WB 140

CEBM012701
Shop
Manual
WB140-2N
WB150-2N
BACKHOE LOADER
SERIAL NUMBERS WB140-2N A20637 and up

WB150-2N A60029 and up
ENGINE S4D106-1
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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2010 Komatsu

Printed in U.S.A.
Komatsu America Corp.
February 2010
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 WB140-2N WB150-2N

FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 b 10-19 10-47
● 00-2 b 01-1 10-20 10-48
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WB140-2N WB150-2N WB140-2N WB150-2N 00-2-1 b

FOREWORD
10-75 10-108 20-20 20-53
10-76 10-109 20-21 20-54
10-77 10-110 20-22 20-55
10-78 10-111 20-23 20-56
10-79 10-112 20-24 20-57
10-80 10-113 20-25 20-58
10-81 10-114 20-26 20-59
10-82 10-115 20-27 20-60
10-83 10-116 20-28 20-61
10-84 10-117 20-29 20-62
10-85 10-118 20-30 20-63
10-86 10-119 20-31 20-64
10-87 10-120 20-32 20-65
10-88 20-33 20-66
10-89 20-1 20-34 20-67
10-90 20-2 20-35 20-68
10-91 20-3 20-36 20-69
10-92 20-4 20-37 20-70
10-93 20-5 20-38 20-71
10-94 20-6 20-39 20-72
10-95 20-7 20-40 20-73
10-96 20-8 20-41 20-74
10-97 20-9 20-42 20-75
10-98 20-10 20-43 20-76
10-99 20-11 20-44 20-77
10-100 20-12 20-45 20-78
10-101 20-13 20-46 20-79
10-102 20-14 20-47 20-80
10-103 20-15 20-48 20-81
10-104 20-16 20-49 20-82
10-105 20-17 20-50 20-83
10-106 20-18 20-51 20-84
10-107 20-19 20-52 20-85
00-2-2 3 WB140-2N WB150-2N

FOREWORD
20-86 ❍ 30-24 b ❍ 30-57 b ❍ 30-90 b
20-87 ❍ 30-25 b ❍ 30-58 b ❍ 30-91 b
20-88 ❍ 30-26 b ❍ 30-59 b ❍ 30-92 b
20-89 ❍ 30-27 b ❍ 30-60 b ❍ 30-93 b
20-90 ❍ 30-28 b ❍ 30-61 b ❍ 30-94 b
20-91 ❍ 30-29 b ❍ 30-62 b ❍ 30-95 b
20-92 ❍ 30-30 b ❍ 30-63 b ❍ 30-96 b
20-93 ❍ 30-31 b ❍ 30-64 b ❍ 30-97 b
20-94 ❍ 30-32 b ❍ 30-65 b ❍ 30-98 b
❍ 30-33 b ❍ 30-66 b ❍ 30-99 b
❍ 30-1 b ❍ 30-34 b ❍ 30-67 b ❍ 30-100 b
❍ 30-2 b ❍ 30-35 b ❍ 30-68 b ❍ 30-101 b
❍ 30-3 b ❍ 30-36 b ❍ 30-69 b ❍ 30-102 b
❍ 30-4 b ❍ 30-37 b ❍ 30-70 b ❍ 30-103 b
❍ 30-5 b ❍ 30-38 b ❍ 30-71 b ❍ 30-104 b
❍ 30-6 b ❍ 30-39 b ❍ 30-72 b ❍ 30-105 b
❍ 30-7 b ❍ 30-40 b ❍ 30-73 b ❍ 30-106 b
❍ 30-8 b ❍ 30-41 b ❍ 30-74 b ❍ 30-107 b
❍ 30-9 b ❍ 30-42 b ❍ 30-75 b ❍ 30-108 b
❍ 30-10 b ❍ 30-43 b ❍ 30-76 b ❍ 30-109 b
❍ 30-11 b ❍ 30-44 b ❍ 30-77 b ❍ 30-110 b
❍ 30-12 b ❍ 30-45 b ❍ 30-78 b ❍ 30-111 b
❍ 30-13 b ❍ 30-46 b ❍ 30-79 b ❍ 30-112 b
❍ 30-14 b ❍ 30-47 b ❍ 30-80 b ❍ 30-113 b
❍ 30-15 b ❍ 30-48 b ❍ 30-81 b ❍ 30-114 b
❍ 30-16 b ❍ 30-49 b ❍ 30-82 b ❍ 30-115 b
❍ 30-17 b ❍ 30-50 b ❍ 30-83 b ❍ 30-116 b
❍ 30-18 b ❍ 30-51 b ❍ 30-84 b ❍ 30-117 b
❍ 30-19 b ❍ 30-52 b ❍ 30-85 b ❍ 30-118 b
❍ 30-20 b ❍ 30-53 b ❍ 30-86 b ❍ 30-119 b
❍ 30-21 b ❍ 30-54 b ❍ 30-87 b ❍ 30-120 b
❍ 30-22 b ❍ 30-55 b ❍ 30-88 b ❍ 30-121 b
❍ 30-23 b ❍ 30-56 b ❍ 30-89 b ❍ 30-122 b
WB140-2N WB150-2N 00-2-3 b

FOREWORD
❍ 30-123 b ❍ 30-156 b ❍ 30-189 b ❍ 30-222 b
❍ 30-124 b ❍ 30-157 b ❍ 30-190 b ❍ 30-223 b
❍ 30-125 b ❍ 30-158 b ❍ 30-191 b ❍ 30-224 b
❍ 30-126 b ❍ 30-159 b ❍ 30-192 b ❍ 30-225 b
❍ 30-127 b ❍ 30-160 b ❍ 30-193 b ❍ 30-226 b
❍ 30-128 b ❍ 30-161 b ❍ 30-194 b ❍ 30-227 b
❍ 30-129 b ❍ 30-162 b ❍ 30-195 b ❍ 30-228 b
❍ 30-130 b ❍ 30-163 b ❍ 30-196 b ❍ 30-229 b
❍ 30-131 b ❍ 30-164 b ❍ 30-197 b ❍ 30-230 b
❍ 30-132 b ❍ 30-165 b ❍ 30-198 b ❍ 30-231 b
❍ 30-133 b ❍ 30-166 b ❍ 30-199 b ❍ 30-232 b
❍ 30-134 b ❍ 30-167 b ❍ 30-200 b ❍ 30-233 b
❍ 30-135 b ❍ 30-168 b ❍ 30-201 b ❍ 30-234 b
❍ 30-136 b ❍ 30-169 b ❍ 30-202 b ❍ 30-235 b
❍ 30-137 b ❍ 30-170 b ❍ 30-203 b ❍ 30-236 b
❍ 30-138 b ❍ 30-171 b ❍ 30-204 b ❍ 30-237 b
❍ 30-139 b ❍ 30-172 b ❍ 30-205 b ❍ 30-238 b
❍ 30-140 b ❍ 30-173 b ❍ 30-206 b ❍ 30-239 b
❍ 30-141 b ❍ 30-174 b ❍ 30-207 b ❍ 30-240 b
❍ 30-142 b ❍ 30-175 b ❍ 30-208 b ❍ 30-241 b
❍ 30-143 b ❍ 30-176 b ❍ 30-209 b ❍ 30-242 b
❍ 30-144 b ❍ 30-177 b ❍ 30-210 b ❍ 30-243 b
❍ 30-145 b ❍ 30-178 b ❍ 30-211 b ❍ 30-244 b
❍ 30-146 b ❍ 30-179 b ❍ 30-212 b ❍ 30-245 b
❍ 30-147 b ❍ 30-180 b ❍ 30-213 b ❍ 30-246 b
❍ 30-148 b ❍ 30-181 b ❍ 30-214 b ❍ 30-247 b
❍ 30-149 b ❍ 30-182 b ❍ 30-215 b ❍ 30-248 b
❍ 30-150 b ❍ 30-183 b ❍ 30-216 b ❍ 30-249 b
❍ 30-151 b ❍ 30-184 b ❍ 30-217 b ❍ 30-250 b
❍ 30-152 b ❍ 30-185 b ❍ 30-218 b ❍ 30-251 b
❍ 30-153 b ❍ 30-186 b ❍ 30-219 b ❍ 30-252 b
❍ 30-154 b ❍ 30-187 b ❍ 30-220 b ❍ 30-253 b
❍ 30-155 b ❍ 30-188 b ❍ 30-221 b ❍ 30-254 b
00-2-4 3 WB140-2N WB150-2N

FOREWORD
❍ 30-255 b ❍ 30-288 b ❍ 30-321 b 90-21
❍ 30-256 b ❍ 30-289 b ❍ 30-322 b 90-22
❍ 30-257 b ❍ 30-290 b ❍ 30-323 b 90-23
❍ 30-258 b ❍ 30-291 b ❍ 30-324 b 90-24
❍ 30-259 b ❍ 30-292 b ❍ 30-325 b 90-25
❍ 30-260 b ❍ 30-293 b ❍ 30-326 b 90-26
❍ 30-261 b ❍ 30-294 b ❍ 30-327 b 90-27
❍ 30-262 b ❍ 30-295 b ❍ 30-328 b 90-28
❍ 30-263 b ❍ 30-296 b ❍ 30-329 b 90-29
❍ 30-264 b ❍ 30-297 b ❍ 30-330 b 90-30
❍ 30-265 b ❍ 30-298 b ❍ 30-331 b 90-31
❍ 30-266 b ❍ 30-299 b ❍ 30-332 b 90-32
❍ 30-267 b ❍ 30-300 b 90-33
❍ 30-268 b ❍ 30-301 b 90-1 90-34
❍ 30-269 b ❍ 30-302 b 90-2 90-35
❍ 30-270 b ❍ 30-303 b 90-3 90-36
❍ 30-271 b ❍ 30-304 b 90-4 90-37
❍ 30-272 b ❍ 30-305 b 90-5 90-38
❍ 30-273 b ❍ 30-306 b 90-6 90-39
❍ 30-274 b ❍ 30-307 b 90-7 90-40
❍ 30-275 b ❍ 30-308 b 90-8 90-41
❍ 30-276 b ❍ 30-309 b 90-9 90-42
❍ 30-277 b ❍ 30-310 b 90-10 90-43
❍ 30-278 b ❍ 30-311 b 90-11 90-44
❍ 30-279 b ❍ 30-312 b 90-12 90-45
❍ 30-280 b ❍ 30-313 b 90-13 90-46
❍ 30-281 b ❍ 30-314 b 90-14 90-47
❍ 30-282 b ❍ 30-315 b 90-15 90-48
❍ 30-283 b ❍ 30-316 b 90-16 90-49
❍ 30-284 b ❍ 30-317 b 90-17 90-50
❍ 30-285 b ❍ 30-318 b 90-18 90-51
❍ 30-286 b ❍ 30-319 b 90-19 90-52
❍ 30-287 b ❍ 30-320 b 90-20 90-53
WB140-2N WB150-2N 00-2-5 b

FOREWORD
90-54
90-55
90-56
90-57
90-58
90-59
90-60
90-61
90-62
90-63
90-64
90-65
90-66
90-67
90-68
90-69
90-70
90-71
90-72
90-73
90-74
90-75
90-76
90-77
00-2-6 3 WB140-2N WB150-2N

FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not possi-
machine. ble, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
● Always wear safety glasses when hitting parts with a 3. When disassembling or assembling, support the
hammer. machine with blocks, jacks or stands before starting
● Always wear safety glasses when grinding parts with a work.
grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or hydrau-
before starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to pre-
work, hang UNDER REPAIR signs on the controls in vent the oil from spurting out. Before disconnecting or
the operator's compartment. removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
6. Decide a place in the repair workshop to keep tools and oil and water to cool before carrying out any work on
removed parts. Always keep the tools and parts in their the oil or water circuits.
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke 3. Before starting work, remove the leads from the battery.
only in the areas provided for smoking. Never smoke ALWAYS remove the lead from the negative (-) termi-
while working. nal first.
WB140-2N WB150-2N 00-3

FOREWORD SAFETY
12
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 any other part. Do not work with any part 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 posi-
tion 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 can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
● When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is
being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed cor-
rectly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-4 WB140-2N WB150-2N

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 under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WB140-2N WB150-2N 00-5

FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00 REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model SYMBOLS 00
Engine volume: Issued for each engine series

So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models following symbols.
These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment Special safety precautions are
be available. Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
standards are necessary when
your distributors. Get the most up-to-date information before
performing the work.
you start any work.
Weight of parts or systems. Cau-
FILING METHOD 00
Weight
tion necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special atten-
2. Following examples show how to read the page number: Tightening
tion for tightening torque during
Example: torque
assembly.
10 - 3 Places to be coated with adhe-

Coat
sives and lubricants etc.
Item number (10. Structure and Function)
Places where oil, water or fuel
Oil, water
Consecutive page number for each item must be added, and the capacity.
Places where oil or water must
3. Additional pages: Additional pages are indicated by a Drain be drained, and quantity to be
hyphen (-) and numbered after the page number. File as drained.
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 (bcd…) is

recorded on the bottom outside corner of the pages.
00-6 WB140-2N WB150-2N

FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
WIRE ROPES 00
rope, or slipping of the rope

from its original winding posi-
1. Use adequate ropes depending on the weight of parts to tion on the load, which can
be hoisted, referring to the table below: result in a dangerous accident
Wire ropes
4. Do not sling a heavy load with ropes forming a wide
(Standard “Z” or “S” twist ropes without galvanizing)
hanging angle from the hook. When hoisting a load with
Rope diameter Allowable load two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
mm kN tons
shows the variation of allowable load (kg) when hoist-
10 9.8 1.0 ing is made with two ropes, each of which is allowed to
sling up to 1000 kg vertically, at various hanging angles.
11.2 13.7 1.4
When two ropes sling a load vertically, up to 2000 kg of
12.5 15.7 1.6 total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
14 21.6 2.2
the other hand, two ropes are subject to an excessive
16 27.5 2.8 force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ 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
WB140-2N WB150-2N 00-7

FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual pres-
sure from hydraulic tank.
WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Accord-
ingly, prepare an oil receiving container.
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the rub-
ber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not indi-
cate an abnormality.
00-8 WB140-2N WB150-2N

TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-9 WB140-2N WB150-2N

12
TYPE 3 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-10 WB140-2N WB150-2N

FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers, plas-
tics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-11 WB140-2N WB150-2N

FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket seal- ● Features: Silicon based, resistant to heat,
ant cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to pre-
LM-G 09940-00051 60 g Can
Molybdenum
vent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-12 WB140-2N WB150-2N

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 Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
00-13 WB140-2N WB150-2N

12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 59 - 74 43.51 - 54.57
12 17 98 - 123 72.28 - 90.72
16 22 235 - 285 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-14 WB140-2N WB150-2N

12
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 Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 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 Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
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.
Taper seal
Tightening torque (Nm {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
00-15 WB140-2N WB150-2N

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 num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 WB140-2N WB150-2N

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
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-17 WB140-2N WB150-2N

12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 WB140-2N WB150-2N

12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB140-2N WB150-2N 00-19

12
kgm to ft. lb. 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 1432.1 1439.4
00-20 WB140-2N WB150-2N

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
WB140-2N WB150-2N 00-21

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, con-
sider 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 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-22 WB140-2N WB150-2N

01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
WB140-2N WB150-2N 01-1

GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Description Unit WB140-2N - A20637 and UP WB150-2N - A60029 and UP
Weight
Minimum 7400 7400

Operating weight kg
Maximum 8800 8800
Loader 1.03 1.03
Bucket capacity m³
Backhoe 0.2 0.2
Forward 1st 6 6
Forward 2nd 11 11
Forward 3rd 21 21
Forward 4th 39 39
Performance
Travel speeds km/h

Reverse 1st 6 6
Reverse 2nd 11 11
Reverse 3rd 21 21
Reverse 4th 39 39
Forward
Max rimpull kg
Reverse
Gradeability Degrees
Outside Wheel
Min. Turning Radius mm
Tip of BOCE
Dimensions
mm
01-2 WB140-2N WB150-2N

12
Model Komatsu S4D106-1FH diesel en- Komatsu S4D106-1FA diesel en-
Type gine four cycle, water cooled, four gine four cycle, water cooled, four
cylinder, direct injection with turbo-cylinder, direct injection with turbo-
charger charger
No. of cylinders - bore x stroke mm
Piston displacement L
Engine
Flywheel horsepower @ 2000 rpm kW 64 72

Maximum torque @ 1400 rpm N•m 330 375
Min fuel consumption g/kWh
High idle rpm
Low idle rpm
Starting motor V kW 24, 7.5
Alternator VA 24, 35
Battery V Ah 24, 112x2
Torque converter
Power Train
Transmission
Reduction gear
Differential
Final drive
Drive type
Wheels and Axle
Front axle
Rear axle
Tire
Wheel rim
Front tire
Inflation pressure kg/cm²
Rear tire
Steering Brakes
Main brake
Parking brake
Type
Structure
WB140-2N WB150-2N 01-3

12
Torque converter L/min
Hydraulic system Cylinders Pumps
Steering L/min
Hydraulic L/min
mm
Work equipment valveType

Set pressure kg/cm²
Travel control valveType
Set pressure kg/cm²
Cooling fan motorType
Work
Link type Simple link

Bucket edge type Flat edge with BOCE and bolt on teeth
01-4 WB140-2N WB150-2N

GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This table is a guide for use when transporting or handling components.
Unit : kg
WB140-2N WB150-2N
Machine Model
A20637 and UP A60029 and UP
WB140-2N WB150-2N 01-5

GENERAL FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier.
When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recom-
mended for this machine.
Ambient Temperature Capacity

Kind of
Reservoir
fluid
-30 -20 -10 0 10 20 30 40 50°C Specified Refill
SAE 5W-30
SAE 10W
SAE 20W-20
Oil API CI-4 or JASO SH-1
Engine oil
SAE 30 7.9 L 7.9 L
pan
SAE 40
SAE 10W-30
SAE 15W-40
SAE 5W*
Hydraulic SAE 10W

150 L 92 L
system SAE 30
SAE 10W-30
Hydraulic
system with See page 3-12 150 L 92 L
biodegrad-
Front axle
6.5 L 6.5 L
diff
Final gear See Note 1 1 L each 1 L each
Rear axle diff 14.5 L 14.5 L
Final gear 1.5 L each 1.5 L each
Transmission 20 L 17 L
ATF GM DEXRON® II D
Brakes 0.8 L 0.8 L
ASTM D975
Diesel No. 1
Fuel tank 130 L -
fuel
ASTM D975 No. 2
Engine cool-
Coolant AF-NAC 14 L -
ing system
OPTION FOR VERY COLD AREAS:If the temperature is below 10°C, contact your distributor for advise on the type of oil
to be used.
01-6 WB140-2N WB150-2N

12 API American Petroleum Institute
ASTMAmerican Society of Testing and Materials
NLGINational Lubricating Grease Institute
SAESociety of Automotive Engineers
Specified CapacityTotal amount of oil including oil for components and piping.
Refill CapacityAmount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20°C. Consult your Komatsu distribu-
tor for your specific needs.
NOTE Use only diesel fuel. The engine mounted on this machine employs electronic control and a high
pressure fuel injection device to obtain good fuel consumption and good exhaust characteristics.
For this reason, it requires high precision for the parts and good lubrication. If kerosene or other
fuel with low lubricating ability is used, there will be a significant drop in durability.
WB140-2N WB150-2N 01-7

12
MEMORANDA
01-8 WB140-2N WB150-2N

10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
2WD MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
POWER FLOW - 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
TRANSMISSION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
4WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
2WD MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
FORWARD REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
1ST THROUGH 4TH SPEED SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
4WD SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
CENTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
COMPLETE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
WB140-2N WB150-2N 10-1

STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45

CONTROL OF DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
PC VALVE, LS VALVE, SERVO PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
LS VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
PC VALVE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
WORKING MODE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
LOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
2 SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
3 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
MECHANICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
LEFT OUTRIGGER SECTION VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
EXCAVATOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
INLET SECTION VIEWS A-A AND B-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
ARM SECTION VIEW C-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
SWING SECTION VIEW D-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
LEFT OUTRIGGER SECTION ˜ VIEW E-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
RIGHT OUTRIGGER SECTION VIEW F-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
BUCKET SECTION VIEW G-G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
BOOM SECTION VIEW H-H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
OUTLET SECTION VIEW J-J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
TELESCOPIC ARM SECTION VIEW K-K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
HAMMER SECTION VIEW L-L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
INTRODUCTION OF THE LS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
DELIVERY COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
LIFD CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
10-2 WB140-2N WB150-2N

MAINTENANCE STANDARD TABLE OF CONTENTS
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
LS DECOMPRESSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
PRESSURE CUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
PPC JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
LEFT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
RIGHT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK . . . . . . . . . . . . . . . . . . . . . . . . 10-100
PPC SUPPLY VALVE - ST2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
PPC TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
PPC HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
PPC ARM AND HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
BOOM ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
MP BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
TELESCOPIC ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
OUTRIGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
FRONT WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
REAR WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
WB140-2N WB150-2N 10-3

MAINTENANCE STANDARD ENGINE MOUNTING
1212
ENGINE MOUNTING
TIER I ENGINE
4WD MACHINES
10-4 WB140-2N WB150-2N

12
2WD MACHINES
B Tier I Engine e Transmission Mount

C Transmission F Rear Axle Input
D Engine Mount G Front Axle Input - 4WD
WB140-2N WB150-2N 10-5

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS ENGINE MOUNTING
12
TIER II ENGINE
4WD MACHINES
10-6 WB140-2N WB150-2N

12
2WD MACHINE
B Tier II Engine e Transmission Mount

C Transmission F Rear Axle Input
D Engine Mount G Front Axle Input - 4WD
WB140-2N WB150-2N 10-7

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS POWER TRAIN
12
POWER TRAIN
4WD MACHINES
B Engine F Front Axle

C Torque Converter G Rear Axle
D Transmission H Front Drive Shaft
E Hydraulic Pump I Rear Drive Shaft
DESCRIPTION
● The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydrau-
lic oil to convert the torque transmitted by the engine b 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 selec-
tor. It also has manual gear selection (four forward gears and four reverse gears).
● 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 and rear axles is reduced by the differentials and then transmitted to the
planetary gear through the differential shafts.
10-8 WB140-2N WB150-2N

MAINTENANCE STANDARD POWER TRAIN
12
POWER FLOW - 4WD
Front Axle Rear Axle
Gears
Trans Diff Planet Total Trans Diff Planet Total
1st 4.28 61.238 5.350 91.362
2nd 2.372 33.939 2.965 50.633
2.385 6.000 2.846 6.000
3rd 1.239 17.685 1.544 26.367
4th 0.662 9.472 0.827 14.123
b Engine E Rear Drive Shaft H Front Drive Shaft

c Convert Transmission F Rear Axle I Front Axle
d Hydraulic Pump G Rear Tires J Front Tires
WB140-2N WB150-2N 10-9

STRUCTURE, FUNCTION & MAINTENANCE STANDARDS POWER TRAIN
12
2WD MACHINES
B Engine e Hydraulic Pump

C Torque Converter F Rear Drive Shaft
D Transmission G Rear Axle
DESCRIPTION
● The driving power for the engine b is transmitted through the flywheel to the converter c. The converter c uses hydrau-
lic oil to convert the torque transmitted by the engine b 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 selec-
tor. It also has manual gear selection (four forward gears and four reverse gears).
● The driving power is transmitted from the transmission flange to the rear g axle through the drive shaft h. The driving
power transmitted to rear axle is reduced by the differential and then transmitted to the planetary gear through the differ-
ential shafts.
10-10 WB140-2N WB150-2N

MAINTENANCE STANDARD POWER TRAIN
12
Rear Axle
Trans Diff Planet Total
5.350 91.362
2.965 50.633
2.846 6.000
1.544 26.367
0.827 14.123
b Engine E Rear Drive Shaft

c Convert Transmission F Rear Axle
d Hydraulic Pump G Rear Tires
WB140-2N WB150-2N 10-11

MAINTENANCE STANDARD TRANSMISSION DIAGRAM
12
TRANSMISSION DIAGRAM
4WD MACHINES
b Engine E Transmission H Rear Axle Flange

c Torque Converter F Reverse Clutch I 4WD Clutch
d Forward Clutch G Hydraulic Pump J Front Axle Flange
10-12 WB140-2N WB150-2N

12
B Converter Valve G Reverse Clutch 1! Control Valve

C Converter H Max Pressure Valve 1@ Check Valve
D Engine I Spin On Filter 1# Check Valve
E Oil Cooler J Pump 1$ 4WD Solenoid
F Forward Clutch 1) Suction Strainer 1% 4WD Clutch
WB140-2N WB150-2N 10-13

12
2WD MACHINES
b Engine E Transmission H Rear Axle Flange

c Torque Converter F Reverse Clutch
d Forward Clutch G Hydraulic Pump
10-14 WB140-2N WB150-2N

12
B Converter Valve F Forward Clutch J Pump

C Converter G Reverse Clutch 1) Suction Strainer
D Engine H Max Pressure Valve 1! Control Valve
E Oil Cooler I Spin On Filter 1@ Check Valve
WB140-2N WB150-2N 10-15

MAINTENANCE STANDARD TRANSMISSION
12
TRANSMISSION
COMPLETE ASSEMBLY
B Shift Lever F Suction Strainer a From Oil Cooler

C Torque Converter G Reverse Solenoid b To Oil Cooler
D Spin On Filter H Forward Solenoid c To Solenoid Valves
E Oil Temperature Sender I 4WD Solenoid d From Solenoid Valves
10-16 WB140-2N WB150-2N

12

E Oil Temperature Sender I 4WD Solenoid d From Solenoid Valves
WB140-2N WB150-2N 10-17

12

E Oil Temperature Sender d From Solenoid Valves
10-18 WB140-2N WB150-2N

12

E Oil Temperature Sender d From Solenoid Valves
WB140-2N WB150-2N 10-19

12
B Pump Drive Shaft H Rear Axle Flange 1# 4WD Clutch

C Forward Reverse Shaft I 3rd Driven Gear 1$ 4WD Clutch Shaft
D Reverse Gear Clutch J 4th Driven Gear 1% Front Axle Flange
E Forward Gear Clutch 1) 4WD Drive Gear 1^ 2nd Driven Gear
F Reverse Idler Gear Shaft 1! 1st Driven Gear 1& Rear Output Shaft
G Drive Gears and Shaft 1@ 4WD Driven Gear
10-20 WB140-2N WB150-2N

12
B Pump Drive Shaft H Rear Axle Flange 1# 4WD Clutch

C Forward Reverse Shaft I 3rd Driven Gear 1$ 4WD Clutch Shaft
D Reverse Gear Clutch J 4th Driven Gear 1% Front Axle Flange
E Forward Gear Clutch 1) 4WD Drive Gear 1^ 2nd Driven Gear
F Reverse Idler Gear Shaft 1! 1st Driven Gear 1& Rear Output Shaft
G Drive Gears and Shaft 1@ 4WD Driven Gear
WB140-2N WB150-2N 10-21

12
B Pump Drive Shaft G Drive Gears and Shaft 1! 1st Driven Gear
C Forward Reverse Shaft H Rear Axle Flange 1@ 2nd Driven Gear
D Reverse Gear Clutch I 3rd Driven Gear 1# Rear Output Shaft
E Forward Gear Clutch J 4th Driven Gear
F Reverse Idler Gear Shaft 1) Gear Spacer
10-22 WB140-2N WB150-2N

12
B Pump Drive Shaft G Drive Gears and Shaft 1! 1st Driven Gear
C Forward Reverse Shaft H Rear Axle Flange 1@ 2nd Driven Gear
D Reverse Gear Clutch I 3rd Driven Gear 1# Rear Output Shaft
E Forward Gear Clutch J 4th Driven Gear
F Reverse Idler Gear Shaft 1) Gear Spacer
WB140-2N WB150-2N 10-23

12
B Gear Shift Lever H 3rd And 4th Selecting Rod 1# Spin On Filter
C Centering Spring I 1st And 2nd Selecting Fork 1$ Cold Oil Relief Valve
D Return Spring J 4th Selecting Sensor 1% Return Spring
E Check Ball 1) 3rd And 4th Selector 1^ Return Spring
F 3rd And 4th Selecting Fork 1! 1st And 2nd Selector 1& Return Spring
G 1st And 2nd Selecting Rod 1@ Suction Strainer
10-24 WB140-2N WB150-2N

12
B Check Ball G Spring Guide Pin 1! Return Spring

C Return Spring H Valve 1@ Spool Return Spring
D Piston I Return Spring 1# Spool
E Return Spring J Valve 1$ Forward Solenoid
F Return Spring 1) Rod 1% Reverse Solenoid
WB140-2N WB150-2N 10-25

12
FORWARD REVERSE CLUTCH
B Reverse Gear E Reverse Clutch Piston a Reverse Clutch Port

C Forward Gear F Thrust Ring b Forward Clutch Port
D Forward Clutch Piston G Shaft c Lubrication Port
1ST THROUGH 4TH SPEED SHAFT
B 2nd Driver Gear E 4th Driven Gear H Thrust Ring

C 1st Driven Gear F 3rd Driven Gear I Synchronizer
D 4WD Gear g Rear Output Shaft J Gear Spacer
10-26 WB140-2N WB150-2N

12
4WD SHAFT
B Front Output Shaft E Cylinder a 4WD Pressure Port

C 4WD Driven Gear F Spring
D Thrust Ring G Disc
WB140-2N WB150-2N 10-27

MAINTENANCE STANDARD FRONT AXLE
12
FRONT AXLE
4WD
COMPLETE ASSEMBLY
B Steering Cylinder E Tie Rod Nut h Mounting Pin Bushing

C Oil Refill Plug F Adjustment Screw a Left Cylinder Port
D Oil Drain Plug G Lock Nut b Right Cylinder Port
Unit:mm
Criteria
Check Item Standard Tolerance Standard Clearance Remedy
Size Shaft Bushing Clearance Limit
0 +0.04
i Pin and Bushing Clearance 50 50 50.19 --- --- Replace
-0.039 0
DIFFERENTIAL
10-28 WB140-2N WB150-2N

B Side Gear H Differential Housing 1# Pinion Bearing Lock Nut

C Ring Gear I Bearing Spacer 1$ Inboard Pinion Bearing
D Driven Gear J Outboard Pinion Bearing 1% Pinion Gear
E Adjustment Lock Nut 1) Lip Seal Ring 1^ Dowel Pin
F Axle Shaft 1! Input Flange 1& Oil Drain Plug
G Dowel Pin 1@ Lip Seal Ring Cover
Unit : mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1* Axle Clearance --- ---
1( Ring and Pinion Gear Backlash 0.17 to 0.23 0.23
Adjust
2) Pinion Preload * 92 to 137 N•m
2! Ring and Pinion Gear Preload * 95.9 to 142.9 N•m
* - Without lip seal ring.
WB140-2N WB150-2N 10-29

12
PLANETARY
B Planetary Carrier J Belleville Washer 1& Lip Ring Seal

C Planetary Gear 1) Upper King Pin Bushing 1* Tapered Roller Bearing
D Ring Gear 1! Lip Ring Seal 1( Retaining Ring
E Carrier Gear 1@ Axle Housing 2) Bolt Bushing
F Wheel Hub 1# Spherical Bearing 2! Stud Bolt
G Lip Ring Seal 1$ Lower King Pin Bushing 2@ Oil Drain Plug
H Upper King Pin 1% Lower King Pin 2# Sun Gear
I Adjustment Shim 1^ Belleville Washer 2$ Retaining Ring
Check Item Criteria Remedy

2% Hub Rotation Torque ---
Adjust
2^ Axle Shaft Clearance ---
10-30 WB140-2N WB150-2N

12
2WD
COMPLETE ASSEMBLY
B Steering Cylinder E Tie Rod Nut h Mounting Pin Bushing

C Oil Refill Plug F Adjustment Screw a Left Cylinder Port
D Oil Drain Plug G Lock Nut b Right Cylinder Port
Unit : mm
Criteria
Size Shaft Bushing Clearance Limit
0 +0.04
i Pin and Bushing Clearance 50 50 50.19 --- --- Replace
-0.039 0
WB140-2N WB150-2N 10-31

12
CENTER HOUSING
B Flange Plug c Flange Housing d Axle Housing
10-32 WB140-2N WB150-2N

12
STEERING KNUCKLE
B Housing Cover J Belleville Washer 1& Housing Plug

C Shaft Plug 1) Upper King Pin Bushing 1* Tapered Roller Bearing
D Screw 1! Housing Plug 1( Oil Drain Plug
E Bearing Retainer 1@ Axle Housing 2) Bolt Bushing
F Wheel Hub 1# Spherical Bearing 2! Stud Bolt
G Lip Ring Seal 1$ Lower King Pin Bushing
H Upper King Pin 1% Lower King Pin
I Adjustment Shim 1^ Belleville Washer

2@ Hub Rotation Torque --- Adjust
WB140-2N WB150-2N 10-33

MAINTENANCE STANDARD REAR AXLE
12
REAR AXLE
COMPLETE ASSEMBLY
B Input Flange F Planetary Portion J Oil Drain Plug

C Differential Portion G Parking Brake Levers 1) Axle Housing Breather
D Brake Portion H Brake Bleeder Screws a Brake Port ................. 40.8 kg/cm²
E Axle Housing I Oil Fill And Level Plugs b Diff Lock Port ......... 1295.4 kg/cm²
10-34 WB140-2N WB150-2N

12
DIFFERENTIAL
B Tapered Roller Bearing G Bearing Lock Nut 1! Lip Oil Seal

C Side Gear H Axle Shaft 1@ Input Flange
D Rotating Gear I Dowel Pin 1# Bearing Spacer
E Ring Gear J Tapered Roller Bearing 1$ Pinion Gear
F Differential Housing 1) Bearing Lock Nut 1% Differential Housing
Unit : mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1^ Axle Clearance --- ---
1& Ring And Pinion Gear Backlash 0.17 to 0.23 0.23
Adjust
1* Pinion Gear Preload * 92 to 138 N•m
1( Pinion Ring Gear Preload * 95.23 to 141.84 N•m
* - Without lip seal ring.
WB140-2N WB150-2N 10-35

12
PLANETARY
B Planetary Gear Carrier H Lip Ring Seal 1# Outer Ring Gear

C Wheel Stud I Shaft Coupler 1$ Oil Fill And Drain Plug
D Wheel Hub J Inner Axle Shaft 1% Bolt Bushing
E Planet Gear 1) Sun Gear Shaft 1^ Planet Gear Shaft
F Gear Carrier 1! Shaft Bushing
G Tapered Roller Bearings 1@ Retaining Ring

1& Hub Rotation Torque ---
Adjust
1* Axle Shaft Clearance ---
10-36 WB140-2N WB150-2N

12
BRAKES
B Disc Plate Bushing f Parking Brake Control Cam j Inner Disc Separator Plate
C Parking Brake Control Rod g Brake Disc Plate 1) Outer Disc Separator Plate
D Brake Bleeder Valve h Actuator Piston
E Parking Brake Lever i Brake Disc Plate Return Spring
Unit : mm
Spring Criteria
Standard Size Repair Limit
Check Item Remedy
Free Installed Installed Free Installed
Length Length Load Length Load
1! Brake Disc Return Spring 27 13 127 N•m 21 10 N•m
1@ Disc Return Spring 35 19 369 N•m 21 10 N•m Replace
1# Disc Thickness 4.85 to 5 3.3
WB140-2N WB150-2N 10-37

