.
4.
Repeat the same steps for the opposite braking unit. ★ Frequently check the oil level in the tank and refill every time the level approaches minimum.
5.
After bleeding air, apply on screws (2) safety plugs (4).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
CAB
12
CAB WARNING! Lower the backhoe work equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL 1.
Raise the front loader arms fully up and set the lock as shown in (A). A. Raise the front end loader unit completely in the air extending the lifting cylinders rods completely. B. Remove cylinder lock assembly small pin (3). Holding on to lock unit (1), pull out lock pin (2). C. Using both hands, lower the lock unit (1) down from its storage position onto the extended lift arm cylinder rod. D. Once on the cylinder rod, install lock pin (2) and small pin (3) and slowly lower the loader arms until it rests on loader lock (1).
2.
Open drain (3) and drain the cooling system. Coolant liquid: 15 l (4 gal)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 3.
Evacuate the air conditioning unit using ports (1) and (2).
4.
Remove the exhaust pipe (6). For details see “EXHAUST STACK” on page 30-39.
5.
Remove the front mat and screws (3). Loosen screw (4) and remove cover (5).
6.
Remove the front seat. See “OPERATOR’S SEAT” on page 3040.
7.
Remove five mounting bolts (3) and lift floor cover (4).
WB156PS-5
CAB
30-63 1
DISASSEMBLY AND ASSEMBLY 8.
Disconnect injection pump control rod (2) from pitman arm (1).
9.
Disconnect hoses (7) from the steering unit. ★ Mark the positions of the lines to prevent mixing positions when reconnecting. ★ Plug the lines and pipe fittings to prevent contamination.
CAB
10. Remove nut (8) and disconnect strap (9) from frame. 11. Disconnect lines (10). ★ Plug the lines and pipe fittings to prevent contamination.
12. Remove screws (11) and remove cover (12).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
CAB
13. Unplug connectors (14) from fuse block (13). ★ Unplug connectors marked: X7 - X8 - X11 - X12 - X126 - X128 - X153 - GND6
14. Lift rear window (15) to the top and remove the rear mat.
15. Remove bolts (22) and platform (23).
★ Only if equipped. 16. Disconnect connectors (25) and (26) from foot button (24). ★ Mark the position of connectors to avoid mixing them up during reinstallation.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
CAB
17. Disconnect the servo control upper and lower pipes (27) from the control valve. ★ Check that all the hoses are marked and routing patterns. ★ Cap lines, hoses and openings to prevent contamination. 18. Lay the hoses inside the cab to gain access to the feed and exhaust hoses.
19. Disconnect servo control supply hoses (29) and (30) from solenoid valve group (28). ★ Mark the lines to avoid mixing them during installation. ★ Cap lines, hoses and openings to prevent contamination.
20. Disconnect parking brake cable (25) from brake caliper.
21. Remove screws (37) and remove cover (38).
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DISASSEMBLY AND ASSEMBLY
CAB
22. Remove nuts (39) as well as front and rear bolts.
Machines Equipped with Air Conditioning 23. Disconnect suction line (41) from compressor (40).
24. Remove screws (42) and remove cover (43).
25. Disconnect hose (45) from condenser (44).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
CAB
26. Remove the hole plugs and install two lifting eyes into the lifting holes provided. 27. Connect cab (46) to the lifting equipment and apply light tension. 28. Lift the cab by approximately 30 cm (11.8 in) and place safety blocks “A” under it.
29. Remove bolts (47) and disconnect ground wire (48). 30. Remove screws (49) and remove cover (50).
31. Loosen straps (51) and disconnect heater hoses (52). ★ Mark the lines to avoid mixing them during installation. ★ Cap lines, hoses and openings to prevent contamination. 32. Remove the cab. Cab: 595 kg (1,312 lb)
INSTALLATION ★ To install, reverse removal procedure. 1.
Recharge the air conditioning unit Quantity of refrigerant (R134a): 2,250 ±150 g Quantity of oil: see the amount recovered
2.
Bleed the air from the steering circuit.
3.
Bleed the air from the braking circuit. ★ Perform all possible backhoe movements to bleed the servo control system.
4.
Adjust the stroke of the parking brake lever. Cab retaining screws: 200 N·m (148 lbf ft) Union (38): 16 N·m (12 lbf ft)
5.
Refill the cooling system.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
12 HYDRAULIC OIL TANK WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by moving all control levers in all directions. Disconnect the cable from battery negative terminal (-) (see “BATTERY” on page 30-48).
REMOVAL 1.
Remove plug (1) and drain the hydraulic oil. Hydraulic oil: Approximately 40 l (10.5 gal)
2.
Remove the operators seat. See “OPERATOR’S SEAT” on page 30-40.
3.
Remove the steering wheel, the transmission control lever (5) and the direction indicator and headlight control lever (6). For details, see “STEERING AND FRONT DASH ASSEMBLY” on page 3052.
4.
Remove covers (9) and remove screws (10) from cover (11).
WB156PS-5
30-69 1
DISASSEMBLY AND ASSEMBLY 5.
Remove screws (7) holding instrument panel housing (8).
6.
Remove screws (9) retaining front trim cover (8).
7.
Fully lower the steering column and extract knob (10).
8.
Slide front trim cover (11) up to remove it.
9.
Remove instrument panel holder (5).
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HYDRAULIC OIL TANK
WB156PS-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
10. Remove fill cap (13) and draw the brake fluid out. ★ Replace cap to prevent contamination. 11. Disconnect oil level and pressure switch connectors (14) and (15).
12. Disconnect brake fluid delivery tubes (16) and (17). ★ Plug all pipes and hoses to prevent contamination.
13. Loosen mounting bolt (18). 14. Remove bolts (19) and remove cover (20).
15. Remove five bolts (21) and metal floor cover (22) off the cab floor.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
16. Remove nuts (23) and disconnect throttle cable (25) from relay rod (24). 17. Disconnect rod (26) from relay rod (24). 18. Disconnect strap (27) holding the steering unit and brake hoses.
19. Remove nut (28) and washer. 20. Disconnect washer hoses (29) and remove complete wiper arm (30).
21. Unplug connector (32) from washer pump (31).
22. Unplug connector (33) from wiper (34).
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
23. Remove bolts (35) and washers. 24. Remove complete bulkhead (36) and move it to the rear of the machine.
25. Remove bolts (37) and cover (38).
26. Lift the rubber bulkhead and disconnect the discharge hose (40) from the tank (39). ★ Plug the pipe to prevent contamination.
27. Disconnect union (41) and pipe (42). ★ Plug the union to prevent contamination.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
28. Disconnect the pump suction pipe (43). ★ Plug the pipe to prevent contamination.
29. Disconnect vent hose (44) and the filter, then remove. 30. Remove the screws and remove fill sleeve (45). ★ Discard the old O-ring.
31. Remove screws and washers (46) and remove the tank's front holder (47).
32. Remove bolts and washers (48) and remove the tank's rear support (49).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
HYDRAULIC OIL TANK
33. Remove two bolts and washers (50) to release complete tank (39).
34. Remove tank (39).
INSTALLATION ★ To install, reverse removal procedure. ★ Bleed the air from the braking circuit. For details, see “BLEED AIR FROM BRAKING CIRCUIT” on page 30-61. ★ Check and adjust the stroke of the throttle lever. 1.
Refill the hydraulic oil. Hydraulic oil: Approximately 40 l (10.5 gal)
2.
Start the engine and check for leaks.
3.
Stop the engine, check the oil level in the tank and, if necessary, top it off.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12
HYDRAULIC PUMP WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by moving all control levers in all directions. Disconnect the cable from battery negative terminal (-) (see “BATTERY” on page 30-48).
REMOVAL 1.
Remove plug (1) and drain the hydraulic oil. Hydraulic oil: Approximately 40 l (10.5 gal) ★ Replace plug to prevent contamination.
2.
Disconnect rear drive shaft (3) from transmission (2).
3.
Disconnect lines (5), (6), (7), and (8) from pump (4). ★ Cap all hoses and openings to prevent contamination.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Disconnect intake line (8) from the pump and drain hose (9). ★ Cap all hoses and openings to prevent contamination.
5.
Remove lower bolt (10) retaining pump (4) and its washer.
6.
Loosen upper bolt (11), but leave it in place.
HYDRAULIC PUMP
Remark Do not remove bolt (11) at this stage.
7.
Install a hydraulic jack (B1) under the pump until the pump is fully supported and stable.
8.
Remove upper bolt (11) and remove pump (4). Pump: 31.5 kg (70 lb)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
12 INSTALLATION ★ To install, reverse removal procedure. Drive shaft bolts: 38 ±1 N·m (28 ±1 lbf ft)
Pump bolts: 220 N·m (162 lbf ft) ★ Refill the hydraulic oil. Hydraulic oil: Approximately 40 l (10.5 gal)
1.
Start the engine and run it at minimum speed to bleed any air.
2.
Stop the engine and check the oil level in the tank and top off if necessary.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12 TRANSMISSION WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by moving all control levers in all directions. Disconnect the cable from battery negative terminal (-) (see “BATTERY” on page 30-48).
REMOVAL 1.
Drain the hydraulic oil. Hydraulic oil: Approximately 40 l (10.5 gal)
2.
Drain the oil from the transmission. Transmission oil: Approximately 20 l (5.2 gal)
3.
Remove pump (1). See “HYDRAULIC PUMP” on page 30-76.
4.
Remove floor panel (2) at the bottom of the cab.
5.
Disconnect rear drive shaft (7) from transmission (6).
WB156PS-5
30-79 1
DISASSEMBLY AND ASSEMBLY 6.
Remove front drive shaft (8).
7.
Disconnect seven solenoid valve connectors (6) and oil temperature sensor connector (7) from transmission (3).
8.
Remove bolts (8) and harness holder (9).
9.
Unplug connector (10) from speed sensor (11).
TRANSMISSION
10. Disconnect delivery hose (12) to oil cooler and return hose (13) from transmission (3). 11. Remove clamp (14).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
12. Remove the bolts and remove cover (19) giving access to the converter coupling flange. 13. Slowly rotate the engine flywheel until the converter retaining bolts (20) are centred in the hole. Remove the four bolts.
14. Support engine (24) with a stand (C) placed under the engine bell housing.
15. Disconnect the transmission oil level pipe (18), remove bolt (19) and remove complete pipe (18).
16. Remove nuts (20) on the vibration dampers (21). Remove bolts (22) transmission supports (23).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION
17. Install transmission holding tool (B2) to a stand that is capable of supporting approximately 60 cm (24 in). 18. Using the holes on the supports, secure tool (B2) to the transmission.
19. Loosen and remove two bolts (24) retaining transmission (3) to engine (17). 20. Move transmission assembly (3) towards the rear of the machine and remove. Transmission: 254 kg (560 lb)
INSTALLATION ★ To install, reverse removal procedure. Transmission: 20 l (5.3 gal)
Hydraulic oil: 40 l (10.5 gal) Front drive shaft bolts (6): 38 N·m (28 lbf ft) Flywheel bolts (20): 64 N·m (47 lbf ft) Support bolts (30): 90 ±5 N·m (66 ±4 lbf ft) Anti-vibration nuts (27): 195 ±20 N·m (144 ±15 lbf ft) Engine-bell-housing (31): 50 ±5 N·m (37 ±4 lbf ft) Gear shift bolt (4): 120 N·m (89 lbf ft) Flywheel bolts (20): Loctite 242 Support bolts (30): Loctite 262 Engine-bell-housing (13): Loctite 262 1.
Tighten the bolts using the alternating crosswise method.
2.
Start the engine to circulate the oil. Check that there are no leaks.
3.
Bleed the air from the working equipment circuits. For details see “BLEED AIR FROM CYLINDERS” on page 30-83.
4.
Stop the engine, check the levels and, if necessary, top them off.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION
BLEED AIR FROM CYLINDERS ★ When the hydraulic cylinders or associated tubes have been removed, it is necessary to bleed air before using the machine again. Bleed one cylinder at a time. 1.
Start the engine and run at high idle for about five minutes to heat the oil.
2.
Reduce speed to low idle and extend and retract the 1st cylinder to be bled several times. ★ Extend and retract pistons until about 100 mm (3.94 in) from their end of stroke.
3.
Stop the engine, check and top off the oil in the tank.
4.
Bring the engine to high idle again and repeat Step 2; return the engine to low idle speed and make a complete travel of the cylinder until the pump reaches its maximum pressure.
5.
Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level in the tank.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12
TRANSMISSION OVERHAUL PROCEDURES WARNING! Before proceeding with any overhaul procedures be sure the transmission is sitting on a level, stable surface. Clean any oil spills immediately and keep your work area clean and clear of debris.
TORQUE CONVERTER REMOVAL ★ Remove the engine and transmission. See “TRANSMISSION” on page 30-79. 1.
Remove the converter (1).
INSTALLATION ★ To install, reverse removal procedure. ★ Ensure that the mating surfaces are clean and free of dents. ★ To aid in mating flywheel, engine and transmission, install a threaded stud “A” as a guide. Bolts: Loctite 262
Bolts: 39 N·m (29 lbf ft)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 PLUGS AND FILTERS
DISASSEMBLY
1.
Drain plug
7.
Connector pipe
13. Plug
2.
Cap screw
8.
Check valve
14. Plug
3.
Cover
9.
O-ring
15. Speed sensor
4.
Oil screen
10. O-ring
16. Temperature sensor
5.
O-ring
11. Cap
17. Transmission
6.
Filter
12. Plug
18. O-ring
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 1. Remove drain plug (1) and drain the oil from the transmission.
2.
Remove two cap screws (2) which fasten the cover for the oil screen.
3.
Remove cover (3).
4.
Remove cover (3) and oil screen (4) along with O-ring (5).
5.
Remove filter (6) and remove connector (7).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
6.
Remove oil filter protection valve (8).
7.
Clean valve (8) and check the condition. ★ Replace valve O-rings (9) and (10).
8.
Remove vent (11) from transmission housing and clean the vent.
9.
To check the FORWARD clutch pressure, remove plug (12).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
10. To check the REVERSE clutch pressure, remove plug (13).
11. To check the lubrication pressure, remove plug (14).
12. Remove speed sensor (15).
13. Remove thermostat (16).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install speed sensor (15) and torque to proper specifications. Sensor: 50 N·m (37 lbf ft)
2.
Install thermostat (16) and torque to proper specifications. Sensor: 30 N·m (22 lbf ft)
3.
Install plugs (12), (13) and (14) and torque to proper specifications.
Plug: 30 N·m (22 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
4.
Install vent (11).
5.
Install oil filter protection valve (8). ★ Install new O-rings (9) and (10).
6.
After installing oil filter protection valve (8), torque to the proper specifications. Valve: 23 N·m (17 lbf ft)
7.
Install connector (7) and tighten to the proper torque. Union: 50 N·m (37 lbf ft)
30-90 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
8.
Install new oil filter (6). ★ Apply a thin coat of transmission fluid to the rubber gasket and tighten filter an additional two-thirds of a turn.
9.
Install new O-ring (5) to filter (4) then install filter.
10. Install cover (3) and bolts (2) then tighten to the proper torque. Bolt: 23 N·m (17 lbf ft)
11. Install drain plug (1) and torque to the proper torque. Plug: 80 N·m (60 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 PUMP
DISASSEMBLY
1.
1.
Torque converter
4.
O-ring
2.
Mounting bolts
5.
Front seal
3.
Pump
6.
Transmission
Remove torque converter (1). See “TORQUE CONVERTER” on page 30-84.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
2.
Remove mounting bolts (2). ★ Mark the location of the pump in relation to the transmission housing for correct installation later.
3.
Loosen pump (3) as shown in the illustration.
4.
Lift pump (3) out of the transmission housing. ★ Do not disassemble oil pump (3).
5.
Remove O-ring (4) and discard it.
WB156PS-5
30-93 1
DISASSEMBLY AND ASSEMBLY 6.
TRANSMISSION OVERHAUL PROCEDURES
Using a seal removal tool, remove and discard seal (5).
ASSEMBLY 1.
Using tool F1, assemble seal (4) on oil pump (2).
2.
Assemble O-ring (3).
3.
Check oil passage holes between pump (2) and half-case or the visual marks aligned.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
4.
Grease the ring to the half boxes to keep it centered with respect to the shaft slot center line and to make the introduction onto the pump easier.
5.
Apply a thin coat of Transmission Assembly Lube to the seat of oil pump (3) and install it into transmission housing (6).
6.
Install bolts (2). Bolts: 23 N·m (17 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 VALVE BODY
DISASSEMBLY
1.
1.
Bolt
5.
Solenoid
9.
O-ring
2.
Valve body
6.
Valve
10. O-ring
3.
Gasket
7.
Valve
11. Transmission
4.
Screw
8.
Filter protection valve
Remove bolts (1).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 2.
Lift off valve body (2).
3.
Remove gasket (3).
4.
Place the control valve unit on a clean workbench.
5.
Remove screws (4) from valves (5) and (6).
6.
Extract valves (5) and (6) with a screwdriver.
WB156PS-5
TRANSMISSION OVERHAUL PROCEDURES
30-97 1
DISASSEMBLY AND ASSEMBLY 7.
Remove valves (5) and (6).
8.
Check the condition of valves (5) and (6).
9.
Remove valve (7).
TRANSMISSION OVERHAUL PROCEDURES
10. Check the condition of valve (7).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
11. Remove oil filter protection valve (8).
12. Check the condition of valve (8). 13. Clean the valve and replace O-rings (9) and (10).
ASSEMBLY 1.
Clean oil filter protection valve (8) and install new O-rings (9) and (10).
2.
Install oil filter protection valves (8).
3.
Tighten valve (8) to the prescribed torque. Valve: 23 N·m (17 lbf ft)
WB156PS-5
30-99 1
DISASSEMBLY AND ASSEMBLY 4.
Install valve (7).
5.
Install ON/OFF (6) and proportional (5) valves.
6.
Install valve mounting screws (4).
7.
Install new gasket (3).
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TRANSMISSION OVERHAUL PROCEDURES
WB156PS-5
DISASSEMBLY AND ASSEMBLY 8.
Install control valve unit (2) to transmission (11).
9.
Tighten bolts (1) to the prescribed torque.
TRANSMISSION OVERHAUL PROCEDURES
Valve: 23 N·m (17 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 HYDRAULIC SUPPLY LINES
DISASSEMBLY
1.
Shaft lubrication supply pipe
4.
4WD supply pipe
2.
2nd speed supply pipe
5.
1st speed supply pipe
3.
4th speed supply pipe
6.
3rd speed supply pipe
1.
Remove pipe (1) (shaft lubrication).
30-102 1
7.
Shaft lubrication supply pipe
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
2.
Remove pipe (2) (2nd speed) and remove related connections.
3.
Remove pipes (3) (4th speed), (4) (4WD), (5) (1st speed) and (6) (3rd speed) unscrewing related connections. ★ Collect connection gaskets.
4.
Remove pipe (7) (shaft lubrication) and related connections.
ASSEMBLY 1.
Assemble pipe (1) tightening the connections to the prescribed torque. Union: 30 N·m (22 lbf ft)
WB156PS-5
30-103 1
DISASSEMBLY AND ASSEMBLY 2.
TRANSMISSION OVERHAUL PROCEDURES
Assemble pipe (2) tightening the connections to the prescribed torque. Union: 30 N·m (22 lbf ft)
3.
Assemble pipes (3), (4), (5) and (6), then tighten related connections to the prescribed torque. Union: 30 N·m (22 lbf ft)
4.
Assemble pipe (7) tightening the connections to the prescribed torque. Union: 30 N·m (22 lbf ft)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 TRANSMISSION HOUSING
DISASSEMBLY
WB156PS-5
1.