12
DIFFERENTIAL LOCK
B Engagement Sleeve e Fork Spacer h Piston Cover

C Locking Pin f Shift Fork i Retaining Ring
D Control Rod g Piston a Diff Lock Port ......... 1295.4 kg/cm²
10-38 WB140-2N WB150-2N

MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
b Delivery Variation Valve a P Port From Hydraulic Tank Suction Line

c Valve Working Mode Solenoid b Case Drain To Suction Line
d Delivery Control Valve c LS Pressure From Loader Control Valve
d Output To Loader Control Valve
WB140-2N WB150-2N 10-39

12
b Delivery Variation Valve a P Port From Hydraulic Tank Suction Line

c Valve Working Mode Solenoid b Case Drain To Suction Line
d Delivery Control Valve c LS Pressure From Loader Control Valve
d Output To Loader Control Valve
10-40 WB140-2N WB150-2N

12
b Lip Seal Ring H Positioning Piston

c Tapered Roller Bearing I Swash Plate Positioning Spring
d Centering Spring J Cylinder Block
e Tapered Roller Bearing 1) Swash Plate Positioning Piston
f Drive Shaft 1! Pump Piston
g Swash Plate 1@ Guide Shoe
WB140-2N WB150-2N 10-41

12
Unit : mm
1# Bearing Preload 0 to 0.05 Adjust
Standard Tolerance Standard Clearance

Remedy
Size Shaft Hole Clearance Limit
1$ Piston To Cylinder Backlash 20 --- 0.065
1% Piston To Shoe Backlash 0.15
1^ Drive Shaft Diameter 34.91

Free Installed Installed Free Installed Remedy
1& Swash Plate Positioning Spring --- 88.7 276 ±12 N Replace
10-42 WB140-2N WB150-2N

12
POWER GOVERNOR f Pressure Cut Off Spring j Internal Spring 1# Throttles

b Spring g Pressure Cut Off Screw 1) External Spring 1$ Throttles
c Piston Rod h Initial Adjust Screw LS VALVE 1% Spool
d Bushing PC VALVE 1! External Spring
e Initial Adjust Spring i Spool 1@ Internal Spring
Unit : mm
Spring Criteria
Check Item Remedy
Install Installed Installed
Free Length Free Length
Length Load Load
1^ Piston Rod Return Spring --- --- --- --- ---
1& Internal Power Reg Spring 125.4 ±10 N
1* External Power Reg Spring 180.2 ±12 N Replace
1( External LS/PC Spring 40.2 ±3 N
2) Internal LS/PC Spring 81.7 ±14 N
WB140-2N WB150-2N 10-43

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
The cylinder block g is supported and connected to the shaft b by the spline a and the shaft is supported by the front and rear
tapered roller bearings.
The tip of the piston g is ball shaped. The shoe e is caulked to it to form one unit in such a way that the piston f and the shoe
together form a spherical bearing.
The swash plate d has a flat surface A and the shoe e remains pressed against this surface while sliding in a circular move-
ment. The swash plate brings highly pressurized oil onto the cylindrical surface B fashioned in the pump body c, which means
that the swash plate slides on a hydrostatically supported bearing.
The pistons f perform their relative movements in an axial direction, inside cylindrical chambers fashioned in the cylinder
block g.
The oil is brought up to pressure in the chambers of the cylinder block g by the rotatory movement of the block itself. The
areas of pressure and suction are determined by the swash plate f. 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 h.
10-44 WB140-2N WB150-2N

12
OPERATION
PUMP OPERATION
1. The cylinder block g rotates together with the shaft b and the shoe
e slides on the flat surface A. The swash plate d moves along the
cylindrical surface B. The angle α formed between the center line
of the shaft and the center line X of the swash plate changes, thus
modifying the axial position of the pistons in relation to the cylin-
der block. Angle α is known as the swash plate angle.
2. When the center line X of the swash plate d maintains the angle α
in relation to the center line of the shaft b, and hence also of the
cylinder block g, the flat surface A acts as a cam for the shoe e.
As the piston f rotates and slides inside the cylinder block, it cre-
ates a difference between the volumes C and D which provokes
intake and discharge of the oil in quantities equal to the difference
between the volumes (D - C = delivery). As the cylinder block
rotates, chamber D loses volume while the volume of chamber C is
increased, thus provoking an intake of oil. The figure indicates the
state of the pump when the intake of chamber D and the delivery of
chamber C have been completed.
3. When the center line X of the swash plate d and the center line of
the cylinder block g are perfectly aligned (the swash plate angle α
= 0), the difference between the volumes C and D within the cylin-
der block becomes 0 and the pump does not take in or deliver any
oil. In practice the swash plate angle α never becomes = 0. Pump
delivery is directly proportional to the swash plate angle α.
CONTROL OF DELIVERY
1. As the swash plate angle α grows larger, the difference between

volumes C and D increases, and the delivery Q also increases. The
swash plate angle is modified by servo pistons I and J.
2. The servo piston I moves in a reciprocating linear motion caused

by pressure signals from the PC and LS valves. The linear move-
ment is transmitted to the swash plate D, which is supported by the
cylindrical surface of the cradle C. The swash plate therefore has a
semi-circular reciprocating movement.
3. The surfaces of the servo pistons receiving the pressures PP and LS are dissimilar. The delivery pressure PP of the main
pump is always passed into the smaller (upper) pressure chamber, whereas the pressure PEN coming from the LS valve is
passed into the larger (lower) pressure chamber.
The movement of the servo piston is governed by the relationship between pressures PP and PEN, as well by the propor-
tions between the surfaces (larger and smaller) of the servo piston.
WB140-2N WB150-2N 10-45

12
PC VALVE, LS VALVE, SERVO PISTON
POWER GOVERNOR LS VALVE PC VALVE

b Spring D Servo Piston E Piston G Servo Piston
c Servo Piston F Spring H Spring
LS VALVE FUNCTION
● The LS valve controls the pump delivery according to the stroke of the control valve level, i.e., in function of the delivery
demands made by the actuators. The LS valve detects the actuators delivery needs by means of the differential pressure PLS
existing between the pump delivery pressure PP and the pressure PLS coming from the control valve. This reading permits con-
trol of the main pump delivery Q. PP, PLS and PLS 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 PLS 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. Pump delivery is propor-
tional to the demands made known by the control valve.
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12
OPERATION
1. When the control valve is in a NEUTRAL position.
● The pressure PLS of the LS coming from the control valve outlet passes into chamber a of the spring of the LS valve. The pres-
sure PP of the pump passes into chamber b of the opposite side.
● The piston rod movement e is determined by the combination of the force generated by the pressure PLS, the force of the
spring g and the force generated on the side opposite the piston rod by the pressure PP.
● Before the engine is started the servo piston d is pushed to the right by the spring b, corresponding to the maximum angle
of the swash plate.
● If all the control valve spools are in their NEUTRAL position when the engine is started, the pressure PLS of the LS will
remain at 4.1 to 8.16 kg/cm² because no oil is flowing through the control valve. At the same time the pump pressure PP
increases and is maintained at a value of about 27.54 kg/cm².
● For this reason the piston e is thrust to the right ( ) and a passage is formed between the delivery lines c and d. This
opening enables the pump pressure PP to enter chamber X of the servo piston d.
● Although the pump pressure PP is always passed into chamber Y of the servo piston c, since the force exerted by that
pressure on piston d exceeds the force exerted on piston, the servo piston b moves to the right ( ), i.e. towards the side
of the minimum angle of the swash plate.
WB140-2N WB150-2N 10-47

12
2. When a control valve lever is activated
● When the control valve lever is moved out of its NEUTRAL position, the opening f is determined, allowing an LS signal to be
generated.
● Until the PLS generates a force less than the force exerted by the spring g on the spool e, the system will remain stable.
● When the opening f is such as to provoke a reduction in PLS, the spool moves to the left ( ) to form a passage between deliv-
ery lines d and e. The chamber X loses pressure and the servo piston causes the swash plate to move towards maximum displace-
ment.
● Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force
exerted by the spring g, and the passage between delivery lines c and d is reopened.
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12
3. When the control valve opening is at its maximum, lever at the end of its stroke.
● When the control lever is moved to full stroke, the spool opening reaches its maximum, the difference between the pump pres-
sure PP and the LS pressure PLS becomes smaller, differential pressure PLS.
● The LS pressure PLS introduced into the chamber a of the LS valve becomes about the same as the pump pressure PP and
the piston e is moved to the left ( ) by the combined forces generated by the pressure PLS and the spring g. The piston
movement closes the delivery line c and forms a passage between lines d and e.
● The pressurized oil present in the chamber X of the servo cylinder D flows through the lines d and e and reaches the pump
drainage chamber, so that the pressure in chamber X of the servo cylinder B becomes equal to the drainage pressure.
● The servo piston D is thus moved to the right ( ) by swash plate movement due to the pressure PP in the chamber Y of the
servo cylinder C. It is drawn in the direction of the increase in angle of the swash plate.
WB140-2N WB150-2N 10-49

12
4. When the spool makes very small movements, fine control.
● When the control valve lever moves in very small increments towards the NEUTRAL position, when the control valve open-
ing f diminishes, the differential pressure PLS between the pump pressure PP and the LS pressure PLS increases.
● If the differential pressure PLS generates on the spool e a difference in force that exceeds the force exerted by the spring g,
the spool moves to the right ( ) and a passage is formed between the delivery lines c and d. The pressure PP is introduced into
the chamber X and the swash plate moves towards its minimum angle.
● When the control valve lever performs small movements towards the position of maximum opening, when the opening f
of the control valve increases, the differential pressure PLS diminishes.
● If the differential pressure PLS generates on the spool e a force difference that does not exceed the force exerted by the
spring g, the spool moves to the left ( ) and a passage is formed between the delivery lines d and e. The chamber X loses
pressure and the servo piston provokes a movement of the swash plate towards maximum displacement.
● Equilibrium is reestablished in the system when the pressure PLS generates on the spool e the difference in force
exerted by the spring g, and hence the passage between delivery lines c and d is also reopened.
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12
5. When pump flow matches the demands of the control valve
● A1 will be the surface of the servo piston d, A2 the surface of the servo piston (2), PEN the pressure acting on the piston b and
PP the pressure acting on the piston side c.
● When pump delivery reaches the quantity demanded by the control valve, the pump pressure PP in chamber b of the LS
valve is in equilibrium with the combined forces of the LS pressure PLS in chamber a, and the force exerted by the spring
g. Once equilibrium has been reached the piston e stops in the central position.
● In this condition the passage from chamber c to chamber d remains only slightly open in order to maintain pressure in
chamber d. A flow of oil is introduced into the servo cylinder d at a pressure that balances the force generated by the
pump pressure PP in the cylinder c. PEN x A1 = PP x A2.
● The stability of the equilibrium is guaranteed by a flow stabilized by the throttle g.
● The force of the spring g is regulated so that the piston e is in equilibrium when PP - PLS = PLS = 18.36 kg/cm². The
pump flow is made proportional to the section of the opening of the control valve, which maintains the differential pres-
sure. PLS = 18.36 kg/cm².
WB140-2N WB150-2N 10-51

12
PC VALVE FUNCTION
● The PC valve performs an approximate power check, and ensures
that the hydraulic horse power absorbed by the pump does not exceed
the horse power delivered by the endothermal engine.
● This is achieved by limiting the pump delivery Q in function of the
delivery pressure PP, 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.
● During operation the delivery Q increases and the delivery pressure
PP also increases simultaneously, the PC valve reduces the pump
delivery Q. When the delivery pressure PP decreases, the PC valve
increases the pump flow.
● The relationships between the pump delivery pressure PP and the
delivery Q are shown in the diagram.
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12
Operation
1. When the load on the actuators is heavy, high pump delivery pressure
● When a higher delivery is required, the LS valve receives a signal from the control valve to bring the pump up to maximum
displacement. When the swash plate moves it also moves the bushing c joined to it by the pin b, which releases the spring d.
● As the pressure of the actuators increases, pressure also increases in the delivery line c. When the calibrated setting of the
spring d is reached, the piston rod e is thrust to the left ( ) and the passage between chamber b and the pump drainage
chamber a is opened.
● The opening of the passage between the chambers b and a generates a flow of oil and hence, due to the calibrated hole g,
a P is generated between chambers f and g at the sides opposite the spool f. P = PP - PPC
● When the value of PP exceeds the value of the spring loading h the spool f moves to the right ( ) opening the passage
between the delivery lines d and e and sending the pump pressure PP towards the servo cylinder i. The pressure PP intro-
duced into chamber X of the cylinder pushes it towards the minimum angle of the swash plate ( ).
WB140-2N WB150-2N 10-53

12
2. When equilibrium has been reached
● When the piston i is pushed to the left ( ) the bushing c is also moved. The oil flow between the chambers b and a is
reduced and the PPC pressure tends to approach the PP pressure value. The P decreases and the spool f is pushed to the left
( ) by the force of the spring h.
● Equilibrium is reached when the force generated by the PP pressure, the force generated by the PPC pressure, and the
force of the spring h are all balanced. The force generated by PP = the force generated by the PPC + the spring force.
● In this condition the passage from chamber d to chamber e remains only slightly open in order to maintain pressure in
chamber e. A flow of oil is introduced into the cylinder i at a pressure that balances the force generated by the pump
pressure PP acting on the cylinder j. PEN x A1 = PP x A2
● The stability of this equilibrium is generated by a continuous stabilized flow from the throttle 1).
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12
3. When the load on the actuators decreases, pump delivery pressure drops
● When the load on the actuators diminishes and the pump delivery pressure PP drops, the PPC. pressure also drops.
● The reduction in the PPC causes the spool e to move and the passage between chambers b, d and a is closed. The PPC
pressure and the PP pressure of the pump are equalized due to the interruption of the oil flow through the calibrated hole
g and the P becomes zero P = PP - PPC = 0.
● The spring h pushes the spool f to the left ( ) closing the passage between the chambers d and e and opening the pas-
sage between chambers e and g.
● The pressurized oil present in chamber X of the servo cylinder i passes through chambers e and g and reaches the pump
drainage chamber, so that the pressure in chamber X of the servo cylinder becomes equal to the drainage pressure. The
servo piston j is caused to move by the PP pressure in chamber Y of the servo cylinder, in the direction of the increase in
the angle of the swash plate.
WB140-2N WB150-2N 10-55

12
4. The function of the spring
● The loading on the springs d and 1! of the PC valve changes in pro-

portion to the angle of inclination of the pump swash plate. The com-
pression of the spring varies with the movements of the servo piston i.
When the piston moves to the left ( ), the spring is compressed. If
the piston moves even further to the left ( ), the spring 1! comes
into action to increase the loading. The overall loading of the
springs is varied by the piston, which either compresses or releases
them.
● The pump absorption torque curve, which indicates the relationship
between the pump delivery pressure PP and the delivery Q, is a
broken line. The position in which the piston i stops, the pump
absorption torque, is determined by the position in which the PPC
pressure applied to the spool e is balanced by the force exerted by
the springs d and 1!.
● As pump delivery pressure PP increases, delivery Q decreases, and
as pressure PP diminishes, pump delivery Q increases.
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12
WORKING MODE SOLENOID VALVE
Function
● Calibration of the pump absorption torque is normally performed

for the working mode E. When the solenoid valve of the working mode
is commutated the absorbed power of the pump is increased, as indi-
cated by the working mode curve.
Operation
WORKING MODE E
● During normal operation, working mode E, the PC valve intervenes when a P1 is generated equal to the loading on the
spring e.
● The P1 is generated by the calibrated hole d in the spool of the PC valve c when, at a determined pump delivery pressure P1,
the valve b puts the delivery line a into discharge, thus generating a flow F1 in the delivery line a.
WB140-2N WB150-2N 10-57

12
WORKING MODE P
● When the solenoid valve g is commutated, working Mode P, the pressurized oil coming from the pump changes its route and
passes through the throttle f, which has a larger diameter than the calibrated hole d.
● Because the throttle f has a larger diameter, the P2 generated is less than is needed to overcome the force generated by
the spring e. The spool of the PC valve c is therefore pushed to the left ( ) by the force of the spring. This shift obliges
the pump to increase displacement and hence the delivery.
● The increase in flow causes an increment of the P2 which, when the loading value of the spring is reached, allows the
spool to shift to the right ( ).
● The pump starts to work in normal fashion once again, and all the valves recommence normal functioning.
10-58 WB140-2N WB150-2N

MAINTENANCE STANDARD STEERING UNIT
12
STEERING UNIT
a. Port LS From the loader control valve

b. Port T To the hydraulic oil tank
c. Port L To the steering cylinder
d. Port D To the steering cylinder
e. Port P From the loader control valve
TECHNICAL DATA
Steering unit type .................................................LAGCSDS160P
Displacement ............................................................... 160 cc/rev.
OPERATION
● The steering unit consists of a control valve and a rotating oil dis-
penser, 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 volume of oil supplied 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.
WB140-2N WB150-2N 10-59

MAINTENANCE STANDARD LOADER VALVE
12
LOADER VALVE
2 SPOOL
a Port D - To the Hydraulic Steering Unit b Loader Relief Valve

b Port A2 - To the Bucket Cylinders c Plug
c Port A1 - To the Boom Cylinders d Ball
d Port LS - To the Pump e Check Valve Spring
e Port T - To the Hydraulic Oil Tank f Priority Valve Piston Rod
f Port P - From the Pump g Priority Valve Spring
g Port B1 - To the Boom Cylinders
h Port B2 - To the Bucket Cylinders
j Port DLS - To the Hydraulic Steering Unit
Unit : mm
Spring Criteria
Check Item Remedy
h Check Valve Spring
i Priority Valve Spring
10-60 WB140-2N WB150-2N

12
b Port Plug G Detent Lock Ball 1! Holding Coil

c Boom Raise Spool H Compensator 1@ Check Valve Spring
d Spool Return Spring I Anti Cavitation Valve 1# Check Valve
e Spool Locking Spring J Bucket Dump Spool
f Detent Ball 1) Spool Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
1$ Spool Return Spring
1% Spool Locking Spring
1^ Spool Return Spring
1& Check Valve Spring
WB140-2N WB150-2N 10-61

12
3 SPOOL VALVE
a Port D - To the Hydraulic Steering Unit k Port B3 - To the Auxiliary Cylinders

b Port A3 - To the Auxiliary Cylinders m Port DLS - To the Hydraulic Steering Unit
c Port A2 - To the Bucket Cylinders b Loader Relief Valve
d Port A1 - To the Boom Cylinders c Plug
e Port LS - To the Pump d Ball
f Port T - To the Hydraulic Oil Tank e Check Valve Spring
g Port P - From the Pump f Priority Valve Piston Rod
h Port B1 - To the Boom Cylinders g Priority Valve Spring
j Port B2 - To the Bucket Cylinders
Unit : mm
Spring Criteria
Check Item Remedy
h Check Valve Spring
i Priority Valve Spring
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12
b Port Plug G Detent Lock Ball 1! Holding Coil

c Boom Raise Spool H Compensator 1@ Check Valve Spring
d Spool Return Spring I Anti Cavitation Valve 1# Check Valve
e Spool Locking Spring J Bucket Dump Spool 1$ Auxiliary Spool
f Detent Ball 1) Spool Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
1% Spool Locking Spring
1^ Spool Return Spring
1& Check Valve Spring
1* Spool Return Spring
WB140-2N WB150-2N 10-63

MAINTENANCE STANDARD BACKHOE CONTROL VALVE
12
BACKHOE CONTROL VALVE
MECHANICAL CONTROL
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12
A Inlet Section J Outlet Section B1 Arm Cylinder Rod
B Arm Cylinder Section A1 Arm Cylinder Barrel B2 Right Swing Cylinder Rod
C Swing Cylinder Section A2 Right Swing Cylinder Barrel B3 Right Outrigger Cylinder Rod
D Right Outrigger Cylinder Section A3 Right Outrigger Cylinder Barrel B4 Left Outrigger Cylinder Rod
E Left Outrigger Cylinder Section A4 Left Outrigger Cylinder Barrel B5 Bucket Cylinder Rod
F Bucket Cylinder Section A5 Bucket Cylinder Barrel B6 Boom Cylinder Rod
G Boom Cylinder Section A6 Boom Cylinder Barrel B7 Telescopic Arm Cylinder Rod
H Telescopic Arm Cylinder Section A7 Telescopic Arm Cylinder Barrel B8 Hammer Inlet Port
I Hammer Cylinder Section A8 Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve C Retainer Plug E Unloading Valve

b Return Spring D Pressure Cut Out Valve
Unit : mm
Spring Criteria
Check Item Remedy
f Return Spring Replace
WB140-2N WB150-2N 10-65

12
ARM SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool g Check Valve Return Spring
b LIFD - Load Independent Flow Divider e Spool Return Spring
C Port Plug f Check Valve
Unit : mm
Spring Criteria
Check Item Remedy
h Spool Return Spring
Replace
i Check Valve Return Spring
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12
SWING SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool g Check Valve Return Spring
C Adjustable Circuit Relief Valve f Check Valve
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-67

12
LEFT OUTRIGGER SECTION VIEW E-E
a Port Plug D Left Outrigger Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
10-68 WB140-2N WB150-2N

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RIGHT OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-69

12
BUCKET SECTION VIEW G-G
a Circuit Relief Valve D Bucket Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
10-70 WB140-2N WB150-2N

12
BOOM SECTION VIEW H-H
a Adjustable Circuit Relief Valve D Boom Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball
WB140-2N WB150-2N 10-71

12
TELESCOPIC ARM SECTION VIEW K-K
a Port Plug D Telescopic Arm Cylinder Spool g Check Valve Return Spring
C Anti Cavitation Valve f Check Valve
Unit : mm
Spring Criteria
Check Item Remedy
Replace
10-72 WB140-2N WB150-2N

12
HAMMER SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-73

12
EXCAVATOR CONTROL
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12
A Inlet Section J Outlet Section B1 Arm Cylinder Rod
B Arm Cylinder Section A1 Arm Cylinder Barrel B2 Right Swing Cylinder Rod
C Swing Cylinder Section A2 Right Swing Cylinder Barrel B3 Right Outrigger Cylinder Rod
D Right Outrigger Cylinder Section A3 Right Outrigger Cylinder Barrel B4 Left Outrigger Cylinder Rod
E Left Outrigger Cylinder Section A4 Left Outrigger Cylinder Barrel B5 Bucket Cylinder Rod
F Bucket Cylinder Section A5 Bucket Cylinder Barrel B6 Boom Cylinder Rod
G Boom Cylinder Section A6 Boom Cylinder Barrel B7 Telescopic Arm Cylinder Rod
H Telescopic Arm Cylinder Section A7 Telescopic Arm Cylinder Barrel B8 Hammer Inlet Port
I Hammer Cylinder Section A8 Hammer Port Plugged
INLET SECTION VIEWS A-A AND B-B
a Unloading Valve C Retainer Plug E Unloading Valve

b Return Spring D Pressure Cut Out Valve
Unit : mm
Spring Criteria
Check Item Remedy
f Return Spring Replace
WB140-2N WB150-2N 10-75

12
ARM SECTION VIEW C-C
a Adjustable Circuit Relief Valve D Arm Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
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12
SWING SECTION VIEW D-D
a Adjustable Circuit Relief Valve D Swing Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-77

12
LEFT OUTRIGGER SECTION Ù VIEW E-E
a Port Plug D Left Outrigger Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
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12
RIGHT OUTRIGGER SECTION VIEW F-F
a Port Plug D Right Outrigger Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-79

12
BUCKET SECTION VIEW G-G
a Adjustable Circuit Relief Valve D Bucket Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
10-80 WB140-2N WB150-2N

12
BOOM SECTION VIEW H-H
a Adjustable Circuit Relief Valve D Boom Cylinder Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
OUTLET SECTION VIEW J-J
a Check Ball
WB140-2N WB150-2N 10-81

12
TELESCOPIC ARM SECTION VIEW K-K
a Port Plug D Telescopic Arm Cylinder Spool g Check Valve Return Spring
C Anti Cavitation Valve f Check Valve
Unit : mm
Spring Criteria
Check Item Remedy
Replace
10-82 WB140-2N WB150-2N

12
HAMMER SECTION VIEW L-L
a Adjustable Circuit Relief Valve D Hammer Spool g Check Valve Return Spring
Unit : mm
Spring Criteria
Check Item Remedy
Replace
WB140-2N WB150-2N 10-83

MAINTENANCE STANDARD CLSS
12
CLSS
CHARACTERISTICS
The term CLSS means Closed Center Load Sensing System, which has
the following characteristics:
● High precision control that is independent of the load applied to the
movement;
● High precision control of digging action even during delicate
manoeuvres.
● Ability to perform complex operations, guaranteed by control of oil
flow in function of the aperture surfaces of the shuttles.
● Energy savings guaranteed by control of pump delivery.
STRUCTURE
● The CLSS system includes the variable flow pump, the control
valve and the working equipment.
● The pump includes the main pump, the PC valve and the LS valve.
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OPERATING PRINCIPLES
1. Control of the angle of the pumping plate.
● The angle of the swash plate and the pump delivery, is controlled in such a way that the differential pressure PLS
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. PLS = pump delivery pressure PP minus pressure PLS of delivery to the actuator.
● If the differential pressure PLS becomes lower than the set pressure of the LS valve, the angle of the swash plate
increases, delivery increasing.
● If the differential pressure PLS increases, the angle of the swash plate decreases.
WB140-2N WB150-2N 10-85

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2. 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 P between the delivery
at the control valve inlet and outlets of the control valve are compensated by these valves. This will obtain the distri-
bution of the pump flow in proportion to the areas of passage S1 and S2 of each valve.
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UNLOADING VALVE
FUNCTION
1. When the control valve is in the NEUTRAL position, the flow of the pump, due to the swash plate being in the minimum
angle position, is sent to the control valve. In these conditions, the pump delivery pressure PP is regulated to 27.5 kg/cm²
by the spring a inside the valve. PP = PLS + spring load with PLS = 6.1 kg/cm²
OPERATION
When the control valve is in the NEUTRAL position
● On the two surfaces of the shuttle b, the pump pressure PP acts on the right side, while the LS signal with pressure PLS
acts on the left side.
● Because a LS signal is generated with a pressure PLS 6.1 ± 2 kg/cm², when the control valve is in the NEUTRAL position,
the pump delivery pressure PP is regulated by the combination of the pressure provided by the spring and by the LS pres-
sure PLS.
● While the pump delivery pressure PP increases until it compensates for the loading on the spring a and for the LS pres-
sure 27.5 kg/cm², the shuttle b moves to the left ( ) and the PP circuit is put into communication with the tank circuit T.
● This system ensures that the pump delivery pressure PP stays regulated at 27.5 kg/cm².
WB140-2N WB150-2N 10-87

12
1. If, during the precision regulations of the control valve, the request for oil flow to the actuators in equal or less than the
delivery values given by the minimum angle of the swash plate, the pump delivery pressure PP is regulated by the pres-
sure PLS + 21.5 kg/cm². Because the unloading valve opens when the differential pressure between the pump delivery
pressure PP and the PLS LS pressure becomes equivalent to the loading of the spring a (21.5 kg/cm²), the differential LS
pressure PLS LS becomes 21.5 kg/cm².
Final control of control valve

● When final control are performed with the control valve, a pressure PLS is generated that pressurizes the spring chamber,
acts on the left extremity of the valve b. The actuator pressure is introduced into the LS circuit and then into the spring
chamber. As a result, the pump pressure PP tends to increase.
● When the differential pressure between the pump delivery pressure PP and the LS pressure PLS has the same value as the
loading on the spring a (21.5 kg/cm²), the shuttle b moves to the left ( ) and the pump circuit PP puts itself into commu-
nication with the tank circuit T. The exceeding pump delivery, relative to the actuator request, is sent to the tank circuit.
● The pump delivery pressure PP is regulated by the combination of the pressure provided by the spring (21.5 kg/cm²) and
by the LS pressure PLS, i.e. when the pressure differential PLS reaches the value of 21.5 kg/cm².
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2. 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 all the pump delivery is sent to the actuators.
When the control valve is in use

● When the control valve shuttle is operated to execute a bigger stroke, the opening section of spool becomes bigger and
consequently the controlled delivery. Because the control valve passage is large, the difference between the LS pressure
PLS and the pump delivery pressure PP is reduced to 18.4 kg/cm², LS pump valve setting.
● Because the differential pressure between the pump delivery pressure PP and the LS pressure PLS is not equal to the
pressure given by the spring loading a (21.5 kg/cm²), the shuttle b is pushed to the right ( ) of 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 is sent to the actuators.
WB140-2N WB150-2N 10-89

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INTRODUCTION OF THE LS PRESSURE
● The LS pressure is the pressure generated by external forces acting on the actuators at the outlet of the control valve.
OPERATION
● When the spool b is activated, pump pressure PP starts to flow into the actuator circuit A through chamber b.
● At the same time the compensator c moves upwards ( ) so that the flow controlled by spool b can flow towards the actu-
ator A. Check valve a do not allow any flow up to when pressure in chamber c is higher than pressure in chamber b. Pres-
sure downstream of the spool flows in the PLS circuit downstream the compensator valve through the orifice d.
● The PLS circuit of the LS is thus in communication with the tank circuit T by means of the LS decompression valve d.
● The system stabilizes when a pressure difference of 18.4 kg/cm² is generated across the spool b between pump pressure
PP and PLS pressure.
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DELIVERY COMPENSATION
INTRODUCTION
The flow sent to each actuator is controlled by the opening area of each spool. While performing complex control, in tradi-
tional control valves the difference between actuators pressure might cause sudden and unexpected movements acceleration in
those actuators operated at lower pressure. The adoption of the pressure compensation valve allow to control those situation
guarantying the proportionality between each actuator. Compensation of actuator deliveries occurs when, during the simulta-
neous activation of two or more movements, the pressure of one actuator drops lower than that of the other, and pump delivery,
if not controlled, tends to be supplied the actuator operating at lower. In the diagram the actuator on the left is requesting
higher pressure.
OPERATION
1. When activating an actuator at a pressure lower than the one already working. While operating actuator A starts operating
actuator B.
● Until the pressure PBV downstream from the shuttle b reaches the same value requested by actuator B, no oil passes.
When the pressure requested by actuator B is exceeded, movement can commence. This creates a flow that adding to the
one controlled by spool d reduces the pressure upstream of spool b and d and therefore the P between PLS and PP.
● The pump compares the delivery pressures PP and PLS and senses that the difference P<18.4 kg/cm². This variation in
P causes an increase in oil flow increasing the swash plate angle. Until the pump realizes a P of 18.4 kg/cm², i.e. until the
increase in oil flow compensates the requirements of the two actuators, the pump will continue to increase delivery.
● P of 18.4 kg/cm², will stabilize as soon as it is restored to. The compensator C is moved upwards by the oil flow and stops
when the aperture between the chambers a and b reduces the passage sufficiently to reduce the pressure in chamber b to
be sent to the actuator.
WB140-2N WB150-2N 10-91

12
2. When a low pressure actuator needs to work at a higher pressure than the other
● If the actuator B needs to work at a higher pressure, PB>PA, the pressure PB will start to increase.
● Since pressure PB is increasing, the compensator c moves upwards to restore the P between the chambers a and b, and
therefore the P does not vary upstream or downstream from the shuttle b.
● When pressure PB exceeds pressure PA the compensator c is fully open and the pressure PB is introduced into the LS
circuit.
● The increased pressure in the LS circuit obliges the pump to increase delivery until the P is restored to 18.4 kg/cm².
● Simultaneously the increase in pressure upstream from the shuttle d generates an increase in P upstream and downstream
from the shuttle. (PAV<PLS<PP)
● Because the pressure PLS which is equal to the pressure PB acts on the upper side of the compensator a, and since the
pressure PAV is lower, the compensator is pushed downwards.
● The compensator stops when the aperture between the chambers c and d generates a reduction of the passage sufficient to
reduce the pressure to be sent to the actuator, and to increase the pressure PAV until the P is restored to the 18.4 kg/cm²
necessary for equilibrium.
10-92 WB140-2N WB150-2N

12
3. When an increase in delivery is required by an actuator
● When an increased delivery is required by actuator A, i.e. when the shuttle d is asked to execute a bigger movement, the
section of the aperture increases.
● The increase in aperture provokes a drop in P between the two sides of the shuttles b and d, because the flow, which has
remained unchanged until now, is divided between both the actuators.
● At the same time the pump senses the variation in P and increases the oil flow until the P is restored to P of 18.4 kg/cm²
between the two sides of the shuttle d and the compensator a changes position in order to restore the P upstream and
downstream from the shuttle d.
WB140-2N WB150-2N 10-93

12
LIFD CONTROL SYSTEM
FUNCTION
● The Load Independence Flow Divider, LIFD, intervenes automatically when the oil flow requested by the actuators
exceeds the maximum delivery guaranteed by the pump. In this case, the oil flow is divided between the various actuators
in proportion to their requirements.
OPERATION
● When, during the simultaneous operation of more than one actuator, one of them needs a higher pressure and the charac-
teristics of the pump are exceeded, the pump guarantees a delivery limited by its calibration curve. At this point less oil
than requested is distributed to all the actuators.
● Because the sections of the apertures remain unchanged, the pressure upstream and downstream from the shuttles drops.
Since the position of the compensator e is determined by the pressure of the LS signal, by the pressure PBV downstream
from the shuttle d and by the flow of oil needed for the movement, the compensator is pushed downwards by the higher
pressure in the upper chamber until the pressure PBV downstream from the shuttle becomes equal to the pressure PAV
downstream from the shuttle b. This equalizes the pressure P of the shuttle.
● Thus the flow of each actuator is reduced by a percentage equal to the reduction or absence of pump delivery. When the
request for performance is excessive, the system can nevertheless guarantee proportionality and gradually for the move-
ments in any load conditions.
● If an increase in delivery is requested, rather than an increase in pressure, and the characteristics of the pump are
exceeded, the system will function in the same way as described for the above case.
10-94 WB140-2N WB150-2N

12
LS DECOMPRESSION VALVE
DESCRIPTION
The LS decompression valve is a throttle that continuously releases a
small quantity of oil from the LS circuit and that, when the shuttles are
brought back to a neutral position, releases the residual LS pressure.
This continued flow renders the PLS pressure increment more gentle
and gradual, and increases stability and control during the phases of
reducing the LS pressure.
OPERATION
● When the LS pressure reaches chamber a of the valve, it generates
a force that opposes the force of the spring a.
● Until the force generated by the LS pressure exceeds the force of
the spring a (LS pressure low) the shuttle b remains at rest and oil
flows through the calibrated orifice b in the tank circuit.
● When the force generated by the LS pressure exceeds the force of
the spring a, the shuttle is pushed upwards ( ) and the passages c
are closed. Oil continues to flow into the chamber d until the force
generated by the pressure contained in chamber d, together with the
force of the spring, exceeds the force generated by the LS pressure.
● The shuttle is pushed downwards ( ) and passage c is opened. The
system is in equilibrium, i.e. the shuttle is at rest, when the quantity
of oil allowed to flow into the tank circuit is equivalent to the quan-
tity that generates a pressure difference P such that PLS x S =
[PLS1 x S + F] where: PLS = LS pressure
PLS1 = LS pressure contained in chamber d
S = Section of the shuttle
F = Force of the spring
WB140-2N WB150-2N 10-95

12
PRESSURE CUT OFF VALVE
DESCRIPTION
The function of the pressure cut off valve is to regulate the maximum
pressure of the LS signal and hence also the pressure of the pump.
OPERATION
● The pressurized oil of the LS reaches the chamber a of the valve.
● When the force generated by the LS pressure on the valve b
exceeds the force of the spring a, the valve is pushed upwards ( )
opening the passage between the chamber a and the tank circuit.
10-96 WB140-2N WB150-2N

12
PRIORITY VALVE
FUNCTION
The function of the priority valve is to distribute oil to the steering unit and to the other hydraulic components. Distribution is
determined by the position of the valve of the priority valve in function of the LS signal, oil delivery from the pump, the pres-
sure of the steering unit and the pressure of the hydraulic circuit. The position of the valve is such as to guarantee that delivery
to the steering unit will always correspond to the actual need.
WB140-2N WB150-2N 10-97

MAINTENANCE STANDARD PPC JOYSTICK
12
PPC JOYSTICK
LEFT VALVE
a Port 1 To Backhoe Arm Control Valve - Crowd In .................................... Port PA1

b Port T To Hydraulic Tank
c Port 4 To Backhoe Swing Control Valve - Right ....................................... Port PB2
d Port 3 To Backhoe Arm Control Valve - Crowd Out.................................. Port PB1
e Port P To Solenoid Valve Group - ST2 ..................................................... Port S1
f Port 2 To Backhoe Swing Control Valve - Left.......................................... Port PA2
10-98 WB140-2N WB150-2N

MAINTENANCE STANDARD PPC JOYSTICK
12
RIGHT VALVE
a Port 1 To Backhoe Boom Control Valve - Lower ...................................... Port PA6

b Port T To Hydraulic Tank
c Port 4 To Backhoe Bucket Control Valve - Dump..................................... Port PA5
d Port 3 To Backhoe Boom Control Valve - Raise....................................... Port PB6
e Port P To Solenoid Valve Group - ST2 ..................................................... Port S1
f Port 2 To Backhoe Bucket Control Valve - Curl........................................ Port PB5
WB140-2N WB150-2N 10-99

MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
DIFFERENTIAL LOCK - BACKHOE BOOM LOCK
A EV4 Backhoe Boom Lock

B EV3 Differential Lock
a Port T To the Transmission
b Port 1 Boom Lock Cylinder
c Port 2 To the Rear Axle
d Port P From the Transmission
10-100 WB140-2N WB150-2N

12
PPC SUPPLY VALVE - ST2
A Y14 PPC Valve a ACC Accumulator

B Y23 Right Outrigger Lower b P To Backhoe Control Valve Port M
c Y16 Right Outrigger Raise c S1 To PPC Valve Port P
d Y24 Left Outrigger Raise d A1 To Backhoe Right Outrigger Valve Port PA4
e Y15 Left Outrigger Lower e A2 To Backhoe Left Outrigger Valve Port PA3
f B2 To Backhoe Left Outrigger Valve Port PB3
g B1 To Backhoe Right Outrigger Valve Port PB4
h T To Hydraulic Tank
WB140-2N WB150-2N 10-101

12
PPC TELESCOPIC ARM
A Y22 Telescopic Arm Retract a A To Backhoe Control Valve Port PA7

B Y21 Telescopic Arm Extend b B To Backhoe Control Valve Port PB7
c P To PPC Supply Valve ST2 Port S1
d T To Hydraulic Tank
10-102 WB140-2N WB150-2N

12
PPC HAMMER
A Y20 Hammer a A To Backhoe Control Valve Port PA8

b P To PPC Supply Valve ST2 Port S1
T To Hydraulic Tank and Backhoe Control
c
Valve Port PB8
WB140-2N WB150-2N 10-103

12
PPC ARM AND HAMMER
A Hammer a T To Hyd. Tank and Control Valve Port PB7

B Y22 Telescopic Arm Retract b B To PPC Supply Valve ST2 Port S1
c Y21 Telescopic Arm Extend c A1 To Backhoe Control Valve Port PB7
d B1 To Backhoe Control Valve Port PA7
e A To Backhoe Control Valve Port PA8
10-104 WB140-2N WB150-2N

MAINTENANCE STANDARD LOADER CYLINDERS
12
LOADER CYLINDERS
BOOM ARM
A Piston Rod Bushing D Piston Retaining Nut G Cylinder Rod

B Barrel Bushing E Four Piece Piston Seal H Cylinder Head
C Cylinder Barrel F Cylinder Piston
Unit : mm
Criteria
49.975 50.15 0.175
i Piston Rod to Head 50 Replace
49.950 50.25 0.300
44.950 45.08 0.13
j Piston Rod Bushing and Pin 45
44.911 45.24 0.33 Replace pin
49.950 50.08 0.13 and bushing
1) Barrel Bushing and Pin 50
49.911 50.24 0.33
CHARACTERISTICS
Unit : mm
Piston Rod Diameter 50
Max Cylinder Length 1880
Cylinder Barrel Bore 85
Min Cylinder Length 1150
Piston Stroke 730
Rod Thread for Piston Nut 55
WB140-2N WB150-2N 10-105

12
BUCKET

Unit : mm
Standard Tolerance Standard Clearance
Piston Rod to Head 50 49.975 50.15 0.175 Replace
i 49.950 50.25 0.300
Piston Rod Bushing and Pin 45 44.950 45.08 0.13 Replace pin
j 44.911 45.24 0.33 and bushing
Barrel Bushing and Pin 50 49.950 50.08 0.13
1) 49.911 50.24 0.33
CHARACTERISTICS
Unit: mm
Piston Stroke 755
10-106 WB140-2N WB150-2N

12
MP BUCKET
A Piston Rod Bushing D Cylinder Piston G Cylinder Barrel

B Cylinder Rod E Four Piece Piston Seal
C Cylinder Head F Piston Retaining Pin
CHARACTERISTICS
Unit : mm
Piston Stroke 230
WB140-2N WB150-2N 10-107

MAINTENANCE STANDARD BACKHOE CYLINDERS
12
BACKHOE CYLINDERS
BOOM
A Piston Rod Bushing E Four Piece Piston Seal i Set Screw

B Barrel Bushing F Cylinder Piston j Stop Pin
C Cylinder Barrel G Cylinder Rod 1) Check Valve
D Stop Ball H Cylinder Head 1! Check Valve Spring
Unit : mm
Criteria
59.970 60.030 0.060
1@ Piston Rod to Head 60 Replace
59.924 60.076 0.152
49.950 50.08 0.13
1# Piston Rod Bushing and Pin 50
49.911 50.24 0.33 Replace pin
49.950 50.08 0.13 and bushing
1$ Barrel Bushing and Pin 50
49.911 50.24 0.33
Spring Criteria
Check Item Remedy
1% Check Valve Spring 35 Replace
CHARACTERISTICS
Unit: mm
Piston Stroke 850
Rod Thread for Piston 41
10-108 WB140-2N WB150-2N

12
ARM

C Cylinder Barrel F Cylinder Piston i Piston Spacer
Unit : mm
Criteria
44.950 45.08 0.13
44.911 45.24 0.33 Replace pin
49.950 50.08 0.13 and bushing
49.911 50.24 0.33
59.970 60.030 0.060
1! Piston Rod to Head 60 Replace
59.924 60.076 0.152
CHARACTERISTICS
Unit: mm
Piston Stroke 920
WB140-2N WB150-2N 10-109

12
BUCKET

Unit : mm
Criteria Remedy
Check Item Standard Tolerance Standard Clearance
59.970 60.030 0.060 Replace
i Piston Rod to Head 60
59.924 60.076 0.152
44.950 45.08 0.13 Replace pin
44.911 45.24 0.33 and bushing
49.950 50.08 0.13
49.911 50.24 0.33
CHARACTERISTICS
Unit: mm
Piston Stroke 765
10-110 WB140-2N WB150-2N

12
TELESCOPIC ARM CYLINDER
A Piston Rod Bushing D Wear Rings G Cylinder Rod

B Barrel Bushing E Piston Seal H Cylinder Head
Unit : mm
Criteria
39.975 40.025 0.050
39.936 40.064 0.128
39.950 40.08 0.13
39.911 40.24 0.33 Replace pin
39.950 40.08 0.13 and bushing
39.911 40.24 0.33
CHARACTERISTICS
Unit: mm
Piston Stroke 1140
WB140-2N WB150-2N 10-111

12
SWING
A Piston Rod Bushing D Cushion Valve G Retaining Screw

B Cylinder Rod E Piston Seal H Cylinder Head
Unit : mm
Criteria
49.970 50.025 0.055
49.924 50.064 0.140
49.950 49.881 - 0.069 Replace pin
49.911 49.950 - 0.039 and bushing
45.050 44.975 - 0.075
1) Inner Bushing and Cylinder 45
45.034 45.000 - 0.034
54.950 55.000 0.050
1! Inner Bushing and Outer Bushing 55 Replace
54.911 55.046 0.135
65.060 65.000 - 0.060
1@ Outer Bushing and Frame 65
65.041 65.046 - 0.005
CHARACTERISTICS
Unit: mm
Min Cylinder Length 446.5
Piston Stroke 231.5
10-112 WB140-2N WB150-2N

12
OUTRIGGER
A Piston Rod Bushing D Retarder Pin G Cylinder Rod

B Barrel Bushing E Piston Seal H Cylinder Head
Unit : mm
Criteria
54.97 55.030 0.060
54.94 55.076 0.136
44.950 45.08 0.13
44.911 45.24 0.33 Replace pin
44.950 45.08 0.13 and bushing
44.911 45.24 0.33
CHARACTERISTICS
Unit: mm
Piston Stroke 515
WB140-2N WB150-2N 10-113

12
BOOM LOCK CYLINDER
A Cylinder Rod c Piston and Seal d Cylinder Barrel

B Cylinder Head and Seal
10-114 WB140-2N WB150-2N

MAINTENANCE STANDARD FRONT WORK EQUIPMENT
12
FRONT WORK EQUIPMENT
WB140-2N WB150-2N 10-115

MAINTENANCE STANDARD FRONT WORK EQUIPMENT
12
Unit : mm
Criteria
44.950 45.08 0.130
a Bucket/Arm Bushing and Pin 45
44.911 45.24 0.329
44.950 45.08 0.130
b Lever/Arm Bushing and Pin 45
44.911 45.24 0.329
44.950 45.080 0.130
c Lever/Cylinder Bushing and Pin 45 Replace
44.911 45.119 0.208
44.950 45.080 0.130
d Cylinder/Arm Bushing and Pin 45
44.911 45.119 0.208
49.962 50.08 0.118
e Arm/Frame Bushing and Pin 50
49.917 50.24 0.323
10-116 WB140-2N WB150-2N

MAINTENANCE STANDARD REAR WORK EQUIPMENT
12
REAR WORK EQUIPMENT
Unit : mm
Criteria
64.940 65.190 0.25
a Top Swing Pin and Bushing 65
64.894 65.264 0.37
64.940 65.190 0.25
b Bottom Swing Pin and Bushing 65
64.894 65.264 0.37
39.950 40.08 0.130
c Bucket/Arm Pin and Bushing 40
39.911 40.24 0.329
39.950 40.08 0.130
d Bucket/Link Pin and Bushing 40
39.911 40.24 0.329
44.950 45.08 0.130
e Link/Arm Pin and Bushing 45
44.911 45.24 0.329
Replace
44.950 45.08 0.130
f Link/Cylinder Pin and Bushing 45
44.911 45.24 0.329
49.950 50.000 0.050
g Boom/Arm Pin and Bushing 50
49.911 50.062 0.151
49.950 50.000 0.050
h Swing/Boom Pin and Bushing 50
49.911 50.062 0.151
44.950 45.08 0.130
i Outrigger/Frame Pin and Bushing 45
44.911 45.24 0.329
44.950 45.2 0.250
j Outrigger/Pad Pin and Bushing 45
44.911 45.3 0.389
WB140-2N WB150-2N 10-117

MAINTENANCE STANDARD REAR WORK EQUIPMENT
12
10-118 WB140-2N WB150-2N

MAINTENANCE STANDARD AIR CONDITIONING
12
AIR CONDITIONING
A Magnetic Clutch E Safety Pressure Switch I Cab Air Circulation Fan

B Compressor F Expansion Valve J Air Conveyor
C Condenser G Evaporator
D Dryer Filter Tank H Clutch Control Sensor
WB140-2N WB150-2N 10-119

MAINTENANCE STANDARD AIR CONDITIONING
The compressor b is driven directly by the engine shaft by means of a

12
belt, and made to rotate by a pulley fitted with an electromagnetically
engaged clutch a. A thermostatic sensor h controls the engagement
and disengagement of the clutch. It disengages the clutch when the
evaporator reaches the lower temperature limit and engages when the
evaporator reaches the upper temperature limit.
The coolant fluid, in gaseous phase is drawn into the compressor where
it is subjected to compression and an intense heating process. In these
conditions the fluid is then sent into the condenser c where, due to the
heat extracted by ambient temperature air flowing over fins, it reaches
condensation temperature, and passes into a high pressure liquid state.
Subsequently the coolant passes into the dryer filter group d which per-
forms three functions: it filters out impurities, absorbs any moisture
present in the circuit and, finally, also functions as a reserve tank. The
coolant in its liquid state is then transferred to the evaporator G, first
passing through an expansion valve F. The task of this valve is the con-
stant metering of the quantity of fluid in order to maintain optimum
evaporation. In the evaporator the coolant fluid is subjected to expan-
sion, bringing it up to the critical evaporation point at a temperature of
approximately -8°C.
The air flow generated by the centrifugal fan I which passes through
the evaporator G at ambient temperature is considerably warmer than -
8°C. For this reason it yields heat to the coolant fluid, bringing it up to
boiling point and complete evaporation. On leaving the evaporator G
the coolant is drawn once more into the compressor d and a new cycle
commences. The yielding of heat from the atmosphere in which the
evaporator is positioned leads to the condensation of the water sus-
pended 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 evapora-
tor. The task of keeping the temperature of the evaporator above 0°C,
and thus within the optimum limits for heat exchange, is entrusted to a
thermostatic sensor H.
The condensate that forms on the evaporator fins G also contains dust,
pollens and particles suspended in the air. Continual condensation there-
fore effectively purifies the air, and the droplets of condensate are dis-
charged to the exterior. A fixed quantity of anti freeze oil is also
introduced into the circuit, with the function of lubricating all the
mechanical parts of the unit. A percentage of this oil circulates con-
stantly throughout the unit in nebulized form, lubricating the compres-
sor, pistons and bearings and the expansion valve. A pressure switch 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 electromag-
netic clutch and hence the functioning of the air conditioning unit.
10-120 WB140-2N WB150-2N

20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLES FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4

STANDARD VALUE TABLES FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
ADJUSTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
ADJUSTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
TENSION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
COMPRESSOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
CHECKING TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
ACCELERATOR PEDAL AND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
ACCELERATOR LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
BRAKE PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
TIER I ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
MASTER CYLINDER ROD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
MICROSWITCHES ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
CHECKING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
TIER II ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
MASTER CYLINDER ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
CHECKING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
HYDRAULIC OIL TANK PRESSURIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
WB140-2N WB150-2N 20-1

TESTING AND ADJUSTING TABLE OF CONTENTS
WORK CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47

BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
CHECK BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
LOADER CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
BACKHOE CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
EXCAVATOR CONTROLS STYLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
MAIN RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
LOADER CONTROL VALVE (2 OR 3 SPOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS) . . . . . . . . . . . . . . . . . . . . . . 20-55
SETTING RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
LOADER CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
BACKHOE CIRCUIT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
TESTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
SETTING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
UNLOADING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
LOAD SENSING (LS) VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CLEANING PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
CIRCUIT AND BRAKE PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
BRAKING GROUP LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
ENGINE SPEED UNDER LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
TORQUE CONVERTER STALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
TORQUE CONVERTER AND HYDRAULIC STALL . . . . . . . . . . . . . . . . . . . . . . . . . 20-69
POWER TRAIN GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
PREPARING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70
CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
ADDITIONAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71
DIRECTIONAL CLUTCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
PREPARATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
RETURN TO DIG DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73
HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
20-2 WB140-2N WB150-2N

TESTING AND ADJUSTING TABLE OF CONTENTS
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-75
BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
OUTRIGGER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-78
AIR CONDITIONING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
TESTING THE WORKING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
CHECKING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
EMPTYING THE AC UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-87
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-92
WARNING! When working with others, use agreed upon signals and do not let unauthorized
persons near the machine.
WARNING! Before checking coolant level, wait until it has cooled. If the radiator cap is
removed when the coolant is hot, the coolant will spurt our and cause burns. Be
careful when working close to moving parts, fan, fan belt, etc. Entanglement with
moving parts can cause serious injury.
WARNING! Before testing, adjusting or troubleshooting, make sure the machine is parked on
firm, level ground. Check that all machine safety devices are applied and that
blocks are in place to prevent the machine from moving.
WB140-2N WB150-2N 20-3

TESTING AND ADJUSTING STANDARD VALUE TABLES FOR ENGINE
12
STANDARD VALUE TABLES FOR ENGINE
Machine Model WB140-2N WB140-2N
Engine S4D106-1FH - TIER I S4D106-2XFH - TIER II
Standard Permissible Standard Permissible
Check Item Test Conditions Unit
Value Value Value Value
High Idle 2375 ± 50 2325 to 2425 2375 ± 50 2325 to 2425
Engine Speed Low Idle RPM 1050 ± 50 1000 to 1100 1050 ± 50 1000 to 1100
Set Idle 2200 ••• 2200 •••
Exhaust Gas Sudden Acceleration Bosch 0.9 1.5 4.0 4.0
Color @ High Idle Speed Index 0.5 1.0 3.5 3.5
Valve Clear- Intake Valve @ 20°C 0.30 ± 0.05 Max 0.35 0.25 ± 0.1 Max 0.35
mm
ance Exhaust Valve @ 20°C 0.30 ± 0.05 Max 0.35 0.25 ± 0.1 Max 0.35
Oil Temperature @ 69 to
kg/cm² 34.9 ± 1 27.5 ± 1 34.9 ± 1 27.5 ± 1
Compression 72°C
Pressure @ Engine Speed Using
RPM 250 250 250 250
Starter Motor
Coolant Temperature
Blow By
within Operating Range @ mm ••• •••
Pressure
High Idle Speed
Oil @ Set Idle 4.48 3.97 to 4.99 4.48 3.97 to 4.99
kg/cm²
Pressure @ Low Idle 1.02 Min 1.02 1.02 Min 1.02
Oil
Entire Speed Range °C 120 Max 120 120 Max 120
Temperature
Fuel Injection
Before Top Dead Center Degrees 12.5 11.5 to 13.5 12.5 11.5 to 13.5
Timing
Fan Belt Deflection when pressed
mm 10 10 to 15 10 10 to 15
Tension with finger force of 10 kg
20-4 WB140-2N WB150-2N

TESTING AND ADJUSTING STANDARD VALUE TABLES FOR ENGINE
12
Engine S4D106-1FA - TIER I S4D106-2SFA - TIER II
Check Item Test Conditions Unit
Value Value Value Value
High Idle 2375 ± 50 2325 to 2425 2375 ± 50 2325 to 2425
Engine Speed Low Idle RPM 1050 ± 50 1000 to 1100 1050 ± 50 1000 to 1100
Set Idle 2200 ••• 2050 ± 100 •••
Exhaust Gas Sudden Acceleration Bosch 0.9 1.5 4.0 4.0
Color @ High Idle Speed Index 0.5 1.0 3.5 3.5
Valve Clear- Intake Valve @ 20°C 0.30 ± 0.05 Max 0.35 0.25 ± 0.1 Max 0.35
mm
ance Exhaust Valve @ 20°C 0.30 ± 0.05 Max 0.35 0.25 ± 0.1 Max 0.35
Oil Temperature @ 69 to
kg/cm² 34.9 ± 1 27.5 ± 1 34.9 ± 1 27.5 ± 1
Compression 72°C
Pressure @ Engine Speed Using
RPM 250 250 250 250
Starter Motor
Coolant Temperature
Blow By
within Operating Range @ mm ••• •••
Pressure
High Idle Speed
Oil @ Set Idle 4.48 3.97 to 4.99 4.48 3.97 to 4.99
kg/cm²
Pressure @ Low Idle 1.02 Min 1.02 1.02 Min 1.02
Oil
Entire Speed Range °C 120 Max 120 120 Max 120
Temperature
Fuel Injection
Before Top Dead Center Degrees 12.5 11.5 to 13.5 12.5 11.5 to 13.5
Timing
Fan Belt Deflection when pressed
mm 10 10 to 15 10 10 to 15
Tension with finger force of 10 kg
WB140-2N WB150-2N 20-5

TESTING AND ADJUSTING STANDARD VALUE TABLES FOR CHASSIS
12
STANDARD VALUE TABLES FOR CHASSIS
Standard Permissible
Component Test Conditions Unit Value Value
Value Value
BHC PPC BHC PPC
2350 2375 2300 to 2350 to
Max
Accelerator Hydraulic oil tempera- ±50 ±50 2400 2425
pedal ture: 50°C 1050 1050 1000 to 1000 to
Min
Engine
Speed
Converter oil tempera- ±50 ±50 1100 1100

RPM
ture: 80°C 1900 1900 1850 to 1850 to
Max
Accelerator Engine oil temp cooling ±50 ±50 1950 1950
fuel circuit: in the limits 1050 1050 1000 to 1000 to
Min
±50 ±50 1100 1100
All Controls a b c a b c a b c a b c
Control Valve
less loader
8 8 8 8 8 8 8 8
arm
mm
Loader Arm 8 8 8 8 8 8 8 8
BHC PPC BHC PPC

Raise 60 to 90 to
Loader Arm Neutral 85 60 to 110 75 100
Lower 90 100
Loader Dump 70 to 90 to
Neutral 115 90 to 140 85 100
Boom Curl 100 100
Backhoe Raise 90 to
Neutral 100 80 to 120 100 55 49 to 60
Boom Lower 110
Backhoe Extend 90 to
Neutral 100 80 to 120 100 55 49 to 60
Arm Retract 110
Engine
Backhoe Dump 90 to
Travel of Levers and Pedals
stopped Neutral 100 80 to 120 100 55 49 to 60

Bucket Curl 110
At the center
Backhoe of the knob Right 90 to
Neutral 100 80 to 120 100 55 49 to 60
Swing lever Left 110
Backhoe Valve reading Up mm 40 to
at the end of Neutral 50 35 to 65 50 ••• •••
Outriggers Down 60
working 10 to
stroke Out 15 10 to 20 15 ••• •••
Telescopic 20
Attachments Neutral
Arm 20 to
on the In 30 20 to 40 30 ••• •••
40
ground 10 to
Right 15 10 to 20 15 ••• •••
Hammer 20
Neutral
Pedal 20 to
Left 30 20 to 40 30 ••• •••
40
Fuel Con- 55 to
Min Max 70 50 to 90 70 70 55 to 85
trol Lever 85
Accelerator 55 to
Min Max 80 60 to 100 70 70 55 to 85
Pedal 85
Steering Right Left 2.2 to Max 2.2 to
Rev Max 2.5 2.2 to 2.5 Max 2.5
Wheel Left Right 2.5 2.5 2.5
20-6 WB140-2N WB150-2N


Value Value
BHC PPC BHC PPC
2350 2375 2300 to 2350 to
Max
Accelerator Hydraulic oil tempera- ±50 ±50 2400 2425
pedal ture: 50°C 1050 1050 1000 to 1000 to
Min
Engine
Speed
Converter oil tempera- ±50 ±50 1100 1100

RPM
ture: 80°C 1900 1900 1850 to 1850 to
Max
Accelerator Engine oil temp cooling ±50 ±50 1950 1950
fuel circuit: in the limits 1050 1050 1000 to 1000 to
Min
±50 ±50 1100 1100
All Controls a b c a b c a b c a b c
Control Valve
less loader
8 8 8 8 8 8 8 8
arm
mm
Loader Arm 8 8 8 8 8 8 8 8
BHC PPC BHC PPC

Raise 90 to
Loader Arm Neutral 85 60 to 110 75 100 60 to 90
Lower 100
Loader Dump 70 to 90 to
Neutral 115 90 to 140 85 100
Boom Curl 100 100
Backhoe Raise 90 to
Neutral 100 80 to 120 100 55 49 to 60
Boom Lower 110
Backhoe Engine Extend 90 to
Neutral 100 80 to 120 100 55 49 to 60
Travel of Levers and Pedals
Arm stopped Retract 110

Backhoe At the center Dump 90 to
of the knob Neutral 100 80 to 120 100 55 49 to 60
Bucket Curl 110
lever
Backhoe Right mm 90 to
Valve reading Neutral 100 80 to 120 100 55 49 to 60
Swing Left 110
at the end of
Backhoe working Up
Neutral 50 35 to 65 50 ••• 40 to 60 •••
Outriggers stroke Down
Telescopic Attachments Out 15 10 to 20 15 ••• 10 to 20 •••
on the Neutral
Arm In 30 20 to 40 30 ••• 20 to 40 •••
ground
Hammer Right 15 10 to 20 15 ••• 10 to 20 •••
Neutral
Pedal Left 30 20 to 40 30 ••• 20 to 40 •••
Fuel Con-
Min Max 70 50 to 90 70 70 55 to 85 55 to 85
trol Lever
Accelerator
Min Max 80 60 to 100 70 70 55 to 85 55 to 85
Pedal
Steering Right Left Max 2.2 to 2.2 to
Rev Max 2.5 2.2 to 2.5 Max 2.5
Wheel Left Right 2.5 2.5 2.5
WB140-2N WB150-2N 20-7

12
Engine S4D106-1FH S4D106-2XFH
Component Test Conditions Unit Value Value Value Value
BHC PPC BHC PPC
Loader Arm ● Tool connection at knob
2.5 2 to 3 2.5 2.5 1.5 to 3.5 1.5 to 3.5
Lever center and at 90° from
lever.
● Value at the 10 mm be-
Loader fore end of working
Bucket stroke.
2.5 2 to 3 1.7 1.7 1.2 to 2.2 1.2 to 2.2
Lever
● Distance between knob
and casing: 95 mm
Backhoe
1.5 1 to 2 1.6 2.0 1.0 to 2.2 1.8 to 2.2
Boom Lever
Force for lever or pedal operation
Backhoe
1.5 1 to 2 1.6 2.0 1.0 to 2.2 1.8 to 2.2
Arm Lever
Backhoe ● Engine speed:
Bucket min. 1.5 1 to 2 1.6 1.4 1.0 to 2.2 1.3 to 1.5
Lever ● Oil temperature:
kg
Backhoe 45 to 55°C
1.5 1 to 2 1.6 1.4 1.0 to 2.2 1.3 to 1.5
Swing Lever ● Tool connection at
Outrigger knob center and
at 90° from the le- 3 2.5 to 3.5 3.8 ••• 2.3 to 5.3 •••
Lever
ver.
Telescopic In 4 3 to 4 4 ••• 3.0 to 4.0 •••
● Tool connection
Arm Lever on edge, for ped- Out 8 6 to 10 8 ••• 6.0 to 10 •••
Hammer als 8 6 to 10 8 ••• 6.0 to 10 •••
Pedal ● Value at 10 mm
Fuel Control before end of
12 10 to 14 4 4 3 to 5 3 to 5
Lever work stroke.
Accelerator
3 2 to 4 4 4 2.5 to 5.5 2.5 to 5.5
Pedal
Brake
30 Max 60
Pedals
20-8 WB140-2N WB150-2N

Loader Con- 209.1

● Engine speed: min 188.65 188.65 ±7.14 209.1 204 204 ±7.14
trol Valve ±10.2
● Oil temperature: 45 to
Backhoe 55°C
Main
209.1
Control 211.08 211.08 ±7.14 209.1 204 204 ±7.14
● Pump: economy mode. ±10.2
Valve
Engine speed: 1500 ±50 178.5 178.5
Steering Unit 178.45 178.45 ±7.14 178.5 178.5
RPM ±10.2 ±7.14
Loader 239.7 239.7
239.63 239.63 ±7.14 239.7 239.7
Bucket Curl ±10.2 ±7.14
Loader
188.7 178.5
Bucket 178.45 178.45 ±7.14 188.7 188.7
±10.2 ±7.14
Dump
Loader 3rd 239.7 239.7
239.63 239.63 ±7.14 239.7 239.7
kg/cm²
Spool ±10.2 ±7.14
Backhoe 306.0 311.1
Individual Circuits
362 362.00 ±7.14 306.0 311.1

Boom Raise ● Engine speed: min ±10.2 ±7.14
Backhoe ● Oil temperature: 45 to 239.7 239.7
249.83 249.83 ±7.14 239.7 239.7
Boom Lower 55°C ±10.2 ±7.14
Backhoe ● Check one at a time 239.7 239.7
249.83 249.83 ±7.14 239.7 239.7
Arm Retract ● Pump: economy mode. ±10.2 ±7.14
Backhoe 249.9 249.9
193.75 193.75 ±7.14 249.9 249.9
Swing ±10.2 ±7.14
Backhoe 239.7 239.7
249.83 249.83 ±7.14 239.7 239.7
Bucket Curl ±10.2 ±7.14
Hammer 173.4 173.4
173.35 173.35 ±7.14 173.4 173.4
Delivery ±10.2 ±7.14
Steering Unit 244.8 244.8
244.73 244.73 ±7.14 244.8 244.8
Safety ±10.2 ±7.14
● Engine speed (w/o load):
2350 ±50
● Hydraulic oil tempera-
2150 2225
Converter ture: 45 to 55°C 2200 2275
2100 ±50 2050 to 2150 to to
Stall ● Converter oil tempera- ±50 ±50
2250 2325
ture: 80°C
● Machine in 4th gear
● Working brakes applied
Converter

RPM
2350 ±50
ture: 45 to 55°C
Converter/ ● Converter oil tempera- 2225 2200
2050 2250
Hydraulic ture: 80°C 2000 ±50 1950 to 2050 to to
±100 ±50
Stall ● Machine in 4th gear with 2325 2300
brakes applied
● Front bucket curled stop
● Steering at the end of
stroke
WB140-2N WB150-2N 20-9

12
Engine S4D106-1FA S4D106-2SFA
BHC PPC BHC PPC
Loader Arm ● Tool connection at knob
2.5 2 to 3 2.5 2.5 1.5 to 3.5 1.5 to 3.5
Lever center and at 90° from
lever.
● Value at the 10 mm be-
Loader fore end of working
Bucket stroke.
2.5 2 to 3 1.7 1.7 1.2 to 2.2 1.2 to 2.2
Lever
● Distance between knob
and casing: 95 mm
Backhoe
1.5 1 to 2 1.6 2 1.0 to 2.2 1.8 to 2.2
Boom Lever
Force for lever or pedal operation
Backhoe
1.5 1 to 2 1.6 2 1.0 to 2.2 1.8 to 2.2
Arm Lever
Backhoe ● Engine speed:
Bucket min. 1.5 1 to 2 1.6 1.4 1.0 to 2.2 1.3 to 1.5
Lever ● Oil temperature:
kg
Backhoe 45 to 55°C
1.5 1 to 2 1.6 1.4 1.0 to 2.2 1.3 to 1.5
Swing Lever ● Tool connection at
Outrigger knob center and
at 90° from the le- 3 2.5 to 3.5 3.8 ••• 2.3 to 5.3 •••
Lever
ver.
Telescopic In 4 3 to 4 4 ••• 3.0 to 4.0 •••
● Tool connection
Arm Lever on edge, for ped- Out 8 6 to 10 8 ••• 6.0 to 10 •••
Hammer als 8 6 to 10 8 ••• 6.0 to 10 •••
Pedal ● Value at 10 mm
Fuel Control before end of
12 10 to 14 4 4 3 to 5 3 to 5
Lever work stroke.
Accelerator
3 2 to 4 4 4 2.5 to 5.5 2.5 to 5.5
Pedal
Brake
30 Max 60
Pedals
20-10 WB140-2N WB150-2N

Loader Con- 209.1

● Engine speed: min 188.65 188.65 ±7.14 209.1 204 204 ±7.14
trol Valve ±10.2
● Oil temperature: 45 to
Backhoe 55°C
Main
209.1
Control 211.08 211.08 ±7.14 209.1 204 204 ±7.14
● Pump: economy mode. ±10.2
Valve
Engine speed: 1500 ±50 178.5
Steering Unit 178.45 178.45 ±7.14 178.5 178.5 178.5 ±7.14
RPM ±10.2
Loader 239.7
239.63 239.63 ±7.14 239.7 239.7 239.7 ±7.14
Bucket Curl ±10.2
Loader
188.7
Bucket 178.45 178.45 ±7.14 188.7 188.7 178.5 ±7.14
±10.2
Dump
Loader 3rd 239.7
239.63 239.63 ±7.14 239.7 239.7 239.7 ±7.14
kg/cm²
Spool ±10.2
Backhoe 306.0
Individual Circuits
362 362.00 ±7.14 306.0 311.1 311.1 ±7.14

Boom Raise ● Engine speed: min ±10.2
Backhoe ● Oil temperature: 45 to 239.7
249.83 249.83 ±7.14 239.7 239.7 239.7 ±7.14
Boom Lower 55°C ±10.2
Backhoe ● Check one at a time 239.7
249.83 249.83 ±7.14 239.7 239.7 239.7 ±7.14
Arm Retract ● Pump: economy mode. ±10.2
Backhoe 249.9
193.75 193.75 ±7.14 249.9 249.9 249.9 ±7.14
Swing ±10.2
Backhoe 239.7
249.83 249.83 ±7.14 239.7 239.7 239.7 ±7.14
Bucket Curl ±10.2
Hammer 173.4
173.35 173.35 ±7.14 173.4 173.4 173.4 ±7.14
Delivery ±10.2
Steering Unit 244.8
244.73 244.73 ±7.14 244.8 244.8 244.8 ±7.14
Safety ±10.2
2350 ±50
2150 2225
Converter ture: 45 to 55°C 2200 2275
2275 ±50 2225 to 2325 to to
Stall ● Converter oil tempera- ±50 ±50
2250 2325
ture: 80°C
● Machine in 4th gear
● Working brakes applied
Converter

RPM
2350 ±50
ture: 45 to 55°C
Converter/ ● Converter oil tempera- 2225 2200
2050 2250
Hydraulic ture: 80°C 2000 ±50 1950 to 2050 to to
±100 ±50
Stall ● Machine in 4th gear with 2325 2300
brakes applied
● Front bucket curled stop
● Steering at the end of
stroke
WB140-2N WB150-2N 20-11

★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe
12
bucket with the standard arm or telescopic arm closed.
Engine S4D106-1FH S4D106-2XFH
BHC PPC BHC PPC
Measuring position
Complete
Working 250 400 250 250 250 250
Equipment
In this position, check the feedback

of each cylinder and the leakage with
Loader
Boom
a load applied to the tip of the cutting mm 30 45 24 24 24 24
Cylinder
edge.
Ground level
● Bucket: normal load (1500 kg)
● Engine stopped
● Oil temperature: 45 to 55°C
Hydraulic Drift of Working Equipment
Make measurements as soon as the