Bolt
8.
Shaft
15. O-ring
2.
Yolk
9.
O-ring
16. Seal
3.
Washer
10. Snap ring
17. Bolt
4.
O-ring
11. Bearing
18. Housing (rear)
5.
Seal
12. Bolt
19. Housing (front)
6.
Bolt
13. Yolk
20. O-rings
7.
Cover
14. Washer
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 1. Remove flange (2) and bolt (1).
2.
If necessary, use a screwdriver and two screws to stop flange rotation.
3.
Collect washer (3).
4.
Remove flange (2) and O-ring (4). ★ Replace the O-ring at each disassembly.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 5.
Remove seal ring (5). ★ This is a destructive operation for the seal ring.
6.
Remove bolts (6) from flange (7).
7.
Remove flange (7).
8.
Extract transmission shaft PTO (8).
WB156PS-5
TRANSMISSION OVERHAUL PROCEDURES
30-107 1
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Remove Teflon seal ring (9) by cutting it. ★ This is a destructive operation for the seal ring.
10. Remove snap ring (10).
11. Remove bearing (11) with tool F2.
12. Remove flange (13) fastening bolt (12). ★ Use a screwdriver and two screws to stop flange rotation.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Remove bolt (12) and washer (14).
14. Remove flange (13) and O-ring (15). ★ Replace the O-ring at each disassembly.
15. Remove seal ring (16). ★ This is a destructive operation for the seal ring.
16. Remove bolts (17) from rear (18) and front (19) half-housings.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
17. Insert a lever in the special slot to detach the cover.
18. Lift front half-housing (19) by means of two hooks.
19. Remove three O-rings (20).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Assemble three new O-rings (20) to rear half-housings (18). ★ Accurately remove from mating surfaces any residual of sealant and clean them with a detergent.
2.
Assemble all the transmission internal parts. ★ Apply a thin film of prescribed sealant on the edge of the rear half-housing. Housing: Loctite 510
3.
Install front half-housing (19) to rear half-housing. Make sure that the bearings on the shafts go straight into the bores in the front half-housing. Push the front half-housing all the way down on the rear half-housing.
4.
Install bolts (17) to rear (18) and front (19) half-housings. ★ Tighten the bolts to the prescribed torque. Bolts: 50 N·m (37 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY 5.
Install seal ring (5) on front shaft output. ★ Use tool F8.
6.
Install flange (2) and a new O-ring (4).
7.
Install washer (3) and bolt (1).
8.
Tighten bolt (1) to the prescribed torque.
TRANSMISSION OVERHAUL PROCEDURES
★ Use screwdriver and two screws to stop flange rotation. Bolts: 139 N·m (103 lbf ft)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Install seal ring (16) on rear shaft output. ★ Use tool F8.
10. Install flange (13) and a new O-ring (15).
11. Install washer (14) and bolt (12).
12. Tighten bolt (12) to the prescribed torque. ★ Use screwdriver and two screws to stop flange rotation. Bolts: 139 N·m (103 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Install bearing (11) on transmission shaft PTO (8).
14. Install snap ring (10).
15. Install Teflon sealing ring (9) according to steps 1 through 6 of the procedure described in ASSEMBLY "Shaft (A) Clutch Pack," using tools F5 - F6 - F7 (see page 126).
16. Insert transmission shaft PTO (8) to the stroke.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
17. Apply a thin film of sealant to flange (7). Flange: Loctite 510 ★ Verify that the two holes for oil passage (A) match.
18. Install bolts (6) to prescribed torque. Bolts: 50 N·m (37 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 CLUTCH PACK (A) AND GEAR SHAFT (D)
DISASSEMBLY
30-116 1
1.
Teflon seal ring
15. Spring
29. Piston
2.
Snap ring
16. Bearing
30. Lock ring
3.
Bearing
17. Drive plate
31. Roll pin
4.
Spacer
18. Clutch plate
32. Lock spring cover
5.
Race
19. Thrust plate
33. Snap ring
6.
Gear
20. Outer O-ring
34. Spring
7.
Needle bearing cage
21. Inner O-ring
35. Drive plate
8.
Spacer
22. Teflon seal rings
36. Clutch pack assembly
9.
Roll pin
23. Snap ring
37. Bearing
10. Snap ring
24. Bearing
38. Piston
11. Clutch pack assembly
25. Thrust washer
39. Outer O-ring
12. Needle bearing cage
26. Gear
40. Inner O-ring
13. Lock spring cover
27. Race
14. Snap ring
28. Thrust washer
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 Shaft A (Clutch Pack) 1.
Simultaneously remove shafts A and D.
2.
Remove Teflon seal ring (1).
3.
Remove snap ring (2).
4.
Install a split bearing puller under the gear as shown in the illustration.
Remark Do not install the split bearing puller between the gear and the bearing and do not use the puller on the gear without the split bearing puller. Doing so will damage the bearing or the gear. ★ Use a two-jaw puller on the split bearing puller. ★ Pull the bearing, gear and spacer until it is free on the shaft.
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DISASSEMBLY AND ASSEMBLY 5.
Remove bearing (3).
6.
Remove spacer (4).
7.
Remove gear (6).
8.
Remove needle bearing cage (7).
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TRANSMISSION OVERHAUL PROCEDURES
WB156PS-5
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Remove spacer (8).
10. Remove roll pin (9).
11. Remove snap ring (10).
12. Use pry-bars to lift and to remove clutch plate lock ring (11) evenly.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Remove clutch plates (18) and drive plates (17). Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
14. Place a reference mark below the groove on the clutch housing.
15. Place a mark on each plate lock ring (11), clutch plate (18) and drive plate (17). ★ These marks will be used for reference during the reassembly procedure.
16. Using tool F9, push down lock spring cover (13).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
17. Remove snap ring (14).
18. Loosen the handles of the threaded rods to release the tension on the spring. 19. Remove the top piece of special tool F9.
20. Remove lock spring cover (13) and spring (15).
21. Remove sleeve (5).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
22. Using low-pressure compressed air in the delivery hole, expel piston (19). WARNING! Do not use high-pressure air to remove piston (19). Doing so will cause the piston to fly out of the clutch housing.
23. Remove Teflon seal ring (20) and inner O-ring (21) from piston. ★ To remove the rings it is necessary to cut them.
24. Rotate the shaft. 25. Remove Teflon seal rings (22) by cutting them.
26. Remove snap ring (23).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
27. Remove bearing (24) with a two-jaw puller.
28. Remove bearing (24) and thrust washer (25).
29. Remove gear (26) and needle bearing cage (12).
★ Repeat the procedure described so far to remove the components of this clutch.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
Gear Shaft D 1.
Remove bearing (16) of shaft D using a two-jaw puller.
2.
Remove bearing (37) of shaft D with a two-jaw puller.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 CLUTCHES AND DISC INSPECTIONS • • • • • •
•
•
• • •
•
• • •
Inspect grooves on shafts for wear or damage. Replace parts if necessary. Inspect output shaft for wear or damage. Check oil passages in the output shaft for restrictions or foreign matter. Check all bearings for smooth areas, pits, galling or other damage. If the clutch discs are to be used again, keep the clutch packs in the same previous dismantling order separate and record which clutch pack goes with each clutch. At each disassembly, use a gauge to check the total thickness of clutch plates to see if they are within the permissible wear limits. If it is not, replace the clutch plates with new ones. Check all clutch plates for burns and inspect the friction material for damage. Inspect the grooves in the friction material for any abnormal wear. Also inspect the clutch drive plates for warped, overheating, pits and/or scratches. If any of the above conditions exists on any of the plates, replace the clutch pack with a new one. If a new clutch pack is to be used, soak it in transmission oil for at least one hour before installing. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Lubricate the contact surfaces of the clutch drive plates with transmission oil. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Check the hole on the input shaft entering the rear half-housing for any damage. This may cause leaks when clutch is installed. Check the splines on the input shaft for damage caused by steel plates. Replace parts as necessary during installation. Number of clutch plates (each side)
6
Number of drive plates (each side)
7
Drive plate thickness
2.5 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness
1.75 ±0.05 mm (0.1 ±0.002 in)
Maximum clutch plate wear (each side)
WB156PS-5
0.2 mm (0.01 in)
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY Shaft (A) Clutch Pack 1.
Install new Teflon ring (20) and O-rings (21) onto the piston outer and inner seats.
★ Apply a thin film of Petroleum Jelly or transmission oil on the sealing rings just inserted. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type.
2.
Insert clutch piston (19) with special tool F10 as protection of seal rings (21).
3.
Assemble sleeve (5).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Assemble spring (15) and cover (13).
5.
Press down on the lock cover (13). Insert lock ring (14). ★ Use tool F9.
6.
Remove tool F9 and install roll pin (9).
7.
Install thrust washer (8).
WB156PS-5
TRANSMISSION OVERHAUL PROCEDURES
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DISASSEMBLY AND ASSEMBLY 8.
TRANSMISSION OVERHAUL PROCEDURES
Insert needle bearing cage (7).
★ To assemble the clutch pack start with gear (6) on a bench. Install clutch plate lock ring (11) so that the reference mark on top of the plate made during disassembly is facing towards the gear.
★ Assemble clutch plates (18) and drive plates (17) on the gear (6). The assembled clutch pack must contain seven drive plates and six clutch plates.
9.
Install the pack assembly by using two screwdrivers.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
10. Install snap ring (10).
11. Install washer (4).
12. Heat bearing (3) to 80 -100° C (176 - 210° F) and install using tool F2.
13. Install the stop ring (2). ★ Measure clearance between clutch plate lock ring and first drive plate (17). ★ The clutch plate lock ring must be lifted against the stop ring. ★ Distance must be 2.3 - 4.3 mm (0.1 - 0.2 in). ★ If distance is not within the specified range, it is likely that the clutch was not installed correctly. ★ Check clutch for proper operation.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
14. Insert Teflon seal ring (1) as follows:
A. Install F5 spacer onto the input shaft with the chamfered end facing in.
B. Slide F5 expander/protector onto the input shaft and on the spacer. ★ The expander/protector will stop in the correct position to install the seal ring in the groove.
C. Heat the Teflon seal ring to 60 - 80oC (140 -176o F) for five minutes. ★ Install the Teflon seal ring onto the expander/protector.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
D. Install F6 pusher over the expander/protector and slide the seal ring until it reaches the groove in the shaft. ★ Remove the pusher, expander/protector, and spacer from the shaft.
E. Install the end of seal installer F7 with the chamfer onto the shaft and over the sealing ring. ★ Use a back and forth twisting motion to allow the seal installer to slip over the top of the sealing ring and seat the sealing ring into the groove. ★ Be careful not to damage the seal ring. ★ After the sealing ring is seated in the groove, remove the seal installer from the shaft.
F.
Turn the seal installer around and slide the end with the narrow chamfer over the shaft and over the seal ring. ★ Leave the seal installer in place for 15 minutes until the sealing ring has cooled and is properly sized and seated in the groove. ★ After the sealing ring has cooled, remove the seal installer from the shaft.
G. Using a feeler gauge between the lock ring (10) and the first drive plate: Check clutch pack backlash. ★ Standard clearance ................. 2.3 - 4.3 mm (0.1 - 0.2 in) ★ If backlash is not within specifications, check for proper assembly of the clutch packs.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
15. Turn the shaft around and carry out steps A - G for the other clutch. ★ Lubricate the ring (25) with transmission oil. See "FUEL, COOLANT, AND LUBRICANT" in the Operator’s Manual for fluid type. Install ring (25) so the notch on the inside rim falls onto the pin. ★ Make sure that the side with the oil grooves is down.
16. Heat bearing (24) to 80 - 100° C (176 - 212° F). ★ Use driver F11 to drive bearing (24) onto the input shaft until the bearing contacts the thrust washer.
17. Install snap ring (23).
18. Install Teflon seal rings (22) as follows: A. Place F12a spacer into F12b expander/protector.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
B. Slide F12b expander/protector and the spacer onto the shaft. ★ The expander/protector will stop in the correct position to install the seal ring in the groove.
C. Heat Teflon seal ring to 60 - 80°C (140 -176° F) for five minutes. ★ Install Teflon (22) seal ring onto the expander/protector.
D. Install F13 pusher over the expander/protector and slide the seal ring until it reaches the groove in the shaft. ★ Remove the pusher, expander/protector, and spacer from the shaft.
E. Install the end of seal installer F14 with the deep chamfer onto the shaft and over the sealing ring. ★ Use a back and forth twisting motion to allow the seal installer to slip over the top of the sealing ring and seat the sealing ring into the groove. Be careful not to damage the seal ring. ★ After the sealing ring is seated in the groove, remove the seal installer from the shaft.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
19. Turn the seal installer around and slide the end with the narrow chamfer over the shaft and over the seal ring. 20. Leave the seal installer in place for 15 minutes until the sealing ring has cooled and is properly sized and seated in the groove. After the sealing ring has cooled, remove the seal installer from the shaft. ★ For the introduction of the other three Teflon rings, repeat the operations from step 18 to step 20, using the following spacer rings: • F12/2 for the 2nd Teflon ring • F12/3 for the 3rd Teflon ring • F12/4 for the 4th Teflon ring Gear Shaft D 1.
Assemble D shaft bearing (16). ★ Use tool F3.
2.
Install D shaft bearing (37). ★ Use tool F3.
3.
Lubricate shaft seat A.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
TRANSMISSION OVERHAUL PROCEDURES
Install shaft assembly D and shaft assembly A. ★ The operation is done correctly if the two shafts are installed at the same time.
CHECKING CLUTCH FUNCTION
•
•
1.
Lubrication oil passage 4.
Forward gear
7.
Reverse gear
2.
Forward clutch passage 5.
Forward clutch pack
8.
Input shaft
3.
Reverse clutch passage
Reverse clutch pack
6.
Apply compressed air to the forward clutch passage. Listen to hear the forward piston moving to lock the forward clutch pack. Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse gear. The reverse gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the problem. Apply compressed air to the reverse clutch passage. Listen to hear the reverse piston moving to lock the reverse clutch pack. Try to move the reverse gear. The reverse gear must not turn on the input shaft. Try to move the forward gear. The forward gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the problem.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 SHAFT (B)
DISASSEMBLY
1.
Seal
10. Thrust plate
19. Clutch piston
2.
Seal
11. Clutch discs
20. O-ring
3.
Bearing
12. Clutch plates
21. O-ring
4.
Gear
13. Thrust washer
22. Shaft
5.
Snap ring
14. Spacer
23. Roll pin
6.
Thrust washer
15. Snap ring
24. Roll pin
7.
Bearing
16. Retaining washer
25. Bearing
8.
Gear
17. Spring
26. Seal
9.
Snap ring
18. Sleeve
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 1. Remove bolts (28) and protection (29).
2.
Lift the three shafts B-C-E at the same time using tool F15.
3.
Remove seals (1) and (2). ★ This is a destructive operation for the seal rings.
4.
Using a two-jaw puller, remove bearing (3) and gear (4).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY 5.
Remove bearing (3) and gear (4).
6.
Remove snap ring (5).
7.
Remove spacer (6).
8.
Remove spring pin (23).
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TRANSMISSION OVERHAUL PROCEDURES
WB156PS-5
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Remove gear (8).
10. Remove roller retainers (7) and washer (13).
11. Remove spring pin (24) and spacer (14).
12. Slightly press thrust plate (10).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Remove snap ring (9).
14. Remove thrust plate (10) by means of two screwdrivers.
15. Remove clutch disc (11) and clutch plates (12) from pack. Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
16. Lower spring (17) retaining washer (16). ★ Use tool F9.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
17. Remove snap ring (15).
18. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
19. Remove washer (16) and spring (17).
20. Remove sleeve (18).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
21. Remove clutch piston (19) by blowing in compressed air through the delivery hole. WARNING! Do not use high-pressure air to remove piston (19). Doing so will cause the piston to fly out of the clutch housing.
22. If to be replaced, remove Teflon seal ring (20) and relevant inner O-ring from outer seat of piston, along with Teflon seal rings (21) and relevant inner O-ring from inner of piston. To remove the rings it is necessary to cut them.
23. Remove Teflon seal ring (26).
24. Remove bearing (25) using a two-jaw puller.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
CLUTCHES AND DISC INSPECTIONS • • • • • •
•
•
• • •
•
• • •
Inspect grooves on shafts for wear or damage. Replace parts if necessary. Inspect output shaft for wear or damage. Check oil passages in the output shaft for restrictions or foreign matter. Check all bearings for smooth areas, pits, galling or other damage. If the clutch discs are to be used again, keep the clutch packs in the same previous dismantling order separate and record which clutch pack goes with each clutch. At each disassembly, use a gauge to check the total thickness of clutch plates to see if they are within the permissible wear limits. If it is not, replace the clutch plates with new ones. Check all clutch plates for burns and inspect the friction material for damage. Inspect the grooves in the friction material for any abnormal wear. Also inspect the clutch drive plates for warpage, overheating, pits and/or scratches. If any of the above conditions exists on any of the plates, replace the clutch pack with a new one. If a new clutch pack is to be used, soak it in transmission oil for at least one hour before installing. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Lubricate the contact surfaces of the clutch drive plates with transmission oil. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Check the hole on the input shaft entering the rear half-housing for any damage. This may cause leaks when clutch is installed. Check the splines on the input shaft for damage caused by steel plates. Replace parts as necessary during installation. Number of clutch plates (each side)
8
Number of drive plates (each side)
8
Drive plate thickness
2.00 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness *
30.5 - 30.7 mm (1.2 - 1.25 in)
Maximum clutch plate wear (each side)
0.20 mm (0.01 in)
Maximum clutch pack wear
1.6 mm (0.1 in)
* Under load of 163 kg (359 lb) •
Inspect the bore of the shaft in the input shaft housing for damage that will cause leakage when the clutch is assembled. Check the slots in the side of the input shaft housing for damage from the tangs on the steel discs.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install bearing (25). ★ Use tool F2.
2.
Assemble new Teflon sealing ring (26). ★ To install ring (26), use tool F5.
3.
Assemble new Teflon ring (20) and relevant inner O-ring, along with new Teflon ring (21) and relevant inner O-rings, respectively, into the piston outer and inner seats.
4.
Apply a thin film of Transmission Assembly Lube on the sealing rings just inserted.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
5.
Insert clutch piston (19) with special tool F10 as protection of seal rings (21).
6.
Install sleeve (18).
7.
Install spring (17) and washer (16).
★ Lower spring (16) lock washer (17). ★ Use tool F9.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
8.
Insert snap ring (15). ★ Ensure that snap ring (15) is well fitted.
9.
Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
10. Assemble clutch pack to shaft (22).
11. Install spacer (14) and spring pin (24).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12. Insert washer (13) and roller bearing (7).
13. Install thrust plate (10) and press it against the clutch pack.
14. Install snap ring (9).
15. Apply compressed air at low-pressure in hole in order to push the thrust plate (10) against the retaining ring (9). Then align the clutch plate (11) spline.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
16. Install gear (8) while aligning the clutch discs carefully.
17. Install spring pin (23).
18. Install washer (6) and lock ring (5).
19. Measure the clutch discs clearance for each clutch assembly. ★ The clutch plate lock ring must be all the way up against the lock ring. ★ Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate (11). ★ Distance ....................... 2.20 - 3.05 mm (0.087 - 0.12 in) ★ If the distance is not within specification, the clutch is probably assembled wrong.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
20. Assemble gear (4) taking care to orientate the shelf facing the clutch and bearing (3). ★ Use tool F16.
21. Assemble Teflon sealing rings (1) and (2). ★ To install the sealing rings use tool F17.
22. Lift the three shafts B-C-E at the same time and insert into the half-housing. ★ Use tool F15.
23. Install protection (29) and tighten screws (28) to the prescribed torque. Bolt: 50 N·m (37 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12
•
1.