Bucket engine is stopped.
15 25 10 10 10 10
Cylinder Measure the changes every 5 min.
and the total change after 15 min.
Complete
Measuring position Max Max Max Max
Working 300 450
325 325 300 300
Equipment
Boom Max Max Max Max

35 50
Cylinder 24 24 24 24
Backhoe
In this position, check the extension

of each cylinder and the leakage with mm
a normal load on the bucket.
Arm On level ground. Max Max Max Max
● Bucket: normal load (450 kg) 15 25
● Engine stopped
engine is stopped.
Bucket Measure the changes every 5 min. Max Max Max Max
and the total change after 15 min. 10 15
20-12 WB140-2N WB150-2N

12
Engine S4D106-1FA S4D106-2SFA
BHC PPC BHC PPC
Measuring position
Complete
Working 250 400 250 250 250 250
Equipment
In this position, check the feedback

of each cylinder and the leakage with
Loader
Boom
a load applied to the tip of the cutting mm 30 45 24 24 24 24
Cylinder
edge.
Ground level
● Bucket: normal load (1500 kg)
● Engine stopped

Bucket engine is stopped.
15 25 10 10 10 10
Cylinder Measure the changes every 5 min.
and the total change after 15 min.
Complete
Measuring position Max Max Max Max
Working 300 450
325 325 300 300
Equipment
Boom Max Max Max Max

35 50
Backhoe
In this position, check the extension

of each cylinder and the leakage with mm
a normal load on the bucket.
Arm On level ground. Max Max Max Max
● Bucket: normal load (450 kg) 15 25
● Engine stopped
engine is stopped.
Bucket Measure the changes every 5 min. Max Max Max Max
and the total change after 15 min. 10 15
WB140-2N WB150-2N 20-13

12
★ The data in the table refers to a machine with a max 500 kg loader bucket and a 600 mm, max 160 kg backhoe bucket with
the standard arm or telescopic arm closed.
BHC PPC BHC PPC
Measuring position
Oil temperature: 45 to 55°C

Backhoe balanced on the guides,
Swing Max Max
bucket in transport position. mm 15 25 Max 20 Max 30
Cylinders 20 30
Arm and bucket cylinder in. Put
the bucket link pin one meter from
the ground and swing at the end
of boom stroke in one of two

directions.
Move the machine onto an incline
of 15° and apply the parking
brake.
Backhoe
Stop the machine. After one min.

check the cylinder feedback
opposite the boom every 5 min.
for a total of 15 min.
Measuring position
Max Max
Outriggers mm 20 30 Max 5 Max 5
5 5
Backhoe balanced. Boom and
arm cylinders in, bucket cylinder
out.
Outriggers at max extension.
Engine stopped.
Check the frame lowering for
each side every 5 min. for a total
of 15 min.
20-14 WB140-2N WB150-2N

12
BHC PPC BHC PPC
Measuring position

Backhoe balanced on the guides,
Swing Max Max
bucket in transport position. mm 15 25 Max 20 Max 30
Cylinders 20 30
Arm and bucket cylinder in. Put
the bucket link pin one meter from
the ground and swing at the end
of boom stroke in one of two

directions.
Move the machine onto an incline
of 15° and apply the parking
brake.
Backhoe
Stop the machine. After one min.

check the cylinder feedback
opposite the boom every 5 min.
for a total of 15 min.
Measuring position
Max Max
Outriggers mm 20 30 Max 5 Max 5
5 5
Backhoe balanced. Boom and
arm cylinders in, bucket cylinder
out.
Outriggers at max extension.
Engine stopped.
Check the frame lowering for
each side every 5 min. for a total
of 15 min.
WB140-2N WB150-2N 20-15

12
S4D106-2XFH - TIER
Engine S4D106-1FH - TIER I
II
Value Value
BHC PPC BHC PPC
Max Max
Boom 2 Max 8 2 2
Loader
8 8
Max Max
Bucket 1.6 Max 6 1.6 1.6
6 6
Max Max
Boom Engine: Max. speed 3.3 Max 13.5 3.3 3.3
13.5 13.5
Cylinder Leakage

Leak check: check the low pressure Max Max
Arm 3 Max 12 3 3
cm³/mm
side of the cylinder. 12 12
Check one cylinder at a time. Max Max
Bucket 2.4 Max 9.5 2.4 2.4
Backhoe
For loader bucket and arm or backhoe 9.5 9.5

swing, check the two cylinders sepa-
rately. Max Max
Swing 3.2 Max 13 3.2 3.2
13 13
Max Max
Outrigger 3.3 Max 13.5 3.3 3.3
13.5 13.5
Telescopic Max Max
1.6 Max 6 1.6 1.6
Arm 6 6
Measuring position
2.9 3.1
Right 3.5 3.1 to 3.9 3.6 3.5 to to
Work Equipment Speed
4.3 3.9
Boom
swing
Backhoe
Right End
Travel Sec
to
Left End Engine speed 1700 to 1750 RPM
Travel Oil temperature: 45 to 55°C
2.9 3.1
Arm horizontal
Left 3.5 3.1 to 3.9 3.6 3.5 to to
Power mode
4.3 3.9
The time referenced is for the
cylinder stroke without the
brake phase
20-16 WB140-2N WB150-2N

12
Standard Permissible Value Value
Component Test Conditions Unit
Value Value
BHC PPC BHC PPC
Max Max
Boom 2 Max 8 2 2
Loader
8 8
Max Max
Bucket 1.6 Max 6 1.6 1.6
6 6
Max Max
Boom Engine: Max. speed 3.3 Max 13.5 3.3 3.3
13.5 13.5
Cylinder Leakage

Leak check: check the low pressure Max Max
Arm 3 Max 12 3 3
cm³/mm
side of the cylinder. 12 12
Check one cylinder at a time. Max Max
Bucket 2.4 Max 9.5 2.4 2.4
Backhoe
For loader bucket and arm or backhoe 9.5 9.5

swing, check the two cylinders sepa-
rately. Max Max
Swing 3.2 Max 13 3.2 3.2
13 13
Max Max
Outrigger 3.3 Max 13.5 3.3 3.3
13.5 13.5
Telescopic Max Max
1.6 Max 6 1.6 1.6
Arm 6 6
Measuring position
2.9 to 3.1 to
Right 3.5 3.1 to 3.9 3.6 3.5
4.3 3.9
Boom
swing
Backhoe
Right End
Travel Sec
to
Left End Engine speed 1700 to 1750 RPM
Travel Oil temperature: 45 to 55°C
Arm horizontal 2.9 to 3.1 to
Left 3.5 3.1 to 3.9 3.6 3.5
Power mode 4.3 3.9
The time referenced is for the
cylinder stroke without the
brake phase
WB140-2N WB150-2N 20-17

12
BHC PPC BHC PPC
Measuring position 3.2
Low- 3.2 to
3.6 3.1 to 4.1 3.5 3.5 to
ered 3.8
Arm 3.8
Cylinders
Out
↕ 2.3
To level 2.3 to
Raised 2.5 2.1 to 2.9 2.6 2.6 to
ground 2.9
● Engine speed: Max 2.9
Loader
● Speed up
1.6 to
Curl 2.5 2.1 to 2.9 2.5 1.9 to
2.2
Bucket 2.9
Cylinders
Out
↕ 2.8
2.6 to
Cylinders Dump 3.2 2.7 to 3.7 3.2 2.8 to
3.1
In ● Engine speed: Max 3.6
● Speed up Sec
Raise 2.3 to
2.3 1.9 to 2.7 2.6 2.6 to
★ 2.9
2.9
Boom ● Engine speed 1700 to 1750

Cylinder in
RPM
↕
Backhoe
The engine speed, 1700 to 1750

Bucket
rpm, is to be checked using the 1.8
teeth on 1.6 to
procedure described in ENGINE Lower 1.6 1.2 to 2.0 2.2 1.9 to
level 2.2
SPEED in this section of the 2.6
ground
manual.
● Backhoe balanced
● Power mode
★ The time referenced is for
the cylinder stroke without
the brake phase
20-18 WB140-2N WB150-2N

12
Stan-
Permissible Standard Permissible
dard
BHC PPC BHC PPC

Measuring position Low- 3.2 to 3.2 to
3.6 3.1 to 4.1 3.5 3.5
ered 3.8 3.8
Arm
Cylinders
Out
↕ 2.3 to 2.3 to
To level Raised 2.5 2.1 to 2.9 2.6 2.6
2.9 2.9
ground ● Engine speed: Max
Loader
● Speed up
Measuring position 2.1 to 1.6 to
Curl 2.5 2.1 to 2.9 2.5 1.9
2.9 2.2
Bucket
Cylinders
Out
↕ 2.8 to 2.6 to
Cylinders Dump 3.2 2.7 to 3.7 3.2 2.8

3.6 3.1
In ● Engine speed: Max
● Speed up Sec
Measuring position Raise 2.3 to 2.3 to
2.3 1.9 to 2.7 2.6 2.6
★ 2.9 2.9
Boom
● Engine speed 1700 to 1750
Cylinder in
RPM
↕
Backhoe
The engine speed, 1700 to 1750

Bucket
rpm, is to be checked using the 1.8 to 1.6 to
teeth on
procedure described in ENGINE Lower 1.6 1.2 to 2.0 2.2 1.9
2.6 2.2
level
SPEED in this section of the
ground
manual.
● Power mode
the cylinder stroke without
the brake phase
WB140-2N WB150-2N 20-19

12
Value Value
BHC PPC BHC PPC
Measuring position
3.0
3.2 to
Open 3.4 2.9 to 3.9 3.4 3.6 to
4.0
3.8
Arm ● Engine speed 1700 to 1750

Cylinder In RPM
↕ The engine speed, 1700 to 1750
Cylinder rpm, is to be checked using the
Out procedure described in ENGINE
manual. 4.0
Close 4.1 to
● Oil temperature: 45 to 55°C 4.3 3.8 to 4.8 4.4 4.5 to
★ 4.9
● Backhoe balanced 4.8

● Power mode
Backhoe
the cylinder stroke without Sec

the brake phase
Measuring position
1.8
2.4 to
Dump 2.1 1.7 to 2.5 2.2 2.6 to
2.8
2.6
Bucket
Cylinder In ● Engine speed 1700 to 1750
↕ RPM
Cylinder The engine speed, 1700 to 1750
Out rpm, is to be checked using the
procedure described in ENGINE
2.6
SPEED in this section of the 2.6 to
Curl 2.9 2.5 to 3.3 3.0 3.1 to
manual. 3.4
3.4
● Power mode
20-20 WB140-2N WB150-2N

12
Stan- Standard Permissible
Permissible Value Value
Component Test Conditions Unit dard
Value
Value BHC PPC BHC PPC
Measuring position
3.0 to 3.2 to
Open 3.4 2.9 to 3.9 3.4 3.6
3.8 4.0
Arm ● Engine speed 1700 to 1750

Cylinder In RPM
↕ The engine speed, 1700 to 1750
Cylinder rpm, is to be checked using the
Out procedure described in ENGINE
manual. Close 4.0 to 4.1 to
● Oil temperature: 45 to 55°C 4.3 3.8 to 4.8 4.4 4.5
★ 4.8 4.9
● Power mode
Backhoe
the cylinder stroke without Sec

the brake phase
Measuring position
1.8 to 2.4 to
Dump 2.1 1.7 to 2.5 2.2 2.6
2.6 2.8
Bucket
Cylinder In ● Engine speed 1700 to 1750
↕ RPM
Cylinder The engine speed, 1700 to 1750
Out rpm, is to be checked using the
procedure described in ENGINE
SPEED in this section of the 2.6 to 2.6 to
Curl 2.9 2.5 to 3.3 3.0 3.1
manual. 3.4 3.4
● Power mode
WB140-2N WB150-2N 20-21

12
BHC PPC BHC PPC
Measuring position
Loader
Lift Arm 0 Max 2 0 0 Max 2 Max 2
● Engine speed: Min.

Check the time needed to lift the
bucket from level ground.
Measuring position
Max Max
Boom 0 Max 2 Max 2 Max 2
● Engine speed: Min. 2 2
Time Lag

With attachments fully extended, Sec
lower the boom and check the
elapsed time from the beginning
of the machine lifting until the
bucket is on level ground.
Backhoe
Measuring position
Max Max
Arm 0 Max 2 Max 2 Max 2
Put the boom at 45° and open the
arm completely with the bucket
curled. Extend the arm cylinder
and check the elapsed time
between arm stop at dead center
and restart movement.
20-22 WB140-2N WB150-2N

12
BHC PPC BHC PPC
Measuring position
Loader
Lift Arm 0 Max 2 0 0 Max 2 Max 2

Check the time needed to lift the
bucket from level ground.
Measuring position
Max Max
Boom 0 Max 2 Max 2 Max 2
Time Lag

With attachments fully extended, Sec
lower the boom and check the
elapsed time from the beginning
of the machine lifting until the
bucket is on level ground.
Backhoe
Measuring position
Max Max
Arm 0 Max 2 Max 2 Max 2
Put the boom at 45° and open the
arm completely with the bucket
curled. Extend the arm cylinder
and check the elapsed time
between arm stop at dead center
and restart movement.
WB140-2N WB150-2N 20-23

12
Standard Permissible Value Value
Component Test Conditions Unit
Value Value
BHC PPC BHC PPC
Measuring position
Bucket ● Engine speed: Min. 0 Max 2 Max 2 Max 2 Max 2 Max 2

Put arm in horizontal position. Tilt
back the bucket cylinder and then
extend it.
Check the elapsed time between
bucket stop at dead center and
the restart movement.

Measuring position
Time Lag
Backhoe
Sec
Outriggers 0 Max 2 Max 2 Max 2 Max 2 Max 2

Boom, arm, and bucket fully
retracted and placed in machine
centre position.
Check the time needed for outrig-
gers to raise the machine from
when they lean on level ground.
Check each outrigger separately.
20-24 WB140-2N WB150-2N

TESTING AND ADJUSTING SPECIAL TOOLS
12
Value Value
BHC PPC BHC PPC
Measuring position
Bucket ● Engine speed: Min. 0 Max 2 Max 2 Max 2 Max 2 Max 2

Put arm in horizontal position. Tilt
back the bucket cylinder and then
extend it.
Check the elapsed time between
bucket stop at dead center and
the restart movement.

Measuring position
Time Lag
Backhoe
Sec
Outriggers 0 Max 2 Max 2 Max 2 Max 2 Max 2

Boom, arm, and bucket fully
retracted and placed in machine
centre position.
Check the time needed for outrig-
gers to raise the machine from
when they lean on level ground.
Check each outrigger separately.
SPECIAL TOOLS
Measurement Point Symbol Code Name Qty Note

Available
Valve clearance A Feeler gauge 1 –
Locally
1 Compression gauge 1 Kit Yanmar
Compression gauge B ATR800208
2 Adapter 1 TOL-97190080
Available
Engine speed C Multi scale tachometer 1 20 to 4000 rpm
Locally
Available
Oil and coolant temp D 1 Digital thermometer 1 -50 to 1200°C
Locally
WB140-2N WB150-2N 20-25

TESTING AND ADJUSTING SPECIAL TOOLS
Available
1 Pressure gauge 2 Full scale 61 kg/cm²
Locally
Available
Locally
Available
E 3 Pressure gauge 1 Full scale 408 kg/cm²
Locally
Hydraulic pressure Available
Locally
5
Servo control kit 1 0 to1020 kg/cm²
6
ATR800200 Delivery 0 to 300 l/
1 Flow meter 1
F min.
2 Pipe fitting kit 1 –
Air bleeding G ATR201490 Tank cap 1 Pump air bleeding
Available
Hand brake L Spring dynamometer 1 Full scale 20 kg
Locally
Available
1 Maintenance station 1 For coolant R134a
Locally
Available Sampling every 15
Air Conditioning unit M 2 Thermometer hygrometer 1
Locally sec
Available
3 Leak detector 1 For coolant R134a
Locally
20-26 WB140-2N WB150-2N

TESTING AND ADJUSTING ENGINE SPEED
12
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 under the following conditions:

● Engine coolant temperature: 68 to 80 °C.
● Hydraulic oil temperature: 45 to 55 °C.
TIER I ENGINE
1. Install and connect tachometer C.
2. Start the engine and check:

● Low idle speed without load, accelerator pedal released in
minimum position. High idle speed without load, accelerator
pedal at the travel end.
● Low idle speed: 1050 ± 50 RPM
● High idle speed: 2375 ± 50 RPM
★ If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stoppers and wiring insulation before
going on with other operations. See “ACCELERATOR PEDAL
AND LEVER” on page 20-42.
TIER II ENGINE
1. Remove the air filter a.
2. Start the engine and check:

● Low idle speed without load, accelerator pedal released in
minimum position. High idle speed without load, accelerator
pedal at the travel end.
● Low idle speed: 1050 ± 50 RPM
● High idle speed: 2375 ± 50 RPM
★ If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stoppers and wiring insulation before
going on with other operations. See “ACCELERATOR PEDAL
AND LEVER” on page 20-42.
WB140-2N WB150-2N 20-27

TESTING AND ADJUSTING VALVE CLEARANCE
12
VALVE CLEARANCE
TIER I ENGINE
★ Measurement conditions:
● Engine: Cold
★ Adjust the clearance between the valves and rocker levers as fol-
lows:
Unit: mm
Engine Intake – Exhaust
With cold S4D106-1FH 0.30 ±0.05
engine S4D106-1FA 0.30 ±0.05
★ Firing order: 1-3-4-2-1 at 180° steps
★ Normal rotation: Counterclockwise from flywheel
★ Cylinder No. 1: Opposite the fan side
ADJUSTING PROCEDURE
1. Remove the air cleaner A, muffler B, and valve cover C.
2. Rotate the crankshaft in its normal direction until the piston to be

checked is at full compression, Top Dead Center (TDC). In this
position the intake and exhaust valves are closed.
3. Loosen the lock nut d and unscrew the tappet e one turn. Check
that valve insert f is laying flat on the valve stem and that it is not
worn. If the valve inserts are damaged, replace them with new ones.
Make sure that the inserts fit and lay flat on the valve stem.
4. Place feeler gauge A between the insert and the rocker lever to be
adjusted. Rotate the tappet e until the rocker lever touches the
gauge. Secure the tappet with lock nut d.
Lock Nut: 14.7 to 19.6 N•m
★ After tightening the lock nut, check the clearance again.
5. Adjust the next cylinder valve using this same procedure. Repeat
the procedure for the other cylinders, according to their firing order.
VALVE COVER INSTALLATION
1. Check condition of valve cover c, gasket g, o-rings h and lock

nuts i; carefully clean the contact surface of the cylinder head.
Install the gasket, valve cover, fit o-rings and lock nuts.
Cover lock nut: 25 ±3 N•m
20-28 WB140-2N WB150-2N

12
TIER II ENGINE
● Engine: Cold
★ Adjust the clearance between the valves and rocker levers as fol-
lows:
Unit: mm
Engine Intake – Exhaust
With cold S4D106-2XFH 0.25 ±0.01
engine S4D106-2SFA 0.25 ±0.01
★ Firing order: 1-3-4-2-1 at 180° steps
★ Normal rotation: Counterclockwise from flywheel
★ Cylinder No. 1: Opposite the fan side
ADJUSTING PROCEDURE
1. Remove the air filter a and the muffler b.
2. Loosen the muffler support screws d and remove the air intake
duct e.
3. Disconnect the fuel feed pipes f. Remove clamp g and loosen

clamp h.
WB140-2N WB150-2N 20-29

12
4. Loosen the fittings i connecting to the pump j on the fuel feed
pipes f.
5. Rotate the pipes f until they become disengaged from the valve
cover 1).
6. Remove the feed-through fittings 1! and their seals.
7. Loosen and remove the screws 1@ retaining the valve cover c.

★ Inspect the grommets.
8. Remove the valve cover c.

★ Inspect the seal. Replace the seal if damaged or cracked.
20-30 WB140-2N WB150-2N

12
9. Rotate the crankshaft in the normal direction until the piston of the
cylinder you want to check reaches the compression position at Top
Dead Center (TDC).
★ In this position, the intake and exhaust valves are closed.
10. Loosen the lock nut 1# and unscrew the tappet by about one half
turn 1$.
11. Introduce the A feeler gauge between the valve link 1% and the
rocker arm 1^; tighten the tappet 1$ until rubbing against the A
feeler gauge. Lock the tappet using the lock nut 1#.
Lock Nut: 22 to 28 N•m
12. Loosen the nut 1& and, while applying pressure to the valve link 1%,
tighten the tappet 1* until it bottoms on the valve 1( and zeroes the
clearances. Lock the tappet using the nut.
Lock Nut: 22 to 28 N•m
★ If the nut 1& is very tight, use pliers to hold the valve link in
position 1%.
WB140-2N WB150-2N 20-31

12
13. Reinstall all previously removed parts.
Valve cover screws 16.7 to 22.5 N•m
Injectors pump fittings 19.6 to 24.5 N•m
Clamp screws 7.8 to 9.8 N•m
20-32 WB140-2N WB150-2N

TESTING AND ADJUSTING COMPRESSION PRESSURE
12
COMPRESSION PRESSURE
WARNING! When measuring the compression pres-

sure be careful not to get caught in the
cooling fan, alternator belt or in any other
rotating parts. For this measurement the
engine should be at operating tempera-
ture. Take every precaution against burns.
● Engine: Operating temperature
● Hydraulic oil: 55 to 60°C.
● Battery: Full charge
● Valve clearance: Adjusted
TIER I ENGINE
1. Disconnect the high pressure pipe a.
2. Remove the nozzle holder b of the cylinder to be checked.
3. Disconnect the connector c of the fuel cut off the solenoid valve
d.
4. Crank the engine with the starting motor.
5. Install B2 adapter and connect B1 pressure gauge. Check that the

seal is installed in the adapter and that it is not damaged.
6. Crank the engine with the starting motor and measure the compres-
sion pressure.
★ Measure the compression pressure at the point where the pres-
sure gauge indicator remains steady.
★ While measuring the compression pressure, monitor the engine
speed with a tachometer; if speed is not within the specified
range, refer to the diagram.
★ Compression value: 35 ±1 kg/cm² @ 250 RPM
★ Minimum permissible: 27.5 ±1 kg/cm² @ 250 RPM
★ Difference between cylinders: 2 to 3 kg/cm²
7. After measuring, reinstall the nozzle holder b, reconnect the high

pressure pipe, feedback pipe and connector c.
Nozzle holder collar bolts: 10 to 12 N•m
High pressure union: 20 to 25 N•m
NOTE: Check compression in all cylinders.
WB140-2N WB150-2N 20-33

12
TIER II ENGINE
1. Access the valves using the same procedure as in “VALVE

CLEARANCE” on page 20-28.
2. Loosen and remove the fittings a retaining the fuel recovery piping
b and the seals.
3. Loosen the fitting c and rotate the piping b outward.
4. Loosen and remove the screw d retaining the bracket e retaining

the injector f.
5. Turn the bracket e over and pull out the injector f.

★ Use care not to allow dirt inside the injector and/or its seat.
6. Disconnect the engine shutdown connector g and ensure that the

accelerator is fully released, no fuel flow.
20-34 WB140-2N WB150-2N

12
7. Using the starter motor, crank the engine complete a few revs.
8. Apply the adaptor B2 and gauge B1 and follow the instructions

provided with the equipment.
★ Check for a seal inside the adaptor and verify that the seal is
not damaged.
9. Crank the engine with the starting motor and measure the compres-
sion pressure.
★ Measure the compression pressure at the point where the pres-
sure gauge indicator remains steady.
★ When measuring the compression pressure, check also engine
speed with a tachometer; if the speed is not within the specified
range, refer to diagram.
★ Compression value: 35 ±1 kg/cm² @ 250 RPM
★ Minimum permissible: 28 ±1 kg/cm² @ 250 RPM
★ Difference between cylinders: 2 to 3 kg/cm²
10. After completing the procedure, reinstall the injector f, reconnect the
fuel return pipe and complete the assembly procedure.
Nozzle holder collar bolts: 8 to 10 N•m
High pressure union: 20 to 25 N•m
NOTE: Check compression in all cylinders.
WB140-2N WB150-2N 20-35

TESTING AND ADJUSTING FUEL INJECTION TIMING
12
FUEL INJECTION TIMING
TIER I ENGINE
★ Check the fuel injection timing of the No. 1 cylinder by means of
the No. 1 delivery valve of the injection pump.
★ The cylinders are numbered 1 2 3 4 starting from the flywheel side.
1. Rotate the crankshaft using the engine pulley a and put the No. 1
cylinder piston at top dead center (TDC).
★ Top dead center (TDC) is shown by the notch d on the pulley a

positioned on zero of the scale e and by the closing of both cylin-
der No. 1 valves.
★ If the notch d of the pulley a is in the zero position on the scale e
but the cylinder No. 1 valves are not closed, rotate the crankshaft
one full turn.
★ After recognition of TDC, rotate the crankshaft counterclockwise,
as viewed from the pulley side, 20°.
2. Disconnect the cylinder No. 1 high pressure tube C from the injec-
tion pump.
3. Rotate the crankshaft slowly in the clockwise direction (as viewed

from the pulley side), checking the fuel level in the No. 1 delivery
holder of the injection pump.
4. Stop the pulley B rotation as soon as the fuel level starts to

increase.
20-36 WB140-2N WB150-2N

12
5. Check the notch d position on the crankshaft pulley a compared
with the scale e; the indicated value should correspond to the angle
of the fuel injection timing.
★ Standard fuel injection timing:
S4D106-1FA ............................................. 12.5° ±1°
S4D106-1FH:............................................ 12.5° ±1°
NOTE: Repeat this procedure several times.
6. If the injection timing does not meet the standard value, rotate the
injection pump f away from or toward the cylinder block after
loosening the pump nuts g (quantity 4) and lock nuts h which
attach the bracket i to the injection pump.
● To RETARD the injection timing, rotate the pump f away
from the cylinder block.
● To ADVANCE the injection timing, rotate the pump f toward
the cylinder block.
7. Tighten the pump lock nuts g at the cylinder block and lock nuts h
at bracket i.
Nuts: 34 to 44 N•m
Bracket lock nut: 44 to 54 N•m
8. Reconnect the cylinder No. 1 high pressure pipe b to the injection

pump.
Delivery pipe union: 20 to 25 N•m
TIER II ENGINE
WARNING! Remove the ignition key.
★ Check the fuel injection timing of No. 1 cylinder by means of the

No.1 delivery valve of the injection pump.
★ The cylinders are numbered 1 2 3 4 starting from the flywheel side.
1.Rotate the crankshaft using the engine pulley and put the No. 1 cyl-
inder piston at top dead center (TDC).
★ Top dead center (TDC) is shown by the notch d on the pulley a posi-
tioned on zero of the scale e and by the closing of all cylinder No.
1 valves.
WB140-2N WB150-2N 20-37

12
★ If the notch d of the pulley a is in the zero position on the scale e but
cylinder No. 1 valves are not closed, rotate the crankshaft one turn.
★ After recognition of TDC, rotate the crankshaft in the counterclock-
wise direction, from the pulley side view, 20°.
2. Disconnect the cylinder No.1 high pressure pipe b from the injec-
tion pump.
3. Rotate the crankshaft slowly in the clockwise direction from the

pulley side, checking the fuel level into the No. 1 delivery valve of
the injection pump.
4. Stop the pulley a rotation as soon as the fuel level starts to

increase.
5. Check the notch d position on the crankshaft pulley a compared

with the scale e; the reading value corresponds to angle of the fuel
injection timing.
Standard fuel injection timing.................................. 12.5° ±1°
NOTE:Repeat checking more than once.
6. If the injection timing is not on the standard value, rotate the injec-
tion pump f inwards or outwards of the engine block after loosen-
ing the pump nuts g.
● To RETARD the injection timing, rotate the pump f outward
from the engine block.
● To ADVANCE the injection timing, rotate the pump f inward
to the engine block.
20-38 WB140-2N WB150-2N

12
7. Tight the pump nuts g at the cylinder block.
Nuts: 34 to 44 N•m
8. Reconnect the cylinder No. 1 high pressure pipe b to the injection

pump.
Delivery pipe union: 20 to 25 N•m
WB140-2N WB150-2N 20-39

TESTING AND ADJUSTING FAN BELT
12
FAN BELT
TENSION CHECK
1. Push the fan belt B at the midway point between the alternator C
and the water pump pulley A. Check the deflection with a pressure
of 10 kg.
● New belt tension: 7 to 9 mm
● In use belt tension: 10 to 15 mm
TENSION ADJUSTMENT
1. Loosen the alternator mounting bolt d and the mounting bolt e of
the adjustment plate.
2. Rotate the alternator c to tension the fan belt b and tighten the
mounting bolts d and e.
3. Check the fan belt b tension.

★ If the belt has been replaced, check the tension again after the first
20 hours of operation.
Bolt d: 44 to 54 N•m
Bolt e: 23 to 29 N•m
20-40 WB140-2N WB150-2N

TESTING AND ADJUSTING COMPRESSOR DRIVE BELT
12
COMPRESSOR DRIVE BELT
CHECKING TENSION
1. Push fan belt b at midway point between compressor c and pulley
d. Check the deflection with a pressure of 10 kg.
● New belt tension: 4 to 6 mm
● In use belt tension: 7 to 10 mm
TENSION ADJUSTMENT
1. Loosen the mounting bolt e of the eccentric d.
2. Use a lever on the eccentric d to correctly tension the belt and

secure the adjustment with bolt e.
3. Recheck the belt b tension.

★ If the belt has been replaced, recheck the tension again after 20
hours of operation.
Bolt: 123 N•m
WB140-2N WB150-2N 20-41

TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR PEDAL AND LEVER
● 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
a manually.
ACCELERATOR PEDAL TRAVEL

1. Make sure that the accelerator pedal a is fully raised and the accel-
erator lever b is at its minimum stroke.
2. Check that the accelerator lever c is in contact with low idle speed
adjusting screw d.
3. Adjust the nut e and locknut f of the accelerator pedal cable, and
the hand accelerator at a distance of 0.2 to 0.3 mm from the lever
g.
20-42 WB140-2N WB150-2N

TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
4. Push the accelerator pedal until the accelerator lever c contacts the
high idle adjusting screw h.
5. Adjust the end travel stopper i of the accelerator pedal a in this

position and secure it with the nut j.
6. Release the accelerator pedal a.
ACCELERATOR LEVER TRAVEL

1. Remove the mat and lateral cover a.
2. Loosen the nut b and tighten the end lever travel bolt c a few
turns.
3. Start the engine.
4. With the lever d, set the hand accelerator idle speeds.

★ High idle TIER I Engine: 2000 ±50 RPM
★ High idle TIER II Engine: 1900 ±50 RPM
★ Low idle: 1050 ±50 RPM
5. Loosen the end lever travel bolt c so that it is in contact with the
lever d and then secure the nut.
6. Bring the engine to low idle and check the accelerator lever idle
speed adjustment by pushing the lever to the end of its stroke.
WB140-2N WB150-2N 20-43

TESTING AND ADJUSTING BRAKE PEDAL TRAVEL
12
BRAKE PEDAL TRAVEL
● EngineStopped
● MachineAttachments on ground
1. Check that the pedal A is at the stopper B and the pedals height
matches side view A measurement. If necessary, correct the height
by adjusting the stopper.
★ A measurement: 313 ± 3 mm
2. Check that pin C can freely run and lock the pedals A.
TIER I ENGINE
MASTER CYLINDER ROD ADJUSTMENT
1. Loosen the nut d which locks the adjusting rod e. Loosen the
adjusting rod until it touches the brake pump piston seat.
2. Tighten the adjusting rod e one turn and lock it with nut d.
3. Repeat Steps 1 and 2 for the other pedal.

★ After tightening the nuts d, check that the adjusting rod e touches
the brake pump piston seat.
MICROSWITCHES ADJUSTMENT
1. Loosen the microswitch locking nuts f.
2. Adjust the microswitches g and make sure there is a minimum

clearance, 1 mm with the pedals in the neutral position, between the
microswitches body and the pedal.
CHECKING ADJUSTMENT
1. Verify the below measurements as shown in the figure.

A measurement......................With pedal in neutral position
B measurement.................With cylinder rod touching pump
C measurement.................With pedal touching microswitch
20-44 WB140-2N WB150-2N

TESTING AND ADJUSTING BRAKE PEDAL TRAVEL
12
TIER II ENGINE
MASTER CYLINDER ROD
1. Loosen the nut d locking the adjusting rod e and loosen until it
touches the brake pump piston seat.
2. Tighten the adjusting rod e one turn and lock it with the nut d.
3. Repeat operations 1 and 2 for the other pedal.

★ After tightened the nuts d, check that the adjusting rod e
touch the brake pump piston seat simultaneously.
CHECKING ADJUSTMENT
1. Verify measurements shown in figure.

A measurement ..............................Pedal in neutral position
B measurement............ Master cylinder rod touching the pump
WB140-2N WB150-2N 20-45

TESTING AND ADJUSTING BLEEDING AIR
12
BLEEDING AIR
HYDRAULIC PUMP
★ Bleeding of air from the pump is necessary: make sure the pump is
full of oil
1. When installing the pump.
2. When replacing connecting hoses between the pump and hydraulic

tank.
3. When replacing the hydraulic oil and hydraulic tank overhaul.

Bleeding air is accomplished as follows:
4. Fill the hydraulic tank with oil and install plug G. Remove plug b
on top side of pump c. Connect plug G to low pressure com-
pressed air connection.
5. Slowly and intermittently introduce compressed air into the

hydraulic tank until oil flows out without air bubbles.
★ Maximum pressure in tank: 0.51 kg/cm²
6. Install plug b and lock it. While slowly depressurizing the hydrau-
lic tank, check the oil level. Add oil as necessary to maintain the
proper level.
7. Start the engine and run it for few minutes before bleeding air from the whole system.
CYLINDERS
★ When the hydraulic cylinders or pipe fittings have been replaced, it is necessary to bleed air before using the machine
again.
★ Operate one movement at a time starting from the lift cylinders.
1. Start the engine and run it at high idle speed for about 5 min. to warm up the oil and pressurize the hydraulic system.
2. Return the engine to low idle speed, extend and retract the piston 4 to 5 times.
★ Extend and retract pistons to within 100 mm of end of stroke.
3. Bring the engine to high idle speed and repeat Step 2. above. Return the engine to low idle speed and make a complete
travel of the piston until the hydraulic pump reaches its maximum pressure.
4. Repeat above operation, starting with Step 2. for all cylinders.
20-46 WB140-2N WB150-2N

12REPEAT ABOVE OPERATION
FOR ALL CYLIN.HE
HYDRAULIC TANK (STARTING
AIR BLEEDING
OIL FROM POINT 2)
IS OBTAINED
1. Put the machine in oil level check position and remove the tank
plug. If necessary add oil to reach the correct level.
2. After stopping the engine wait for a few minutes until the air bub-
bles disappear on oil surface.
3. Install the tank plug.

HYDRAULIC OIL TANK PRESSURIZATION
1. With engine at low idle speed, slowly extend all cylinders to their
end of stroke.
2. Stop the engine and remove tank plug.
3. Check the condition of gasket and reassemble plug.

★ Avoid increasing the engine speed until after completing all air
bleeding procedures and after the pressurization of oil tank.
★ After air bleeding procedures, operate the engine at low idle speed
for about 10 minutes before starting to work.
WORK CIRCUITS
1. Put all work attachments on level ground, stop the engine.
2. Move all control levers in all directions to completely release

remain pressure in the cylinders and the main circuit.
3. Slowly loosen the oil filler from the tank to remove any residual
pressure.
BRAKE CIRCUIT
★ You must bleed air from the braking circuit every time maintenance
is performed on the braking circuit, a component is replaced, or
when air has entered the circuit. Machine must be stopped with all
attachments on level ground.
1. Make sure that oil in the brake system tank a is at maximum level.
Remove the pedal lock pin.
2. Remove the safety plugs and connect a plastic hose to the bleed
screws b to catch the oil.
3. Push the brake pedals to the bottom. Keeping them pushed, loosen
the bleed screw b of the left brake until the pedals reach the end of
their stroke.
4. Keeping the pedal at the end of its stroke, tighten the bleed screw
b.
WB140-2N WB150-2N 20-47

12
5. Release the brake pedals, wait for few seconds and repeat above
operations two or three times until oil without air bubbles flows out
from the bleed screw.
6. Repeat same operations for the right brake unit.
7. Disconnect the pedal lock pin.
8. Push one brake pedal to bottom and, keeping it pushed, loosen the
bleed screw b of one of the two braking units until the pedal
reaches the end of its stroke.
★ Check that oil without air bubbles flows out from the bleed
screw b.
9. Repeat same operations for the other brake unit.

★ Frequently check the oil level in the tank and refill it when the
level approaches minimum.
★ After bleeding the air, reinstall the safety plugs on the screws
b.
CHECK BRAKE CIRCUIT
1. Start the engine and lower the backhoe outrigger and force them
downwards in order to raise the rear wheels.
2. Engage forward gear in order to move the wheels.
3. Return the machine to neutral and lower it. Stop the engine.
4. Apply 50 kg on the pedal and verify measure D.
5. Insert the pedal lock pin and applying the same mass, verify the
measurement D.
★ D measurement, one pedal: Not < 165 mm
★ D measurement with both pedals: Not < 170 mm
20-48 WB140-2N WB150-2N

TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
INTRODUCTION
A Engine D Loader Control Valve G Backhoe Relief Valve

B Transmission E Backhoe Control Valve H Steering Valve
C Hydraulic Pump F Loader Relief Valve I Filtered Return To Tank
● The machine is equipped with two control valves having the following functions:
● Loader Control Valve, 2 or 3 spools: For front work attachments control.
● Backhoe Control Valve, 6, 7 or 8-spools: For rear work attachments control.
● The two control valves are each protected against overpressure by a main relief valve with adjustable setting.
● Control valves are fed by hydraulic pump P1 which is controlled by a priority valve when the steering unit is used.
WB140-2N WB150-2N 20-49

12
LOADER CONTROL VALVES
2 SPOOL LOADER CONTROL VALVE

Cylinder Control Port
Arm Lift A1
a
Lower B1
Bucket Curl A2
b
Dump B2
3 SPOOL LOADER CONTROL VALVE

Cylinder Control Port
Arm Lift A1
a
Lower B1
Bucket Curl A2
b
Dump B2
MP Bucket Or Retract A3
C Attachment
Extend B3
20-50 WB140-2N WB150-2N

12
BACKHOE CONTROLS STYLE VALVE
6 SPOOL BACKHOE CONTROL VALVE

Bottom Port Top Port
a Arm Close A1 Open B1
b Swing Left A2 Right B2
C Left Outrigger Up A3 Down B3
d Right Outrigger Up A4 Down B4
e Bucket Dump A5 Curl B5
f Boom Lift A6 Lower B6

g Telescope Arm In A7 Out B7

h Hammer Run A8 Blank B8
WB140-2N WB150-2N 20-51


20-52 WB140-2N WB150-2N

12
EXCAVATOR CONTROLS STYLE VALVE



WB140-2N WB150-2N 20-53


20-54 WB140-2N WB150-2N

TESTING AND ADJUSTING MAIN RELIEF VALVES
12
MAIN RELIEF VALVES
★ The pressure readings are to be taken from check points on both
control valves. Measurement conditions:
● EngineStopped at operating temperature
● Hydraulic oil55 to 60°C
● Parking brakeApplied
TESTING
LOADER CONTROL VALVE (2 OR 3 SPOOL)
1. Connect the pressure gauge E3 to the pressure adapter B of the

front shovel control valve A.
2. Start the engine and bring up to max speed and check the nominal
pressure of the main relief valve E by rolling the front bucket to the
end of its stroke.
Nominal pressure:
WB140-2N: .................................................... 189 ±7 kg/cm²
WB150-2N: .................................................... 204 ±7 kg/cm²
BACKHOE CONTROL VALVE (6, 7 OR 8 SPOOLS)
1. Connect the pressure gauge E3 to the pressure adapter D of the

backhoe control valve c.
2. Start the engine and bring up to max speed and check the nominal
pressure of the main relief valve F while forcing the bucket into
maximum curl position.
Nominal pressure:
WB140-2N: .................................................... 211 ±7 kg/cm²
WB150-2N: .................................................... 224 ±7 kg/cm²
★ If the main relief valve pressures do not correspond to the nominal

values, they must be reset.
SETTING RELIEF PRESSURE
WARNING! For adjustments, prepare the machine as

for pressure testing.
1. Remove safety plug.
2. Loosen lock nut g.
3. Force the specific control lever to the end of its stroke.

● Loader: Force the bucket into the maximum curl position.
● Backhoe: Force the bucket into the maximum curl position.
WB140-2N WB150-2N 20-55

TESTING AND ADJUSTING MAIN RELIEF VALVES
12
4. Adjust the pressure with the adjusting screw h.
● To INCREASE the pressure, rotate the adjusting screw in the
CLOCKWISE direction.
● To DECREASE the pressure, rotate the adjusting screw in the
COUNTERCLOCKWISE direction.
5. Tighten the locknut g to secure the adjustment.
6. Reinstall safety plug.
20-56 WB140-2N WB150-2N

TESTING AND ADJUSTING LOADER CIRCUIT RELIEF VALVES
12
LOADER CIRCUIT RELIEF VALVES
● Engine: Stopped at operating temperature
● Hydraulic oil: 55 to 60°C
● Parking brake: Applied
TESTING PRESSURE
loader control valve.
2. Start the engine and bring the hand accelerator lever up to 1050
rpm.
3. Set the main relief valve c to a value 30 kg/cm² higher than the
maximum pressure to be tested.
4. Check the circuit relief valve d, e, f and g single movement

pressure. Refer to the following tables for the cylinder and its
movement.
d Raise the loader arm so that the bucket will clear the ground.
Fully curl the bucket and read and record the pressure on the
gauge.
e Raise the loader arm so that the bucket will clear the ground.
Fully dump the bucket and read and record the pressure on the
gauge.
f Raise the loader arm so that the bucket will clear the ground.
Fully extend the cylinder and read and record the pressure on
the gauge.
g Raise the loader arm so that the bucket will clear the ground.
Fully retract the cylinder and read and record the pressure on
the gauge.
Unit: kg/cm²
Port Description Pressure
d A2 Bucket Dump 235
e B2 Bucket Curl 166
f A3 Cylinder Retract 235
g B3 Cylinder Extend 235
WB140-2N WB150-2N 20-57

TESTING AND ADJUSTING LOADER CIRCUIT RELIEF VALVES
12
SETTING PRESSURE
★ The pressure must be set while the control lever, for the cylinder
being tested, is forced to the end of its stroke.
1. Remove the safety plug h.
2. Loosen the locknut i.
3. Adjust the pressure with the adjusting screw j.

● To INCREASE the pressure, rotate CLOCKWISE.
● To DECREASE the pressure, rotate COUNTERCLOCK-
WISE.
4. Tighten locknut i to secure the adjustment.
Locknut: 10 ±1 N•m
WARNING! After the pressure is adjusted, install the

safety plug h to avoid unauthorized tam-
pering.
5. Reset the main relief valve pressure to the standard value after all
of the secondary valves have been checked and set.
20-58 WB140-2N WB150-2N

TESTING AND ADJUSTING BACKHOE CIRCUIT RELIEF VALVES
12
BACKHOE CIRCUIT RELIEF VALVES
● Engine: Stopped at operating temperature
TESTING PRESSURE
backhoe control valve a.
2. Start the engine and bring the hand accelerator lever up to 1050
rpm.
3. Set the main relief valve c to a value 40 kg/cm² higher than the
maximum pressure to be tested.
4. Check the circuit relief valve d, e, f, g, h and i single move-

ment pressure. Refer to the following tables for the cylinder and its
movement.
d Spread the backhoe along the ground. Curl the bucket and fully
retract the arm cylinder. Read and record the pressure on the
gauge.
e Place the backhoe in the transport position and lock the boom.
Swing the backhoe to the full right. Read and record the pres-
sure on the gauge.
f With the backhoe in the transport position and the boom lock
in place, swing the backhoe to the full left. Read and record the
pressure on the gauge.
g With the backhoe centered raise the boom and extend the arm
the bucket will clear when curled. Fully curl the bucket and
read and record the pressure on the gauge.
h Place the backhoe in the transport position and lock the boom.
Lower the boom and read and record the pressure on the
gauge.
i The backhoe boom raise circuit valve pressure can only be

checked and set during a bench test.
WB140-2N WB150-2N 20-59

TESTING AND ADJUSTING BACKHOE CIRCUIT RELIEF VALVES
12
Unit: kg/cm²
Port Description Pressure
d A1 Arm Retract 245
e B2 Swing Right 184
F A2 Swing Left 184
G B5 Bucket Curl 245
H B6 Boom Lower 245
I A6 Boom Raise 357 ★
J A8 Not Used 163
★ The backhoe boom raise circuit valve pressure can only be checked
and set during a bench test.
SETTING PRESSURE
★ The pressure must be set while the control lever, for the cylinder
being tested, is forced to the end of its stroke.
1. Remove the safety plug 1).
2. Loosen the locknut 1!.
3. Adjust the pressure with the adjusting screw 1@.

WISE.
4. Tighten locknut 1! to secure the adjustment.
Locknut: 10 ±1 N•m
WARNING! After the pressure is adjusted, install the

safety plug 1) to avoid unauthorized tam-
pering.
5. Reset the main relief valve pressure to the standard value after all
of the secondary valves have been checked and set.
20-60 WB140-2N WB150-2N

TESTING AND ADJUSTING UNLOADING VALVE
12
UNLOADING VALVE
● Engine: Stopped and at working temperature.
● Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
● Working mode: Power
TESTING
1. Disconnect the hose b from the load sensing line. Install a tee and
reconnect the hose.
2. Remove the plug c and install pressure adapter.
3. Connect pressure gauge E5 to the adapter.
4. Start the engine and set it at 1050 ±50 rpm. Without any machine
movement, all the control levers in the neutral position, read the ρP
pressure.
ρP - Unloading Valve ......................................... 24.5 kg/cm²
★ If the ρP value is not within the limits, adjust the unloading
valve a.
ADJUSTMENT
1. Remove plug e, spring f, washers g, and valve body h.
2. Place a shim d under the spring f and install the valve.

● One shim, 1 mm thick, increases the ρP by 3 kg/cm².
Plug: 100 N•m
WB140-2N WB150-2N 20-61

TESTING AND ADJUSTING LOAD SENSING (LS) VALVE
12
LOAD SENSING (LS) VALVE
● Engine: Stopped and at working temperature.
● Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
● Working mode: Power
TESTING
1. Disconnect the hose b from the load sensing line. Install a tee and
reconnect the hose.
2. Remove the plug c and install a pressure adapter.
3. Connect the pressure gauge E5 to the adapter.
4. Start the engine and set at 1050 ±50 RPM. Without any machine
movement, and all levers in the neutral position, read the ρP pres-
sure on the gauge.
ρP - Unloading Valve ......................................... 24.5 kg/cm²
★ If the ρP value is not within this limit, adjust the unloading
valve.
5. Raise the boom up to the end of its stroke and read the ρP pressure
on the gauge.
ρP - Load Sensing Valve ................................... 21.5 kg/cm²
★ If the ρP value is not within limits, adjust the load sensing
valve a.
ADJUSTMENT
1. Remove the cover nut e. Loosen the locknut f.
2. Adjust the pressure using the adjustment screw g.

WISE.
3. Tighten the locknut f to secure the adjustment.
Locknut: 21 N•m
4. Check the gasket d and install the nut e.
Cover Nut: 21 N•m
20-62 WB140-2N WB150-2N

TESTING AND ADJUSTING FLOW VALVE
12
FLOW VALVE
● Engine: Stopped at working temperature
● Machine: Safe, parking brake applied
● Control valve lever: Neutral position
1. Disconnect the hose a from the load sensing line. Install the tee b
and reconnect the hose.
2. Connect a pressure port and gauge E1 to the tee b.
3. Connect a second gauge E1 to the rear control valve pressure port

c.
4. Start the engine and at low idle without any machine movement,
check the pressure on both gauges.
★ P pressure at control valve gauge: 30 ±3 kg/cm²
★ Normal pressure PLS: 6 ±2 kg/cm²
This value is due to the influence of the counterpressure
present in the steering circuit.
★ If any variations are found, they do not represent a problem

provided that the difference of 21 ±1 kg/cm² between the two
readings is respected.
5. If the difference between the readings is higher than 24 ±1 kg/cm²,

stop the engine and release the residual pressures.
6. Thoroughly clean the valve d and reinstall it.
Valve: 20 N•m
7. If, after cleaning the valve d, the value still does not fall within the
tolerance limits of 24 ±1 kg/cm², install a new valve.
WB140-2N WB150-2N 20-63

TESTING AND ADJUSTING PRIORITY VALVE
12
PRIORITY VALVE
TESTING
1. Connect a pressure gauge E2 to the pressure adapter a of the back-
hoe control valve.
2. Start the engine and set it at 1500 ±50 rpm. Check the gauge E2
pressure value with a stopped steering wheel.
● Pressure Value24 kg/cm²
3. Slightly turn the steering wheel and check that pressure increases.
Continue turning the steering wheel to the end of a full turn and
check that while forcing the steering wheel, pressure increases to
the normal value.
● Backhoe Controls: 178 ±10 kg/cm²
● Excavator Controls: 178 ±7 kg/cm²
★ If the pressure does not reach the normal value, reset the pres-
sure of the steering unit
★ If the pressure indicated by the gauge does not change while
turning the steering wheel, and it takes excessive force to turn
the wheel, the priority valve b needs to be cleaned.
CLEANING PRIORITY VALVE
1. Remove the priority valve plug d, spring e and rod f.
★ Carefully check and make notes on the disassembly so that you
can reassemble the priority valve.
2. Remove the plug g and ball h of the inside valve and the spring i.
Check that the hole j and nozzle c are completely clean. Replace
the spring i, ball h and plug g
Plug: Loctite 542
Plug: 20 N•m
★ Do not allow any Loctite to enter the hole j. Remove all

excess Loctite from the rod f.
3. Lubricate the rod f and install it in its seat. Make sure that it slides
freely. Insert the spring e and plug d.
Plug: 100 N•m
4. Start the engine and execute several steering manoeuvres. If the

fault is not corrected, replace the complete steering column with a
new one.
20-64 WB140-2N WB150-2N

TESTING AND ADJUSTING STEERING SYSTEM
12
STEERING SYSTEM
★ Measurement condition:
TESTING
1. Connect a pressure gauge E2 to the pressure adapter a of the back-
hoe control valve.
2. Start the engine and set at 1500 ±50 rpm. Turn the steering wheel
from end to end.
3. Force the steering wheel to the end of its rotation and check the
pressure.
● Backhoe Controlled Pressure: 178 ±10 kg/cm²
● Excavator Controlled Pressure: 178 ±7 kg/cm²
4. Check the pressure at the other end of the steering direction as well.
SETTING
★ If the pressure is not within the permissible limits, reset the pres-
sure on the upper valve b of the steering unit.
1. Remove the plug c. Insert a wrench and loosen the screw d.
2. Adjust the pressure with the screw e.

WISE.
3. Stop the engine. Secure the adjustment screw e by tightening

screw d.
4. Install the plug E making sure that the gasket f is properly seated.
WB140-2N WB150-2N 20-65

TESTING AND ADJUSTING BRAKE SYSTEM
12
BRAKE SYSTEM
★ Measurement condition:
● Engine: Stopped
● Machine: on solid and level ground, with the equipment raised
and safety devices engaged.
● Brake pedals: independent, with the fluid container level at
maximum.
Brake system testing is accomplished in two parts:
1. Testing the circuit and brake pump tightness.
2. Leak tightness test of the braking group.
WARNING! If both the tests give positive results,

check for leaks in the piping of the braking
system.
CIRCUIT AND BRAKE PUMP TEST

1. Disconnect the equalizer connecting pipe a from the brake pumps
b of the circuit being tested.
2. Securely plug the equalizer orifice A when the pipe is discon-

nected.
3. Remove clamp d and disconnect delivery lines e from the pumps.
4. Connect a pressure gauge E2 to the pump b.
5. Push the brake pedal corresponding to the pump and bring the cir-
cuit up to a pressure.
● Brake Pressure: 122 kg/cm².
★ Do not exceed the maximum permissible value of 153 ±5 kg/
cm².
6. Keep the pedal pushed for at least 2 minutes and check that the
pedal pressure and position remain steady.
★ If the position of the pedal changes to maintain the pressure,
the pressure loss is due to leaks inside the pump. This can be
confirmed by checking the oil. If there are leaks, it will show
signs of mixing.
7. Repeat the test for the other brake pump.
20-66 WB140-2N WB150-2N

TESTING AND ADJUSTING BRAKE SYSTEM
12
BRAKING GROUP LEAK TEST
1. Disconnect the delivery tube e of the braking group being tested.
2. Connect the tee between delivery line f and the braking group.
★ Make sure to insert pressure adapter between the braking
group and the cut off valve g.
3. Connect pressure gauge E2 to the pressure adapter of the tee and

open the valve g.
4. Operate the brake pump to feed pressure into the circuit to a pres-
sure of about 122 kg/cm².
★ Do not exceed the maximum permissible value of 158 ±5 kg/
cm².
5. Close valve g to maintain pressure in the braking group being

tested.
6. Release the brake pedal and observe the pressure indicated on

gauge E2 for 2 minutes.
★ If the pressure value shows a negative change, it means that the
braking piston seals are defective.
WARNING! For further confirmation of the leak can be

obtained by an increase in the oil level in
the axle, which leads to a mixing of the
oils. Change all the sealing rings between
the axle sections, and carry out a com-
plete lubrication oil change.
7. Repeat the test for the other braking group, follow the same
method.
8. Reassemble the braking circuit
WARNING! After testing and any repairs, bleed air

from the brake units, see BLEEDING AIR.
WB140-2N WB150-2N 20-67

TESTING AND ADJUSTING ENGINE SPEED UNDER LOAD
12
ENGINE SPEED UNDER LOAD
● Hydraulic oil: 45 to 55 °C
● Power train oil: Working temperature
● Brake pedals: Connected
● Machine: on solid and level ground with the equipment raised
Two tests must be performed:
1. Stall test with the torque converter under load.
2. Stall test with the torque converter and the hydraulic system under
load.
★ The tests must be performed after a no load test of the engine
speed. For details, see ENGINE SPEED.
WARNING! During the following tests, while acceler-

ating the engine with the gear engaged,
the condition of the brake disks can also
be checked. If, while force is being
exerted on the brake pedals, the machine
moves, even slowly;
A. Release the accelerator immediately and stop the
engine.
B. Check the wear on the brake disks and change them
before completing the tests.
PREPARING THE MACHINE

1. Prepare the tachometer C to measure the engine rpm.
★ When mounting an electronic transducer tachometer on a die-
sel delivery line to the injection nozzles, make sure that it is
placed far away from the clamp.
WARNING! Make sure that the brake pedals are fas-

tened together with the cotter pin b.
TORQUE CONVERTER STALL

1. Start the engine at set at the lowest idle. Engage 4th gear and apply
the brake firmly.
2. While keeping the brake applied, accelerate the engine gradually up

to high idle and measure the speed reached.
★ WB140-2N TIER I Engine: 2100 ±50 rpm
★ WB140-2N TIER II Engine BH Controls: 2200 ±50 rpm
★ WB140-2N TIER II Engine EX Controls: 2275 ±50 rpm
★ WB150-2N TIER I Engine: 2275 ±50 rpm
★ WB150-2N TIER II Engine BH Controls: 2200 ±50 rpm
★ WB150-2N TIER II Engine EX Controls2275 ±50 rpm
3. Release the accelerator pedal and move on to the next test.
20-68 WB140-2N WB150-2N

TESTING AND ADJUSTING ENGINE SPEED UNDER LOAD
12
TORQUE CONVERTER AND HYDRAULIC STALL
1. Start the motor at set at the lowest idle. Engage 4th gear and apply the brake firmly.
2. While keeping the brake applied, 4th gear engaged, accelerate the engine gradually and at the same time activate the con-
trol valve lever to curl the front bucket, and turn the steering wheel and hold it at the end of its stroke.
3. Once the maximum engine speed and maximum pressure of the bucket circuit have been reached, note the speed reached
by the engine.
★ TIER I Engine: 2000 ±50 rpm
★ TIER II Engine BH Controls: 2050 ±50 rpm
★ TIER II Engine EX Controls: 2250 ±50 rpm
● If the engine rpm are higher than the permissible limit in both tests, check the delivery pressure to the converter and
the clutch pressures.
● If the engine rpm is lower than the permissible limit, check the condition of the air filter, the engine compression, the
timing, the injection pump, and the valve clearances.
WB140-2N WB150-2N 20-69

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:
1. Converter oil pressure.
2. Clutch engagement pressures for both directions of travel.

★ Test conditions:
● Engine: Stopped
● Machine: On solid and level ground with the equipment raised
PREPARING THE MACHINE
1. Prepare the tachometer C to measure the engine rpm.
placed far away from the line clamp.

tened together with the cotter pin b.
CONVERTER OIL PRESSURE

1. Remove the plug P22 and connect pressure gauge E6.
2. Start and engine and heat all the fluids up to working temperature.
Make sure that the power train oil reaches a temperature of 80
±5°C.
3. With the engine at low idle, check the pressure on the pressure
gauge E6.
★ Normal pressure: Min. 0.5 kg/cm²
4. Gradually increase the engine speed to high idle. Take a new read-
ing from the pressure gauge E6.
★ Normal pressure: 9.2 kg/cm²
5. Bring the engine back to low idle and compare the pressure with
the normal value.
★ Normal pressure: Min. 0.5 kg/cm²
★ If the maximum pressure value drops to below the permissible
lower limit, the power train pump needs an overhaul.
20-70 WB140-2N WB150-2N

TESTING AND ADJUSTING POWER TRAIN GROUP
12
CLUTCH PRESSURE
1. Remove the access plate from the cab floor.
2. Remove plug P19 and connect pressure gauge E6.
3. Start and heat the engine and all the fluids up to working tempera-
ture. Make sure that the power train oil reaches a temperature of 80
±5°C.
4. With the engine at low idle, check the pressure on the gauge E6.
★ Normal pressure: Max. 0.32 kg/cm²
5. Select the REVERSE gear and gradually increase the engine speed
to high idle. Take a new reading from the pressure gauge E6.
★ Normal pressure: 11 to 13 kg/cm²
6. Bring the engine back to low idle and place the transmission in neu-
tral. Compare the pressure with the normal value.
★ Normal pressure: Max. 0.36 kg/cm²
7. Remove the pressure adapter and replace the plug P19.
Plug 23 N•m
8. Repeat the same test for the FORWARD gear, reading the pressure
from the plug P18.
● If the pressures are different for the travel directions, there is a
loss of pressure on the clutch piston with lowest pressure.
ADDITIONAL PRESSURES
P17 Oil Cooler Back Pressure
★ FWD/REV clutch in neutral: 0.5 to 5 kg/cm²
★ FWD/REV clutch ENGAGED: 0.5 to 3.5 kg/cm²
P21 4WD Engagement Pressure
★ @ 900 RPM: 13 to 14 kg/cm²
★ @ 2200 RPM: 13 to 15.5 kg/cm²
WB140-2N WB150-2N 20-71

TESTING AND ADJUSTING DIRECTIONAL CLUTCHES
DIRECTIONAL CLUTCHES
● Engine: Stopped.
● Machine: on solid and level ground with the equipment raised
★ This test must be performed after having checked the pressures of
the power train group.
PREPARATION OF THE MACHINE
1. Prepare tachometer C to measure the engine rpm.
placed far away from the line clamp.
WARNING! During the following tests, while acceler-

ating the engine with the gear engaged,
the condition of the brake disks can also
be checked. If, while force is being
exerted on the brake pedals, the machine
moves, even slowly;
A. Release the accelerator immediately and stop the
engine.
B. Check the wear on the brake disks and change them
before completing the tests.

tened together by the cotter pin a.
TESTING
1. Start and heat the engine and all the fluids up to working tempera-
ture. Make sure that the power train oil reaches a temperature of 80
±5°C.
2. With the engine at low idle, accelerate to high idle. Check that the
rpm remain within permissible limits.
3. Brake hard and bring the engine up to high idle.
4. Maintaining the braking action and the acceleration, engage the

FORWARD gear and check that the engine speed decreases until it
is once again within permissible limits.
5. Repeat this test in REVERSE gear.

★ If the rpm are higher than the permissible limits, the clutches are
worn, and must be replaced.
20-72 WB140-2N WB150-2N

TESTING AND ADJUSTING RETURN TO DIG DEVICE
12
RETURN TO DIG DEVICE
★ Adjustment conditions:
● Machine: On solid and level ground
● Engine: Stopped
● Parking brake: Engaged
1. Rest the bucket on the ground, making sure that the bottom is paral-
lel to the surface.
2. Stop the engine and remove the sensor guard a.
3. Check that there is a distance of 3 to 4 mm between the sensor C

and rod D. If necessary, loosen the nuts E and adjust the distance
until the indicated measurement is obtained. Tighten the nuts to
secure the adjustment.
4. Loosen screw F and move bracket G towards the rear until the sen-
sor is completely free of rod D.
5. Start the engine and set at low idle. Adjust the position of the
bracket G until the sensor C is engaged.
★ When the rod contacts the sensor, the warning lamp b will be
activated.
6. Secure the bracket G position by tightening the screw.
7. Perform several tests by raising and dumping the bucket. If the

bucket is able to rest flat on the ground, reinstall the sensor guard
a.
WB140-2N WB150-2N 20-73

TESTING AND ADJUSTING HYDRAULIC DRIFT
12
HYDRAULIC DRIFT
★ If working attachments drift, check if the drift is due to the cylinder
seals or the control valve.
● Remove and install pipes only after any residual pressure has
been removed.
LOADER
LIFT CYLINDER
1. Position the bucket vertically with the cutting edge or teeth resting
on 10 cm blocks a.
2. Stop the engine and remove any residual hydraulic pressure.
3. Disconnect the hoses B and C from the lift cylinders D and plug
them.
4. Plug the lift cylinder base side. Apply a temporary hose to the rod
side to catch any oil leakage.
5. Start the engine and retract the bucket until the cutting edge or teeth
tilt 15° above horizontal.
6. Stop the engine and check the bucket link position for 5 minutes.
● If the bucket link has no lowering movement, drift is due to the
control valve.
To check each cylinder, proceed as follows:
7. Position the bucket vertically with the teeth resting on 10 cm thick

blocks.
8. Remove the plug (installed earlier in Step 4) from the base side of
one cylinder.
9. Start the engine and retract the bucket until the teeth tilt 15° above
horizontal.
10. Stop the engine and check the bucket position for 5 minutes.
● If the bucket link has a lowering movement, drift is due to gas-
ket seals of the plugged cylinder.
11. Repeat Steps 7 through 10 to check the other cylinder.
20-74 WB140-2N WB150-2N

12
BUCKET CYLINDER
1. Position the bucket on level ground and tilt the cutting edge or teeth
up 15° a. Put a 1500 kg weight into the bucket. Stop the engine and
remove any residual hydraulic pressure.
2. Disconnect the hoses B and C from the dump cylinders D and plug
them.
3. Plug the dump cylinder base side. Apply a temporary hose to the
rod side to catch any oil leakage.
4. Start the engine and raise the bucket up to horizontal alignment of

the bucket hinge and arm hinge.
5. Stop the engine and check the bucket cutting edge or teeth position
for 5 minutes.
● If the bucket has no swing movement, drift is due to the control
valve.
To test the individual cylinders, proceed as follows:
6. Lower the bucket to the ground.
7. Remove the plug from one of the cylinders installed on the base
side in Step 3.
8. Start the engine and raise the bucket as indicated in Step 4.
9. Stop the engine and check the position of the bucket cutting edge or
teeth for 5 minutes.
● If the bucket cutting edge or teeth turn, the drift is due to the
gasket seals of the plugged cylinder.
10. Repeat Steps 6 through 10 to test the other cylinder.
WB140-2N WB150-2N 20-75

12
BACKHOE
★ Test condition:
● Backhoe: Aligned
● Outriggers: Raised
BOOM CYLINDER
1. Position the machine with its arm in vertical position with the bot-
tom of the bucket resting on level ground.
3. Disconnect hoses B and C from cylinder D and plug them.
4. Plug the cylinder head side.
5. Apply a temporary hose to the base side to catch any oil leakage.
6. Start the engine and extend the arm completely.
7. Stop the engine and check the boom position for 5 minutes.
● If the boom has a lowering movement, drift is due to cylinder
gaskets.
● If the boom has no lowering movement, drift is due to the con-
trol valve.
ARM CYLINDER
1. Position the machine with its arm a fully extended with the bucket
opened and teeth on the ground.
20-76 WB140-2N WB150-2N

12
3. Disconnect the hoses B and C from the arm cylinder D and plug
them.
★ If a safety valve is installed, remove it for this test.
4. Plug the arm cylinder port on the rod side. Attach a temporary hose
to the base side to catch any oil leakage.
5. Start the engine and raise the boom.
6. Stop the engine and check the arm position for 5 minutes.
● If the arm has a lowering movement, the drift is due to the cyl-
inder gaskets.
● If the arm has no movement, the drift is due to the control
valve.
BUCKET CYLINDER
1. Position the machine with the bucket arm vertical and the bottom of
the bucket resting on level ground.
2. Put a 450 kg weight a into the bucket
3. Stop the engine and remove any remaining hydraulic pressure.
4. Disconnect hoses b and c from bucket cylinder d and plug them.
5. Plug the bucket cylinder hole on the base side and attach a tempo-
rary hose to the rod side to catch any oil leakage.
WB140-2N WB150-2N 20-77

12R
6. Start the engine and raise the boom.
7. Stop the engine and check the bucket position for 5 minutes.
● If the bucket has an opening movement, drift is due to cylinder
gaskets.
● If the bucket has no movement, drift is due to the control valve.
OUTRIGGER TESTING
1. Position the machine with its arm in vertical position with the bot-
tom of the bucket resting on level ground.
2. Place support stands a of a suitable height beneath the outriggers,

and bring the cylinder eyes to a horizontal position.
3. Without forcing them, lower the outriggers onto the support stands.
4. Stop the engine and release any residual hydraulic pressure.
5. Remove the hoses b and c from the cylinders d and plug them.
6. Plug the cylinder base side c. Apply a temporary hose to the rod
side to catch any oil leakage.
7. Start the engine. Use force on the boom to raise the machine and
remove the support stands supporting the outriggers.
8. Lower the machine and stop the engine.
9. Check the outriggers position for 5 minutes.