Lubrication oil passage
3.
2nd speed gear
2.
2nd speed clutch oil passage
4.
2nd speed clutch pack
5.
Input shaft
Try to rotate the 2nd speed gear. The 2nd speed gear must turn freely on the input shaft. Apply compressed air of approximately 87 psi to the 2nd speed gear clutch passage. Hear the 2nd speed gear piston moving to lock the 2nd speed gear clutch pack. Try to move the 2nd speed gear. The 2nd speed gear must not turn on the input shaft. If the clutch does not work correctly, disassemble the clutch to find the problem.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 SHAFT (C)
DISASSEMBLY
1.
Bearing
16. Seal ring
31. Washer
46. Bearing
2.
Spacer
17. Seal ring
32. Clutch pack
47. Bushing
3.
Gear
18. Seal ring
33. Thrust plate
48. Seal ring
4.
Snap ring
19. Seal ring
34. Snap ring
49. Seal ring
5.
Thrust plate
20. Plug
35. Gear housing
50. Spacer
6.
Clutch pack
21. Pin
36. Bearing
51. Seal ring
7.
Bearing
22. Pin
37. Gear
52. Seal ring
8.
Washer
23. Shaft
38. Snap ring
53. Seal ring
9.
Snap ring
24. O-ring
39. Thrust plate
54. Gear
10. Lock washer
25. O-ring
40. Clutch pack
55. Bearing
11. Spring
26. Clutch piston
41. Snap ring
56. Bushing
12. Bushing
27. Bushing
42. Thrust washer
57. Spacer
13. Thrust plate
28. Spring
43. Spring
58. Bearing
14. O-ring
29. Lock washer
44. Clutch piston
15. Seal ring
30. Snap ring
45. O-ring
WB156PS-5
30-151 1
DISASSEMBLY AND ASSEMBLY 1.
Remove bolts (59) and protection (60).
2.
Lift the three shafts, B-C-E, at the same time. ★ Use tool F15.
3.
Using a puller, remove bearing (58).
4.
Remove spacer (57).
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TRANSMISSION OVERHAUL PROCEDURES
WB156PS-5
DISASSEMBLY AND ASSEMBLY 5.
Remove gear (54) with its inner parts.
6.
Overturn the group. ★ Push down the thrust plate (39).
7.
Remove snap ring (38).
8.
Remove thrust plate (39) using two screwdrivers.
WB156PS-5
TRANSMISSION OVERHAUL PROCEDURES
30-153 1
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Remove clutch pack (40).
Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
10. Push down thrust washer (42) to allow lock ring removal (41). ★ Use special tool F9.
11. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
12. Remove the lock ring (41), the thrust washer (42) and spring (43).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Remove clutch piston (44) by blowing in compressed air through the delivery hole.
14. If to be replaced, remove Teflon seal ring (45) and O-ring from outer seat of piston (44).
15. Remove Teflon seal (53) and inner O-ring from gear (54).
16. Remove gear (37) using a two-jaw puller. 17. Remove bushing (47) and (56), roller bearing (46) and (55), and spacer (50).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
18. Check the condition of removed parts (46), (47), (50), (55) and (56).
19. Remove O-rings (48) and (52) from bushing (50).
20. Check the wear condition of Teflon seal rings (49) and (51). If replacement is necessary, cut Teflon seal rings (49) and (51) to remove them from bushing (50). This is a destructive operation for the seal rings.
21. Remove gear (35).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
22. Remove roller retainer (36).
23. Remove spacer (31).
24. Push down on thrust plate (33) to set free lock ring (34).
25. Remove snap ring (34).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
26. Remove thrust plate (33) using two screwdrivers.
27. Remove clutch pack (32). Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
28. Remove spring pin (22).
29. Lower spring (28) and lock washer (29). ★ Use tool F9
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
30. Remove snap ring (30).
31. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of special tool F9.
32. Remove lock ring (30), thrust washer (29) and spring (28).
33. Extract clutch piston (26) from its seat by blowing in compressed air through the delivery hole. WARNING! Do not use high-pressure air to remove piston (26). Doing so will cause the piston to fly out of the clutch housing.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
34. Remove bushing (27) and clutch piston (26).
35. Remove Teflon seal ring (25) and relevant inner O-ring from outer seat of piston, along with Teflon seal rings (24) and relevant inner O-ring from inner seat of piston. ★ To remove the rings, it is necessary to cut them.
36. Overturn shaft (23). ★ Cut and remove the seal rings (16), (17), (18) and (19).
37. Using a puller, remove bearing (1).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
38. Remove spacer (2).
39. Remove gear (3).
40. Remove roller retainers (7) and washer (8).
41. Remove roll pin (21).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
42. Push down thrust plate (5) to set free lock ring (4).
43. Remove snap ring (4).
44. Remove thrust plate (5) using two screwdrivers.
45. Remove clutch pack (6). Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
46. Lower spring (11) and lock washer (10). ★ Use tool F9.
47. Remove snap ring (9).
48. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
49. Remove lock ring (9), lock washer (10) and spring (11).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
50. Extract thrust plate (13) from its seat by blowing in compressed air through the delivery hole. WARNING! Do not use high-pressure air to remove thrust plate (13). Doing so will cause the piston to fly out of the clutch housing.
51. Remove bushing (12) and thrust plate (13).
52. If to be replaced, remove Teflon seal ring (15) and relevant inner O-ring from outer seat of piston, along with Teflon seal rings (14) and relevant inner O-ring from inner seat of piston.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 CLUTCHES AND DISC INSPECTIONS • • • • • •
•
•
• • •
•
• • •
Inspect grooves on shafts for wear or damage. Replace parts if necessary. Inspect output shaft for wear or damage. Check oil passages in the output shaft for restrictions or foreign matter. Check all bearings for smooth areas, pits, galling or other damage. If the clutch discs are to be used again, keep the clutch packs in the same previous dismantling order separate and record which clutch pack goes with each clutch. At each disassembly, use a gauge to check the total thickness of clutch plates to see if they are within the permissible wear limits. If it is not, replace the clutch plates with new ones. Check all clutch plates for burns and inspect the friction material for damage. Inspect the grooves in the friction material for any abnormal wear. Also inspect the clutch drive plates for warped, overheating, pits and/or scratches. If any of the above conditions exists on any of the plates, replace the clutch pack with a new one. If a new clutch pack is to be used, soak drive plates in transmission oil for at least one hour before installing. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Lubricate the contact surfaces of the clutch drive plates with transmission oil. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Check the hole on the input shaft entering the rear half-housing for any damage. This may cause leaks when clutch is installed. Check the splines on the input shaft for damage caused by steel plates. Replace parts as necessary during installation.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 1st GEAR CLUTCHES Number of clutch plates (each side)
6
Number of drive plates (each side)
6
Drive plate thickness
2.20 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness *
27.5 - 27.7 mm (1.1 - 1.1 in)
Maximum clutch plate wear (each side)
0.15 mm (0.01 in)
Maximum clutch pack wear
0.9 mm (0.04 in)
3rd GEAR CLUTCHES Number of clutch plates (each side)
6
Number of drive plates (each side)
6
Drive plate thickness
2.00 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness *
30.5 - 30.7 mm (1.2 - 1.25 in)
Maximum clutch plate wear (each side)
0.20 mm (0.01 in)
Maximum clutch pack wear
1.6 mm (0.1 in)
4th GEAR CLUTCHES Number of clutch plates (each side)
6
Number of drive plates (each side)
6
Drive plate thickness
2.00 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness *
15.9 - 16.1 mm (1.0 - 1.0 in)
Maximum clutch plate wear (each side)
0.2 mm (0.01 in)
Maximum clutch pack wear
0.8 mm (0.03 in)
* Under load of 163 kg (359 lb)
•
Inspect the bore of the shaft in the input shaft housing for damage that will cause leakage when the clutch is assembled. Check the slots in the side of the input shaft housing for damage from the tangs on the steel discs.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Assemble new Teflon ring (53) and relevant inner O-Ring on gear (54) using special tool F21.
2.
Assemble O-Ring (52).
3.
Calibrate Teflon ring (53) using special tool F20.
4.
Assemble new Teflon ring (45) with relative O-ring on clutch piston (44).
5.
Apply a thin film of Transmission Assembly Lube on the outer edge and in the inner part of clutch piston (44) and assemble in gear (54).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
6.
Insert spring (43), thrust washer (42) and snap ring (41).
7.
Lower spring (43) and lock washer (42). ★ Use tool F9.
8.
Insert snap ring (41). ★ Ensure that snap ring (41) is well fitted.
9.
Loosen the handles of the threaded rods to release the tension from the spring. Remove the top piece of the F9 special tool.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
10. Install clutch pack (40) and thrust plate (39) into gear (54).
11. Install retaining ring (38) making sure it is correctly seated.
12. Measure the clutch discs clearance for each clutch assembly. ★ The clutch plate lock ring must be all the way up against the lock ring. ★ Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate (40). ★ Distance ................. 1.725 - 2.375 mm (0.068 - 0.093 in) ★ If the distance is not within specification, it is likely that the clutch is incorrectly assembled.
13. Assemble new Teflon ring (25) and relevant inner O-ring, along with new Teflon ring (24) and relevant inner O-rings, respectively, into the piston (26) outer and inner seats.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
14. Apply a thin film of Transmission Assembly Lube on the sealing rings just inserted.
15. Insert clutch piston (26) with special tool F10 as protection of seal rings (24).
16. Assemble sleeve (27).
17. Assemble spring (28) and retainer washer (29).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
18. Install spring (28) lock washer (29). ★ Use tool F9.
19. Insert snap ring (30). ★ Ensure that snap ring (30) is well fitted.
20. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
21. Remove tool F9 and install roll pin (22).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
22. Install thrust washer (31) into shaft (23). ★ Apply a thin film of Transmission Assembly Lube under washer (31) to avoid its falling when overturning the shaft.
23. Install washer (31) on pin (22).
24. Insert clutch pack (32) on main shaft (23).
25. Install roller bearing (36) and thrust plate (33).
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
26. Install snap ring (34).
27. Apply compressed air at low-pressure in hole (a) to push thrust plate (33) against retaining ring (34). Then align clutch plate (32) spline.
28. Measure the clutch discs clearance for each clutch assembly. ★ The clutch plate lock ring must be all the way up against the lock ring. ★ Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate (32). ★ Distance ..................... 1.50 - 1.95 mm (0.059 - 0.077 in) ★ If the distance is not within specification, it is likely the clutch is incorrectly assembled.
29. Insert gear (35) while aligning clutches with gear groves carefully.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
30. Insert gear (37) on shaft (23) by side shown in figure.
31. Install gear assembly (54) on main shaft (23).
32. Assemble bushing (47) and needle bearing (46) with special tool F2.
33. Install new O-rings (48) and (52) to the bushing (50).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
34. Install new sealing rings (49) and (51) to bushing (50) using tools F22, F23 and F24.
35. Install bushing (50) on main shaft (23) with special tool F2. ★ The reference mark must be on the top surface.
36. Install bushing (56) and needle bearing (55) with special tool F2.
37. Install spacer (57).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
38. Assemble bearing (58). ★ Use tool F2.
39. Turn the shaft. ★ Assemble new O-ring with relative Teflon ring (14) into the piston (13) outer seat. ★ Assemble new O-ring with relative Teflon ring (15) into the piston (13) inner seat.
40. Apply a thin film of Transmission Assembly Lube on the sealing rings just inserted.
41. Install clutch piston (13) with special tool F10 as protection of seal rings (15).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
42. Install sleeve (12).
43. Install spring (11) and washer (10).
44. Lower spring (11) lock washer (10). ★ Use tool F9.
45. Insert snap ring (9). ★ Ensure that the snap ring (9) is well fitted.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
46. Loosen the handles of the threaded rods to release the tension from the spring. ★ Remove the top piece of the F9 special tool.
47. Install roll pin (21).
48. Insert clutch pack (6) on main shaft (23).
49. Install thrust plate (5).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
50. Install snap ring (4).
51. Apply compressed air at low-pressure in hole to push thrust plate (5) against retaining ring (4). Then align clutch pack (6) spline.
52. Measure the clutch discs clearance for each clutch assembly. ★ The clutch plate lock ring must be all the way up against the lock ring. ★ Use a feeler gauge to measure the distance between the clutch plate lock ring and the first clutch plate (6). ★ Distance ....................... 2.20 - 3.05 mm (0.086 - 0.12 in) ★ If the distance is not within specification, it is likely the clutch is incorrectly assembled.
53. Install thrust washer (8) and roller bearing (7).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
54. Install gear (3).
55. Install thrust washer (2).
56. Install bearing (1) with special tool F2.
57. Install Teflon sealing rings (16), (17), (18) and (19). ★ Use special tool F5.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12
•
•
•
1.
1st clutch oil passage
5.
3rd gear clutch pack
9.
1st gear clutch pack
2.
3rd clutch oil passage
6.
4th gear clutch pack
10. Main shaft
3.
4th clutch oil passage
7.
4th gear
11. Lubrication oil passage
4.
3rd gear
8.
1st gear
Verify that all the gears can freely rotate on the main shaft. Apply compressed air of approximately 87 psi to the 1st speed gear clutch passage. Hear the 1st speed gear piston moving to lock the 1st speed gear clutch pack. Try to move the 1st speed gear. The 1st speed gear must not turn on the input shaft. If the clutch does not work correctly, disassemble the clutch to find the problem. Apply compressed air of approximately 87 psi to the 3rd speed gear clutch passage. Hear the 3rd speed gear piston moving to lock the 3rd speed gear clutch pack. Try to move the 3rd speed gear. The 3rd speed gear must not turn on the input shaft. If the clutch does not work correctly, disassemble the clutch to find the problem. Apply compressed air of approximately 87 psi to the 4th speed gear clutch passage. Hear the 4th speed gear piston moving to lock the 4th speed gear clutch pack. Try to move the 4th speed gear. The 4th speed gear must not turn on the input shaft. If the clutch does not work correctly, disassemble the clutch to find the problem.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 1. Hook three shafts B-C-E using special tool F15. ★ Lift shafts B-C-E at the same time and insert the unit into the half-housing. ★ Use tool F15.
2.
Install protection (60) and tighten screws (59) to the specified torque. Bolt: 50 N·m (37 lbf ft)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 SHAFT (E)
DISASSEMBLY
1.
Bearing
7.
O-ring
13. Pin
19. Bearings
2.
Snap ring
8.
Clutch piston
14. Piston
20. Cup
3.
Shim
9.
O-ring
15. Clutch pack
21. Bearing
4.
Washer
10. Pusher pin
16. Thrust plate
22. Seal
5.
Beveled washers
11. O-ring
17. Snap ring
23. Seal
6.
Bushing
12. Clutch housing
18. Gear
1.
Remove bolts (24) and protection (25).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY 2.
Lift three shafts, B-C-E, at the same time. ★ Use tool F15.
3.
Remove seals (22) and (23). ★ This is a destructive operation for the seal rings.
4.
Using a two-jaw puller, remove bearings (21) and (1). ★ Remove spacer (20).
5.
Remove gear (18).
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TRANSMISSION OVERHAUL PROCEDURES
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
6.
Remove roller bearing (19).
7.
Overturn shaft (12). ★ Press beveled washers (5) and remove retaining ring (2). ★ Use tool F25.
8.
Remove shim (3) and washers (4).
9.
Remove beveled washers (5) and spacer (6).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
10. Remove snap ring (17).
11. Remove thrust plate (16) and clutch pack (15). Remark After removing the clutches and plates, be sure to keep them assembled and in order of assembly. Mark the top and bottom for reassembly order.
12. Remove piston (14).
13. Extract piston (8) using pins (10) as pusher.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
14. Remove inner (7) and outer (9) O-rings. ★ Replace the O-rings at each disassembly.
15. Remove O-rings (11) from pins (10). ★ Replace the O-rings at each disassembly.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 CLUTCHES AND DISC INSPECTIONS • • • • • •
•
•
• • •
•
• • •
Inspect grooves on shafts for wear or damage. Replace parts if necessary. Inspect output shaft for wear or damage. Check oil passages in the output shaft for restrictions or foreign matter. Check all bearings for smooth areas, pits, galling or other damage. If the clutch discs are to be used again, keep the clutch packs in the same previous dismantling order separate and record which clutch pack goes with each clutch. At each disassembly, use a gauge to check the total thickness of clutch plates to see if they are within the permissible wear limits. If it is not, replace the clutch plates with new ones. Check all clutch plates for burns and inspect the friction material for damage. Inspect the grooves in the friction material for any abnormal wear. Also inspect the clutch drive plates for warped, overheating, pits and/or scratches. If any of the above conditions exists on any of the plates, replace the clutch pack with a new one. If a new clutch pack is to be used, soak it in transmission oil for at least one hour before installing. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Lubricate the contact surfaces of the clutch drive plates with transmission oil. See "FUEL, COOLANT, AND LUBRICANTS" in the Operator’s Manual for fluid type. Check the hole on the input shaft entering the rear half-housing for any damage. This may cause leaks when clutch is installed. Check the splines on the input shaft for damage caused by steel plates. Replace parts as necessary during installation. Number of clutch plates (each side)
9
Number of drive plates (each side)
9
Drive plate thickness
2.00 ±0.05 mm (0.1 ±0.002 in)
Clutch plate thickness *
33.8 - 34.0 mm (1.3 - 1.34 in)
Maximum clutch plate wear (each side)
0.15 mm (0.01 in)
Maximum clutch pack wear
1.35 mm (0.1 in)
* Under load of 163 kg (359 lb) •
Inspect the bore of the shaft in the input shaft housing for damage that will cause leakage when the clutch is assembled. Check the slots in the side of the input shaft housing for damage from the tangs on the steel discs.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Insert inner (7) and outer (9) O-rings on clutch piston (8).
2.
Insert O-rings (11) on pins (10).
3.
Insert pins (10) on clutch piston (8).
4.
Apply a thin film of Transmission Assembly Lube on O-Rings and position the pins on clutch piston (8) in correspondence with the holes on output shaft.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
5.
Overturn shaft (12) and fully insert clutch piston (8).
6.
Insert piston (14) on shaft (12) with tapered edge facing down.
7.
Mount clutch pack (15) starting with drive plate (A) followed by clutch plate (B).
8.
Mount thrust plate (16) on shaft (12).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 9.
TRANSMISSION OVERHAUL PROCEDURES
Assemble retaining ring (17).
10. Assemble gear (18).
11. Assemble roller bearing (19) and spacer (20).
12. Assemble bearing (21) using special tool F2.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
13. Turn shaft (12). Make sure that the disk/counter-disk pack and the piston are correctly seated.
14. Preassemble spacer (6), washer (4) and lock ring (2).
15. Using a thickness gauge, measure X between washer (4) and lock ring (2). ★ Subtract from X fixed S1 (S1=1.80 mm) (0.071 in). ★ The result S is the thickness of shims (3) which has to be inserted between washer (4) and locking (2). S=X-S1=X-1.80 mm (0.071 in)
16. Pick the (S) shim (3) from the range of shims available. ★ Choose a shim that will provide a piston travel of 1.70-1.90 mm (0.067 - 0.075 in). Shim Range Shim - mm (in)
30-192 1
0.1 (0.004)
0.3 (0.012)
0.5 (0.020)
WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
17. Disassemble washer (4) and lock ring (2).
18. Insert beveled washer (5). ★ Check the orientation of beveled washer (5).
19. Install washer (4) and shims (3) with thickness S defined at step 16.
20. Install washers (5) and assemble retaining ring (2). ★ Use tool F25.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
21. Install bearing (1) using tool F16.
22. Install Teflon sealing rings (22) and (23). ★ Use special tool F5.
23. Use tool F4 for piston operation check and correct adjustment check.
24. In order to verify the seal of rings (7) and (9), feed the piston chamber with oil at 10.19 kg/cm2 (145 psi) and check with a dial gauge located as shown in the photo if the real stroke is included between 1.7 and 1.9 mm (0.067 and 0.075 in).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
TRANSMISSION OVERHAUL PROCEDURES
12
1.