● If one or both outriggers have a lowering movement, drift is
due to one or both cylinders.
● If there is no lowering, drift is due to the control valve.
20-78 WB140-2N WB150-2N

TESTING AND ADJUSTING AIR CONDITIONING UNIT
12
AIR CONDITIONING UNIT
● Machine on level ground with the work equipment raised and
safety devices engaged
● Parking brake: Engaged
TESTING THE WORKING TEMPERATURE

1. Connect the maintenance station to the high pressure valve and the
low pressure valve.
2. Start the engine and bring it up to a speed of 1500 rpm.
3. Switch on the AC unit using the switch in the cab.
4. Select an intermediate ventilation speed inside the cab.
5. Use the thermometer M2 to check that the temperature inside the cab is equal to or lower than the ambient temperature.
★ If the temperature of the cab is higher than the ambient temperature, open the doors and widows and wait until the cab
temperature stabilizes at the outside value.
6. Close the doors and windows and let the AC unit operating these conditions for 5 to 10 minutes.
7. Use the thermometer M2 to check the temperature of the air at the central outlets.
★ Position the probe as close as possible to the air outlets.
8. Compare the average value of the measured temperatures using the following table:
Ambient Air Temp °C 20 25 30 35
Outgoing Air Temp °C 6 to 8 8 to 10 8 to 12 9 to 14
9. 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.
CHECKING THE UNIT
Check the unit after the Steps 1 through 4.and 6. of the preceding paragraph. A diagnosis of faults in the unit is based upon the
working pressures.
When the pressures do not fall within the values given in the following table, the causes must be found by checking the high-
pressure and low pressure gauges.
WB140-2N WB150-2N 20-79

12
Unit: kg/cm²
Outside Air Temperature °C Unit with R134a.
Low Pressure High Pressure
Min Max Min Max
20 1.2 2.5 6.0 9.0
25 1.0 2.5 7.5 10.5
30 1.1 2.4 9.5 13.0
35 1.3 2.4 12.0 15.5
40 1.5 1.8 18.0 18.8
45 1.8 1.9 21.5 22.0
The following conditions can be found:
CONDITIONS CAUSES - FAULTS
LP high to HP normal or low ● Electromagnetic pulley that slips or does not engage correctly
● Expansion valve blocked in open position
● Compressor damaged
LP low to HP high or normal ● Expansion valve blocked in closed position or obstructed
● Filter saturated with moisture
● Obstruction in the LP line or in the HP line between the filter and the evaporator.
LP normal to HP normal ● Infiltration of hot air into the evaporator group, the pipes or the cab
● Hot air circulating in the heating group
● Formation of ice on the evaporator
LP high to HP high ● Normal condition with very high ambient temperature, higher than 43°C
● Excess coolant, 30 to 35% more
● Overheating of condenser
● Air present in the unit
● Obstruction in the HP line between the compressor and the condenser filler tube
behind the measurement point of the HP
LP normal or low to HP low ● Normal condition with very low temperature, lower than 5°C
● Lack of coolant, 70 to 75% less, probable leakages
● Obstruction in the HP line between the compressor and the condenser filler tube
before the measurement point of the HP
LP roughly equal to HP ● Compressor belt missing
● Electromagnetic pulley that slips or does not engage
EMPTYING THE AC UNIT
1. Connect the maintenance station M1 to service valves a and b
and follow the specific maintenance station instructions relative to
the drainage of the unit.
2. Disconnect the group to be substituted or reconditioned immedi-

ately after switching off the maintenance station. Plug the removed
or disconnected connection tubes tightly and with a minimum of
delay.
20-80 WB140-2N WB150-2N

3. Carefully check the quantity of R134A recovered and contained in the disassembled parts, since the same quantity must
be replaced when the air conditioning unit is filled.
WB140-2N WB150-2N 20-81

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 in case it does not survive 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
phases
Broken half shaft Replace half shaft
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
phases
Overloading/incorrect weight distribution Remove excessive weight and redistribute load following instructions
Excess noise
CAUSES REMEDY
phases
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.
20-82 WB140-2N WB150-2N

12
Uneven wear of tires
CAUSES REMEDY
phases
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 vehicle begins to kick.
pneumatic wear on sharp turns.
Friction noise
CAUSES REMEDY
phases
Damaged or worn out axle parts Check the condition of the ring gear, pinion gear, bearings, etc.
Replace when necessary.
Incorrect adjustment of bevel gear set. Replace or adjust as required.
Parts of the trans worn out transmission gears, U
joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
phases
WB140-2N WB150-2N 20-83

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 Oil level
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 Replace
heard while decelerating, disappears while increas-
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
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
20-84 WB140-2N WB150-2N

12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment (excessive backlash) for the adjustment of the bevel gear set free backlash.
Pinion nut loosened

Ring gear tooth broken
CAUSES REMEDY
Load bump Replace bevel gear set. Adjust bevel gear set free backlash
Incorrect gear adjustment insufficient 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 lubri-
Worn out pinion bearings cants, fill to proper levels and replace according to the recommended
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 REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
Axle beam body bent

CAUSES REMEDY
Vehicle overloaded Replace axle beam body
Vehicle accident
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil Replace bearings, use correct lubricants, fill to proper levels and
Excessive use replace according to the recommended schedule.
Normal wear out

Pinion nut loosened
WB140-2N WB150-2N 20-85

12
Oil leakage from gaskets and seals
CAUSES REMEDY
Prolonged operation at high temperature Replace the gasket or seal and matching surface if damaged. Use cor-
Oil gasket assembled incorrectly rect lubricants, fill to proper levels and replace according to the recom-
mended schedule.
Seal lip damaged
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened worn. Replace bevel gear set if required
Pinion axle backlash

Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Insufficient lubrication; contaminated oil, improper Use correct lubricants, fill to proper levels and replace according to the
lubrication recommended schedule. Replace all scratched washers and those with
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
ule.
Insufficient lubrication; contaminated oil
Bent or broken half shaft or half shaft broken at wheel side
CAUSES REMEDY
Vehicle intensively operated or overloaded Replace. Check that wheel support is not worn out or incorrectly
Wheel support loosened adjusted.
Beam body bent
20-86 WB140-2N WB150-2N

12
REAR AXLE
Wheel vibration; front tire resistance; half shaft breakage.

CAUSES REMEDY
phases
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
phases
No differential action; jamming while steering.
CAUSES REMEDY
phases
Excess noise
CAUSES REMEDY
phases
WB140-2N WB150-2N 20-87

12
Uneven wear of tires
CAUSES REMEDY
phases
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 vehicle begins to kick.
pneumatic wear on sharp turns.
Friction noise
CAUSES REMEDY
phases
Damaged or worn out axle parts Check the condition of the ring gear, pinion gear, bearings, etc.
Replace when necessary.
Incorrect adjustment of bevel gear set. Replace or adjust as required.
Parts of the trans worn out transmission gears, U
joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
phases
20-88 WB140-2N WB150-2N

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 Oil level
Poor or worn oil 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 Replace
heard while decelerating, disappears while increas-
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
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
WB140-2N WB150-2N 20-89

12
Ring gear teeth broken at the outer side
CAUSES REMEDY
Excessive gear load compared to the one foreseen Replace bevel gear set. Carefully follow the recommended operations
Incorrect gear adjustment, excessive backlash for the adjustment of the bevel gear set free backlash.
Pinion nut loosened

Ring gear tooth broken
CAUSES REMEDY
Load bump Replace bevel gear set. Adjust bevel gear set free backlash.
Incorrect gear adjustment, insufficient 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 lubri-
Worn out pinion bearings cants, fill to proper levels and replace according to the recommended
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 REMEDY
Excessive use Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication replace according to the recommended schedule.
Axle beam body bent

CAUSES REMEDY
Vehicle overloaded Replace axle beam body
Vehicle accident
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil Replace bearings. Use correct lubricants, fill to proper levels and
Excessive use replace according to the recommended schedule.
Normal wear out

Pinion nut loosened
20-90 WB140-2N WB150-2N

12
Oil leakage from gaskets and seals
CAUSES REMEDY
Prolonged operation at high temperature Replace the gasket or seal and matching surface if damaged. Use cor-
Oil gasket assembled incorrectly rect lubricants, fill to proper levels and replace according to the recom-
mended schedule.
Seal lip damaged
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use Replace the flange. Check that the pinion spline is not excessively
Pinion nut loosened worn. Replace bevel gear set if required
Pinion axle backlash

Fatigue failure of pinion teeth
CAUSES REMEDY
Exhaustive use Replace bevel gear set
Continuous overload
Pinion and ring teeth breakage
CAUSES REMEDY
Crash load of differential components Check and/or replace other differential components
Side gear spline worn out
CAUSES REMEDY
Excessive use Replace differential gear group. Replace half shaft if required
Thrust washer surface worn out or scratched
CAUSES REMEDY
Lack of lubrication; contaminated oil, improper Use correct lubricants, fill to proper levels and replace according to the
lubrication recommended schedule. Replace all scratched washers and those with
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES REMEDY
Excessive use axial pinion Replace bearing. Check pinion axial backlash. Use correct lubricants,
Excessive pinion axial backlash fill to proper levels and replace according to the recommended sched-
ule.
Insufficient lubrication; contaminated oil
Bent or broken half shaft or half shaft broken at wheel side
CAUSES REMEDY
Vehicle intensively operated or overloaded Replace. Check that wheel support is not worn out or incorrectly
Wheel support loosened adjusted.
Beam body bent
WB140-2N WB150-2N 20-91

12
TRANSMISSION
Vehicle does not move

CAUSES REMEDY
Faulty supply to solenoid valves 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
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 synchronizers Replace
Blocked reverse lever Repair
Worn clutch Replace/repair clutch
No drive transmission, broken gears, shafts, bear- Check/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
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 connec- Repair/Replace
tions
Damaged sensors Replace
20-92 WB140-2N WB150-2N

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 oil thermostat Replace
Incorrect oil level Add oil
Worn oil pump Replace
Wheels rotate when vehicle is raised
CAUSES REMEDY
Clutch plate drag Repair/Replace
Low oil temperature (high oil viscosity) Wail 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 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
Electrical system fault Repair/Replace
Worn clutch plates Replace
Low oil temperature (high oil viscosity) Wail for oil to reach operating temperature (stall test)
Overheating See “Overheating”
Damaged hydraulic system Repair/Replace
WB140-2N WB150-2N 20-93

12
Gear remains engaged
CAUSES REMEDY
Damaged/jammed shuttle shaft lever Repair/Replace
Damaged hydraulic system Repair/Replace
Damaged clutch Repair/Replace
Damaged gear lever rod Replace
Damaged synchronizer Replace
No 4WD power transmission
CAUSES REMEDY
Damaged 4WD clutch Replace
Hydraulic system fault Repair/Replace
Faulty brake sensor Check/Replace
Gear shift will not engage
CAUSES REMEDY
Damaged shifter Replace
Damaged synchronizer Replace
20-94 WB140-2N WB150-2N

30 REMOVAL AND INSTALLATION
METHOD OF USING THIS MANUAL ..............................30-3 RADIATOR OIL COOLERS ........................................... 30-49
REMOVAL OR INSTALLATION OF ASSEMBLIES .... 30-3 REMOVAL.................................................................. 30-49
PRECAUTIONS DURING SERVICE OPERATIONS.......30-4 INSTALLATION.......................................................... 30-51
REMOVAL PRECAUTIONS ........................................ 30-4 AC CONDENSER .......................................................... 30-52
INSTALLATION PRECAUTIONS ................................ 30-4 REMOVAL.................................................................. 30-52
SPECIAL TOOLS .............................................................30-5 INSTALLATION.......................................................... 30-53
LISTING....................................................................... 30-5 MUFFLER ...................................................................... 30-54
SKETCHES ................................................................. 30-7 REMOVAL.................................................................. 30-54
ENGINE COMPONENTS...............................................30-10 INSTALLATION.......................................................... 30-54
LOADER CYLINDER LOCK...........................................30-11 EXHAUST STACK ......................................................... 30-55
LOCKING PROCEDURES ........................................ 30-11 REMOVAL.................................................................. 30-55
STARTER.......................................................................30-12 INSTALLATION.......................................................... 30-55
REMOVAL ................................................................. 30-12 ENGINE HOOD ............................................................. 30-56
INSTALLATION ......................................................... 30-12 REMOVAL.................................................................. 30-56
ALTERNATOR ...............................................................30-13 INSTALLATION.......................................................... 30-56
REMOVAL ................................................................. 30-13 CAB ............................................................................... 30-57
INSTALLATION ......................................................... 30-13 TIER I ENGINE .......................................................... 30-57
AC COMPRESSOR .......................................................30-14 TIER II ENGINE ......................................................... 30-61
REMOVAL ................................................................. 30-14 AC AND HEATER.......................................................... 30-66
INSTALLATION ......................................................... 30-15 REMOVAL.................................................................. 30-66
INJECTION PUMP .........................................................30-16 INSTALLATION.......................................................... 30-67
TIER I ENGINE.......................................................... 30-16 FUEL TANK ................................................................... 30-68
TIER II ENGINE......................................................... 30-19 REMOVAL.................................................................. 30-68
VALVE COVER ..............................................................30-22 INSTALLATION.......................................................... 30-69
TIER I ENGINE.......................................................... 30-22 HYDRAULIC TANK ....................................................... 30-70
INJECTION NOZZLE .....................................................30-25 INSTALLATION.......................................................... 30-71
TIER I ENGINE.......................................................... 30-25 ENGINE AND TRANSMISSION .................................... 30-72
THERMOSTAT...............................................................30-28 INSTALLATION.......................................................... 30-77
TIER I ENGINE.......................................................... 30-28 PISTON PUMP .............................................................. 30-79
COOLANT PUMP...........................................................30-30 INSTALLATION.......................................................... 30-80
TIER I ENGINE.......................................................... 30-30 TRANSMISSION ........................................................... 30-81
TURBOCHARGER.........................................................30-35 INSTALLATION.......................................................... 30-84
REMOVAL ................................................................. 30-35 DISASSEMBLY .......................................................... 30-85
INSTALLATION ......................................................... 30-37 REASSEMBLY ......................................................... 30-133
CYLINDER HEAD ..........................................................30-38 TORQUE CONVERTER .............................................. 30-177
TIER I ENGINE.......................................................... 30-38 REMOVAL................................................................ 30-177
TIER II ENGINE......................................................... 30-42 INSTALLATION........................................................ 30-178
BATTERY DISCONNECT SWITCH...............................30-47 STEERING VALVE ...................................................... 30-179
REMOVAL ................................................................. 30-47 REMOVAL................................................................ 30-179
INSTALLATION ......................................................... 30-47 INSTALLATION........................................................ 30-180
COUNTERWEIGHT .......................................................30-48 COLUMN CONTROL SWITCHES............................... 30-181
REMOVAL ................................................................. 30-48 REMOVAL................................................................ 30-181
INSTALLATION ......................................................... 30-48 INSTALLATION ..................................................30-182
WB140-2N WB150-2N 30-1 b

REMOVAL AND INSTALLATION TABLE OF CONTENTS
REMOVAL ............................................................... 30-181 BOOM.......................................................................30-329

INSTALLATION ....................................................... 30-182 SWING BRACKET ...................................................30-330
MASTER BRAKE CYLINDER ..................................... 30-183 OUTRIGGERS .........................................................30-331
REMOVAL ............................................................... 30-183
INSTALLATION ....................................................... 30-183
LOADER CONTROL VALVE....................................... 30-185
REMOVAL ............................................................... 30-185
INSTALLATION ....................................................... 30-186
2WD FRONT AXLE ..................................................... 30-187
REMOVAL ............................................................... 30-187
INSTALLATION ....................................................... 30-188
DISASSEMBLY........................................................ 30-188
4WD FRONT AXLE ..................................................... 30-198
REMOVAL ............................................................... 30-198
INSTALLATION ....................................................... 30-199
DISASSEMBLY........................................................ 30-199
REASSEMBLY......................................................... 30-208
REAR AXLE ................................................................ 30-224
REMOVAL ............................................................... 30-224
INSTALLATION ....................................................... 30-225
DISASSEMBLY........................................................ 30-225
REASSEMBLY......................................................... 30-240
LOADER CYLINDERS ................................................ 30-259
BOOM ...................................................................... 30-259
BUCKET .................................................................. 30-263
INSTALLATION ....................................................... 30-264
MP BUCKET CYLINDER ......................................... 30-268
FRONT EQUIPMENT .................................................. 30-274
BUCKET .................................................................. 30-274
BOOM ...................................................................... 30-275
BACKHOE CONTROL VALVE .................................... 30-278
BACKHOE CONTROL ............................................. 30-278
INSTALLATION ....................................................... 30-279
EXCAVATOR CONTROLS ...................................... 30-279
PPC CONTROLS ........................................................ 30-283
PPC VALVE ............................................................. 30-283
SUPPORT RELEASE CABLES ............................... 30-284
SUPPORT RETURN GAS SPRING ........................ 30-287
SOLENOID VALVE .................................................. 30-289
SERVO CONTROL FEED VALVE........................... 30-290
BACKHOE CYLINDERS.............................................. 30-291
BOOM ...................................................................... 30-291
INSTALLATION ....................................................... 30-291
ARM ......................................................................... 30-297
BUCKET .................................................................. 30-301
INSTALLATION ....................................................... 30-302
TELESCOPIC ARM ................................................. 30-306
OUTRIGGERS ......................................................... 30-311
SWING ..................................................................... 30-317
BOOM LOCK ........................................................... 30-321
BACKHOE WORK EQUIPMENT................................. 30-323
BOOM TO BUCKET................................................. 30-323
BUCKET .................................................................. 30-324
STANDARD ARM .................................................... 30-325
TELESCOPIC ARM ................................................. 30-326
INNER ARM ............................................................. 30-327
INNER ARM GUIDES .............................................. 30-328
30-2 b WB140-2N WB150-2N

REMOVAL AND INSTALLATION METHOD OF USING THIS MANUAL
12
METHOD OF USING THIS MANUAL
REMOVAL OR INSTALLATION OF PARTS OR ASSEMBLIES
A. When removing or installing any parts or unit assemblies, the order of work and techniques used are given for removal
operations. The order for installation operations is not given unless specified.
B. Any special techniques applying only to the installation procedures are marked . The same mark is placed after the
relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
[Example]
{ { { { ASSEMBLY............................................................. Component.
REMOVAL................................................................................. Operation to be performed.
WARNING .......................................................................... Precaution related to safety when carrying out the operation.
1.XXXX A ................................................................................. Step in operation.
★................................................................................................. Technique or important point to remember when removing
XXX (1).
2. ▲ ▲ ▲ ▲ B ............................................................ Indicates a technique is listed for use during installation
............................................................................................. See Lubricant and Coolant Table.

INSTALLATION........................................................................ Operation to be perform
● .................................................................................................. Carry out installation in the reverse order of removal.
............................................................................................. Technique used during installation.
★................................................................................................. Technique or important point to remember when installing.
● Adding water, oil ..................................................................... Step in operation.
★................................................................................................. Point to remember when adding water or oil.
............................................................................................. Quantity when filling with oil or water.
1. General precautions when carrying out installation or removal, disassembly or assembly of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the
operation.
2. Listing of special tools
① For details of the description, part number, and quantity of any tool (A1, etc.) that appears in the operation procedure,
see the SPECIAL TOOLS given in this manual.
➁ Special tools marked ★ in the table cannot be supplied.
➂ Special tools with part number 79{T-{{{{-{{{ in the table are prohibited for supply.
➃ Special tools marked { in the sketch column are tools introduced in this manual in sketches for special tools. Howev-
er, note that Komatsu cannot accept any responsibility for special tools manufactured according to the sketch.
3. General precautions when carrying out installation or removal (disassembly or assembly) of units given together as PRE-
CAUTIONS WHEN CARRYING OUT OPERATION, be sure to follow these precautions when performing the opera-
tion.
4. List of special tools: For details of the description, part number and quantity of any tools that appear in the operation pro-
cedure, see SPECIAL TOOLS.
Remark A procedure that must be observed when performing a certain operation.
WB140-2N WB150-2N 30-3 1

REMOVAL AND INSTALLATION PRECAUTIONS DURING SERVICE OPERATIONS
12
PRECAUTIONS DURING SERVICE OPERATIONS
When dissembling, assembling or installing a part or component, always follow these listed general rules of safety. Failure to
do so may result in damage to the system being repaired or injury to the technician doing the repair.
REMOVAL PRECAUTIONS
• Unless indicated otherwise, always lower all work equipment down until it rests firmly on the ground.
• Always trap and recycle all coolants and oils. Be sure your containers are large enough.
• Cap, cover or plug any openings to prevent dirt or debris from entering when you remove a component or part.
• Before removing a cylinder, secure the ram in a retracted position.
• Before removing or disassembling any parts, mark the order in which they came apart.
• When removing hydraulic couplings, always support the line or hose you are removing it from to avoid twisting or kink-
ing the line.
• When removing any lines always tag the line with a reference tag or mark as to where it is to be installed.
• When using eye bolts to lift an item be sure the eye bolt is installed all the way in the part you will be lifting.
• When removing a part in a wet attachment, be sure you have the proper drain pans to catch any residual fluids.
• Keep your work area clean and organized at all times.
INSTALLATION PRECAUTIONS
• Always use the specified torque when tighten nuts or bolts. Never dry torque a fastener, always lubricate the fastener be-
fore torquing it.
• Never use impact tools to start a nut or bolt. Always start nuts and bolts by hand first.
• Secure all cotter keys according to the instructions listed.
• When using adhesives on surfaces or fasteners, be sure the surface is clean and free of oil, dirt or grease.
• Clean all parts before installing them.
• Be sure snap rings are installed correctly and firmly in place.
• When installing a component always follow the tightening pattern for multiple fasteners.
30-4 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION SPECIAL TOOLS
12
SPECIAL TOOLS
LISTING
Remark
Necessity: NEC ■ ...................... Cannot be substituted, should always be used.
● ...................... Extremely useful if available, can be substituted with localized part
New Remodel N/R: N ...................... Tools with new part numbers, newly developed for this model.
R ...................... Tools with upgraded part numbers, remodeled from items already
available for other models.
Blank................ Tools already available for other models, used w/o any modification.
Tools marked { in the Sketch column are tools introduced in the sketches of the special tools.
Component Symbol Part Number Part Name NEC Qty N/R Sketch Nature Of Work
1 ATR200620 Cylinder stand ● 1 Cylinder overhaul
Bushing driver - ∅40 mm 1
2 Localize Bushing installation
960117005 1
3 Seal compressor Piston seal
960117006 1
4A Gland wrench - ∅-- mm ■ 1 { Loader MP bucket
4B Gland wrench - ∅85 mm ■ 1 { Backhoe telescopic arm
4C Gland wrench - ∅95 mm ■ 1 { Loader bucket
4D Gland wrench - ∅100 mm ■ 1 { Loader boom
4E Gland wrench - ∅110 mm ■ 1 { Backhoe bucket
4F Gland wrench - ∅125 mm ■ 1 { Backhoe arm/outrigger
5 Gland wrench - ∅140 mm ■ 1 { Backhoe boom
6 ATR200300 Gland wrench - ∅90 mm ■ 1 { Backhoe swing
Six point socket - 45 mm 1
7 Localize Six point socket - 55 mm 1 Piston retention
Six point socket - 65 mm 1
Wiper seal driver - ∅40 mm 1
8 Localize Rod wIper seal
Work Cylinders A Wiper seal driver - ∅55 mm 1
ATR201000 Seal guide - ∅78 mm piston 1
9 ATR201050 Seal guide - ∅94 mm piston 1 Piston seal installation
ATR201160 Seal guide - ∅40 mm rod 1
10 ATR201180 Seal guide - ∅50 mm rod 1 Piston rod installation
ATR201200 Seal guide - ∅85 mm barrel 1
Piston/gland in barrel
11 ATR201250 Seal guide - ∅100 mm barrel 1 12Piston/gland in
barrel
WB140-2N WB150-2N 30-5 1

Component Symbol Part Number Part Name NEC Qty N/R Sketch Nature Of Work
Air Conditioning Unit B Localize Maintenance station 1 Draining and refilling
CA 119 033 Universal driver handle ■ 1 { Used with drivers
1 CA 715 027 Bushing driver ■ 1 { Wheel carrier bushing
2 CA 715 265 Ring nut adjuster ■ 1 { Differential ring nut
3 CA 715 022 Pinion gear wrench ■ 1 { Pinion gear
4 CA 119 099 Pinion gear wrench ■ 1 { Pinion gear
5 CA 119 225 Bearing driver ■ 1 { Pinion bearing cups
6 CA 715 023 False pinion gear ■ 1 {
7 CA 119 228 False differential half ■ 1 { Differential set up
8 CA 119 182 False differential half ■ 2 {
9 CA 715 021 Bearing driver ■ 1 { Pinion bearing cone
10 CA 119 230 Bearing driver ■ 1 { Differential bearing cone
Front Axle D
11 CA 715 087 Seal driver ■ 1 { Pinion shaft seal
12 CA 715 163 Seal driver ■ 1 {
Axle pivot pin
13 CA 715 164 Bushing driver ■ 1 {
14 CA 715 034 Bushing driver ■ 1 { King pin bushings
Housing ends
16 CA 715 396 Seal driver ■ 1 {
Steering knuckle
18 CA 715 087 Seal driver ■ 1 {
19 CA 715 035 Bearing driver ■ 1 { Lower king pin
20 CA 715 026 Bearing driver ■ 1 { Wheel hub bearing cup
21 CA 119 143 Seal driver ■ 1 { Wheel hub seal
1 CA 715 027 Bushing driver ■ 1 { Wheel carrier bushing
2 CA 715 265 Ring nut adjuster ■ 1 { Differential ring nut
3 CA 715 022 Pinion gear wrench ■ 1 {
Pinion gear
4 CA 119 099 Pinion gear wrench ■ 1 {
5 CA 715 380 Bearing driver ■ 1 { Pinion bearing cups
6 CA 715 128 False pinion kit ■ 1 { Pinion gear
7 CA 715 388 False differential kit ■ 1 { Differential
8 CA 715 167 Bearing driver ■ 1 { Pinion bearing cones
9 CA 715 028 Bearing driver ■ 1 { Differential bearing cones
Rear Axle E
10 CA 715 391 Bearing driver ■ 1 { Differential bearing cups
11 CA 119 033 Universal driver handle ■ 1 { Used with drivers
12 CA 715 056 Insert kit ■ 1 { Brake piston
13 CA 715 055 Backlash kit ■ 1 { Ring and pinion gears
14 CA 715 466 Seal ring driver ■ 1 { Pinion gear
Axle housing
16 CA 715 467 Seal driver ■ 1 {
17 CA 715 026 Bearing driver ■ 1 {
Wheel hub
18 CA 119 143 Seal driver ■ 1 N {
1 CA 715 354 Seal driver ■ 1 N { Front output flange
2 CA 715 501 Seal driver ■ 1 N { Rear output flange
3 CA 715 358 Spring compressor ■ 1 N { Forward reverse clutch
Transmission F 4 CA 715 004 Bearing driver ■ 1 N {
Main shaft
5 CA 715 149 Bearing driver ■ 1 N {
6 CA 715 410 Spring compressor ■ 1 N { 4WD Shaft
7 CA 715 409 Seal driver ■ 1 N { Oil pump
1 Puller ■ 1
Fuel Injection Pump X Fuel pump
2 Puller bollts ■ 2
30-6 1 WB140-2N WB150-2N

12
SKETCHES
Unit - mm
ITEM A4A A4B A4C A4D A4E A4F A5 A6
a 492 492 492 492 492 492 492 492
b 20 20 20 20 20 20 20 20
c 35 35 35 35 35 35 35 35
d 480 480 480 480 480 480 480 480
e 115 125 130 140 155 170 120
f 85 95 100 110 125 140 90
g 55 65 70 80 95 110 60
h 30 30 30 30 30 30 30 30
i R27.5 R32.5 R35 R40 R47.5 R55 R30
j R42.5 R47.5 R50 R55 R62.5 R70 R45
1) R57.5 R62.5 R60 R70 R77.5 R85 R60
1! R100 R100 R100 R100 R100 R100 R100 R100
1@ 5x45° 5x45° 5x45° 5x45° 5x45° 5x45° 5x45° 5x45°
1# 6 6 6 6 6 6 6 6
1$ 12 12 12 12 12 12 12 12
1% 9 9 9 9 9 9 9 9
1^ 35 35 35 35 35 35 35 35
1& 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8
1* 6.4 6.4 6.4 6.4 6.4 6.4 6.4 6.4
1( 6x6 6x6 6x6 6x6 6x6 6x6 6x6 6x6
2) 22 22 22 22 22 22 22 22
2! 80 80 80 80 80 80 80 80
2@ 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5
WB140-2N WB150-2N 30-7 1

12
D D1 D2 D3 D4 D5
D6 D7 D8 D9 D10 D11
D12 D13 D14 D15 D16 D17
D18 D19 D20 D21
E1 E2 E3 E4 E5 E6
E7 E8 E9 E10 E11 E12
E13 E14 E15 E16 E17 E18
30-8 1 WB140-2N WB150-2N

12
F1 F2 F3 F4 F5 F6
F7
WB140-2N WB150-2N 30-9 1

REMOVAL AND INSTALLATION ENGINE COMPONENTS
12
ENGINE COMPONENTS
★ For removal, installation, disassembly and assembly of engine
components, see the ENGINE SHOP MANUAL.
30-10 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION LOADER CYLINDER LOCK
12
LOADER CYLINDER LOCK
For removal and installation of components under the engine hood that
cannot be easily accessed without raising the front end loader. In order
to remove, install or service these components the front end loader must
be raised and properly secured in place. Failure to do so may result in
injury or even death to the technician performing these procedures.
LOCKING PROCEDURES
In A, the front end loader cylinder lock b must be used any time you
will be performing maintenance on the machine with the front end load-
er raised. To use the cylinder lock:
1. In B, remove the cylinder lock assembly pin a holding on to the

lock unit b.
2. Using both hands lower the lock unit b down from it’s storage po-
sition and remove it from the lift arm.
3. Raise the front end loader unit completely in the air extending the
lifting cylinders.
4. Install the cylinder lock b in the position shown in A, keeping the

safety pin boss against the lift cylinder gland nut.
5. Insert the safety pin a completely into the predrilled holes and lock
the pin in place with the smaller pin provided.
6. Slowly lower the front end loader unit until it makes contact with
the cylinder lock.
7. Check to be sure the cylinder lock is securely in place before pro-

ceeding with any procedures under the front end loader.
WB140-2N WB150-2N 30-11 1

REMOVAL AND INSTALLATION STARTER
12
STARTER
REMOVAL
1. With the front loader raised and secured in place, stop the engine
and set the parking brake.
2. Cut off the electrical supply to the system using the knob a of main
electrical disconnect switch b.
3. To disconnect the electrical supply, turn the battery disconnect

switch counterclockwise. To connect the electrical supply turn the
switch clockwise
WARNING! Never remove or service the starter without

disconnecting the electrical supply.
4. Disconnect the electrical wiring d and tag the wires.
5. Loosen the two bolts e holding the starter in place and carefully re-
move the starter motor c.
Remark Do not let the starter hang by the wiring harness, dam-
age to the wiring may result. Remove the wiring first
before removing the starter motor.
INSTALLATION
• Carry out installation in the reverse order of removal.
Starter motor mounting bolts .................................. 80 N•m
30-12 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION ALTERNATOR
12
ALTERNATOR
REMOVAL
1. With the front end loader raised and secured in place, stop the en-
gine and set the parking brake.
2. Cut off the electrical supply to the system using the knob a of main
electrical disconnect switch b.
3. To disconnect the electrical supply, turn the battery disconnect

switch counterclockwise. To reconnect the electrical supply turn
the switch clockwise.
WARNING! Never remove or service the alternator with-

out disconnecting the electrical supply.
4. Disconnect the exciter cable c, the connector d and f.
5. Loosen the adjustment bolt g and h mount i. Loosening these

fasteners will leave the alternator f free to move.
6. Loosen the bolt h and remove the bolt g.
7. Push the alternator f rearward towards the engine to remove the

belt j.
8. Once the belt j is off the alternator, remove support bolt h and lift
the alternator f from the mounting boss.
INSTALLATION
★ Adjust the fan belt tension. For details, see TESTING AND
ADJUSTMENT.
WB140-2N WB150-2N 30-13 1

REMOVAL AND INSTALLATION AC COMPRESSOR
12
AC COMPRESSOR
WARNING! Do not discharge refrigerant into the open
atmosphere, doing so is in violation of the law and could
produce dangerous gasses if exposed to an open flame.
REMOVAL
1. With the front end loader raised and secured in place, stop the en-
gine and set the parking brake.
2. Remove the fan guard A.
3. Before preceding with any removal procedures, it is important to

capture and recycle all the refrigerant from the system first. Re-
move the caps B and C and install the recycling machine B.
4. Disconnect the electrical connector d from the compressor g.
5. Loosen the idler pulley bolt e and remove the belt f from the com-
pressor.
6. Once the system is completely discharged, special tool B remove

the bolt i from the bracket j. Once the suction and delivery lines
1) and 1@ are removed, cap and plug to prevent moisture from enter-
ing into system.
30-14 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION AC COMPRESSOR
12
7. Remove the front mounting bolts 1@ and rear nuts 1#.
8. Carefully lift the compressor g from the mounting boss along with
the heat shield 1!.
INSTALLATION
★ Adjust the compressor belt tension. For details, see section

TESTING AND ADJUSTMENT.
Idler pulley mounting bolt .................................... 123 N•m
- TIER I Engine
Compressor mounting bolt ..................................... 32 N•m
- TIER II Engine
★ Tighten the flanges on the compressor.
Compressor mounting bolt ..................................... 32 N•m

R134A quantity - TIER I Engine.............................. 975 g
R134A quantity - TIER II Engine.................2250 ±150 g
WB140-2N WB150-2N 30-15 1

REMOVAL AND INSTALLATION INJECTION PUMP
12
INJECTION PUMP
WARNING! Fully raise the front working equipment and
engage the safety stop. Lower the backhoe to the ground.
Set the parking brake.
TIER I ENGINE
REMOVAL
1. Cut off the electrical supply to the system using the knob b of main
electrical disconnect switch a. To disconnect the electrical supply,
turn the battery disconnect switch lever counterclockwise. To re-
connect the electrical supply turn the switch lever clockwise
★ Plug all tubes that have been removed or disconnected to prevent

entry of impurities.
2. Remove the engine coolant liquid container c.
3. Disconnect the fuel supply e and flow back hoses f from the in-
jection pump d.
4. Disconnect the high pressure pipes g.
5. Disconnect the fuel feed hose i and delivery tube j from the feed
pump h.
6. Disconnect the tube 1) from the oil level dipstick and remove it.
Remove the support bracket 1! of the pump.
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12
7. Disconnect the accelerator control cable support 1# from the lever
1@.
8. Disconnect the engine stop solenoid 1$ from the injection pump d.

Lift out the entire group.
9. Remove the retaining clip 1% of the injection pump lubrication tube.
10. Disconnect the lubrication tube 1^.
11. Remove the access cover 1& to the distribution gear and the oil filler
plug 1*.
WB140-2N WB150-2N 30-17 1

12
12. Loosen and lift off the retaining nut 1( and safety washer 2) of the
pump driving gear 2!.
★ Take great care not to drop the safety washer 2) into the pump
casing.
13. Remove the driving gear 2! of the pump d.
★ Before removing the pump driving gear, mark its position with
respect to the idle gear.
★ For removal, use puller X1. The puller bolts X2 thread direct-
ly into the gear 2!. Take care not to damage the pump shaft
threads. During removal, be careful not to let the key 2@ drop
into the housing.
14. Take out the four nuts 2$ and remove the injection pump d with its
o-ring seal 2#.
INSTALLATION
• To install, reverse the removal procedure.
Fuel feed hoses ..............................................25 to 34 N•m
Bolt, pump side..............................................44 to 54 N•m
Fuel feed hoses ..................................................22 ±8 N•m
★ Put in a new safety cotter pin.
Cover gasket ....................................................ASL800070
Cover bolts.............................................................. 18 N•m
30-18 1 WB140-2N WB150-2N

12
★ Align the marks between the gears before installing the pump
and mounting the nut.
Gear locking nut ............................................84 to 93 N•m
Pump locking nut...........................................35 to 43 N•m
1. Check fuel injection timing, for details, see TESTING AND AD-
JUSTMENTS.
TIER II ENGINE
REMOVAL
turn the battery disconnect switch lever counterclockwise. To con-
nect the electrical supply turn the switch lever clockwise
★ Plug and cap all tubes and fittings that have been removed or dis-
connected to prevent entry of impurities.
3. Disconnect the fuel supply e and flow back f hoses from the in-
jection pump d.
4. Disconnect the high pressure pipes g.
WB140-2N WB150-2N 30-19 1

12
5. Disconnect the tube h from the oil level dipstick and remove.
6. Disconnect the hoses i and j from the feed pump 1).
7. Disconnect the connector 1!.
8. Disconnect the accelerator control cable support 1@ from the lever

1#.
9. Remove the retaining clip 1$ of the injection pump lubrication tube.
10. Disconnect and remove the lubrication tube 1%. Remove the bracket
1^.
11. Remove the access cover 1& to the distribution gear and the oil filler
plug 1*.
30-20 1 WB140-2N WB150-2N

12
12. Loosen and lift off the retaining nut 1( and safety washer 2) of the
pump driving gear 2!.
★ Take great care not to drop the safety washer 1( into the pump
casing.
13. Remove the driving gear 2! of the pump c.
★ Before removing the pump driving gear, mark its position with
respect to the idle gear.
★ For removal use a puller X1. The puller bolts X2 bolt directly
into the gear 2!. Take great care not to damage the pump shaft
thread. During removal, be careful not to let the key 2@ drop in-
to the housing.
14. Take out the four nuts 2$ and remove the injection pump d with its
o-ring seal 2#.
INSTALLATION
Bolt, pump side..............................................44 to 54 N•m
Fuel feed hoses ..................................................22 ±8 N•m
Cover gasket ....................................................ASL800070
Cover bolts.............................................................. 18 N•m
★ Align the marks between the gears before installing the pump
and mounting the nut.
Gear locking nut ............................................84 to 93 N•m
Pump locking nut...........................................35 to 43 N•m
1. Check fuel injection timing, for details, see TESTING AND AD-
JUSTMENTS.
WB140-2N WB150-2N 30-21 1

REMOVAL AND INSTALLATION VALVE COVER
12
VALVE COVER
TIER I ENGINE
REMOVAL
1. Remove the air filter a and muffler b. Remove the hardware and
valve cover c.
2. Check condition of valve cover c, gasket e, o-rings f and plugs

f; carefully clean the contact surface of the cylinder head.
INSTALLATION
Cover lock nuts ..................................................25 ±3 N•m
TIER II ENGINE
REMOVAL
1. Remove the air filter A and the muffler B.
2. Loosen the muffler support bolts c and remove the air intake duct
d and cold start aid e.
★ Cap the turbocharger and intake holes to prevent contamina-

tion.
★ Inspect the seals for signs of damage.
30-22 1 WB140-2N WB150-2N

12
3. Disconnect the injector fuel feed pipes f.
4. Remove clamp g and loosen clamp h.
5. Loosen the fittings of the fuel feed pipes i on the pump j.
6. Rotate the pipes f until they become disengaged from the valve
cover 1).
7. Remove the feed through fittings 1! and their seals.
WB140-2N WB150-2N 30-23 1

12
8. Loosen and remove the bolts 1@ retaining the valve cover 1).
★ Inspect the grommets.
9. Remove the valve cover 1).
★ Inspect the seal. Replace the seal if it is damaged or cracked.

INSTALLATION
Bolt .....................................................................45 to 55 N•m
Bolt ................................................................... Loctite 262
Union .................................................................19 to⎟24 N•m
Bolt ........................................................................ 7 το 9 N•m
Nut ......................................................................16 to 22 N•m
30-24 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION INJECTION NOZZLE
12
INJECTION NOZZLE
TIER I ENGINE
REMOVAL
nect the electrical supply turn the switch lever clockwise.
2. Disconnect the for a clogged air filter sensor c.
3. Remove the air filter d, the supporting bracket e and the intake
sleeve f.
4. Remove the muffler, for details, see MUFFLER.
5. Remove the intake duct g.
6. Loosen the clip h and remove the high pressure lines i.
7. Disconnect the fuel flow back pipes j.
8. Remove the nuts 1) that secure the collar 1! and take out the injector
1@, the seating 1# and the proection piece 1$.
9.
INSTALLATION
Bracket bolt....................................................... Loctite 262
Bracket bolt....................................................45 to 55 N•m
Bracket bolt....................................................... Loctite 262
High pressure pipes............................................24 ±4 N•m
Hose clamp bolts ...............................................10 to 12 N•m
Collar lock nuts .................................................10 to 12 N•m
WB140-2N WB150-2N 30-25 1

12
TIER II ENGINE
REMOVAL
2. Disconnect the sensor c for a clogged air filter.
3. Remove the air filter d, the supporting bracket e and the intake
sleeve f.
4. Remove the muffler, for details, see MUFFLER.
5. Remove the intake duct g and the cold start aid h.
★ Cap the turbo and intake holes to prevent contamination.

★ Inspect the seals for signs of damage.
6. Remove clamp i and loosen clamp j.
7. Remove the valve cover, see VALVE COVER.
30-26 1 WB140-2N WB150-2N

12
8. Loosen and remove the fittings 1) retaining the fuel recovery pipe
1!, and the seals.
9. Loosen the fitting 1@ and rotate the pipe 1# outward.
10. Loosen and remove the bolt 1# retaining the injection nozzle clamp
1$.
11. Turn the bracket 1% over and pull out the injection nozzle 1^.
★ Use care not allow dirt inside the injection nozzle and the in-
jector nozzle seat.
INSTALLATION
Clamp bolts........................................................10 to 12 N•m
Union ...................................................................8 to 10 N•m
Bracket bolt .......................................................22 to 28 N•m
WB140-2N WB150-2N 30-27 1

REMOVAL AND INSTALLATION THERMOSTAT
THERMOSTAT
TIER I ENGINE
REMOVAL
★ Drain the engine coolant liquid.
Coolant liquid ...............................................................18 l
2. Disconnect the cable c to the clogged air filter indicator d and re-
move the entire suction filter e.
3. Remove the fan guard f.
4. Disconnect the radiator connection sleeve h from the thermostat

cover g.
5. Take out the bolts and remove the thermostat cover g.
6. Remove the gasket i, the thermostat j and the ring seal 1).
★ Put in new seals.
INSTALLATION
A. Refill the coolant liquid tank.
Coolant liquid ...............................................................18 l
B. Start the engine at low idle to circulate the coolant liquid

through all circuits.
C. Accelerate gradually up to 1700 rpm. After about one minute,
stop the engine and check or top up the level in the container.
★ Check that there are no leaks.
Cover bolts.....................................................22 to 28 N•m
30-28 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION THERMOSTAT
12
TIER II ENGINE
REMOVAL
connect the electrical supply turn the switch lever clockwise.
Coolant liquid ...............................................................18 l
2. Disconnect the cable c to the clogged air filter indicator d and re-
move the entire filter e.
3. Remove the fan guard f.
4. Disconnect the radiator upper hose h from the thermostat cover g.
5. Take out the bolts and remove the thermostat cover g.
6. Remove the gasket i, the thermostat j and the ring seal 1).
★ Put in new seals.
INSTALLATION
Coolant liquid ...............................................................18 l

Cover bolts.....................................................22 to 28 N•m
WB140-2N WB150-2N 30-29 1

REMOVAL AND INSTALLATION COOLANT PUMP
COOLANT PUMP
TIER I ENGINE
REMOVAL
Coolant liquid ...............................................................18 l
3. Remove the fan guard d.
4. Disconnect the cable e of the clogged filter indicator and remove

the air filter f.
5. Remove the alternator and its support g for details, see ALTER-
NATOR.
30-30 1 WB140-2N WB150-2N

12
6. AC Machines: Remove the air-conditioning unit compressor h and
its supports. Put the compressor to one side, for details, see AC
COMPRESSOR.
7. Disconnect the cab heating pipes i.
8. Disconnect the temperature sensor cables.
9. Remove the radiator oil cooler, for details, see RADIATOR.
10. Remove the fan j, the spacer 1) and the pulley 1!.
11. Remove the four bolts 1@ and then the pump 1#.
★ Replace all seals with new ones.
INSTALLATION
A. Refill the coolant liquid tank. Start the engine at low idle to cir-
culate the coolant liquid through all circuits.
Coolant liquid ...............................................................18 l
WB140-2N WB150-2N 30-31 1

12 B. Accelerate gradually up to 1700 rpm. After about one minute,

★ Check that there are no leaks. Apply tension to the alternator
belt.
Bolts for alternator support ..............................22 to 28 N•m
Bolts for pulley and fan ....................................44 to 54 N•m
Pump bolts .........................................................22 to 28 N•m
Locking bolt for compressor ..................................... 64 N•m
TIER II ENGINE
REMOVAL
Coolant liquid ...............................................................18 l
30-32 1 WB140-2N WB150-2N

12
3. Remove the fan guard d.
4. Disconnect the cable e of the clogged filter indicator and remove

the air filter f.
5. Remove the alternator and its support g, for details, see ALTER-
NATOR.
6. AC Machines: Remove the AC compressor H and its supports. Put

the compressor to one side, for details, see AC COMPRESSOR.
7. Disconnect the cab heating pipes I.
8. Disconnect the temperature sensor cables.
9. Remove the radiator oil cooler, for details, see RADIATOR.
WB140-2N WB150-2N 30-33 1

12
10. Remove the fan J, the spacer 1) and the pulley 1!.
11. Remove the bolts 1@ and then the complete pump 1#.
★ Replace all seals with new ones.
INSTALLATION
Coolant liquid ...............................................................18 l

★ Apply tension to the alternator belt.
Bolts for alternator support ..............................22 to 28 N•m
Bolts for pulley and fan ....................................44 to 54 N•m
Pump bolts .........................................................22 to 28 N•m
Locking bolt for compressor ..................................... 64 N•m
30-34 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION TURBOCHARGER
12
TURBOCHARGER
REMOVAL
2. Disconnect the clogged air filter indicator d cable c and remove

the air cleaner e.
3. Remove the muffler, see MUFFLER.
4. Disconnect the turbo g coupling f from the intake manifold.
WB140-2N WB150-2N 30-35 1

12
5. Remove the bolts out of the clips h and disconnect the tube i that
delivers the lube oil.
6. Remove the tube retaining bolts j and the bolts 1) that secure the
flange of the lubrication oil drain tube 1!.
7. Remove the bolts 1@ that join the turbo to the coupling, and remove
the coupling 1#.
8. Remove the bolts 1$ and remove the bracket 1%.
9. Remove the nuts 1^, and washers 1& and lift off the turbocharger g.
★ Carefully check the state of all the sealing gaskets. Replace them if
there is any sign of damage.
30-36 1 WB140-2N WB150-2N

12
INSTALLATION
Tube bolts .......................................................... 23 to 28 N•m

Flange bolts........................................................8 to 9 N•m
Coupling joint bolts .......................................... 23 to 28 N•m
Bracket bolts...................................................... 23 to 28 N•m
1. Start the engine and check that there are no leaks in the turbocharg-
er lubrication tubes.
WB140-2N WB150-2N 30-37 1

REMOVAL AND INSTALLATION CYLINDER HEAD
12
CYLINDER HEAD
TIER I ENGINE
REMOVAL
Coolant liquid ...............................................................18 l
2. Remove the container c.
3. Disconnect the cable d of the clogged air filter sensor e and re-
move the air filter f and its support.
★ Remove the turbocharger, see TURBOCHARGER.
4. AC unit: Remove the alternator g, the compressor h and the sup-

porting bracket i. For details, see ALTERNATOR and AC COM-
PRESSOR.
30-38 1 WB140-2N WB150-2N

12
5. Remove the support j.
6. Disconnect the cable 1) of the cold start. Remove the suction mani-
fold 1! and the cold start 1@.
7. Remove the diesel fuel filter 1# and place it to one side. Disconnect
the clip 1$ that secure the heater pipes.
8. Disconnect the breather tube 1% from the engine head.
9. Remove the muffler 1^. For details, see MUFFLER.
10. Remove the muffler support bracket 1&.
WB140-2N WB150-2N 30-39 1

12
11. Disconnect the cables 1* from the temperature sensors 1(.
12. Disconnect the heating pipes 2). Remove the radiator connection
pipes 2!.
13. Remove the coolant liquid pump, see COOLANT PUMP.
14. Disconnect the fuel return hose 2@ from the nozzles and remove the
nozzles, see INJECTION NOZZLE.
15. Remove the valve cover 2#.
16. Remove the valve rocker arm shaft 2&.
★ Loosen the nuts and unscrew the tappets by 2 to 3 turns
17. Remove the rocker arm control rods 2$.
18. Remove the bolts 2% and the cylinder head 2^. Follow the indicated
sequence for loosening the bolts.
★ Sequence to be followed >>>>>>

★ Loosen the cylinder head retaining bolts in two stages.
INSTALLATION
Coolant liquid ...............................................................18 l
B. Check that there are no leaks.
30-40 1 WB140-2N WB150-2N

12
Support bolts........................................................... 32 N•m
Front bolts M8 ........................................................ 32 N•m
Side bolts M10........................................................ 64 N•m
Front bolts M8 ........................................................ 64 N•m
Side bolts M10........................................................ 32 N•m
Intake line bolts................................................. Loctite 262
Bracket and Intake line bolts .........................45 to 55 N•m
Pipe fittings....................................................25 to 34 N•m
Collar lock nuts.............................................. 10 to 11 N•m
★ Check the condition of the seals of the tappet cover and the o-
rings of the fastening nuts. Thoroughly clean the contact sur-
faces on the cylinder heads.
Collar lock nuts..............................................22 to 28 N•m
★ Check that the tappets are firmly engaged in their rods and that
the valve collars are correctly assembled.
Tappet rods..........................................................Engine oil
★ Start tightening the rocker arm shaft from the center towards
the outside bolts and nuts for the rocker arm shaft.
Rocker arm shaft bolts and nuts.....................23 to 28 N•m

★ Adjust the valve clearances.
★ Assemble a new gasket. Tighten the bolts, manually at first, and

then in two stages, following the sequence indicated. >>>
Bolt and cylinder block threads ..........................Engine oil
Cylinder head bolts - 1st................................84 to 98 N•m

Cylinder head bolts - FINAL ....................182 to 191 N•m
Start the engine at low idle to circulate the coolant liquid through
all circuits. Accelerate gradually up to 1700 rpm. After about one
minute, stop the engine and check or top up the level in the contain-
er.
WB140-2N WB150-2N 30-41 1

12
TIER II ENGINE
REMOVAL
Coolant liquid ...............................................................18 l
2. Remove the container c.
3. Disconnect the cable d of the clogged air filter sensor e and re-
move the air filter f and its support.
★ Remove the turbocharger, see TURBOCHARGER.
4. AC unit: Remove the alternator g, the compressor h and the sup-

porting bracket i. For details, see ALTERNATOR and AC COM-
PRESSOR.
30-42 1 WB140-2N WB150-2N

12
5. Remove the support j.
6. Disconnect the cable 1) of the cold start.
7. Remove the valve cover 1!, see VALVE COVER.
★ Replace the gasket.
8. Remove the fuel filter 1@ and move it to one side.
★ Mark the hoses for easier reassembly.
9. Disconnect the clips 1# that secure the heater pipes.
WB140-2N WB150-2N 30-43 1

12
10. Disconnect the breather tube 1$ from the engine head.
11. Loosen the screws 1% and remove the muffler support 1^.
12. Disconnect the cables 1& and 1( from the temperature sensors 1* and
2).
13. Disconnect the heating pipes 2!.
14. Remove the radiator connection pipes 2@.
15. Remove the coolant pump 2# and hardware 2$, see COOLANT
PUMP.
30-44 1 WB140-2N WB150-2N

12
16. Remove the injection nozzles 2%, see INJECTION NOZZLE.
★ Protect the injection nozzle hole and threads to prevent con-

tamination.
17. Loosen the tappets of the rocker arms 2 to 3 turns, 4 places.
18. Loosen and remove the screws 2^ and remove the rocker arm shaft
2&.
19. Loosen and remove the screws 2* and remove the whole cylinder
head 2(.
20. Follow the indicated order for loosening the bolts.
21. >>>>>
★ Loosen the cylinder head retaining bolts in two stages.
INSTALLATION
Coolant liquid ...............................................................18 l
B. Check that there are no leaks.
WB140-2N WB150-2N 30-45 1

12
Support bolts........................................................... 35 N•m
Front bolts M8 ........................................................ 32 N•m
Side bolts M10........................................................ 64 N•m
Front bolts M8 ........................................................ 64 N•m
Side bolts M10........................................................ 32 N•m
★ Check the condition of the seals of the valve cover and the o-rings
of the fastening nuts. Thoroughly clean the contact surfaces on
the cylinder heads.
Cover lock nuts ..............................................17 to 22 N•m
★ Check that the tappets are firmly engaged in their rods and that
the valve collars are correctly assembled.
Tappet rods..........................................................Engine oil
★ Start tightening the rocker arm shaft from the center towards
the outside bolts and nuts for the rocker arm shaft.
Rocker arm shaft bolts and nuts.....................23 to 28 N•m

★ Adjust the valve clearances, see 20 VALVE CLEARANCE.
★ Assemble a new gasket.
Bolt and cylinder block threads ..........................Engine oil

★ Tighten the bolts, manually at first, and then in two stages, fol-
lowing the sequence indicated >>>>>>
Cylinder head bolts - 1st................................84 to 98 N•m
Cylinder head bolts - FINAL ....................182 to 191 N•m
1. Start the engine at low idle to circulate the coolant liquid
2. Accelerate gradually up to 1700 rpm. After about one minute,
30-46 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION BATTERY DISCONNECT SWITCH
12
BATTERY DISCONNECT SWITCH
REMOVAL

1. Remove the battery cover a from the fuel tank b housing.
2. Loosen the battery hold down c and move the battery d outwards.
Lift the protective flap e.
3. Remove the negative (-) terminal clamp first and then the positive
(+) terminal clamp next.
WARNING! It is important that the negative (-) battery ter-

minal clamp is removed first. Doing so will prevent the
chance of a short to ground causing sparks.
4. Once the battery is completely disconnected, open the engine hood

and remove the mounting bolts f that secure the switch g to the
frame.
5. Remove the bolts f that secure the disconnecting switch support g

to the frame. Turn the switch h over and remove the cables i and
j.
★ Make a note of the cable attachment locations.
INSTALLATION
WARNING! It is important that the positive (+) battery ter-

minal clamp is installed first. Doing so will prevent the
1. When installing the battery cables, hook the positive (+) cable up
first then the negative (-) cable next.
★ Adjust the engine hood guide 1).
WB140-2N WB150-2N 30-47 1

REMOVAL AND INSTALLATION COUNTERWEIGHT
12
COUNTERWEIGHT
REMOVAL

1. Loosen the front mounting bolts a slightly first. Using a forklift

truck, position the forks into the openings on the counterweight b
front.
2. Tilt the forks back slightly and remove the mounting bolts a and
washers c carefully.
WARNING! When performing this operation, stand clear

of the counterweight in case it should slip off the forks.
3. Remove the counterweight b carefully.
Counterweight.......................................................... 300 kg
INSTALLATION
Counterweight mounting bolts ............................. 330 N•m
30-48 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION RADIATOR OIL COOLERS
12
RADIATOR OIL COOLERS
REMOVAL
1. Remove the engine hood and gas struts a first, see ENGINE
HOOD.
2. Remove the bolts b and front frame c.
Completely eliminate all residual pressures in all circuits.

For details, see TESTING AND ADJUSTMENTS.
★ Drain and capture all engine coolant and recycle.
WARNING! Do not dump engine coolants down the drain,

on to the ground or into a body of water, doing so is in
violation of the law.
Engine coolant ..............................................................18 l
3. Disconnect the cable d from the horn e. Loosen the bracket g bolts
f.
4. AC Machines: Capture and recycle the refrigerant first, then re-

move the lines h and i. Cap both lines immediately.

WB140-2N WB150-2N 30-49 1

12
5. Disconnect the engine hoses j and 1).
6. Slowly loosen the hoses 1! and 1@ to drain the hydraulic oil from the
radiator 1#. When the oil is fully drained, complete disconnection of
the hoses, and plug them to prevent entry of impurities.
7. Loosen the radiator nuts 1$ and remove them.
8. Disconnect the hoses 1%, cap and plug them to prevent entry of im-
purities.
9. Take out the nuts 1% of the lower iso mounts and remove the entire
radiator group.
30-50 1 WB140-2N WB150-2N

12
INSTALLATION
★ Refill the engine coolant.
Coolant refill amount....................................................18 l
★ Recharge the air conditioning system.
TIER I Engine R134a quantity.................................... 1 kg

TIER II Engine R134a quantity............................. 2.25 kg
★ Align the radiator with the fan and make sure that the fan is in-
serted in the inner conveyor for 2/3 of the blade width.
★ Ensure that the level of hydraulic oil in the tank is at max.
★ Ensure that the level of transmission oil is at max.

1. Start the engine at low idle to circulate all the fluids and to fill up
the systems.
2. Accelerate gradually up to 1700 rpm. After about one minute, stop

the engine and top off all levels.
★ Check carefully that there are no leaks.
WB140-2N WB150-2N 30-51 1

REMOVAL AND INSTALLATION AC CONDENSER
12
AC CONDENSER
REMOVAL

1. Remove the engine hood and gas struts a first, see ENGINE
HOOD.
2. Remove the bolts b and front frame c.

3. Disconnect the cable d from the horn e. Loosen the bracket g

bolts f.
4. Capture and recycle the refrigerant first, then remove the lines h
and i. Cap and plug both lines immediately.

5. Loosen mounting bolts j and remove them.
6. Remove mounting bolt f and lift out the condenser.
30-52 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION AC CONDENSER
12
INSTALLATION

WB140-2N WB150-2N 30-53 1

REMOVAL AND INSTALLATION MUFFLER
12
MUFFLER
REMOVAL
1. Loosen the exhaust clamp a and remove it from the stack pipe b.
2. Remove mounting bolts c.
3. Remove the four bolts d and remove the complete muffler e.
INSTALLATION
★ Replace all gaskets with new.
30-54 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION EXHAUST STACK
12
EXHAUST STACK
REMOVAL
1. Loosen the exhaust clamp a and remove it from the stack pipe b.
2. Take out two of the three lower screws c of the connecting flange
d.
★ Loosen the third screw and leave it in place for safety.
3. Take out the nut e and the washer of the upper anti vibration unit
f.
4. Take out the last screw c and remove the exhaust pipe g.
INSTALLATION
WB140-2N WB150-2N 30-55 1

REMOVAL AND INSTALLATION ENGINE HOOD
12
ENGINE HOOD
WARNING! Lower all working equipment to the ground.
Stop the engine and remove the ignition key.
REMOVAL
1. Loosen and remove the screws a and washers and remove the front
grill b.
2. Fully raise the engine hood c, remove the safety pins d and dis-
connect the gas spring e from the chassis.
3. Remove the snap rings f and washers g.
4. Pull out the fulcrum pins h while holding the engine hood c.
5. Remove the hood c.
INSTALLATION
★ Check the lock engagement.
30-56 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION CAB
12
CAB
WARNING! Be sure all work equipment is lowered to the
ground. Turn the electrical supply off using the discon-
nect switch a. On machines equipped with air condition-
ing, capture and recycle all refrigerants before proceeding
with any removal procedures.
TIER I ENGINE
REMOVAL
1. Disconnect the throttle linkage and accelerator pedal cable b from

the injection pump mounting support c.
2. Disconnect the parking brake cable D and the differential lock tube
F from the rear axle E. Cap the opening.
3. Disconnect the brake lines G from the rear axle E.
★ Cap the openings and mark the line locations and lines.
WB140-2N WB150-2N 30-57 1

12
4. Disconnect the hoses H from the front axle steering cylinder.
5. Disconnect the steering valve lines i, j and 1) from the valve.
6. Disconnect the transmission connectors 1! and 1@ as well as the

ground cable 1#.
7. Disconnect the five connectors 1$ from the sensor, the speed control
connector 1% and the solenoid connector 1^ from the transmission.
8. Disconnect the harness 1& from the grounding stud.
9. Disconnect the connector 1* from the bucket control lever.
10. Disconnect the converter connector 1( from the switch.
11. Disconnect the differential and backhoe solenoid connector 2).
12. Disconnect the power engagement connector 2!.
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12
13. Disconnect the harness connector 2@ from the alarm, 2# from the
rear lights 2$ and from the backhoe control.
14. Disconnect the heater core hoses 2% and 2^.
15. Capture and recycle the refrigerant first, then remove the lines 2&
and 2* connecting the expansion valve 2(. Cap and plug both lines
immediately.

16. Remove the lower left guard from the bottom of the cab and dis-
connect connector 3) from the fuel level indicator.
17. Remove the floor mat 3! and fender trim piece 3@.
★ Push the boot on the shifter lever 3# down into the trim piece
3@.
WB140-2N WB150-2N 30-59 1

12
18. Remove the outrigger control lever knobs 3$ and lift the cover 3% off
the control levers.
19. Remove the self locking nuts 3^ and the four fasteners that secure
the cab in place.
20. Disconnect hoses 3& and 3* from the control valve 3( and cap all
openings.
21. Remove the protective plugs and install two eyebolts A into the
threaded holes on the cab.
22. Using the tool shown, carefully lift the cab 4) off the frame. Slowly
raise the cab making sure the electrical leads and control levers
clear the chassis frame.
Cab weight ............................................................... 630 kg
INSTALLATION
★ Check the adjustments of the throttle and accelerator pedal, see

★ Check the adjustment of the parking brake lever, see TEST-

ING AND ADJUSTMENT.
★ Bleed the air from the brake system, see TESTING AND AD-
JUSTMENT.
★ Bleed the air from the steering circuit, see TESTING AND
ADJUSTMENT.
Cab mounting bolts............................................... 170 N•m
30-60 1 WB140-2N WB150-2N

12
TIER II ENGINE
REMOVAL
1. Disconnect the throttle linkage and accelerator pedal cable b from

the injection pump mounting support c.
2. Disconnect the parking brake cable D and the differential lock tube
F from the rear axel E. Cap the opening.
3. Disconnect the brake lines G from the rear axle E.
★ Cap and plug the openings and mark the locations and lines.
4. Disconnect the hoses H from the front axle steering cylinder.
WB140-2N WB150-2N 30-61 1

12
5. Disconnect the steering valve lines i, j and 1) from the valve.
6. Disconnect the transmission connectors 1! and 1@ as well as the

ground cable 1#.
7. Disconnect the five connectors 1$ from the sensor, the speed control
connector 1% and the solenoid connector 1^ from the transmission.
8. Disconnect the harness 1& from the grounding stud.
9. Disconnect the connector 1* from the bucket control lever.
10. Disconnect the converter connector 1( from the switch.
11. Disconnect the differential and backhoe solenoid connector 2).
12. Disconnect the power engagement connector 2!.
13. Disconnect the harness connector 2@ from the alarm, 2# from the
rear lights 2$ and from the backhoe control.
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12
14. Disconnect the heater core hoses 2% and 2^.
15. Capture and recycle the refrigerant first, then remove the lines 2&
and 2* connecting the dryer 2( to the expansion valve 3). Cap and
plug both lines immediately.

16. Remove the lower right and left guards from the bottom of the cab
and disconnect connector 3! from the fuel level indicator.
17. Remove the floor mat 3@ and fender trim piece 3#.
★ Push the boot on the shifter lever 3$ down in the trim piece 3@.
18. Remove the outrigger control lever knobs 3% and lift the cover 3^ off
the control levers.
WB140-2N WB150-2N 30-63 1

12
19. Remove the platform 3&.
20. Disconnect the control valve hoses 3( from the junction blocks 3*.
IMPORTANT - Ensure that both the hoses and their con-

nection positions are clearly marked. Cap the hoses and
holes to prevent contamination.
21. Loosen and remove the self locking nuts 4) and remove the bolts
that secure the cab.
22. Disconnect hoses 4! and 4@ from the control valve 4# and cap all
openings.
23. Remove the protective plugs and install two eyebolts A into the
threaded holes on the cab.
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12
24. Using the tool shown, carefully lift the cab 4$ off the frame. Slowly
raise the cab making sure the electrical leads and control levers
clear the chassis frame.
Cab weight ............................................................... 630 kg
INSTALLATION
★ Check the adjustments of the throttle and accelerator pedal, see

★ Check the adjustment of the parking brake lever, see TEST-

ING AND ADJUSTMENT.
JUSTMENT.
★ Bleed the air from the steering circuit, see TESTING AND
ADJUSTMENT.
Cab mounting bolts............................................... 170 N•m
WB140-2N WB150-2N 30-65 1

REMOVAL AND INSTALLATION AC AND HEATER
12
AC AND HEATER
Remark
If the machine is not equipped with air conditioning, per-
form only those operations relating to the heating unit.
nect switch a. On machines equipped with air condition-
ing, capture and recycle all refrigerants before proceeding
with any removal procedures.
REMOVAL
★ Capture and recycle the refrigerant first, then proceed with remov-
ing the system.
★ Drain and capture all engine coolant and recycle.
Coolant liquid ...............................................................18 l
WARNING! Do not dump engine coolants down the drain,

on to the ground or into a body of water, doing so is in
violation of the law.
1. Disconnect the flexible hose B of the heater valves.
2. Disconnect the connector of the power supply cabling c and the

clamp d.
3. Disconnect the connector f from the pressure switch e.
4. Disconnect the delivery pipe h and the return pipe i from the ex-
pansion valve g.
★ Immediately cap and plug the tubes and the orifices tightly to
prevent impurities from entering into the air conditioning cir-
cuit. Reuse the o-ring.
30-66 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION AC AND HEATER
12
5. Disconnect the pipes 1) from the fan cooler j.
6. Disconnect the tubes 1! and 1@ that connect with the engine.
7. Remove the four nuts 1# and remove the group j.
INSTALLATION

★ Refill the engine coolant.
Coolant refill amount....................................................18 l
★ Start the engine and use a leak detector to check the AC unit.
WB140-2N WB150-2N 30-67 1

REMOVAL AND INSTALLATION FUEL TANK
12
FUEL TANK
nect switch a.
REMOVAL
★ Position a suitable collection pan under the fuel tank. Remove the
filler cap b from the fuel tank. Remove the bottom plug in order to
drain the fuel.
Fuel: max ....................................................................130 l
1. Remove the lower left guard shield c from the cab.
2. Remove the hose clamp d nut e and move the hoses out of the
way.
3. Remove battery cover f from fuel tank g housing.
4. Loosen the battery hold down h and bracket i and move the bat-
tery j outwards. Lift the protective flap if needed. Remove the
negative (-) terminal clamp 1) first and then the positive (+) termi-
nal clamp 1! next. Remove the battery and store in a well ventilated
area.
WARNING! It is important that the negative (-) battery ter-

minal clamp is removed first. Doing so will prevent the
5. Disconnect the fuel level indicator 1@ connector 1# and supply pump

connector 1$.
6. Disconnect the supply and return lines 1%, 1^ and cap the openings.
★ Mark the locations and hoses for proper reassembly.
7. Remove the bolts 1& and the guard 1*.
30-68 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION FUEL TANK
12
8. Support the fuel tank and remove the mounting bolts 1(. Remove
the fuel tank carefully.
Empty fuel tank weight.............................................. 74 kg
INSTALLATION
★ Refill the fuel tank:
Fuel: max ....................................................................130 l
Fuel tank bolts ...................................................... 120 N•m
1. Bleed air from the fuel circuit then start the engine.
WB140-2N WB150-2N 30-69 1

REMOVAL AND INSTALLATION HYDRAULIC TANK
12
HYDRAULIC TANK
nect switch a.
REMOVAL
1. Remove the lower right guard b and step plate c.
2. Drain the reservoir d as follows:
A. Position a suitable collection pan under the hydraulic tank

B. Remove the fill plug e to aid in drainage.
C. From under the tank, remove the drain plug f and allow the oil
to drain.
Hydraulic oil .................................................................92 l
30-70 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION HYDRAULIC TANK
12
3. Disconnect the lower suction line G and hoses H from the tank.
Cap or plug all openings.
4. Disconnect the upper lines I, J and 1) and remove the check valve
1! and T adapter piece 1@.
★ Mark the hose locations and hoses for proper reassembly.
5. Support the tank and remove the four retaining bolts 1#. Carefully
remove the tank from the chassis.
Empty hydraulic tank weight..................................... 77 kg
INSTALLATION
★ Refill the hydraulic tank:
Fuel: max ......................................................................92 l
Fuel tank bolts ...................................................... 120 N•m
1. Bleed air from the hydraulic circuit then start the engine. See
★ Stop the engine and check oil level.
WB140-2N WB150-2N 30-71 1

REMOVAL AND INSTALLATION ENGINE AND TRANSMISSION
12
ENGINE AND TRANSMISSION
nect switch a.
★ Into suitable containers, drain the following systems:
Hydraulic system.......................................................... 92 l
Cooling system............................................................. 18 l
Transmission system .................................................... 16 l
WARNING! Do not dump any of the above systems
down the drain, on to the ground or into a body of
water, doing so is in violation of the law.
★ Capture and recycle the AC refrigerant.

atmosphere, doing so is in violation of the law and
could produce dangerous gasses if exposed to an
open flame.
REMOVAL
1. Remove the front work equipment, see BOOM.
2. Remove the engine hood, see ENGINE HOOD.
3. Remove the counterweight b, c see COUNTERWEIGHT.
4. Remove the radiator oil cooler, see RADIATOR OIL COOLERS.
5. Lift the shift boot d and disconnect the switch e. Remove the
transmission shift lever f.
6. Disconnect rear drive shaft h from transmission g.
30-72 1 WB140-2N WB150-2N

12
7. On 4WD machines, remove the front drive shaft i.
8. Disconnect the suction hose 1) and drain line 1! from the pump j.
Cap or plug all openings. Disconnect the pump solenoid.
9. Disconnect the LS line 1@ and the delivery line 1# from valve 1$.
Cap or plug all openings.
10. Disconnect the transmission unit 1%, solenoid valve 1&, connectors
1^, ground strap 1*, oil cooler lines 1( and the wiring harness clamps
2). Cap or plug all openings.
WB140-2N WB150-2N 30-73 1

12
11. Disconnect engine coolant temperature sensor 2! and 2@.
12. Disconnect cab heater hoses 2# from the coolant pump.
13. Disconnect the oil pressure sensor 2$ and the engine stop solenoid
2%.
14. Disconnect cable 2^ from cold start equipment, cab heater hose sup-
port 2& and fuel tank back flow line 2*.
30-74 1 WB140-2N WB150-2N

12
15. Disconnect the throttle and accelerator cables 2( from the support
3).
16. Disconnect the fuel lines 3@ from the water separator 3! and cap or
plug all openings. Remove the separator.
17. Disconnect the motor wiring 3# from the starter motor 3$.
18. Disconnect the wiring 3% from the alternator 3^.
WB140-2N WB150-2N 30-75 1

12
19. AC machines; Disconnect the refrigerant lines 3* and 3( from the
compressor 3& and cap or plug all openings.