4WD oil passage
3.
4WD lubrication oil passage 5.
2.
4WD drive gear
4.
Shaft
Beveled washers
25. Apply compressed oil pressure of approximately 10.19 kg/cm2 (145 psi) to the 4WD clutch passage. Listen to hear the piston moving to unlock the clutch pack and believed washers compressing. Try to move the 4WD gear. The 4WD gear must turn freely on the 4WD shaft. If the clutches do not work correctly, disassemble the clutches to find the problem. 26. Lift three shafts B-C-E at the same time and insert into the halfhousing. ★ Use tool F15.
27. Assemble protection (25) and tighten screws (24) to the proper torque value. Bolts: 50 N·m (37 lbf ft)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
ENGINE
12
ENGINE WARNING! Before any disassembly procedures are started, be sure the machine is sitting on firm, smooth and level surface. Lower all work equipment to the ground, set the parking brake, chock the wheels and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL ★ Before proceeding with engine removal procedures, remove the engine hood, front guard and disconnect the front loader assembly from the machine as shown in the illustration. ● See “ENGINE HOOD” on page 30-21. ● See “FRONT GUARD” on page 30-23. ● See “FRONT-END LOADER ASSEMBLY” on page 30-303.
1.
Disconnect fuel inlet line (1). ★ Cap all lines, hoses and openings to prevent contamination.
2.
Disconnect fuel return line (2). ★ Cap all lines, hoses and openings to prevent contamination.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 3.
Disconnect starter electrical supply (3) from the starter.
4.
Disconnect ground (4), engine to chassis connection.
5.
Open drain valve (5) and drain the engine coolant at the front of the radiator.
ENGINE
WARNING! Slowly loosen the radiator cap to release the pressure inside the cooling system. A. Set a suitable size container under the engine coolant drain to catch the coolant that is drained from the cooling system. B. Place the drain hose into the container and open the drain valve two to three turns to drain the engine coolant. Remark Do not drain coolant on the ground, in rivers or lakes or in a city sewer system. Coolant must be captured and recycled. Engine coolant: Approximately 15 l (4 gal)
WB156PS-5
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DISASSEMBLY AND ASSEMBLY 6.
Disconnect alternator connection (6) and remove lower radiator hose (8) as well as lower heater hose (7).
7.
Disconnect and remove upper radiator hose (9) and upper heater hoses (10).
8.
Disconnect turbocharger intake hose (11) and remove air cleaner assembly (12) from the engine. ★ Be sure to cap the turbocharger inlet after removing hose (11) to prevent debris from entering the turbo inlet side.
9.
Remove the muffler and piping assembly (13). ★ Be sure to cap the turbocharger outlet after removing muffler (13) to prevent debris from entering the turbo outlet side.
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ENGINE
WB156PS-5
DISASSEMBLY AND ASSEMBLY
ENGINE
10. Disconnect refrigerant lines (14) and remove air conditoner compressor (15) from the engine. ● See “AIR CONDITIONER COMPRESSOR” on page 30-35. ★ Cap all lines, hoses and openings to prevent contamination.
11. Disconnect wiring harness (16) from the related engine connectors.
12. Remove fan guard (17) and related radiator shroud components. ● See “RADIATOR” on page 30-24.
13. Remove belts (18) and fan assembly (19) from engine. ● See “AIR CONDITIONER COMPRESSOR BELT” on page 30-38.
WB156PS-5
30-199 1
DISASSEMBLY AND ASSEMBLY
ENGINE
14. Remove upper heat shrouding (20) from top of fire wall.
15. Remove hydraulic tank (21). ● See “HYDRAULIC OIL TANK” on page 30-69.
16. Install lifting eye “A” to the muffler inner mounting hole. 17. Attach a lifting device to lifting eye “A” and to engine front bracket and apply a slight tension to the chains or cables.
30-200 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
ENGINE
18. Remove access cover (22) and remove the four flywheel-to-converter mounting bolts.
19. Support the front of the transmission with a lifting device.
20. Remove mounting bolts (23) on each side and remove engine guard (24) from under machine.
21. Remove hose bracket (25) and remove fourteen flange bolts (26) from the top, left and right side and bottom of the transmission bell-housing.
WB156PS-5
30-201 1
DISASSEMBLY AND ASSEMBLY
ENGINE
22. Remove the front engine mounting bolts (27) and prepare to lift the engine from the chassis.
23. Remove engine (28). Engine: Approximately 350 kg (770 lb)
INSTALLATION ★ To install, reverse removal procedure. Nuts: 200 N·m (148 lbf ft) ★ Check transmission oil level before starting the engine. ★ Thoroughly check the connectors to ensure that they are properly connected. ★ Start the engine and let it idle for a couple of minutes.
30-202 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
12 CONTROL VALVE ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Move backhoe assembly fully to the right or left and swing the boom at a full 90° to access the rear of the machine.
2.
Lower the outriggers to the ground. Curl the bucket and allow it to rest on the ground on its back as shown in the illustration.
3.
Apply the parking brakes and stop the engine.
4.
Release all residual pressure.
5.
Lift rear window (1) to the top.
6.
Remove the rear mat.
7.
Remove four bolts (2) and remove floor plate (3).
WB156PS-5
30-203 1
DISASSEMBLY AND ASSEMBLY 8.
Loosen clamp (4) on the control valve support frame (5) (four bolts).
9.
Disconnect lower servo control and actuator hoses (6) together with all accessible side hoses (7) from control valve. ★ Mark the positions of the lines to prevent mixing positions when reconnecting. ★ Cap the lines and pipe fittings to prevent contamination.
CONTROL VALVE
10. Disconnect upper servo control hoses (8) and actuator hoses (9) from control valve. ★ Mark the positions of the lines to prevent mixing positions when reconnecting. ★ Cap the lines and pipe fittings to prevent contamination. 11. Lay the servo control hoses inside the cab to gain access to the delivery, exhaust, and actuator hoses.
12. Turn tubes (10) that provide direct connection away from control valve and retain their position by temporarily tightening clamp (4) on frame (5).
30-204 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
CONTROL VALVE
13. Unplug connector (11) from backhoe plate lockout solenoid valve (12).
14. Support control valve (13) by means of two slings connected to a lifting device to be introduced through the cab opening. ★ Apply slight tension to the slings. ★ Pay special attention to sling routing to prevent damaging the unions.
15. Loosen and remove four bolts (14) and the relative washers. 16. Lift the valve through the rear of the cab or lower it onto a platform under the machine. 8-spool control valve: 45 kg (99 lb) 10-spool control valve: 50 kg (110 lb)
INSTALLATION ★ To install, reverse removal procedure. ★ Install control valve from top. ★ Start the machine to circulate the oil; check to ensure that there are no leaks. ★ Bleed the air from the working equipment circuits. ★ Stop the engine, check the hydraulic oil level and top it off.
WB156PS-5
30-205 1
DISASSEMBLY AND ASSEMBLY
STEERING SOLENOID VALVE
STEERING SOLENOID VALVE WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by moving all control levers in all directions. Disconnect the cable from battery negative terminal (-) (see “BATTERY” on page 30-48).
REMOVAL 1.
Mark and disconnect all hoses (2) from solenoid valve group (1). ★ Cap all lines, hoses and openings to prevent contamination.
2.
Mark and unplug all connectors (5) (No. 2) and (6) (No. 2) from solenoid valve (3) and (4) (No. 4).
3.
Remove bracket (8) mounting bolts (7) (No. 2), unplug connectors (9) and remove steering solenoid valve group (1).
INSTALLATION ★ To install, reverse removal procedure. ★ Run the engine and steer a few times in both directions, using alternatively the 2-wheel steering mode and the 4-wheel steering mode.
30-206 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE ASSEMBLY
12 FRONT AXLE ASSEMBLY WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL ★ Start the engine and force the bucket downwards in order to raise the machine and the front wheels. ★ Place two stands “A” and some blocks beneath the chassis. ★ Slowly lower the machine onto the blocks, checking to be sure the wheels remain at least 5 cm (2 in) above the ground. ★ Fully raise the front working equipment and engage the safety stop. See “ENGINE HOOD” on page 30-21.
1.
Remove the engine hood (3) and the front guard. See “ENGINE HOOD” on page 30-21 and “FRONT GUARD” on page 30-23. ★ If equipped, remove the front counterweight. Counterweight: 170 kg (375 lb)
2.
Remove the front wheels. Wheel: 52 kg (115 lb)
3.
Remove front drive shaft cover (1) by removing two bolts (2) on each side.
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30-207 1
DISASSEMBLY AND ASSEMBLY 4.
Disconnect front drive shaft (4) from axle (3).
5.
Disconnect lines (5) from the steering cylinder and cap them to prevent contamination.
6.
Disconnect lubrication tube (6) from axle pin (7).
7.
Position a jack “B” and blocks “C” beneath the axle. Raise the jack until the blocks can be forced under axle arms (3). ★ It should be possible to lower the jack 10 cm (4 in) in order to disengage the axle from the supports.
8.
Remove the nut and remove retaining bolt (8) from axle pin (7).
9.
Install a slide hammer into the central hole of the axle pin (7). Pull out the axle pin.
FRONT AXLE ASSEMBLY
10. Lower the jack until the axle is disengaged. 11. Remove entire front axle assembly (3). 4WD: Approximately 262 kg (130 lb)
INSTALLATION ★ To install, reverse removal procedure. Front closing bolts: 300 N·m (221 lbf ft) Nuts for front wheels: 370 N·m (273 lbf ft) Bolts on transmission side: 38 N·m (28 lbf ft) ★ Bleed the air from the Load Sensing circuit. Axle pin - bushings: ASL 800050 ★ Check the oil level in the tank and start the engine. ★ Perform a few complete steering maneuvers in both directions to bleed the air from the steering circuit.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 FRONT AXLE OVERHAUL PROCEDURES WARNING! Before proceeding with any overhaul procedures, be sure the front axle is sitting on a level, stable surface. Clean oil spills immediately and keep your work area clean and clear of debris.
STEERING CYLINDER ASSEMBLY DISASSEMBLY
WB156PS-5
1.
Castellated nut
8.
Ball joint
15. Gland
2.
Tie rod
9.
Nut
16. Seal ring
3.
Steering knuckle
10. Tie rod
17. Cylinder rod
4.
Nut
11. Axel end
18. Seal ring
5.
Ball joint
12. Castellated nut
19. Cylinder
6.
Bolt
13. Scraper
20. O-ring
7.
Cylinder
14. O-ring
21. Scraper
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
1.
Loosen tie rod end (2) locknut (1) until it is over the end of the threaded pin.
2.
Drive nut (1) with a hammer in order to loosen tie rod (2) from steering knuckle housing (3). ★ Do not strike the end of the threaded pin. This will damage the pin.
3.
Loosen nuts (4) and (9) and remove tie rods (2) and (10).
4.
Remove fastening bolts (6) from the cylinder, then remove cylinder (7) from its housing using a rubber hammer.
5.
Remove only those parts that need to be overhauled and/or replaced.
6.
Remove cylinder gland (15) from cylinder (19).
7.
Remove the cylinder gland and rod (17) from cylinder case (19). ★ Replace all sealing rings (16) and (18), O-rings (14) and (20), and scrapers (21) and (13) in cylinder body (19) and rod (17).
ASSEMBLY 1.
Install all new sealing rings (16) and (18), O-rings (14) and (20), and scrapers (21) and (13) to gland (15), to rod piston (17) and into cylinder body (19).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
2.
Slide preassembled (17) rod into cylinder body (19).
3.
Install ball joints (5) and (8), nuts (4) and (9) and tie rods (2) and (10) at the rod (17) ends and tighten. Tie rods: 300 N·m (221 lbf ft)
4.
Install steering cylinder to center body (7) together with tie rods.
5.
Assemble and tighten steering cylinder bolts (6) with torque wrench. Bolts: 120 N·m (89 lbf ft)
6.
Align the steering knuckle with the axle (parallel wheel hub).
7.
Adjust ball joint (5) so that the ball joint can be inserted into the steering knuckle arm. ★ It is important to unscrew locking nut (9) to carry out this operation.
WB156PS-5
30-211 1
DISASSEMBLY AND ASSEMBLY 8.
Insert tie rod (2) into its own housing on steering knuckle (3).
9.
Assemble and tighten lock nut (1) with a torque wrench.
FRONT AXLE OVERHAUL PROCEDURES
Nut: 220 N·m (162 lbf ft) ★ Repeat the operation for the opposite side. 10. Install lock nuts (4) and (9) of tie rods (3) and (10) only when the toe-in adjustment has been carried out.
Checking Toe-in 1.
Install two one-meter-long linear “A” bars that are identical to each other to the wheel flanges; lock them into position by tightening two nuts onto the wheel hub studs.
2.
Position the bars so they are centered in relation to the middle of the wheel axle, then check to ensure that they are perfectly resting against the hub. ★ Ensure that the piston is centered in relation to the cylinder.
3.
Using a tape measure, measure the distance in mm “M” from the farthest bar ends, and tighten or loosen the tie rods until the distance is the same on both sides. ★ Keep the minimum value, swinging the measurement point.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
4.
Check the difference of the measurements between the wheel hubs diameter ends to be sure it is within the requested tolerance range. ★ The nominal toe-in (A) value is referred to the external diameter of the wheel hubs flange, therefore the measured toe-in value (M) at the bars ends must be related to the ratio between length of the bar and flange diameter. ★ Nominal toe-in = A 2 mm (0.1 in) ★ Measured toe-in = M 5 mm (0.2 in)
5.
If toe-in is incorrect, with two wrenches, adjust the tie rod nuts, in or out, to set the tie rods equally until the toe-in is within the required tolerance.
6.
Once adjustment is complete, tighten the retaining nuts on the tie rods. Nuts: 250 N·m (184 lbf ft)
WB156PS-5
30-213 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
Camber Angle Adjustment 1.
Use the same bars “A” for the toe-in adjustment and a long bar to extend over the machined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.
★ Adjust the angle of 65° and position it on the long bar. ★ Move a wheel side till it forms the angle.
2.
Adjust the steering angle retainer, bolt in or out using bolts (1) on the bar body, locking them with locknut (2). Lock nut: 150 N·m (111 lbf ft)
3.
Steer completely towards the other side and repeat the same operations.
30-214 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 FRONT AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1.
Screw
5.
Bearings
9.
Snap ring
2.
Plug
6.
Gear
10. O-ring
3.
Carrier
7.
Bearings
4.
Pin
8.
Thrust washer
★ Before draining the oil, position the axle end (3) with the plug (2) on the upper part and loosen it in order to eliminate any possible inner pressure, then remove it completely. 1.
Turn the hub upside-down till the drain hole (2) is at its lowest point.
2.
Drain the oil completely.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
3.
Remove screws (1).
4.
Remove planetary carrier (3) from the epicyclic reduction gear and remove O-ring (10).
Removing the Planetary Gears (If Necessary) 1.
Remove snap ring (9) from each pin (4).
2.
Remove gears (6) from the pins.
3.
Recover rollers (7) and (5) and inspect their condition.
4.
Remove thrust washers (8). ★ When new planetary gears are used, it is advisable to install new roller bearings.
30-216 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 ASSEMBLY ★ Reinstall all epicyclic reduction gear components: planetary gears carrier (3), gears (6), needle bearings (5) and (7), washer (8) and snap rings (9) of every pin (4). ★ With new gears, it is advisable to install new needle rollers.
1.
Insert needles (5) and (7) into gears (6).
2.
Grease needles (5) and (7).
3.
Insert gears (6) with assembled needles in the planetary carrier pins.
4.
Install a new O-ring (10).
5.
Install planetary gear carrier (3) to epicyclic reduction gear.
6.
Install retaining screws (1). Screws: 25 N·m (18 lbf ft)
★ Use recommended oil in epicyclic reduction gear and axle body. 7.
Install plug (2) to axle end. Plug: 80 N·m (60 lbf ft)
WB156PS-5
30-217 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 AXLE END HUB ASSEMBLY
DISASSEMBLY
30-218 1
1.
Snap ring
10. Stud
19. Bolt
2.
Washer
11. Hub
20. Nut
3.
Washer
12. Bearing cup
21. Bolt
4.
Ring gear
13. Seal ring
22. Bushing
5.
Screw
14. Steering knuckle
23. Seal
6.
Bushing
15. Bearing cone
24. Axel shaft
7.
Carrier
16. Lower king pin
25. Beveled washer
8.
Retaining ring
17. Bolt
26. Axle housing
9.
Bearing cone
18. Upper king pin
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 WARNING! Before disassembling the wheel hub, it is advisable to secure it with a belt or a sling on a hoist or any other supporting device, in order to avoid its accidental fall that could damage the wheel hub group or cause injury. 1.
Insert a lever between steering knuckle (14) and the axle beam and fit it into the double U-Joint. With the lever pushing the double UJoint in the direction of the wheel hub lock ring (1) may be removed. ★ Do not damage the double U-Joint.
2.
Remove lock ring (1) from the double U-Joint shaft and collect washers (2) and (3) (illustrated on previous page).
3.
Remove bolts (5) from wheel carrier (7) group.
★ In order to remove wheel carrier group (7) from its housing, insert two of bolts (5) in the threaded extraction holes.
WB156PS-5
30-219 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
4.
Extract and remove hub-lock ring gear (7) together with epicyclic ring gear (4).
5.
Remove hub-lock ring gear (8) from epicyclic ring gear (4). ★ Check the wear conditions of the components.
Only if Necessary 1.
Remove centering bushings (6) of the hub lock ring gear with a hammer and special tool D1.
2.
Remove hub (11), using levers and a hammer to facilitate the operation. ★ Collect bearing cone (9).
3.
Position unit on a flat surface and remove seal ring (13) with a pry-bar. ★ This is a destructive operation for the seal ring.
4.
Take bearing cups (9) and (12) out on both sides of the hub, using a hammer and a suitable tool.
5.
Remove bearing cone (12) from the steering knuckle using a suitable, commercially available puller.
6.
Remove bolts (19) and (17) from upper (18) and lower king pin (16). ★ Before removing the king pins, secure the steering knuckle with a hoist or other supporting device.
7.
Remove king pins (18) and (16) and collect bevelled washers (25) and (27).
30-220 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
8.
Remove steering knuckle (14) from the axle beam and from shaft (24).
9.
Lay steering knuckle (14) on a flat surface and remove seal ring (23) with a pry-bar. ★ This is a destructive operation for the seal ring.
10. Turn steering knuckle (14) and take bushing (22) out, using a driver and a hammer.
WB156PS-5
30-221 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install bushing (22) into steering knuckle (14) with special tool D2 and a hammer or a press.
2.
Assemble seal ring (23) into steering knuckle (14) with special tool D3 and a hammer.
3.
Lubricate the ring.
Ring: ASL 800050
4.
Position lower king pin (16) on a workbench and assemble the cone of spherical joint (15) with special tool D4 using a press. Grease the king pin housings with grease ASL 800050.
5.
Install beveled washers (25) and (27) on to the king pin housings (16) and (18).
6.
Secure steering knuckle (7) group using a sling.
7.
Lubricate the seal ring lip and protect the splined end of the axle shaft by wrapping it in adhesive tape to avoid damage to the seal ring. After assembly, remove the adhesive tape. Assemble the steering knuckle on the axle beam.
8.
Install two king pins, the upper (16) and the lower (18), and tighten retaining screws (17) and (19). Screw: 190 N·m (140 lbf ft)
★ Make sure beveled washers (25) and (27) remain in their position. ★ If bearings (9) and (12) need to be replaced, make sure the distances “A,” “B” and “C” are within the permissible range. ★ A = 5.900 - 5.905 mm (0.232 - 0.232 in) ★ B = 52.229 - 52.279 mm (2.1 - 2.1 in) ★ C = 23.072 - 23.173 mm (1.0 in)
30-222 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY 9.
FRONT AXLE OVERHAUL PROCEDURES
Place wheel hub (11) on a workbench and install both cups of the taper roller bearings (9) - (12) in position using special tool D5 under a press or with a hammer.
10. Insert seal ring (13) into wheel hub (11) with special tool D6 and a hammer.
11. Install the cone of tapered roller bearing (12) on steering knuckle end (14). 12. Install wheel hub (11) on steering knuckle (14) and place the other cone of taper roller bearing (9) in position.
13. Position wheel carrier (7) on a workbench and install the bushings (6) to the carrier surface level with special tool D1. ★ At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.
14. Preassemble the wheel carrier, epicyclic ring gear group (7) and (4) with special locking ring (8) shown in figure.
WB156PS-5
30-223 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
15. Install wheel carrier group on to the wheel hub using two projecting bushings (6) as dowel pins. 16. Install relative bolts (5) in order to attach the ring bevel gear with the wheel hub.
17. Install all the hub dowel bushings completely using special tool D1 and a hammer. 18. Install wheel carrier (7) bolts (5) and tighten. Bolts: 120 N·m (88 lbf ft)
19. Install washers (2) and (3) to the axle shaft and install stop ring (1) by pushing it from the end of the serrated hub.
30-224 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 AXLE HOUSING
DISASSEMBLY
1.
1.
Axle housing
4.
Axle busing
7.
Seal
2.
King pin bushing
5.
Seal
8.
Bushing
3.
Cup
6.
Axle shaft
Remove axle shaft (6) from axle housing (1).
WB156PS-5
30-225 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
2.
Remove seal (5) from axle (1). ★ This is a destructive operation for the seal rings.
3.
Remove axle bushing (4) from the axle housing. ★ Examine the bushing before removal and replace only if the wear conditions require this.
4.
Remove upper king pin bushings (2) and cup (3) from the king pin housings. ★ Examine the bushing and housing before removal and replace depending on wear conditions.
5.
Remove seal (7) from axle (1). ★ This is a destructive operation for the seal rings. ★ If necessary, remove Pivot bushings (8) with a three-point extractor or a suitable driver and a hammer. ★ Do not damage the bushing housing.
30-226 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12! ASSEMBLY 1.
Using tool D7 and a hammer, install bushing (2) and cup (3). ★ To make installation easier, allow the bushings and cups to cool in liquid nitrogen at less than -100° C (-148° F).
2.
Install bushing (4) into the axle beam with tool D9 and a hammer.
3.
Install seal (5) in the axle with tool D10 and a hammer. ★ Fill 3/4 of the seal ring cavity with grease ASL 800050.
4.
Lubricate bushing (4) and seal ring lip (5). Insert axle shaft (6) into the housing. ★ Take care not to damage the sealing ring.
5.
Install two new bushings (8) and two new seal rings (7) in the housing (1) using tools D8 and D11.
WB156PS-5
30-227 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 DIFFERENTIAL
DISASSEMBLY
1.
1.
Differential housing
6.
Bolt
11. Bolt
2.
Bolt
7.
Adjuster ring nut
12. Guide pin
3.
Adjuster ring nut
8.
Guide pin
13. Carrier
4.
Bearing cup
9.
Guide pin
14. Axle housing
5.
Ring nut retainer
10. Bearing cap
Remove bolts (2) on the differential housing (1). Remove differential assembly (1) from axle housing (14). ★ Support the differential carrier with a sling or other appropriate means when removing.
30-228 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY 2.
FRONT AXLE OVERHAUL PROCEDURES
Remove bolts (6) and remove two ring nut retainers (5).
★ Before removing bolts, mark mounting caps (10) and the differential housing with permanent reference marks to avoid inverting them when reassembling the unit. ★ Mark the area between ring (3) and adjusters (7) and the differential (1) housing as well.
3.
Remove adjuster ring nuts (3) and (7) using tool D12.
4.
Remove four bolts (11) and remove two caps (10). ★ Ensure that center bushings (9) remain seated in the differential housing.
WB156PS-5
30-229 1
DISASSEMBLY AND ASSEMBLY 5.
FRONT AXLE OVERHAUL PROCEDURES
Remove carrier assembly (13). ★ Take care not to lose the bearings that are removed together with differential carrier (13). ★ Do not mismatch cups (4) if bearings are not to be replaced.
ASSEMBLY 1.
Assemble complete differential carrier (13), with outer cups (4) of the tapered roller bearings. ★ Take care not to invert the outer races of the tapered roller bearings.
2.
Place differential carrier (13) and two bearing caps (10) and bolts in their holes. ★ Check the positions of the bushings and caps using the reference marks on them and on differential housing (1).
3.
Install the caps loosely with their respective bolts (11).
4.
Install two adjustment ring nuts (3) and (7) in the differential housing using tool D12, so preload on the carrier bearings is slight. ★ Tap lightly with a soft hammer in order to properly set the bearings in position.
30-230 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
5.
Install a magnetic dial indicator “A” to the differential housing so that the dial indicator’s foot is at a right angle with the side of the gear teeth.
6.
Lock the pinion in place and move the ring gear alternatively taking note the pinion ring gear backlash.
7.
Repeat the operation on two or more points (teeth), rotating the ring gear to obtain an average value.
8.
Check to be sure it is within the requested range: 0.18 - 0.28 mm (0.010 - 0.011 in).
9.
Adjust the ring nuts (3) and (7) using tool D12. ★ If the measured backlash is less than the given tolerance range, tighten ring nut (3) and loosen ring nut (7). ★ If the measured backlash is higher than the given tolerance range, tighten ring nut (7) and loosen ring nut (3).
10. Make sure that the bearings are slightly preloaded; if necessary, repeat previous adjustment until the specified conditions are reached. 11. Once pinion/ring gear backlash is determined, measure total bearing preload (T) (pinion/ring gear system) using a spring gauge with the cable wound around the spindle pinion end. ★ The reading should be within the following values: T=(P+3.75) - (P+5.75) daN where P is the effectively measured pinion preloading.
★ All preloadings should be measured without seal (13) in place.
WB156PS-5
30-231 1
DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12. If the measurement is not within the required range, check each component and adjust ring nuts (3) and (7) of the differential carrier mounting. A. If total preload is less than the specified values, tighten ring nuts (3) and (7) the same amount, while keeping pinion/ring gear backlash unchanged. B. If total preload is greater than the specified values, loosen ring nuts (3) and (7) the same amount, while keeping pinion/ ring gear backlash unchanged.
13. When all adjustments are complete, install the ring nut retainers (5) and their respective bolts (6), and tighten to the specified torque. Bolts: 266 N·m (169 lbf ft)
14. Tighten bolts (11). Bolts: 266 N·m (169 lbf ft)
★ Before installing into housing, make sure they are perfectly clean. ★ Spread a film of adhesive on the contact surface between axle housing (14) and differential housing (1). Loctite: 510
15. Check two dowel pins (12) and (8) are in their proper locations.
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
16. Tighten retaining bolts (2) to the proper torque. 17. Refill the tank with oil. Bolts: 169 N·m (125 lbf ft)
Pinion Gear Contact Test ★ To check the gear tooth contact between the ring and pinion gear, paint the ring gear with red lead paint.
★ The marking test should be always carried out on the ring gear teeth and on both sides. ★ OK - Correct contact: If the pinion gear is properly adjusted, the mark on the ring gear surfaces will be within specifications. ★ Z - Excessive contact on the tip of the tooth: Move the ring gear away from the pinion in order to adjust the backlash. ★ X - Excessive contact at the tooth base: Move the pinion away from the ring gear and then adjust the ring gear to the pinion in order to reset the backlash.
★ To correct: ★ Move the pinion in direction 1 for X contact adjustment. ★ Move the pinion in direction 2 for Z contact adjustment.
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 PINION
DISASSEMBLY
1.
1.
Pinion gear
6.
Washer
11. Seal
2.
Shim
7.
Housing
12. O-ring
3.
Bearing
8.
Bearing
13. Cover
4.
Washer
9.
Retaining washer
5.
Collapsible spacer
10. Lock nut
Remove cover (13) from the differential housing.
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DISASSEMBLY AND ASSEMBLY 2.
Remove seals (12) and (11) from cover (13). ★ This is a destructive operation for the seals.
3.
Install differential carrier (1) in a vise.
4.
Remove lock nut (10) using special tools D14-D15. ★ This operation will damage the lock nut (10).
5.
Remove lock nut (10) and collect its retaining washer (9).
FRONT AXLE OVERHAUL PROCEDURES
★ Tap the shaft with a soft hammer to remove the pinion gear (1). ★ Be careful not to drop pinion gear (1). 6.
Recover washers (4) and (6), discard spacer (5) and bearing cone (8).
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
7.
To remove bearing cone (3) from pinion gear (1), use a commercially available puller.
8.
Recover bearing cone (3) and shim (2) under it.
9.
Check all pinion components for wear. ★ The lock nut (10) and spacer (5) must be replaced when reassembling the unit.
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Place differential support (7) on a work bench.
2.
Install bearing cups (3) and (8) into housing using special tool D16 and a hammer.
★ Use the kit consisting of the special tools called “false pinion” D17 and “false differential box” D18 and D19 and a depth gauge.
3.
Install bearing cones (3) and (8) to their respective seats.
4.
Assemble the “false pinion” and nut (10).
5.
Tighten nut - but do not overtighten - until backlash is eliminated.
6.
Install tool D18, D19 to bearing seats in differential housing (7) and retain with bearing caps.
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DISASSEMBLY AND ASSEMBLY 7.
FRONT AXLE OVERHAUL PROCEDURES
Installation method D18, D19: ★ Use a depth gauge to measure distance “X” (distance between the axis of the differential bearings and the point at which the pinion head, or base of bearing, is supported).
★ In order to determine the thickness (S) required between the pinion and the bearing, subtract the value (V), stamped on the pinion head (Vaguer depth), from the measured value (X). S=X-V mm
★ Pick the (S) shim (2) from the range of shims available. Shim Range Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
8.
Remove special tool D18, D19 from differential support.
9.
Remove nut (10), false pinion, and bearing cones (3) and (8).
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
10. Install selected shim (2) to pinion shaft (1) with the chamfer facing the gear. 11. Install bearing (3) onto pinion shaft (1) using a press and driver D20, and ensure that the bearing is fully locked into position. 12. Install shims (4) and (6), and a new collapsible spacer (5). ★ Use only one new spacer.
13. Install pre-assembled pinion gear (1) to differential housing (7), and install bearing inner cone (8) to pinion shaft end as shown. 14. To install bearing (8), use driver D20 and a hammer.
15. Insert washer (9) and install new lock nut (10) on to the pinion end.
16. Tighten nut in (10), using the wrench for nut D14 and for pinion retainer D15. 17. The torque setting is given by the preload measurement on bearings (3) and (8). 18. Tighten nut (10) step by step. ★ If it is tightened too much, the spacer (5) should be replaced and the procedure repeated. ★ When you check the preload, it is advisable to tap both pinion ends with a soft hammer to help seat bearings (3) and (8).
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
19. Measure preload P of tapered bearings (3) and (8) using a force gauge with the string wound around the splined end of pinion (1). ★ Adjustment is carried out by gradually increasing the tightening torque of the ring nut (10), paying attention not to overtighten. ★ All preloadings should be measured without the seal. ★ P=9.2-13.7 daN
20. Once you have reached the preloading value, stake the lock nut (10). ★ Do not carry out the steps below until you have completed the adjustment of preload P.
21. Assemble seals (11) to cover (13) using tool D21 and a hammer. 22. Install new O-ring (12) to cover (13). Lubricate O-ring (12) and seal (11).
23. Install cover (13) to differential support.
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
12 CARRIER
DISASSEMBLY
1.
Bolt
5.
Axle gears
9.
2.
Bearing
6.
Thrust washer
10. Carrier half
3.
Carrier half
7.
Spider gears
11. Ring gear
4.
Counter-discs
8.
Pin
1.
Lock the carrier in a vise.
2.
Remove all bolts (1) on ring gear (11). ★ This will separate both halves (3) and (10), so take care not to drop the internal components.
3.
Remove the gear (11).
WB156PS-5
Spider shaft
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE OVERHAUL PROCEDURES
4.
Disassemble the differential carrier in two separate halves (3) and (10), complete with the relevant components. ★ Mark the two half-housings with reference marks. ★ Recover the components from both halves. ★ Check the wear conditions of the components.
5.
Remove bearings (2) from carrier halves (3) and (10), using a puller.
ASSEMBLY 1.
Assemble the cones of the new taper roller bearings (2) on the half carriers (3) and (10) using the special tool D13 and a hammer.
2.
Position housing (3) on a workbench and assemble all inner components: locking differential counter-discs (4), axle gears (5), spider shaft (9), spider gears (7), thrust washers (6), pin (8), as shown in illustration.
3.
Join the two halves, aligning the reference marks made during disassembly.
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DISASSEMBLY AND ASSEMBLY 4.
FRONT AXLE OVERHAUL PROCEDURES
Install the ring gear (11) and then tightening the bolts (1). Bolts: 95 N·m (70 lbf ft)
Bolt: Loctite 270
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DISASSEMBLY AND ASSEMBLY
REAR AXLE ASSEMBLY
12
REAR AXLE ASSEMBLY WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL ★ For added safety, place the backhoe bucket with its back on the ground while holding the arm in the upright position. ★ Lower the bucket to the ground as well.
1.
Lower backhoe outriggers (1) and force them downwards in order to raise rear wheels (2) by approximately 5 cm (2 in).
2.
Prepare a safety stand “A” approximately 65 cm (26 in) high, beneath the backhoe chassis. Pull up the outriggers until the machine is resting on the stand “A.”
3.
Stop the engine and take off rear wheels (2). Wheel 163 kg (350 lb)
4.
Remove the rear wheels with jack stands “A” in place and outriggers (1) in the lowered position as shown in the illustration. WARNING! Completely lower the machine on to the jack stands before removing the tires. Lower the outriggers (1) to the ground after the machine is resting on the jack stands for extra safety.
5.
Disconnect cable (3) from parking brake (4).
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DISASSEMBLY AND ASSEMBLY 6.
Disconnect differential lock hose (5). ★ Cap the hose to prevent contamination.
7.
Disconnect service brake lines (7) from axle (6).
8.
Disconnect lines (7) from hoses (8); loosen and remove clamp (9) and lines (7). ★ Cap pipes and hoses to prevent contamination.
9.
Disconnect drive shaft (10) from the rear axle.
REAR AXLE ASSEMBLY
10. Position a jack “C” beneath the axle. 11. Raise the jack until it can be forced under the axle. ★ It should be possible to lower the jack by approximately 20 mm (8 in).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE ASSEMBLY
12. Remove bolts (11). 13. Lower the jack until axle (6) is disengaged from the chassis. 14. Remove the entire axle. Rear axle: 430 kg (948 lb)
INSTALLATION ★ To install, reverse removal procedure. Lug nuts: 500 ±9.8 N·m (369 ±7 lbf ft) 1.
Bleed the air from the braking circuits.
2.
Adjust the stroke of the parking brake lever. Drive shaft bolts: 38 N·m (28 lbf ft) Axle retaining bolts: 1,000 N·m (737 lbf ft)
Axle retaining bolts: Loctite 262
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 REAR AXLE OVERHAUL PROCEDURES WARNING! Before proceeding with any overhaul procedures be sure the rear axle is sitting on a level, stable surface. Clean up any oil spills immediately and keep your work area clean and clear of debris.
PARKING BRAKE ASSEMBLY DISASSEMBLY
WB156PS-5
1.
Lock nut
5.
Rotor
9.
Caliper support
2.
Bolts
6.
Shim
10. Seal
3.
Brake caliper
7.
O-ring
11. Differential housing
4.
Snap ring
8.
Bolt
12. Dowel pin
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
1.
Loosen nut (1).
2.
Remove bolts (2). ★ Proceed with care, in order to avoid damaging the brake pads.
3.
Remove brake caliper (3).
4.
Remove snap ring (4) and rotor (5). ★ Collect shim (6) and O-ring (7).
5.
Remove bolts (8) caliper support (9).
6.
Remove caliper support (9) from the differential housing.
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DISASSEMBLY AND ASSEMBLY 7.
REAR AXLE OVERHAUL PROCEDURES
Remove seal (10) from differential housing (11) with a puller. ★ This is a destructive operation for the seal ring.
ASSEMBLY 1.
Install new seal (10) into in the differential housing using special tool E1.
2.
Install dowel pin (12) and the brake caliper support (9) on the differential housing (11).
3.
Tighten bolts (8). Bolts: 80 N·m (59 lbf ft)
4.
Lubricate O-ring (7). O-ring: ASL 800050
5.
Insert shim (6) on the spined pinion end, new O-Ring (7), input flange (5) and lock ring (4).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
6.
Position brake caliper (3) on disc (9). ★ Be careful to avoid damaging the brake pads.
7.
Install bolts (2) and tighten nuts (1) to the prescribed torque. ★ Once the nuts are tightened, check to make sure that a 1 ±0.5 mm (0.04 ±0.020 in) gap remains between nuts (1) and the spacers shown. Nuts: 115 N·m (85 lbf ft) Bolts: 45 N·m (33 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 MAINTENANCE
1.
Lever arm
8.
Balls plate
15. Sleeve
2.
Adjustment bolt
9.
Bolt/sleeve
16. Shim
3.
Boot
10. Retention spring
17. Shim
4.
Cam assembly
11. Shim
18. Sleeve
5.
Torque plate
12. Nut
19. Bolt
6.
Brake pads
13. Nut
20. Mounting bracket
7.
Torque plate
14. Balls
1.
Install mounting bolts through sleeves (9) and attach brake mounting locking nuts as far as possible on mounting bolts. This is not required if brake assembly comes with the sleeve/bolt subassembly. Position the brake over disc gap and align with mounting holes in mounting bracket.
2.
Thread mounting bolts (9) into mounting bracket, adjusting bolts until a 0.5 - 1.5 mm (0.2 - 1.0 in) space exists between the sleeves and the locking nuts. Tighten the locking nuts to 115 N·m (85 lbf ft) of torque against the bracket.
3.
Refer to Adjustment Procedure to set backlash of installed brake assembly.
Brake Pad Adjustment Procedure 1.
Loosen adjustment nuts (12 and 13).
2.
Tighten inner adjustment nut (12) until firm contact is made with the disc by the linings. Torque to 13 -14 N·m (10 lbf ft).
3.
Be sure the control lever is in the brake apply position.
4.
Back off inner adjustment nut (12) four to six turns and check that disc is free to move.
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DISASSEMBLY AND ASSEMBLY 5.
REAR AXLE OVERHAUL PROCEDURES
Tighten outer locking nut (13) against inner adjustment nut (12) to lock adjustment bolt (2) in place. Tighten at 61 -74 N·m (45 - 55 lbf ft).
Ball and Cam Replacement 1.
Remove both adjustment locking nuts (12, 13), thrust, stainless steel and hardened washer (11, 16, 17), lever (1), and boot (3) from adjustment bolt (2).
2.
Remove outer cam (4) and ball assembly (8) from adjustment bolt (2).
3.
Use a screwdriver or similar tool, to gently pry inner cam (4) protrusions on back of cam loose from torque plate (5), and remove from adjustment bolt (2). Remove seal (15) from adjustment bolt (2).
4.
Install new seal (15) on adjusting bolt (2), inserting it through inner cam (4) until seal (15) bottoms out on torque plate.
5.
Lubricate the cams’ thrust surfaces before installing the cams (4). Cam surface: ASL 800050
6.
Install new cam (4) on adjustment bolt (2), taking care to orient protrusions into holes in torque plates (5).
7.
Install ball assembly (8) onto adjusting bolt (2), orienting balls into pockets of inner cam (4). Install outer cam (4) onto adjustment bolt (2), orienting pockets onto ball assembly (8). Install boot (3) over cam assembly.
8.
Install lever (1), using protrusions on back of outer cam (4) and holes in lever (1) to orient lever to proper operating position.
9.
Install remaining washer and nuts and follow adjustment procedures.
10. Check to ensure that the coated side of shim (11) is oriented towards the steel washer (17). Lining Replacement 1.
Loosen two adjustment locking nuts (12, 13) enough to remove each torque plate (5, 7) away from disc far enough to provide backlash to remove old carrier and lining assemblies and install new ones. (It may be necessary to remove one or both nuts.)
2.
Collapse the two lining retraction springs (10) and remove them from brake head assembly.
3.
Remove torque plates (5 and 7) away from disc, move carrier and brake pads (6) out of pockets, and remove the brake head assembly from the side.
4.
Before installing new pads, it is necessary to apply grease between bushings (9) and pad supports (5 and 7). Bushings: ASL 800050 ★ Once grease has been applied, slide the supports onto the bushings to distribute grease evenly.
5.
Install new carrier and lining assemblies (6) in each torque plate (5 and 7).
6.
Install the two lining retention springs (10) into brake head assembly. Be sure the spring’s “feet” are positioned properly in the holes in both lining carrier assemblies (6).
7.
Adjust brake.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 Sleeve Seal Replacement 1.
Loosen the two locking nuts on the mounting bolts and remove the mounting bolt/sleeve assembly (9) from the brake.
2.
Insert sleeve seals (18) between the torque (5 and 7) and align with the sleeve bores.
3.
Lubricate the mounting bolt/sleeve fit before installing. Bushings: ASL 800050
4.
Install the mounting bolt/sleeve assembly through the front pad support (5), the sleeve seals (18) and the rear pad support (7).
Replacing the Cable Attachment Bracket 1.
Remove bolts (19) from bracket (20) pad support (5).
2.
Remove bracket (20).
3.
Position bracket (20) in correspondence with the threaded holes of pad support (5).
4.
Attach bracket (20) to front torque plate (5) with appropriate bolts (19). Bolts: 63 N·m (46 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 SERVICE BRAKE ASSEMBLY
DISASSEMBLY
1.
1.
Bolt
8.
Shouldered bolt
15. Inner cylinder
2.
Hub
9.
Washers
16. O-ring
3.
Axle housing
10. Brake cylinder
17. O-ring
4.
Axle half shaft
11. Lock ring
18. O-ring
5.
Brake disc
12. Shouldered bolt kit
19. O-ring
6.
Brake plate
13. Washers
7.
Pin
14. Bushing
Drain the oil completely from the differential. Differential oil: Approximately 15 l (4 gal)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
2.
Remove all but two of cap screws (1).
3.
Sling outer hub (2).
4.
Insert two dowel rods to enable removal.
5.
Remove last two cap screws (1) and separate hub (2) from axle (3).
6.
Carefully pull hub (2) away from axle and half shaft (4), make sure that brake disks (5) and plates (6) stay with the hub.
7.
Stand the hub up, mark the reaction plate (5) that was against the axle housing (3). Remove reaction (6) and brake disks (5) and pins (7). ★ Check friction plate and brake separator condition. ★ If brake discs are to be replaced, soak the new discs (for each differential) in oil for at least 24 hours.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
8.
Remove axle shaft (4) from wheel hub assembly (2).
9.
Remove bolts (8) and beveled washers (9) from brake cylinder (10).
★ Check to ensure that shouldered bolts (8) and beveled washers (9) are not damaged. 10. If brake discs are being replaced, replace bolts and washers with the new kit.
11. Remove lock ring (11) and remove self-adjuster (12).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12. Place self-adjuster (12) onto special tool E2 and drive out spring clips (13) from the adjuster.
13. Inspect adjuster bushing (14) for wear. ★ Repeat procedure for the remaining two self-adjust kits.
14. Use an acceptable flat bar and pry brake piston (10) up from the hub.
15. Remove brake piston (10) and inner cylinder (15).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
16. Remove O-rings (16) and (17) from brake piston (10).
17. Remove O-ring (18) from inner cylinder (15).
18. Remove and replace O-ring (19). ★ Replace the O-ring at each disassembly.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install new O-ring (19) onto hub (2).
2.
Install O-ring (18) onto inner cylinder (15).
3.
Install O-rings (16) and (17) onto brake piston (10).
4.
Lubricate O-rings (16), (17) and (18), and install complete piston (15) to brake cylinder (10). O-ring: ASL 800050
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
★ Use hydraulic oil to lubricate the brake cavity of the hub housing (2) and mount pins (7). Cylinder cavity: ASL 800050
5.
Install complete brake cylinder (10) and remove pins (7).
6.
Place bushing (14) inside calibrated ring E2 with the chamfer facing upwards.
7.
Place pin E2 into brake adjuster (14).
8.
Install spring clips (13) taking care to rotate them 90° clockwise in respect to the one mounted before.
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DISASSEMBLY AND ASSEMBLY 9.
REAR AXLE OVERHAUL PROCEDURES
Using driver E2, push rings (13) until solid contact against calibrated ring E2 is obtained. ★ Repeat procedure for the remaining self-adjusts.
10. Insert adjuster (12) into brake piston (14), and make sure that the chaffered side is up.
11. Install snap rings (11) into the self-adjuster bore.
★ Check to ensure that spring ring teeth are facing the self-adjust kit as shown in the following illustration. ★ Snap ring (11) orientation and beveled washers (9).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12. Install bevelled washers (9) to shouldered bolt (8) taking care to orient them as shown in the previous illustration.
13. Install shouldered bolts (8) and spring washers (9) and tighten to the required torque Bolts: 16 N·m (12 lbf ft)
14. Install half shaft (4) and brake separator plate pins (7) into the axle housing.
15. Using the reference mark made during disassembly, place inner brake separator plate (5) into axle housing.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
16. Place inner brake disk (6) and second brake separator (5). ★ If brake discs (6) are replaced, soak discs (for each differential) in oil at least 24 hours prior to installation.
17. Install outer brake disk (6) and make sure the slots of the inner and outer brake disks are aligned with each other.
18. Sling hub assembly (2) and guide onto axle (3). 19. Lift and rotate the half shaft while pushing the hub onto the axle.
20. Install bolts (1) tighten to the required torque. Bolts: Loctite 270
Bolts: 226 N·m (167 lbf ft) 21. Tighten using the alternating crosswise method.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
22. Fill axle with oil. Differential oil: Approximately 15 l (4 gal)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 REAR AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1.
1.
Bolt
6.
Snap ring
11. Bearing
2.
Planetary gear
7.
Roller bearings
12. Hub seal
3.
Retaining washer
8.
Retainer nut
13. Bearing
4.
Retaining washer
9.
Axle end housing
14. Race
5.
Planetary carrier
10. Wheel flange
Loosen bolts (1). ★ Replace bolts with a new set.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
2.
Mark planetary gears (2), retaining washer (3) and indexed washer (4).
3.
Remove bolts (1), retaining washer (3) and indexed washer (4).
4.
Mark the mounting position of retaining washer (3) and indexed washer (4) on planetary carrier (5).
5.
Sling planetary carrier assembly (5).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
6.
Locate snap ring (6) slot and open it while raising planetary carrier (5).
7.
Only if necessary, remove from planetary carrier (5), gears (2) and their related roller bearings (7) (66 per gear). ★ Keep all the components of each gear together as a set.
8.
Using spanner E4, loosen and remove ring nut (8).
9.
Use suitable puller and separate hub housing (9) from wheel end (10).
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
10. Sling hub housing (9) and remove it from wheel flange (10). ★ Collect bearing cone (11).
11. Remove from hub housing (9) the outer race of bearing (11).
12. Remove from hub housing (9) the outer race of bearing (12). ★ This is a destructive operation for the seal ring.
13. Remove from hub housing (9) the outer race of bearing (13).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
14. Remove from wheel flange (10) spacer (14).
15. Using an angle grinder, cut the cage and etch bearing race (13). 16. Use a chisel to cut and remove bearing inner race (13). Remark Do not use a cutting torch to remove this bearing, damage to the axle end may occur.
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install bearing outer races (13) and (11) to hub (9) using special tool E5 and a press. Using special tool E6 install hub seal (12).
2.
Install bearing inner race (13) to wheel flange (10) using a suitable driver and a press.
3.
Install spacer (14) on wheel flange (10).
4.
Sling hub (9) and carefully install it onto wheel flange (10). ★ Clean all sealing surfaces. ★ Take care not to damage the hub seal (12).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
5.
Install bearing inner race (11) using a suitable driver and a hammer.
6.
Install ring nut (8).
7.
Using spanner E4, tighten ring nut (8) to the required torque. Ring nut: 1,000 N·m (738 lbf ft)
8.
Apply a light coat of Lithium-based grease to the planetary carrier (5) stud to hold the needle bearings (7) (33 bearings) in place. Grease: ASL 800050
★ Use all the components corresponding to the marks made during disassembly.
9.
Install the planetary gear (2) and the remaining needle rollers (7) (33 bearings) into the side gear.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
10. Sling planetary carrier (5) and lower it into hub (9).
★ During installation locking ears of the planetary carrier (5) must engage ring nut (8) as shown in illustration.
11. In order to simplify the installation, align the hole on planetary carrier (5) with ring nut (8) as shown.
12. Open snap ring (6) and slowly lower planetary carrier (5).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
13. Install washers (3) and (4) and tighten bolts (1); apply the specified sealant and tighten to the required torque. ★ Replace bolts with new ones. Bolts: Loctite 270
Bolts: 79 N·m (58 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 DIFFERENTIAL
DISASSEMBLY
1.
1.
Bolt
4.
Bolt
7.
Carrier
2.
Axle housing
5.
Ring nut
8.
Bearing
3.
Differential
6.
Ring nut
Drain the oil completely from the differential. Differential oil: Approximately 15 l (4 gal)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
2.
Remove bolts (1).
3.
Separate from axle housing (2) differential (3) using pry bars in slots.
4.
Sling differential housing (3) and remove it.
5.
Remove bolts (4) securing ring nuts (5) and (6).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
6.
Use tool E7, unscrew adjuster ring nuts (5) - (6).
7.
Remove differential case (7). The external rings (8) and (9) are removed together with the differential housing. ★ Do not mismatch bearings if bearings are not to be replaced.
ASSEMBLY 1.
Using driver E8, install bearing outer races (8) and (9) to differential housing (7). ★ Do not mismatch bearings if bearings are not to be replaced.
2.
Position complete differential carrier (7) with bearings on differential housing (3).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
3.
Insert and tighten adjustment ring nuts (5) and (6) in the differential support with tool E7, so as to preload the differential bearings slightly. ★ Tap lightly with a soft hammer to properly set the bearings in position.
4.
Place a magnetic dial indicator on the differential support so that the feeler is at right angles with the side of a tooth from the ring gear. A. Lock the pinion and move the ring gear alternatively and note the pinion ring gear backlash, measured with the dial indicator. B. Repeat the operation on two or more points (teeth), rotating the ring gear, to obtain an average value. C. Check the measured backlash value to see if it is within the required range: 0.21 - 0.29 mm (0.08 - 0.11 in).
5.
Adjust by operating the adjuster ring nuts (5) and (6), using tool E7.
6.
Adjust the ring nuts (5) and (6) remembering that: ★ If the measured backlash is less than the given tolerance range, unscrew adjuster ring nut (6) and screw in adjuster ring nut (5) by the same measure. ★ If the measured backlash is greater than the given tolerance range, unscrew adjuster ring nut (5) and screw in adjuster ring nut (6) by the same measure.
7.
Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
8.
Once the pinion ring gear backlash has been established, measure the total rotational torque Tr of the bearings (pinion ring gear system), using a torque wrench and special tool E9. ★ Total rotational torque should be measured without pinion retaining ring. ★ Rotational torque Tr must be within the following range: Tr = (Pr+0.58) - (Pr+0.87) N·m where Pr is the actual rotational torque of pinion alone.
9.
If the reading is not within the required range, thoroughly check the assembly of each component and adjuster ring nuts (5) and (6) of the differential support caps: ★ If total preload is less than the specified value, tighten the adjuster ring nuts (5) and (6) by the same amount, while keeping the pinion ring gear backlash value unchanged. ★ If total preload is greater than the specified value, loosen the adjuster ring nuts (5) and (6) by the same amount, while keeping the pinion ring gear backlash value unchanged.
10. To test the tooth contact on the ring gear teeth, paint the ring gear with red lead paint. ★ The marking test should be always carried out on the ring gear teeth and on both sides.
Contact ★ OK-Correct contact: ● If the ring gear is well adjusted, the mark on the teeth surfaces will be regular. ★ Z - Excessive contact on the tooth tip: ● Adjust the pinion to the ring gear and then move the ring gear away from the pinion in order to adjust the backlash. ★ X - Excessive contact at the tooth base: ● Move the pinion away from the ring gear and then adjust the ring gear to the pinion in order to adjust the backlash.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
Movements to Correct A. Move the pinion in drection 1 for type X contact adjustment. B. Move the pinion in direction 2 for type Z contact adjustment.
11. When all adjustment procedures are complete, lock adjuster ring nuts (5) and (6) into position with bolts (4). Tighten screws (4) to the required torque. Bolts: 10 N·m (7 lbf ft)
12. Before matching surfaces, make sure that they are perfectly clean, degrease and clean them with appropriate detergents. Spread a film of adhesive on the contact surface between axle housing (2) and differential carrier (3). Contact surfaces: Loctite 510
13. Assemble differential (3) to axle housing.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
14. Tighten all bolts (1) to the required torque. Bolts: 169 N·m (125 lbf ft) 15. Refill the hydraulic oil. Differential oil: Approximately 15 l (4 gal)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 DIFFERENTIAL LOCK
DISASSEMBLY
1.
1.
Plug
6.
Bushing
11. O-ring
2.
Fork
7.
Spring
12. O-ring
3.
Shaft
8.
Bushing
13. Snap ring
4.
Spring
9.
O-ring
5.
Snap ring
10. Piston
Loosen plug (1) but do not remove it.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
2.
Hold differential lock fork (2) down to release the block inside of the housing, remove plug (1).
3.
Pull differential fork lock (2) up and place a flat piece of steel under shaft (3) to keep it from moving.
4.
Compress spring (4) until snap ring (5) is released.
5.
Remove snap ring (5).
6.
Remove bushing (6).
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DISASSEMBLY AND ASSEMBLY 7.
Remove spring (4).
8.
Remove shaft (3) from differential housing.
9.
Remove fork (2), spring (7) and bushing (8) from shaft (3).
REAR AXLE OVERHAUL PROCEDURES
10. Remove O-ring (9) from plug (1) and O-rings (11) and (12) from the piston (10).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 ASSEMBLY 1.
Install new O-rings (11) and (12) on piston (10) and O-ring (9) on plug (1). Lubricate the O-rings.
2.
Lubricate shaft (3) with clean hydraulic oil.
3.
Install fork (2) on shaft (3) as shown in figure.
4.
Install bushing (8) and spring (7) onto shaft. ★ Mount spacer (8) with the chamfer towards snap ring (13).
5.
Insert shaft (3) in the differential housing.
6.
Install spring (4).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
7.
Place bushing (6) on the shaft. Make sure the chamfer in the bushing is facing out.
8.
Pull differential lock fork (2) up and place a flat piece of steel under the shaft (3) to keep it from moving down.
9.
Compress spring (4) using a proper tool and install snap ring (5). ★ Remove the piece of steel under shaft (3).
10. Hold differential lock fork (2) down to catch a block inside of the housing; then install plug (1). ★ Hand tighten the plug (1).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
11. Tighten plug (1) to the required torque. Plug: 180 N·m (133 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 CARRIER
DISASSEMBLY
1.
Bearing race
8.
Axle gear
15. Thrust washer
22. Axle gear
2.
Bearing race
9.
Plug
16. Spider gear
23. Thrust washer
3.
Sleeve
10. Pin
17. Thrust washer
24. Differential housing
4.
Snap ring
11. Cap screw
18. Pin
25. Pin
5.
Housing cover
12. Ring gear (not shown)
19. Spacer
6.
Anti-rotation pin
13. Pin
20. Spider gear
7.
Thrust washer
14. Spider gear
21. Thrust washer
★ If differential bearings are to be replaced, remove bearing outer races (1) and (2). 1.
Remove sleeve (3).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
2.
Remove snap ring (4).
3.
Remove housing cover (5), remove anti-rotation pin (6) and thrust washer (7).
4.
Remove axle gear (8).
5.
Remove three plugs (9) from the carrier.
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DISASSEMBLY AND ASSEMBLY 6.
Remove three pins (10) securing the spider pins in the carrier.
7.
Remove ring gear cap screws (11) and ring gear (12).
8.
Push pin (13) towards flat surface side (14). ★ The pin can be pushed in only one direction.
9.
Remove planetary gear (14) and thrust washer (15).
WB156PS-5
REAR AXLE OVERHAUL PROCEDURES
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
10. Push pin (13) out of the housing and remove planetary gear (16) and thrust washer (17).
11. Push short spider pins (18) out of spacer (19) by pushing them through the hole in spacer (19).
12. Remove pins (18), spider gears (20) and thrust washers (21).
13. Remove axle gear (22) and thrust washer (23) from the housing.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
14. Remove differential locking pins (25) from housing (24).
ASSEMBLY 1.
Install and lubricate new O-rings (26) on pins (25). O-ring: ASL 800050
2.
Install pins (25) in differential housing (24).
3.
Lubricate and install sun gear (22) and thrust washer (23). Gear: Differential oil
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DISASSEMBLY AND ASSEMBLY 4.
REAR AXLE OVERHAUL PROCEDURES
Lubricate and install planetary gear (20) and its respective thrust washer (21) and install pins (18) forward enough to support them. ★ Align the flats on the pins facing upward. Gear and pin: Differential oil
5.
Install spacer (19) and install pins (18), taking care to align the holes with those on the differential housing (24).
6.
Lubricate and install spider gear (16) and thrust washer (17). ★ Install pin (13) as far as it will go. ★ Align pin (13) with the flats on the pin facing up. Gear and pin: Differential oil
7.
Lubricate and install spider gear (14) and thrust washer (15) then install pin (13). ★ Align the hole on differential housing (24). Gear and thrust washer: Differential oil
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DISASSEMBLY AND ASSEMBLY 8.
REAR AXLE OVERHAUL PROCEDURES
Install differential ring gear (12), apply sealant and tighten cap screws (11) to the required torque. Cap screw: Loctite 270
Cap screw: 155 N·m (114 lbf ft)
9.
Install pins (10) and tighten plugs (9) to the prescribed torque. Plugs: 25 N·m (18 lbf ft)
10. Install planetary gear (8).
11. Apply a thin coat of grease to cover (5) and install shoulder ring (7). Cover: ASL 800050
12. Install anti-rotation pin (6) to cover (5) and install cover (5) to differential housing.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
13. Lock cover (5) into position with snap ring (4).
14. Install sleeve (3) and make sure that sleeve fits snugly into position. ★ To make installation easier, rotate side gear (22).
15. Install bearing outer rings (1) and (2) using driver E8. ★ Do not invert bearings.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
12 PINION
DISASSEMBLY
1.
Lock nut
5.
Washer
9.
2.
Washer
6.
Collapsible spacer
10. Washer
3.
Pinion gear
7.
Bearing
4.
Washer
8.
Bearing
1.
Place differential carrier (1) in a vise.
2.
Remove lock nut (1) using special tools E9 - E10. ★ This operation will damage the lock nut (1).
WB156PS-5
Housing
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
3.
Remove lock nut (1) and collect its retaining washer (2).
4.
Tap the shaft with a soft hammer to remove pinion gear (3). ★ Take care not to drop pinion gear (3).
5.
Recover washers (4) and (5), collapsible spacer (6) and bearing inner ring (7).
6.
Remove bearing outer races (7) and (8) from differential support (9) using a driver and a hammer.
7.
To remove bearing inner bearing (8) from pinion gear (3), use a commercially available puller. ★ Recover bearing (8) and the shim (10).
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DISASSEMBLY AND ASSEMBLY 8.
REAR AXLE OVERHAUL PROCEDURES
Check all pinion components for wear. ★ Ring nut (1) and collapsible spacer (5) must be replaced.
ASSEMBLY 1.
Place differential housing (9) on a workbench.
2.
Install outer bearing (7) and (8) using special tools E11 - E12 and a hammer.
3.
Insert inner bearing (7) and (8) in the housings.
4.
Assemble the false pinion E13 and its lock nut (1).
5.
Tighten till the backlash is eliminated.
6.
Install special tool E14 to the differential housing (9).
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
7.
Use a depth gauge to measure distance “X” (distance between the axis of the housing bearings and the point at which the pinion gear is supported, or base of the bearing).
8.
To adjust ring gear pinion measure the distance “A” with a depth gauge. Calculate the value “X” as follows: ★ X =(A+C)-B mm where “B” and “C” are known.
9.
In order to determine the necessary thickness value (S) between the pinion and the bearing, subtract the value (V), stamped on the pinion head (V= requested distance), from the measured value (X). ★ S = (X - V) mm
10. Select the shim with the thickness value (S) from among the range of available shims (10), and install it onto shaft under the pinion gear. ★ The chamfer on the ID of the shim (10) must be toward the pinion gear (3). Shim Range Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
11. Remove special tool E14 from housing (9). 12. Remove lock nut (1), false pinion E13, and the bearing cones (7) and (8).
13. Select a suitable shim (10) and install with the chamfer facing the gear. Then install bearing inner ring (8) to pinion (3) with a press and tool E3. Check to ensure that it fits snugly in place.
14. Install washers (4) and (5) and a new collapsible spacer (6) on the pinion gear (3). ★ Always use new collapsible spacer (6).
15. Install bearing (7) to pinion end. ★ To install bearing (8), use special tool E3 and a hammer.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE OVERHAUL PROCEDURES
16. Insert lock nut washer (2) and install new lock nut (1) on the pinion end.
17. Install lock nut (1), using the wrench for lock nut E10 and for pinion retainer E9. ★ The torque setting is given by the preload measurement on bearings (7) and (8). 18. Tighten lock nut (1) step-by-step. ★ If it is tightened too much, the spacer (6) should be replaced and the procedure repeated. ★ When you check the preload, it is advisable to tap both pinion (3) ends with a soft hammer, to help set bearings (7) and (8).
19. To measure the rotational torque (Pr) of tapered bearings (7) and (8), use a torque wrench and tool E9. ★ Adjustment is carried out by gradually increasing the tightening torque of lock nut (1), paying attention not to overtighten. ★ All preload settings should be measured without the seal. ★ Rotational torque should be within the following range: Pr = 2.0 - 2.4 N·m (1.5 - 2.0 lbf ft)
20. When you have the requested preload value, stake lock nut (1).
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DISASSEMBLY AND ASSEMBLY
FRONT LOADER PPC VALVE
12 FRONT LOADER PPC VALVE WARNING! Before any disassembly procedures are started, be sure the machine is on a firm, smooth and level surface. Lower all work equipment to the ground, set the parking brake, chock the wheels and disconnect the battery (see “BATTERY” on page 30-48).
REMOVAL 1.
Lower the front loader to the ground and neutralize the controls.
2.
Remove four screws (1), PPC valve and parking brake cover (2).
3.
Unplug connector (3).
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DISASSEMBLY AND ASSEMBLY 4.
Disconnect five hoses (5) from PPC valve (4). ★ Before disconnecting hoses, make sure they are marked for their proper location. ★ Cap all lines, hoses and openings to prevent contamination.
5.
Remove bolts (6) and remove complete PPC valve (4).
FRONT LOADER PPC VALVE
INSTALLATION ★ To install, reverse removal procedure. ★ Carefully inspect the hoses for the proper position when connecting them.
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DISASSEMBLY AND ASSEMBLY
FRONT-END LOADER ASSEMBLY
12 FRONT-END LOADER ASSEMBLY WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
LOADER BOOM CYLINDERS ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Install blocks “A” between bucket cylinders tie bar (1) and spacer (2) of fulcrum lever (3) on the side to be removed.
2.
Remove snap-ring (4) and internal retaining spacer (5) for piston rod attachment pin (6).
3.
Remove tie strap (7) retaining cylinder return hose (8).
4.
Place a sling around the cylinder and connect it to a hoisting device. ★ Do not sling the cylinder return hose with the cylinder barrel.
5.
Remove pin (6) to expose piston eye and rod end (9).
6.
Remove rod.
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DISASSEMBLY AND ASSEMBLY 7.
Lower cylinder (10) until it rests on blocks “B.”
8.
Start the engine to retract the cylinder rod.
9.
Stop the engine and eliminate any residual pressure.
FRONT-END LOADER ASSEMBLY
10. Remove hoses (8) and (11), and remove hose clamp (12). ★ Cap all lines, hoses and openings to prevent contamination. 11. Remove snap-ring (13) and spacer (14). 12. Remove cylinder assembly (10). Cylinder: Approximately 46 kg (101 lb)
INSTALLATION ★ To install, reverse removal procedure. ★ When aligning the positions between the hole and the pin, run the engine at a low speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders.
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DISASSEMBLY AND ASSEMBLY
FRONT-END LOADER ASSEMBLY
12 BUCKET CYLINDERS ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Remove strap retaining the cylinder return hose (1).
For the Right-Hand Cylinder Only 2.
If installed, disconnect the return-to-dig sensor, mark its location, and then remove the lift bracket.
3.
Remove bucket position rod (2).
4.
Place a sling round cylinder (3) and insert a block “A” between spacer (4) of piston fulcrum lever (5) and link (6). ★ Do not sling the cylinder return hose with the cylinder barrel.
5.
Remove snap-ring (7) and internal retaining spacer (8) for cylinder attachment pin (9).
6.
Remove pin (9) to expose cylinder rod eye.
7.
Start the engine to retract rod (10).
8.
Stop the engine and eliminate any residual pressure from all circuits.
9.
Remove hoses (1) and (11), and remove hose clamp (12). ★ Cap all lines, hoses and openings to prevent contamination.
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DISASSEMBLY AND ASSEMBLY
FRONT-END LOADER ASSEMBLY
10. Remove snap-ring (13) and spacer (14). 11. Remove cylinder (3). Tilt cylinder: Approximately 35 kg (77 lb)
12. Recover spacer (15) between frame and cylinder.
INSTALLATION ★ To install, reverse removal procedure. ★ When aligning the positions between the hole and the pin, run the engine at a low speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary. Machines Equipped with Return-to-dig Only ★ Check sensor position and adjust as necessary.
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DISASSEMBLY AND ASSEMBLY
FRONT-END LOADER ASSEMBLY
12 FRONT LOADER BUCKET ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Stop the engine and release residual pressures.
2.
Remove bolts (1) and pins (2) from lever (3).
3.
Rest lever (3) on the boom.
4.
Remove bolts (4) and pins (5) of the bucket.
5.
Start the engine and put the machine into reverse gear in order to disengage boom (6). Standard bucket: 436 kg (961 lb)
INSTALLATION ★ To install, reverse removal procedure. ★ When aligning the positions between the hole and the pin, run the engine at a low idling speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050
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DISASSEMBLY AND ASSEMBLY
FRONT-END LOADER ASSEMBLY
12 LOADER BOOM ASSEMBLY ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Remove the tilt cylinders. See “FRONT LOADER BUCKET” on page 30-307.
2.
Disconnect the cylinders from boom (1) and rest them on wooden blocks “A” placed on the front axle. See “BUCKET CYLINDERS” on page 30-305.
3.
Open the front hood and remove bolts (2) that lock oscillation pins (3) for boom (4).
4.
Close the front hood.
5.
Put a sling around boom (4) as shown in the illustration, and attach it to the hoist. Apply a slight tension to the cables.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 6.
Using a puller, remove pins (5) of arm (4) together with snap ring and spacer.
7.
Start the engine and put the machine into reverse gear travel until boom (4) is clear from the machine.
8.
Place two stands (a) in position and lower the boom until it is resting on them.
FRONT-END LOADER ASSEMBLY
Front equipment: Approximately 1,100 kg (2,425 lb)
INSTALLATION ★ To install, reverse the removal procedure, if necessary using the front towing hook. ★ When aligning the positions between the hole and the pin, run the engine at a low idling speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders.
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DISASSEMBLY AND ASSEMBLY
BACKHOE PPC VALVE
12
BACKHOE PPC VALVE ★ Do this procedure on a flat, level and smooth surface. ★ The following removal procedure applies to both PPC valves.
REMOVAL 1.
Lower the outriggers to the ground. Fold the bucket and rest the arm at right angles with the ground.
2.
Release the backhoe plate and stop the engine.
3.
Release all residual pressure in all circuits.
4.
Lift cab rear window up to the top.
5.
Fully raise boot (1).
6.
Loosen and remove screws (2) retaining PPC valve (3) and armrest (4).
7.
Raise the armrest from the rear side and remove screw (7) retaining rear guard (6).
8.
Cut the retaining clamp and lower boot (5).
9.
Loosen and remove screw (8) and rear guard (6).
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DISASSEMBLY AND ASSEMBLY
BACKHOE PPC VALVE
10. Unplug connector (9). 11. Ensure that the hoses are marked (10), then disconnect the hoses from the PPC valve. ★ Mark the positions of the lines to prevent mixing positions when reconnecting. ★ Cap the lines and pipe fittings to prevent contamination.
12. Remove PPC valve (11).
INSTALLATION ★ To install, reverse removal procedure. ★ Carefully inspect the hoses for the proper position when connecting them.
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DISASSEMBLY AND ASSEMBLY
PPC VALVE SUPPORT RELEASE CABLES
12
PPC VALVE SUPPORT RELEASE CABLES ★ Do this procedure on a flat, level and smooth surface. ★ The following removal procedure applies to both PPC valves.
REMOVAL 1.
Lower the outriggers and the equipment to the ground; stop the engine.
2.
Remove rear mat (1).
3.
Remove bolts (2) and remove platform (3).
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DISASSEMBLY AND ASSEMBLY
PPC VALVE SUPPORT RELEASE CABLES
4.
Fully raise boot (4).
5.
Remove screws (5) that retain the PPC valve and armrest (6).
6.
Raise the armrest from the rear side and remove screw (7) retaining rear guard (8).
7.
Cut the retaining clamp and release lower boot (9).
8.
Remove screws (10) and remove rear cover (8).
9.
Remove screws (11) and raise boot (12) and retaining edge (13). ★ Raise until the lower fulcrum and locking assembly become fully disengaged.
10. Remove retaining screws (14) from lock actuating lever assembly (15). 11. Remove entire lever assembly (15).
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DISASSEMBLY AND ASSEMBLY
PPC VALVE SUPPORT RELEASE CABLES
12. Loosen nut (16) and disengage sheath (18) from support (17). 13. Disconnect cable (20) from lower locking lever (19).
14. Loosen nut (21) and unscrew tensioner (22). Disengage control cable (20) from release control lever (15).
INSTALLATION AND ADJUSTING ★ To install, reverse removal procedure. 1.
Using tensioner (22), adjust cable tension to obtain safe locking and friction-free unlocking of the column.
2.
Lock the nut while holding the tensioner into position (21).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
PPC VALVE GAS STRUT
12 PPC VALVE GAS STRUT ★ Do this procedure on a flat, level and smooth surface. ★ The following removal procedure applies to both PPC valves.
REMOVAL 1.
Lower the outriggers and the equipment to the ground; stop the engine.
2.
Remove rear mat (1).
3.
Remove bolts (2) and remove platform (3).
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DISASSEMBLY AND ASSEMBLY 4.
Loosen stop knob (4) of the PPC valve support (5) you are working on.
5.
Fully raise boot (6).
6.
Remove screws (7) that retain the PPC valve and armrest (8).
7.
Raise the armrest from the rear side and remove screw (9) retaining rear cover (10).
8.
Cut the retaining clamp and release lower boot (11).
9.
Remove screw (12) and rear cover (10).
PPC VALVE GAS STRUT
10. Remove screws (13), raise boot (14) and retaining edge (15). 11. Raise until gas strut (16) becomes fully disengaged.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
PPC VALVE GAS STRUT
12. Loosen nut (17) and remove snap ring (18) and washer (19). 13. Disconnect gas strut (16) and remove it.
INSTALLATION ★ To install, reverse removal procedure.
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30-317 1
DISASSEMBLY AND ASSEMBLY
SOLENOID VALVE
12
SOLENOID VALVE ★ It is advised to do this procedure on a flat level smooth surface.
REMOVAL 1.
Lower the outriggers and the equipment to the ground; stop the engine.
2.
Disconnect the connector (1) and remove the seat (2).
3.
Remove the rear mat and remove the floor cover (5) closing off the floor.
4.
Disconnect all connectors (6) from the solenoid valves.
5.
Check to ensure that all connectors have marks on them, and note their plug positions. ★ Mark then disconnect all hoses (7). ★ Cap lines, hoses and openings to prevent contamination.
6.
Remove two bolts (8) and washers; remove the solenoid valve group (9) together with the accumulator.
INSTALLATION ★ To install, reverse removal procedure. ★ Start the engine and perform all possible maneuvers to eliminate the air from all circuits.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
BACKHOE ASSEMBLY WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking brake and chock the wheels. Remove the starting key and disconnect the battery (see “BATTERY” on page 30-48).
BUCKET CYLINDER ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Extend arm (1) completely and fully open bucket (2).
2.
Lower boom (3) until the arm is resting on a stand (A) and tip of the arm is on a block (B).
3.
Rest the bucket teeth on the ground.
4.
Stop the engine and release the pressures in cylinder (4) by moving the control lever several times.
5.
Place a sling around bucket cylinder (4).
6.
Remove locknut (5), washer, and pin (6) from rod end (7). ★ Do not use a chisel and hammer or a pipe wrench to remove or install lock nut (5). Use the proper spanner wrench as shown in the illustration.
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30-319 1
DISASSEMBLY AND ASSEMBLY 7.
Disconnect bucket supply lines (8) and (9). ★ Cap all hoses and openings to prevent contamination.
8.
Remove snap-ring (10) and remove pin (11).
9.
Once free, lift bucket cylinder (4) off the machine.
BACKHOE ASSEMBLY
Bucket cylinder: 49 kg (108 lb)
Machines with Telescopic Arm Only 1.
Disconnect lines (11) and (12).
2.
Remove bolts (13) and remove pin (14).
3.
Remove cylinder (4).
INSTALLATION ★ To install, reverse the removal procedure. ★ Replace locknut (5) with a new one. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 TELESCOPIC ARM CYLINDER ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Open arm (1) completely and lower it until it rests on stand “A” that is roughly 40 cm (16 in) high.
2.
Extend arm (2) until it rests on a block “B” and let the bucket teeth rest on the ground.
3.
Stop the engine and release cylinder (3) residual pressures by moving the command pedal several times.
4.
Place a sling around cylinder (3).
5.
Remove snap ring and remove pin (4).
6.
Start the engine to retract the piston.
7.
Stop the engine and release any residual hydraulic pressure from all circuits by operating the control levers in all directions.
8.
Take out safety pin (5).
9.
Disconnect lines (6), (7), (8) and (9). ★ Cap all lines, hoses and openings to prevent contamination.
10. Remove clamp (10). 11. Remove bolts (11) and pin (12). 12. Remove cylinder (3).
INSTALLATION ★ To install, reverse the removal procedure. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment. Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
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30-321 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 ARM CYLINDER ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Extend arm (1) partly to make room for cylinder rod (4) clearance.
2.
Rest the bucket and arm completely on the floor.
3.
Using blocks (B) to elevate stand (A), lower boom (2) until the boom is resting on stand (A).
★ At this time, be sure there will be enough clearance when arm cylinder rod end (7) is retracted to clear the arm mounting bosses. 4.
Stop the engine and release the pressures in cylinder (4) by moving the control lever several times.
5.
Remove retaining bolt and nut (6).
6.
Pull pin (8) out and allow arm cylinder (4) to rest on boom, then retract arm cylinder rod (7) completely.
7.
Sling arm cylinder (4) and remove supply lines (9) and (10). Lift cylinder (4) to see if rod end (7) will clear the arm mounting bosses then lower cylinder (4) back down to rest on boom. ★ Cap all hoses and openings to prevent contamination.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 8.
BACKHOE ASSEMBLY
Support boom cylinder (5) with a block (B) and re-sling cylinder (4) to prepare for final removal. Once both cylinders are supported, remove pin (11).
★ When removing pin (11) from cylinders (4) and (5), be sure to keep track of shims (12) on each side of the boom mounting bosses and pivot points.
9.
Once pin (11) is removed, lift arm cylinder (4) from the machine.
INSTALLATION ★ To install, reverse the removal procedure. ★ It is recommended to install pin (10) and shims (12) first. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
WB156PS-5
30-323 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 BOOM CYLINDER ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Extend arm (1) partly to make room for cylinder rod (4) and (5) clearance.
2.
Rest the bucket and arm completely on the floor.
3.
Using blocks (B) to elevate stand (A), lower boom (2) until the boom is resting on stand (A).
4.
Remove hydraulic supply lines (6) and (7) from boom cylinder (5). ★ Cap all hoses and openings to prevent contamination.
5.
Sling cylinders (4) and (5) and remove pin (11). Be sure to place block (B) under boom cylinder (5) for support.
6.
Once pin (11) has been removed, shims (12) can be retrieved.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 7.
Rest arm cylinder (4) on the boom and re-sling boom cylinder (5) for removal.
8.
Remove bolt and nut (13) and prepare to remove pin (16) from cylinder (5).
9.
Remove snap ring (14) and washer (15) then almost completely remove pin (16), being careful not to unseat backhoe lock springs. ★ Do not remove the pin (16) completely, remove just enough to free boom cylinder (5) from its mounting position.
BACKHOE ASSEMBLY
10. Lift boom cylinder (5) off of the machine.
INSTALLATION ★ To install, reverse the removal procedure. ★ It is recommended to install pin (6) first. Be careful when aligning the springs for the lock mechanism. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idling speed. WARNING! Do not insert fingers into the holes to check alignment. Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
WB156PS-5
30-325 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 SWING CYLINDERS ★ Do this procedure on a flat, level and smooth surface.
REMOVAL ★ Center the backhoe and leave the backhoe plate unlocked. ★ Lower the outriggers to the ground. Curl the bucket and allow it to rest on the ground on its back. ★ Apply the parking brakes, stop the engine and remove the starting key. ★ Release all residual pressure by operating the hydraulic controls (including any optional device pedals) several times in all directions.
1.
Remove hose bundle clamp bolts (1) and remove hose clamp assembly.
2.
Group the hoses and sling them up out of the way using a sling (A) to hold them in place as shown in the illustration.
3.
Remove two front hydraulic supply hoses (2) and (3) on the cylinders you will be removing. ★ Cap all hoses and openings to prevent contamination.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Remove one rear hydraulic supply hose (4) on the cylinders you will be removing. ★ Cap all hoses and openings to prevent contamination.
5.
Remove four bolts (5) and prepare to lift top support frame (6) off of the swing cylinders.
6.
Using two people, lift top support frame (6) off of the swing cylinders with a pry bar.
BACKHOE ASSEMBLY
Top frame bracket: 27 kg (60 lb)
7.
Remove nuts and bolts (7) on both swing cylinders to prepare for removing both pins (8) completely. ★ It is important to remove both pins in order to be able to move the swing cylinders for removal.
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30-327 1
DISASSEMBLY AND ASSEMBLY 8.
Remove both swing cylinder pins (8) to allow for removal of swing cylinders.
9.
Once the pins are removed, you can swing the cylinders (9) to the right or left and remove them individually by lifting them out.
BACKHOE ASSEMBLY
10. To remove a swing cylinder, slightly pry up on swing cylinder (9) and lift it out. ★ It is advised to use two people to lift cylinder (9) out of machine. Swing cylinder: 37 kg (82 lb)
INSTALLATION ★ To install, reverse the removal procedure. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
30-328 1
WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 BOOM LOCK CYLINDER ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Center the backhoe with the arm vertical and the back of the bucket on the ground.
2.
Make sure that the safety stop (2) is raised.
3.
Stop the engine and release the residual hydraulic pressures.
4.
Remove nut (1) retaining linkage cover (2).
★ Once nut (1) is removed from linkage cover (2), lay linkage (2) onto the boom cylinder so lock cylinder (3) is exposed.
5.
Remove line (4) and remove four bolts (5) to remove the lock cylinder. ★ Cap all hoses and openings to prevent contamination.
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30-329 1
DISASSEMBLY AND ASSEMBLY 6.
To remove boom lock (10) or lock arm linkage (2), remove nut (6) from bolt (9).
7.
Carefully retaining spring (7), slide bolt (9) out of boom lock (10) and retain spacer (8).
8.
Remove snap ring and spacer (11) and slide boom lock arm (10) off of the boss.
9.
Once boom lock (10) is removed, spring (7) can be removed.
BACKHOE ASSEMBLY
INSTALLATION ★ To install, reverse the removal procedure. 1.
Start the engine and perform several lock and release maneuvers to fill up and bleed air from the unit.
BACKHOE BUCKET ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Place the bucket on a level surface, resting on its back.
2.
Remove safety pin (1) and connecting pin (2) between bucket (3) and tie-rods (4).
3.
Remove safety pin (5) and pin (6) that attaches the bucket to arm (7). Standard bucket: 158 kg (348 lb)
INSTALLATION ★ To install, reverse removal procedure.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 BACKHOE ARM ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Extend backhoe arm (1) and boom (2) enough to allow disconnection of arm cylinder (4).
2.
Rest bucket and arm (1) completely on the floor.
3.
Using blocks (B) to elevate stand (A), lower boom (2) until the boom is resting on stand (A).
★ At this time, be sure there will be enough clearance when arm cylinder rod end (7) is retracted to clear the arm mounting bosses. 4.
Stop the engine and release the pressures in cylinder (4) by moving the control lever several times.
5.
Remove retaining bolt and nut (6).
6.
Pull pin (8) out and allow arm cylinder (4) to rest on boom, then retract arm cylinder rod (7) completely.
★ Be sure there is enough clearance between arm cylinder (4) rod end (7) and arm boss (1).
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30-331 1
DISASSEMBLY AND ASSEMBLY 7.
Remove hydraulic supply lines (5) from arm cylinder (3). ★ Cap all hoses and openings to prevent contamination.
8.
Remove retaining bolt and nut (6) from pin (9).
9.
Sling arm (1) with bucket attached as shown in illustration.
BACKHOE ASSEMBLY
10. Remove pin (9) from arm (1). Be sure to retrieve shims (10).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
11. Once pin (9) is extracted and shims (10) are collected, lift arm (1) off of boom (2). Arm, bucket and bucket cylinder: 464 kg (1,022 lb)
INSTALLATION ★ To install, reverse the removal procedure. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
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30-333 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 TELESCOPIC ARM ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Remove bucket (1). For details see “BACKHOE BUCKET” on page 30-330.
2.
Remove bucket cylinder (2) and link (3). For details, see “BUCKET CYLINDER” on page 30-319.
3.
Remove the arm cylinder. For details, see “TELESCOPIC ARM CYLINDER” on page 30-321. ★ For safety, plug all the disconnected hoses.
4.
Remove lock nut (4), washer, pin (5) and links (6).
5.
Connect telescopic arm (7) to a hoisting tackle. ★ Use the bucket pin hole and the safety pin holes.
6.
Start the engine and, maintaining constant tension on the section of cable or chain connected to the bucket coupling, slowly raise the boom until both sections of cable or chain are under slight tension.
7.
Stop the engine and loosen by several turns the gib adjustment bolts.
8.
Loosen the bolts on both sides.
9.
Slide out telescopic arm (7). Telescopic arm: 439 kg (968 lb)
INSTALLATION ★ To install, reverse the removal procedure. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Tighten locknut completely, then release it half a turn.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 TELESCOPIC ARM GIBS ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Remove the bucket. For details see “BACKHOE BUCKET” on page 30-330.
2.
Partially extend the second arm (1).
3.
Rest the arm (2) on a trestle “A” about 80 cm (3.5 ft) high.
4.
Remove bolts (3), spring washers and upper guides (4).
5.
Connect telescopic arm (1) to a hoisting tackle. ★ Use the bucket pin hole and the safety pin holes.
6.
Slowly raise telescopic arm (1) until it rests on the supporting surfaces of the upper gibs.
7.
Loosen nuts (5) and remove the adjustment dowel bolts (6).
8.
Raise lower gibs (7) and slide them out.
INSTALLATION ★ To install, reverse removal procedure. Guides and second arm guides: ASL800040 ★ Adjust the clearances, keeping telescopic arm (1) aligned with respect to arm (2).
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30-335 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 BACKHOE BOOM ★ To remove the backhoe boom, the arm, bucket and boom cylinder must be removed. See “ARM CYLINDER” on page 30-322, “BOOM CYLINDER” on page 30-324 and “BACKHOE ARM” on page 30-331 before proceeding to remove the backhoe boom. ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
After arm, bucket and related cylinders are removed from boom (2), prepare to remove hoses (3). ★ Keep track of what cylinders and positions the hoses are in before removing them.
2.
Remove hose clamp (1) and remove hose bundle (3).
3.
Sling the backhoe boom in the manner shown in the illustration.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 4.
Once backhoe boom is properly slung, remove the lower mounting bolts (4) and pins (5) (one on each side).
5.
Once lower pins are removed, lift backhoe boom (2) from machine.
BACKHOE ASSEMBLY
Backhoe boom: 267 kg (589 lb)
INSTALLATION ★ To install, reverse the removal procedure. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
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30-337 1
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 BACKHOE SWING FRAME ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Remove the working equipment.
2.
Remove bolts (1) and remove pins (2) that connect the swing cylinders (3).
3.
Remove boom safety cylinder (4). For details, see “BOOM LOCK CYLINDER” on page 30-329.
4.
Remove snap ring (7), washer (8) and nut (4).
5.
Slide bolt (5) out of linkage (6) and lock lever (9).
6.
Remove lock lever (9) from boss pin (10).
7.
Remove the swing bracket (8) and the relative shim (13) adjustments to given clearance. Bracket: 133 kg (293 lb)
INSTALLATION ★ To install, reverse the removal procedure. When aligning the positions between the hole and the pin, run the engine at low idle. WARNING! Do not insert fingers into the holes to check alignment. Internal bushing: ASL 800050 Pin: ASL 800050 1.
Insert shims (13).
2.
Start the engine and bleed the air from the cylinders. See “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 OUTRIGGER CYLINDERS ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Center the backhoe with the arm vertical and the back of the bucket on the ground.
2.
Lower outriggers to the ground and prepare to remove the rear wheel and cylinder. Rear wheel (standard size): 163 kg (350 lb)
3.
Remove the rear wheel and support the machine as shown in the illustration using jack stand (A).
4.
Sling outrigger cylinder (1) as shown in the illustration.
5.
Remove hydraulic supply lines (2) and tag each line as to its location on the cylinder connection. ★ Cap all hoses and openings to prevent contamination.
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DISASSEMBLY AND ASSEMBLY 6.
Remove bolt and nut (3) and extract pin (4) from cylinder and boss.
7.
Remove bolt and nut (5) and extract pin (6) from cylinder and boss.
8.
After removing pins (4) and (6) lift cylinder (1) off of the outrigger.
BACKHOE ASSEMBLY
Outrigger cylinder: 53 kg (116 lb)
INSTALLATION ★ To install, reverse the removal procedure. ★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050 ★ Start the engine and bleed the air from the cylinders. For details, see “BLEED AIR FROM CYLINDERS” on page 30-83. ★ After bleeding the air, check the oil level in the tank. Top off tank, if necessary. ★ Install rear wheel.
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WB156PS-5
DISASSEMBLY AND ASSEMBLY
BACKHOE ASSEMBLY
12 OUTRIGGER ARMS ★ Before removing outrigger arms, the outrigger cylinder must be removed. See “OUTRIGGER CYLINDERS” on page 30339. ★ Do this procedure on a flat, level and smooth surface.
REMOVAL 1.
Sling outrigger arm (7) as shown in the illustration.
2.
Remove bolt and nut (8) then remove pin (9).
3.
Lift outrigger arm (7) from machine. Outrigger arm: 173 kg (381 lb)
INSTALLATION ★ To install, reverse the removal procedure. WARNING! Do not insert fingers into the holes to check alignment.
Internal bushing: ASL 800050
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CYLINDER OVERHAUL
12
WORK EQUIPMENT CYLINDER OVERHAUL WARNING! Before proceeding with any overhaul procedures be sure the cylinder you are working on is sitting on a firm, level and smooth surface. Clean up any oil spills immediately and keep your work area clean and clear of debris.
LOADER AND BACKHOE CYLINDERS DISASSEMBLY 1.
Position cylinder to be disassembled (1) to equipment U1.
2.
Using wrench U2 with torque amplifier, fully unscrew gland nut (2).
3.
Extract complete piston (3). ★ Place a receptacle to collect the oil.
4.
Position complete piston (3) to equipment U1.
5.
Using a wrench U3 with torque amplifier, remove nut (4) retaining piston (5) from the following cylinders: ★ Loader lift .......................................................55 mm (2.2 in) ★ Loader bucket ...............................................50 mm (1.97 in) ★ Boom..........................65 mm (3.0 in) (remove safety dowel) ★ Arm .................................................................65 mm (3.0 in) ★ Bucket .............................................................55 mm (2.2 in) ★ Outriggers .......................................................65 mm (3.0 in) ★ Telescopic arm ................................................46 mm (1.8 in)
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 6.
WORK EQUIPMENT CYLINDER OVERHAUL
Slide piston (6) and gland nut (2) off rod (5).
Arm Only ★ Note down direction of installation of stop bushing (5a).
Boom Cylinder Rod Only 1.
Remove plug (7) and rotate end (8) to let balls (9) out.
2.
Remove end (8).
All Cylinders 1.
Remove guide ring (10) and seal (11) from piston (5).
2.
Remove O-ring (12) with anti-extrusion ring, O-ring (13), snap ring (14) and scraper ring (15) from gland.
3.
Remove packing (16) and (17). ★ Note direction of anti-extrusion ring and position of seal (12) for installation.
Boom Gland Nut 1.
Remove bushing (18).
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CYLINDER OVERHAUL
ASSEMBLY 1.
Lubricate surfaces to prevent damage to the gaskets, seals, Orings, scraper, etc. Surface: Hydraulic oil ★ Do not force sealing rings into place; heat them instead in hot water at 50 - 60° C (122 - 140° F) before installing.
Boom Gland Only 1.
Using tool U6, install bushing (18).
All Cylinders 1.
Using tool U7, install scraper ring (15) and snap ring (14).
2.
Assemble packing (16) and (17). ★ Check direction of installation.
Assemble Piston 1.
Using tool U4 expand seal (11) and fit it on the piston.
2.
Calibrate seal (11) using calibrator U5.
Boom Cylinder Only 1.
Install anti-extrusion rings and O-ring (12).
2.
Assemble guide ring (10).
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WB156PS-5
DISASSEMBLY AND ASSEMBLY 3.
WORK EQUIPMENT CYLINDER OVERHAUL
Install rod (6), end (8), and ten balls (9); install plug (7). Plug: Loctite 262
Plug: 23 ±2 N·m (17 ±1.5 lbf ft)
4.
Install piston (5) to rod (6).
Arm Cylinder Only ★ Check orientation of brake bushing (5a).
1.
Assemble complete piston.
2.
Install rod (6) to equipment U1.
3.
Remove any existing dirt from the rod and install head (2).
Boom Cylinder Only 1.
Thread piston (5) onto rod (6) and lock into position with wrench U3 and torque amplifier. Piston: 280 - 290 kg (2,025 - 2,098 lbf ft)
2.
Install safety dowel (19) and tighten until snug. Dowel: Loctite 542
WB156PS-5
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DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT CYLINDER OVERHAUL
All Cylinders 1.
Install gland nut (2) and piston (5); coat piston thread with sealant. Piston: Loctite 262
2.
Install nut (4) and, using wrench U3 with torque amplifier, lock piston in place using the following torque values: Loader lift: 2,000 ±200 N·m (1,475 ±147 lbf ft) Loader bucket: 2,000 ±200 N·m (1,475 ±147 lbf ft) Arm: 2,845 ±284 N·m (2,098 ±209 lbf ft) Bucket: 2,845 ±284 N·m (2,098 ±209 lbf ft) Outriggers: 2,160 ±220 N·m (1,593 ±162 lbf ft)
Final Assembly 1.
Lubricate piston seals (5) and head gaskets (2) and install piston into cylinder (1).
2.
Position cylinder (1) to equipment U1 and tighten gland nut (2) using tool U2; tighten to the following torque: Loader lift: 700 ±70 N·m (516 ±52 lbf ft) Loader bucket: 700 ±70 N·m (516 ±52 lbf ft) Arm: 961 ±88 N·m (709 ±65 lbf ft) Bucket: 1,177 ±1,373 N·m (868 ±1,012 lbf ft) * Outriggers: 785 ±78 N·m (579 ±57 lbf ft) Boom: 981 ±98 N·m (723 ±72 lbf ft) ★ Loosen to 0 N·m (0 lbf ft), tighten up to 392 N·m (289 lbf ft), and then tighten angle-wise for 3.5 - 4.5 mm (0.14 - 0.2 in).
3.
When assembly is complete, plug union fitting holes to prevent contamination.
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WORK EQUIPMENT CYLINDER OVERHAUL
12 SWING CYLINDERS
DISASSEMBLY 1.
Place cylinder (1) on the apparatus U1. Engage the fulcrum pins in the suitable support.
2.
Using tool U2, unscrew gland nut (2) and extract it completely from cylinder (1).
3.
Remove the complete piston (3). ★ Place a receptacle to collect the oil.
4.
Attach the piston rod end to the mobile group of the apparatus U1.
5.
Remove safety screw (4) (M8-1.25).
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WORK EQUIPMENT CYLINDER OVERHAUL
6.
Remove the complete piston (6) with tool U8. ★ If tool U8 is not being used, drill four holes (∅ 10) and loosen the complete piston.
7.
Slide piston (6) and head (2) off rod (5).
8.
Remove guide ring (7), seal (8), O-ring (9) and their respective anti-extrusion rings from piston.
9.
Remove snap ring (10), spacer (11) and ring (12). ★ Note the orientation of ring (12) and the position of spacer (11).
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10. Remove O-ring (13) with anti-extrusion ring, O-ring (14), snap ring (15) and scraper ring (16) from head. 11. Remove gasket (17) and (18). ★ Note direction of installation of anti-extrusion ring and position of ring (13). 12. Remove bushing (19).
ASSEMBLY ★ Lubricate surfaces to prevent damage to the gaskets, seals, Orings, scraper, etc. Surface: Engine oil ★ Do not force sealing rings into place; heat them in hot water at 50 60° C (122 - 140° F) before installing. Head 1.
With tool U6, install bushing (19).
2.
Assemble seals (17) and (18). ★ Check direction of installation.
3.
Using tool U7, install scraper ring (16) and snap ring (15).
4.
Install O-ring (13).
Piston 1.
Using tool U4, expand seal (8) and fit it on the piston.
2.
Calibrate seal (8) using calibrator U5.
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DISASSEMBLY AND ASSEMBLY 3.
Install anti-extrusion rings and O-ring (9).
4.
Assembly the guide ring (7).
5.
Install ring (12), spacer (11) and snap ring (10) to rod (5). ★ Note orientation of ring (12).
WORK EQUIPMENT CYLINDER OVERHAUL
Assembling the Complete Piston 1.
Install rod (5) to equipment U1.
2.
Remove any existing dirt from the rod and install the head (2).
3.
This step varies for either original parts or new parts. Follow proper directions for your case.
With original parts only A. Thread piston (6), and tighten with tool U8 until threaded hole H of safety screw (4) is perfectly aligned.
With new parts A. Thread the piston (6) in. Make sure it contacts the rod (5) and then tighten.
Piston: 734 ±49 N·m (541 ±36 lbf ft)
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B. Drill hole H for safety screw (4) on the seam of thread between rod and piston. ★ Hole ∅ 6.8 − depth 31 mm (1.22 in) Thread: M8-1.25 − depth 25 mm (0.98 in) 4.
Remove any dirt or shaving and install the safety screw (4).
Screw: Loctite 262
Screw: 13.25 ±1.45 N·m (117 ±13 lbf in) 5.
Caulk screw (4) in four locations.
Final Assembly 1.
Lubricate piston seal (6) and head gasket (2) and introduce piston into cylinder (1).
2.
Piston cylinder (1) to equipment U1 and tighten head (2) using tool U2; tighten to torque.
Head: 785 ±78.5 N·m (579 ±58 lbf ft) ★ When assembly is complete, plug cylinder union fittings to prevent contamination.
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MEMORANDUM
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90
DIAGRAMS AND SCHEMATICS
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 1 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3 2 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5 3 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7 4 OF 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 RIGHT SIDE DASH (WIRING - 1 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11 HARNESS AND SWITCHES (WIRING - 2 OF 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13 RELAYS AND SWITCHES (WIRING - 3 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 HARNESS (WIRING - 4 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17 MOTORS AND CONTROLS (WIRING - 5 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19 SOLENOIDS (WIRING - 6 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21 OPTIONAL 4WS (WIRING - 7 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23 LIST OF CONNECTORS (WIRING - 8 OF 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
WB156PS-5
90-1
DIAGRAMS AND SCHEMATICS
90-2
WB156PS-5