20. Disconnect the wiring harness connectors 4) and 4!.
21. Remove the support shield 4@ and slide it towards the engine.
22. Disconnect the muffler clamp 4# from the pipe 4$.
30-76 1 WB140-2N WB150-2N

12
23. Attach a chain hoist to the engine bracket 4% and muffler support 4^.
Apply slight tension to the chains and measure and adjust them for
a proper lift.
★ The chains should have a total length of 800 mm and the dif-
ference between chain lengths should be 53 mm.
★ The shortest length should be attached to bracket 4%.
★ When lifting tension is applied, the distance between chains
should be 200 mm.
24. Loosen and remove the nuts 4& from the support grommets 4* and
remove the bolts 4(.
25. Lift the engine and transmission up and out carefully. Make sure all
items listed are disconnected.
Engine and transmission .......................................... 740 kg
INSTALLATION
★ Fill the hydraulic tank, cooling system, and transmission.
Hydraulic system ..........................................................92 l

Cooling system .............................................................18 l
Transmission system.....................................................16 l
★ If equipped with air conditioning, recharge the system.
Refrigerant R134a - TIER I Engine ............................ 1 kg

Refrigerant R134a - TIER II Engine ....................... 2.5 kg
★ Drive shaft bolts
Drive shaft bolts...................................................... 70 N•m
Drive shaft bolts................................................ Loctite 262
WB140-2N WB150-2N 30-77 1

12
★ Axle mounting nuts
Axle mounting nuts ................................................ 70 N•m
★ Fill the pump housing and lines, see section TESTING AND
ADJUSTMENT.
★ Bleed the air from the fuel system.
Vibration grommet nuts ........................................ 175 N•m
1. Start the engine to circulate the oil and coolant liquid. Check that
there are no leaks.
2. Use a leak detector to check the leak tightness of the delivery and
return pipes of the AC compressor.
3. Bleed the air from the working equipment circuits, see TESTING
AND ADJUSTMENTS.
4. Stop the engine, check the levels and, if necessary, top them off.
30-78 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION PISTON PUMP
120000
PISTON PUMP
nect switch a.
★ Into suitable containers, drain the hydraulic system:
WARNING! Do not dump the hydraulic oil down the

drain, on to the ground or into a body of water, doing
so is in violation of the law.
REMOVAL
1. Disconnect the suction hose c and drain line d from the piston
pump b. Cap and plug all openings.
2. Disconnect the delivery line e and the LS signal line f. Cap and
plug all openings. Disconnect the solenoid connector g.
3. Remove the drive shaft h.
4. Support the piston pump with a suitable hoist.
5. Remove the two mounting bolts I and then carefully remove the
pump.
Piston pump ............................................................... 40 kg
WB140-2N WB150-2N 30-79 1

REMOVAL AND INSTALLATION PISTON PUMP
12
6. Discard o-ring j and replace with new.
INSTALLATION
★ Fill the hydraulic system.
★ Fill the pump housing and lines. For details, see TESTING
AND ADJUSTMENT.
Suction flange fasteners........................................ 100 N•m
Delivery flange fasteners ........................................ 60 N•m
Transmission bolts ............................................ Loctite 262
Transmission bolts .................................................. 70 N•m
Axle nuts................................................................. 70 N•m
Pump bolts ........................................................ Loctite 262
Pump bolts ............................................................ 220 N•m
1. Start the engine to circulate hydraulic oil through the system.
2. Stop the engine and check for leaks.
30-80 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION TRANSMISSION
12
TRANSMISSION
nect switch a.
REMOVAL
1. Remove the piston pump, see PISTON PUMP.
2. Lift the gearshift boot b and unclip the connector c from the
switch. Remove the gear shift lever d.
3. Remove the filler tube e from the transmission.
4. Remove the drive shaft f.
5. Remove the cover g and six retaining bolts h from the flex plate i
and flywheel.
★ Mark the flex plate and flywheel with a location point.
WB140-2N WB150-2N 30-81 1

12
6. Unclip the connectors j from the solenoids and temperature sensor

1).
7. Disconnect the four tubes 1! and the controls.
8. Remove the support shield 1@ and slide it back towards the engine.
30-82 1 WB140-2N WB150-2N

12
9. Attach the engine/transmission to a chain hoist using bracket 1# and
muffler support 1$. Apply tension to the chain and lift engine slight-
ly.
10. Remove the nuts 1%, bolts 1^ and rubber grommets 1&.
11. Remove the transmission support 1* and attach the support brack-
ets.
12. Using a lifting tool and spacers secure the transmission 1( in place
with mountings.
13. Remove the twelve converter housing bolts 2).
WB140-2N WB150-2N 30-83 1

12
14. Carefully slide the transmission 1( back and lower it until it is all
the way down on the jack.
Transmission............................................................ 230 kg
INSTALLATION
★ Fill the hydraulic tank, cooling system, and transmission.
★ Fill the pump housing and lines, see TESTING AND AD-
JUSTMENT.
Lever bolts .............................................................. 70 N•m
Filler pipe bolts ................................................. Loctite 262
Flex plate bolts........................................................ 70 N•m
Flex plate bolts.................................................. Loctite 262
Iso mount nuts ...............................................196 ±19 N•m
1. Start the engine to circulate the oil. Check that there are no leaks.
AND ADJUSTMENTS.
3. Stop the engine, check the levels and, if necessary, top off.
30-84 1 WB140-2N WB150-2N

12
DISASSEMBLY
WB140-2N WB150-2N 30-85 1

12
EXTERNAL GROUP
1. Mount the transmission a in a suitable stand.
2. Remove the bolts b and the main control valve c.
3. Remove the gasket d and discard.
★ Replace with a new gasket every time the valve is removed.
4. Remove the three bolts e that fasten the distribution plate f.
30-86 1 WB140-2N WB150-2N

12
5. Remove the distribution plate f.
6. Remove the gasket g and discard.
★ Replace with a new gasket every time the distribution plate is

removed.
7. Remove the bolts H that secure the cover I and remove the filter J
complete with the o-ring 1).
8. Remove the bolts 1! and remove the 4WD solenoid 1@.
WB140-2N WB150-2N 30-87 1

12
9. Remove the bolts 1! and remove the 2WD plate 1@.
10. Remove the gasket 1#.
★ Replace with a new gasket every time the 4WD solenoid or

plate is removed.
11. Remove the filter 1$.
12. Remove the filter fitting 1%.
13. Remove the valve spool 1^.
14. Remove the spring 1&.
15. Use a puller for blind holes, extract the priority valve 1*.
★ The priority valve is factory calibrated and should not be mod-

ified. If it appears to be damaged, replace it with a new one.
30-88 1 WB140-2N WB150-2N

12
16. Only if necessary;
Remove the two caps 1(. The caps should only be removed if there
are leakages.
Caps .................................................................. Loctite 542
17. Loosen and take out the screws 2) that secure the shifter group 2!.
18. Remove the group 2! and the o-ring 2@.
19. Mount two bolts in the holes in the flange 2# and, holding the flange
steady, remove the central bolt 2$.
20. Remove the washer 2%.
21. Remove the o-ring 2^ and the flange 2#.
★ Replace the o-ring 2^ every time the flange is removed.
WB140-2N WB150-2N 30-89 1

12
22. Mount two bolts in the flange 2& holes and, holding the flange
steady, remove the central bolt 2*.
23. Remove the washer 2(.
24. Remove the flange 2&. Remove the internal o-ring 3).
★ Replace the o-ring 3) every time the flange is removed.
TRANSMISSION HOUSING
30-90 1 WB140-2N WB150-2N

12
1. Loosen and remove the bolts a that secure the rear housing B.
2. Loosen and remove the bolts c.
3. Using a pry lever, separate the cover d from the transmission hous-
ing.
4. Remove the cover d with the hydraulic pump drive shaft e.
WB140-2N WB150-2N 30-91 1

12
5. Remove the snap ring g that secures the shaft e.
6. Use a plastic mallet to extract the shaft e from the bearing g.
7. Remove the bearing g from the cover d.
8. Turn the cover d over and take out the seal ring h and discard.
★ Replace with a new seal ring.
9. Remove the sealing ring I from the shaft.
★ The two seal ends must be unhooked in order to remove them.
10. With a punch, remove the pins J and 1) that fasten the differential
lock rings 1! and 1@ of the shifter rods.
30-92 1 WB140-2N WB150-2N

12
11. Remove the differential lock rings 1! and 1@.
12. Remove the screws 1# that secure the plate 1$.
13. Remove the plate 1$.
14. Use a magnet to remove the two balls 1% from the hole between the
two shifter rods.
15. Remove the cap 1^.
WB140-2N WB150-2N 30-93 1

12
16. Use a magnet to extract the spring 1& and the ball 1*.
★ Repeat steps 15 and 16 for the other cap.
17. Remove the bearing retaining snap ring 1( of the secondary shaft 2).
18. Remove the bearing retaining snap ring 2! of the main shaft 2@.
19. Turn the transmission over and remove the three bolts 2#.
30-94 1 WB140-2N WB150-2N

12
20. Remove the bolts 2$, then remove the cover 2%.
21. Remove the o-ring 2^ and the seal ring 2& from the cover.
22. Loosen and remove the retaining bolts 2* of the pump 2(.
23. Using two levers opposite each other, raise the pump 2( smoothly.
WB140-2N WB150-2N 30-95 1

12
24. Take out the pump 2( complete with its seal ring 3).
25. Slightly raise the input shaft 3! and remove the bearing retaining
snap ring 3@.
26. Attach a hoist to the front flange 3# of the transmission and apply a
slight tension. Using two levers opposite each other, separate the
flange from the transmission housing.
30-96 1 WB140-2N WB150-2N

12
WB140-2N WB150-2N 30-97 1

12
27. 4WD; Slowly raise the front flange 3#, keeping it horizontal.
★ If necessary, assist the raising operation with a lever and also

by knocking on the shaft of the front drive with a plastic mal-
let.
28. Remove the lock ring 3$ complete with the sealing rings 3%.
29. Remove the two hooked seal rings 3% from the lock ring.
★ They can be removed by unhooking the two extremities. Re-

place with new hooked seal rings 3% each time they are re-
moved.
30. Remove the bearing 3^ of the main shaft and the bearing 3& of the
secondary shaft.
30-98 1 WB140-2N WB150-2N

12
31. Remove the bearing 3* from the seat of the front flange 3%.
32. Remove the fittings 3( and take out the pipe 4) complete with the
copper washers.
33. Remove the o-rings 4! between the front housing and the transmis-
sion housing.
34. Remove the 4WD shaft 4@.
WB140-2N WB150-2N 30-99 1

12
35. Remove the input shaft 3! and the reverse shaft 4$.
36. Turn the transmission over. Connect a hoist suitable for the upper
gears.
37. Raise the secondary shaft 2) with the hoist and at the same time
raise the main shaft 2@ by hand.
★ The forks and shifters for 1st/2nd and 3rd/4th gears are also
raised at the same time. If any part remains in place, it can be
separated by tapping with a plastic mallet.
38. Raise the secondary shaft 2) until the shifter forks 4* and 4( can be
moved. Then remove the shaft.
30-100 1 WB140-2N WB150-2N

12
39. Remove the shifter fork 4* for the 1st/2nd gears.
40. Remove the shifter fork 4( for the 3rd/4th gears.
★ Make a note that this fork fits in the upper hole of the transmis-
sion housing.
41. Remove from the transmission housing, the 4WD clutch gear 5).
42. Remove the bearing 5!.
WB140-2N WB150-2N 30-101 1

12
43. Remove the caps 5@ and seals 5# for the pressure adapters, the vent
plug 5$ and the temperature sensor 5%.
44. Only if necessary; 4WD, remove the fittings 5^ and the pipe 5&
45. Only if necessary; 2WD, remove the plugs 5^ in the housing.
INPUT SHAFT
1. Remove the seal ring a.
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12
2. Remove the snap ring b that retains the bearing c to the shaft.
WB140-2N WB150-2N 30-103 1

12
3. Use a separator applied beneath the gear d and a puller, to force the
bearing d off of the shaft e.
★ Use a protective cap on the head of the shaft.
4. Remove the bearing d.
5. Remove the spacer f and bearing ring g.
6. Remove the gear d.
7. Remove the spring pin h.
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12
8. Remove the roller bearings i.
9. Remove the bearing ring j.
10. Remove the retainer ring 1).
11. Use two levers to remove the bearing 1!.
12. Remove the spring pin 1@.
WB140-2N WB150-2N 30-105 1

13. Install the upper part of the tool F3 and the three threaded tie rods
12
complete with nuts, used to fasten the component parts of the tool
between them.
14. Gradually and evenly tighten the nuts in order to compress the
spring 1$ and to gain access to the snap ring 1#.
15. Remove the snap ring 1#.
16. Gradually and evenly loosen the nuts and the tie rods on the tool
F3 until the spring 1$ tension has been eliminated. Remove the up-
per part of the tool and the tie rods.
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12
17. Remove the spring retainer plate 1% and the spring 1$.
18. Remove the clutch pack.
★ Make a note of the assembly sequence of the separator plates

1^ and friction disks 1&. Make a mark on the assembly side of
the clutch pack. If the friction disks have a thickness of less
than 1.65 mm, they must be replaced.
19. Using low pressure compressed air, remove the piston 1*.
★ Take great care not to damage the surfaces and edges of the
piston.
Max air pressure ................................................... 6 kg/cm²
20. Remove the seal ring 1(.
WB140-2N WB150-2N 30-107 1

21. Apply the tool F3 to the other side of the shaft group, forward gear
12
clutch in the upper position. Secure the tool in a vise.
22. Remove the seal rings 2).
23. Remove the snap ring b that retains the bearing c to the shaft.
24. Use a separator applied beneath the gear and a puller, to force the
bearing c off of the shaft e.
25. Remove the bearing C and spacer ring 2!.
26. Remove the spring pin h, then the gear 2@.
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12
27. Take out the first roller bearing i and the spacer 2#.
28. Remove the second roller bearing i and the bearing ring j.
29. Reinsert gear 2@ aligning teeth of the friction discs. The gear will be
for clutch removal. Remove the retainer ring 1).
30. Using two screwdrivers under the bottom separator plate, lift the
clutch pack and backing plate with gear from the shaft.
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12
31. With the gear facing down, remove the separator plates 1^ and fric-
tion discs 1&.
★ Make a note of the assembly sequence of the separator plates

and friction disks. Make a mark on the assembly side of the
clutch pack. If the friction disks have a thickness of less than
1.65 mm, they must be replaced.
Friction disc minimum thickness.......................... 1.65 mm
32. Remove the backing plate 1!.
33. Remove the spring pin 1@.
34. Install the upper part of the tool F3 and the three threaded tie rods
complete with nuts, used to fasten the component parts of the tool
between them. Gradually and evenly tighten the nuts in order to
compress the spring and to gain access to the snap ring 1#.
35. Remove the snap ring 1#.
36. Gradually and evenly loosen the nuts and the tie rods on the tool
F3 until the spring tension has been eliminated. Remove the upper
part of the tool and the tie rods.
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12
37. Remove the spring retainer plate 1% and the spring 1$.
38. Using low pressure compressed air, remove the piston 1*.
★ Take great care not to damage the surfaces and edges of the
piston.
39. Remove the seal ring 1(.
40. Remove the seal ring 2$.
★ New seal rings must be installed each time they are disman-
tled.
★ Check the shaft, rotating parts, bearings and the gears for signs
of wear, pitting or scoring. Replace the damage components.
★ Discard all seal rings replace with new.
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12
SECONDARY SHAFT
1. Position the secondary shaft group a on plastic blocks, as illustrat-

ed.
★ Do not use wooden blocks.
2. Position a separator beneath the gear b with the conical edge fac-
ing downwards.
★ Do not force the separator against the synchronizer assembly.
3. Position a puller and force the bearing c until is can be removed

from the shaft d.
4. Remove the bearing c.
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12
5. Remove the bearing ring e.
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12
6. Remove the 3rd speed gear B.
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12
7. Remove the synchronizer ring f of the 3rd and 4th synchronizer
assembly in order to reach the snap ring g.
8. Remove the snap ring g.
9. Remove the bronze ring h
10. Remove the synchronizer and arrange it on some plastic blocks in-
side a container.
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12
11. Using a driver, extract the hub i, the balls j, the blocks 1) and
spring 1! from the sleeve 1@.
12. Remove the 2nd bronze ring h from the synchronizer ring f.
14. 4WD; Remove the 4th speed gear 1#. Remove the snap ring g. Re-
move the 4WD gear 1$.
15. 2WD; Remove the 4th speed gear 1#. Remove the snap ring g. Re-
move the gear spacer 1$.
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12
16. Turn the shaft over so that the 2nd speed gear faces upwards. Re-
move outer bearing race 1%.
17. Remove the snap ring 1^.
18. Position a bearing separator under the gear 1& with the conical edge
facing downwards.
★ Do not force the separator against the synchronizer assembly.
19. Position a puller and force the inner bearing race 1% off the shaft d.
20. Remove the inner the bearing race 1% and the bearing spacer ring 1*.
21. Remove the pin 1(.
22. Remove the 2nd speed gear 1&.
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12
23. Remove the spacer 2).
24. Remove the synchronizer ring 2! from the 1st and 2nd speed syn-
chronizer in order to reach the snap ring g.
26. Remove the synchronizer and arrange it on some plastic blocks in-
side a container.
27. Turn the synchronizer over and remove the other ring 2!.
28. Remove the steel ring 2@ and the bronze ring 2# from each side of
the synchronizer.
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29. Remove the tapered friction ring 2$ from each side of the synchro-
nizer.
30. Place the sleeve 2% on some plastic blocks inside a container. Using
a plunger, extract the hub 2^, the balls 2&, the blocks 2* and the
springs 2(.
31. Remove the spacer 2).
33. Remove the 1st speed gear 3).
34. Remove the last snap ring g.
35. Check all component parts and, for any damage to the gears, inner
or outer tooth bases, or bearings, replace them with new ones.
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12
36. Check the clearance of the synchronizer assemblies at three differ-
ent points, 120° apart.
★ Minimum clearance permissible ....................................1.3 mm

If the clearance is less than this, put in new synchronizer.
37. Check the shaft, especially where bearing inner races will be in-
stalled. No wear or scoring, even if only localized, can be allowed.
Check the springs of the synchronizer for cracks, heat distortion or
wear. Replace as necessary.
MAIN SHAFT - TIER I ENGINE
1. Mark the gears and the main shaft a to avoid exchanging the com-
ponent parts.
2. Position the group with the bearing upwards and remove the snap
ring b.
3. Mount a separator under the gear with the conical edge down. Posi-
tion a puller and force the bearing C until it can be detached from
the shaft.
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12
4. Remove the bearing c.
5. Remove the bearing ring d.
6. Remove the gear e.
7. Turn the shaft over and, with a plastic mallet, slide the gear f off
the shaft g.
8. Position a separator beneath the inner bearing race h. Position a

puller and force the bearing ring until it can be extracted from the
shaft.

★ Make a note of the direction of assembly.
MAIN SHAFT - TIER II ENGINE
★ Remove the ball bearing c from gear shaft a only if replacement is

necessary. It will be destroyed upon removal.
1. Remove the snap ring b.
2. Mount a separator under the gear with the conical edge down. Posi-
tion a puller and force the bearing C until it can be detached from
the shaft.
3. Remove the bearing ring d.
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12
4. Position a separator beneath the inner bearing race e. Position a

puller and force the bearing ring until it can be extracted from the
gear shaft a.
REVERSE SHAFT
1. Position a separator under the bearing a with the conical edge fac-
ing down. Position a puller and force the bearing until it can be de-
tached from its seating.
★ Use a protective cap on the shaft b.
2. Turn the shaft over and repeat the same operations for the remain-
ing bearing c.
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12
SHIFTER FORKS
★ Make accurate notes of the sequence of assembly of the shafts and

forks.
★ The forks and shifter rods must be replaced with new ones every
time the synchronizer is changed.
1. Extract the pins a or b, between the shafts c or d and the forks e

or f and slide off.
WB140-2N WB150-2N 30-123 1

12
4WD SHAFT
★ A plug a is mounted in the central hole of the shaft b. Do not

remove this plug unless it is absolutely necessary.
1. Using tool F6, press the spring retainer C until the snap ring D can
be released. Release the pressure slowly.
2. Remove the snap ring D.
3. Remove the spring retainer c and six springs e.
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12
4. Remove the spring housing f and 4WD gear g.
5. Remove the o-rings h and i from the shaft c.
6. Check the thickness X of the lugs on the 4WD gear g.
★ Minimum X permissible ..............................................3.52 mm

★ If the projections are worn, also check the 4WD clutch gear.
SHIFTER HOUSING
WB140-2N WB150-2N 30-125 1

12
1. Remove the retaining clamps a and remove the boot b.
2. Remove the two pins c.
3. Remove the snap ring d.
4. Remove the bushing e.
5. Remove the spring f.
6. Remove the shift lever g from the housing h.
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12
4WD SOLENOID
1. Remove the end nut a with o-ring b.
2. Slide the solenoid c off the cartridge d.
3. Remove the cartridge d from the housing e. Remove the seal f

from the cartridge and replace with seal kit.
MAIN CONTROL VALVE
1. Remove the retaining nut A of the coils B and C.
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12
2. Remove the copper washers D.
3. Remove the outer coil b.
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12
4. Remove the o-ring e from the outer coil.
5. Remove the intermediate o-ring e.
6. Remove the outer coil b.
7. Remove the o-ring e from the internal coil.
8. Remove the last o-ring e.
9. Do not disassemble the coil connector f. The connector must only

be disassembled when replacing a coil.
10. Loosen the coil support g.
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12
11. Remove the valve group complete with spool h.
12. Take out the screws i and remove the cover j.
13. Remove the outer modulation piston 1) from the cover.
14. Remove in sequence the outer spring 1!, inner spring 1@, middle
spring 1# and pin 1$.
★ Replace the springs.
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12
15. Remove the first gasket 1%.
★ Discard and replace the gasket.
16. Remove the plate 1^.
17. Remove the ball 1& and the spring 1*.
18. Remove the second gasket 1%.
★ Discard and replace the gasket.
19. Remove the inner modulation piston 1(.
20. Remove the snap ring 2).
21. Remove the flow regulator 2!.
22. Remove the spring 2@.
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12
23. Remove the flow regulator piston 2#.
24. Remove the cap 2$.
Only if necessary;
25. Remove the snap ring 2%.
26. Remove the cap 2^ of the spool that selects the direction of move-
ment.
27. Remove the spring 2&.
28. Remove the spacer 2*.
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12
Only if necessary;
29. Remove the four plugs 2( and plug 3).
★ Beneath each plug there is a copper washer that must be re-

placed each time it is disassembled.
REASSEMBLY
MAIN CONTROL VALVE
1. Install the spacer a in the valve body.
★ The chamfer on the center hole must face towards the inside of
the valve body.
2. Insert the spring b.
3. If removed install the snap ring c into the valve body.
4. Install the cap d with a new o-ring.
5. Install the cap e with a new o-ring.
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12
6. Lubricate the regulating piston F with clean trans oil and install it
in the valve body.
★ The perforated surface must face towards the inside of the

valve body.
7. Install the spring g.
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12
8. Install the flow regulator h.
9. Install the snap ring i and seat it in the groove.
★ Make sure that the snap ring is completely inserted into its
seating.
10. Lubricate the inner modulation piston j with clean trans oil and in-
stall it so that the smallest diameter hole faces towards the inside of
the valve body.
11. Install the spring 1).
12. Install the first gasket 1!.
13. Install the ball 1@.
14. Position the plate 1# on the first gasket, then place the second gas-
ket 1! on the plate.
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12
15. Install concentrically the pin 1$, the small spring 1%, then the medi-
um spring 1^ inserted into the spring with the largest diameter 1&.
16. Insert the pin and spring group into the valve body.
★ The pin 1$ must face towards the inside of the body.
17. Lubricate the outer modulation piston 1* and Install it in the cover
1(.
★ The closed extremity of the piston 1( must face towards the

cover 1*.
18. Install the cover 1( and secure it with the screws 2) using the alter-
nating crosswise pattern.
Cover screws........................................................... 11 N•m
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12
19. Install a new o-ring on the solenoid plunger 2! and lubricate the o-
ring with clean transmission oil.
20. Lubricate the spool 2#, insert it in the solenoid plunger 2@, and in-
stall the group.
★ Check carefully that the extremity of the spool is engaged in

the spring.
21. Tighten the solenoid plunger 2@.
Solenoid plunger..................................................... 23 N•m
22. Install the o-rings 2# on both sides of the internal coil and lubricate
them with clean transmission oil.
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12
23. Install the complete inner coil 2% on the solenoid plunger 2@.
24. Install the o-rings 2$ on both sides of the external coil and lubricate
them with clean transmission oil.
25. Install the complete external coil 2^ on the solenoid plunger 2@.
26. Install the copper washer 2&.
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12
27. Install the nut 2* and tighten it, keeping the two coils aligned.
Retainer nut.......................................................7 to10 N•m
4WD SOLENOID
1. Install a new seal kit a to the cartridge b and mount in the valve
housing c.
2. Slide the solenoid coil d onto the cartridge with the connector fac-
ing the outside of the valve housing.
3. Install a new o-ring e and secure with the nut f.
WB140-2N WB150-2N 30-139 1

12
SHIFTER HOUSING
1. Lubricate the ball of the shift lever a and install the lever in its
housing seating b.
2. Align the shift lever a with its seating b. The flat surface A of the
lever must be parallel to the side B of the housing and the grooves
C must match with the holes D in the housing.
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12
3. Install the spring c then the bushing d.
4. Install the snap ring e to the groove of the lever a.
5. Install the retaining pins f.
6. Install the boot g to the housing and lever and secure it with the
clamp h. Install a new o-ring i to the housing.
4WD SHAFT
1. Install new o-rings a and b to the shaft c. Lubricate the o-rings

with clean trans oil.
2. Install the 4WD gear d and spring housing e to the shaft. Insert the
return springs f into the housing.
3. Install the spring retainer g to the shaft. Position the snap ring h
near its groove on the shaft.
WB140-2N WB150-2N 30-141 1

12
4. Using tool F6 compress the springs and move the snap ring h into
its groove.
5. If removed, install the shaft plug i.
SHIFTER GROUP
★ Lightly coat the shifter rails and forks with clean trans oil.
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12
1. Slide the shifter fork a onto the notched end of the rail b and align
the pin holes. Secure the fork to the rail with the spring pin c.
2. Slide the shifter fork d onto the notched end of the rail e and align
the pin holes. Secure the fork to the rail with the spring pin f.
REVERSE SHAFT
1. Using a suitable driver, bottom each bearing a on the reverse shaft

b.
MAIN SHAFT - TIER I ENGINE
1. Heat the bearing a inner race to 80 to 100°C. Using tool F5 bot-

tom the race on the shaft b.
★ Check the direction of assembly.
2. Turn the shaft b over and using a plastic mallet, install the gear c.
WB140-2N WB150-2N 30-143 1

12
3. Install the gear d.
4. Lubricate the bearing ring e with clean trans oil. Install it with the
lubrication slots facing down.
5. Heat the bearing f to 80 to 100°C. Using tool F4, bottom the inner
race on the shaft.
★ The snap ring groove on the outside of the bearing outer cage
must be facing upwards.
6. Install the snap ring g.
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12
MAIN SHAFT - TIER II ENGINE
1. Heat the bearing a inner race to 80 to 100°C. Using tool F5 bot-

tom the race on the shaft b.
★ Check the direction of assembly.
2. Lubricate the bearing ring C with clean trans oil. Install it with the
lubrication slots facing down.
3. Heat the bearing D to 80 to 100°C. Using tool F4, bottom the inner
race on the shaft.
★ The snap ring groove on the outside of the bearing must be fac-
ing upwards.
4. Install the snap ring E.
WB140-2N WB150-2N 30-145 1

12
SECONDARY SHAFT
★ Unless otherwise indicated, lubricate all parts with clean transmis-

sion oil.
1. Install the snap ring a on the shaft b.
2. Install the 1st speed gear c.
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12
3. Install the snap ring a.
4. Install the spacer d.
WB140-2N WB150-2N 30-147 1

12
5. Position the hub e on the sleeve f. Install the springs g, the
blocks h and the balls i into the hub.
6. Use a screwdriver or a plunger to push the balls i into the blocks

h. Press on the hub to engage the balls in the sleeve f until they
are engaged in the central seating of the sleeve.
7. Install the tapered friction ring j on the synchronizer.
8. Install the bronze ring 1) and the steel ring 1!.
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12
9. Install the synchronizer ring 1@.
★ The flat surface of the teeth should face upwards.
10. Turn the group over and install the tapered friction ring j on the
synchronizer.
11. Install the bronze ring 1) and the steel ring 1!.
12. Install the synchronizer on the shaft.
★ The seat side for the snap ring faces down.
WB140-2N WB150-2N 30-149 1

12
14. Install the upper synchronizer ring 1@.
★ The flat surface of the teeth must face upwards.
15. Install the spacer d and the 2nd speed gear 1#.
16. Install the pin 1$.
17. Lubricate the bearing ring 1% and install.
★ The lube slots face down and the pin engages in the open cut
out.
18. Heat the inner bearing ring 1^ to 80 to 100°C and with tool F5 bot-
tom against the bearing ring 1%.
★ The wide base of the bearing ring faces down.
19. Install the snap ring 1&.
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12
20. 4WD; Turn the shaft over and install the 4WD gear 1*, snap ring a
and 4th speed gear 1(.
21. 2WD; Turn the shaft over and install the gear spacer 1*, snap ring a
and 4th speed gear 1(.
★ The ring must be installed in the lowest groove and behind the
gear.
23. Install the bronze ring 2) on the synchronizer ring 2!.
24. Position the hub 2@ in the sleeve 2#. Install the springs 2$, blocks 2%
and balls 2^ in the hub.
WB140-2N WB150-2N 30-151 1

12
25. Use a screwdriver to push the balls 2^ into the blocks 2%. Press on
the hub to engage the balls in the sleeve 2# until they are engaged in
the central seating of the sleeve.
26. Install the 2nd bronze ring 2).
27. Install the 3rd and 4th speed synchronizer.
★ The side with the seating for the snap ring a should face
downwards.
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12
29. Install the synchronizer ring 2!.
30. Install the 3rd speed gear 2&.
31. Install the bearing ring 2*.
★ Make sure that the lubrication slots are facing down.
32. Heat the bearing 2( to 80 to 100°C and using tool F4, bottom it
against its seat.
★ Check that the snap ring groove on the outside of the bearing is
facing up.
WB140-2N WB150-2N 30-153 1

12
FORWARD REVERSE CLUTCH
★ Unless otherwise specified, lubricate the pieces with clean trans oil.
1. Lubricate the seal rings a and install them on the pistons b.
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12
2. Install the seal ring c to the rear of the input shaft.
3. Lubricate the seats of the shaft d and the complete piston b. Install
the piston.
★ Be careful not to slice or cut the seals during installation
4. Install the spring e and retainer plate f.
★ The collar of the retainer plate must center the spring.
5. Install the tool F3 and fasten the two parts together with the tie
rods. Tighten them equally and evenly as much as necessary to be
able to install the snap ring g.
WB140-2N WB150-2N 30-155 1

12
6. Install the spring pin h.
7. Lubricate and install the bearing ring i. The chamfer on the bear-
ing ring must face up and engage on the spring pin.
8. Remove the tool F3.
9. Lubricate and install the first roller bearing j, the spacer 1) and the
second bearing j.
10. Install the retainer plate 1! on the gear 1@.
11. Install in sequence a separator plate 1# and a friction disk 1$ ending

with a separator plate.
★ Separator plates 1#.......................................................6 per side

★ Friction discs 1$...........................................................5 per side
★ Immerse the clutch disks in clean trans oil before assembling.
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12
12. Align the tangs of the separator plates and turn the clutch over. Us-
ing two screwdrivers as a support, position the clutch in the hous-
ing.
13. Install the snap ring 1%.
14. Install the spring pin 1^.
15. Lubricate the bearing ring 1& and install it on the shaft.
★ The lubrication holes must face towards the gear.

★ Make sure the spring pin engages in the seating of the bearing
ring 1&.
16. Heat the bearing 1* to 80 to 100°C and with tool F4 bottom it

against its stop.
17. Install the snap ring 1(.
WB140-2N WB150-2N 30-157 1

12
18. Lubricate the seal rings 2) and Install them on the shaft.
★ Position the notches on the seal rings 120° apart.
19. Turn the clutch shaft over and repeat the Steps 2 through 15 in or-
der.
★ For this clutch, Step 9 does not include a bearing spacer 1).
20. Install the spring pin 1^.
21. Lubricate the bearing ring 2@ and install it on the shaft.
★ Make sure that the lube slots face down and that the spring pin
is engaged in the seating of the bearing ring.
22. Install the spacer 2#.
23. Heat the bearing 2$ to 80 to 100°C and using tool F4 bottom it on

the spacer.
★ The seating for the snap ring groove must face up.
24. Install the snap ring 2%.
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12
25. Lubricate the seal ring 2^ and install it on the shaft.
26. Check the clearance of each clutch group using a feeler gauge C in-
serted between the retaining plate and the first steel disk.
★ Clearance limits ...................................................2.3 to 4.3 mm
Clutch Function Check
TEST ILLUSTRATION
Slowly insert compressed air into the clutch port b for the forward gear. a Drive shaft
Listen for the piston movement that locks the clutch. In this condition, b FORWARD Clutch Gear Port
the forward gear d should be locked while the reverse gear e should be
c REVERSE Clutch Gear Port
able to rotate freely on the input shaft a.
d FORWARD Gear
Max air pressure...........................................................6 kg/cm² e FORWARD Clutch Pack
Repeat the test for the port c. In this condition the forward gear d f REVERSE Clutch Pack
should rotate freely on the input shaft a while the reverse gear g should g REVERSE Gear
be locked.
★ If the conditions are not attained, disassemble the group and look
for the causes of the malfunction.
WB140-2N WB150-2N 30-159 1

12
TRANSMISSION HOUSING
30-160 1 WB140-2N WB150-2N

12
1. If removed, 4WD; Install the clutch tube a and lock it in place with
the fittings b.
Tube fittings............................................................ 40 N•m
2. If removed, 2WD; Install the port plugs b.
Port plugs ................................................................ 40 N•m
3. Install the temperature sensor f, breather plug e and caps d seals

c for the pressure adapters to the housing g.
4. Install the bearing h.
WB140-2N WB150-2N 30-161 1

12
5. Install the gear i.
★ The side with the raised areas must face towards the inside of
the transmission.
6. Connect a hoist to the upper gear of the secondary shaft J and posi-
tion it above its seat. Engage the forks 1) and 1! in the synchronizer
rings.
★ The forks for the 3rd and 4th gears must be placed in the upper
hole.
7. Lower the entire group J, centering the pieces in their seats. At the
same time, slide in the main shaft 1@, taking care with the mating of
the gears.
8. Rotate the housing g by 90° and install the snap ring 1# on the
bearing of the main shaft j.
★ After Installing the snap ring, push the main shaft against the
snap ring.
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9. Install the snap ring 1$ on the bearing of the secondary shaft J.
★ After Installing the snap ring, push the secondary shaft against
the snap ring.
10. Install the balls 1% and the springs 1^ in the housing.
11. Install the plugs 1& with the copper washers.
Plugs ....................................................................... 80 N•m
12. Insert the balls 1* into the hole between the shifter rods 1) and 1!.
13. Position the plate 1(.
WB140-2N WB150-2N 30-163 1

12
14. Secure the plate 1( with the screws 2).
Screw ................................................................ Loctite 542
Screw ...................................................................... 50 N•m
15. Install the lock rings 2! and 2@ on the shifter rods secure with the
pins.
16. Install the input shaft 2# and the reverse shaft 2$ together.
17. Install the 4WD shaft 2%.
★ Make sure that the shaft 2% has engaged with the gear i and
the bearing h.
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12
18. If removed, install the tube 2^ on the front housing. Secure with the
banjo fittings 2& and the copper washers 2*.
Tube fittings............................................................ 50 N•m
19. Degrease the sealing surface of the housing g and coat it evenly
with sealant.
Housing............................................................. Loctite 510
★ Do not allow any of the sealant to penetrate anywhere where

oil flows or into the seats of the o-rings.
20. Position the three o-rings 2(.
21. Lubricate the bearings 3) and 3! and install them on the main and
secondary shafts.
WB140-2N WB150-2N 30-165 1

12
22. Install the front housing 3@ on the rear housing g.
★ Make sure that all the bearings have seated correctly into the
front housing.
23. Push the two housings together.
24. Thread in all the bolts by 3# by hand.
★ Tighten the bolts using the alternating cross pattern method.
Housing bolts .......................................................... 50 N•m
25. Thread in the bolts 3$ by hand.
★ Tighten the bolts using the alternating cross pattern method,

starting from the center.
Housing bolts .......................................................... 50 N•m
30-166 1 WB140-2N WB150-2N

12
26. Install the new sealing rings 3^ on the lock ring 3%.
★ Hook up the seals and position them 180° apart.
27. Lubricate the lock ring 3% and install it on the 4WD shaft 2%.
28. Install the bearing 3& on the shaft.
WB140-2N WB150-2N 30-167 1

29. Lubricate the seal ring 3( and, using the tool F1, install it in the
12
cover 3*.
★ Pay careful attention to the direction of assembly.
30. Install the o-ring 4) to the cover 3*.
31. Lubricate the seal rings 3( and 4) and install the cover on the hous-
ing 3!.
32. Install the bolts 4! and tighten them.
Cover bolts.............................................................. 23 N•m
33. Pull the shaft 2# towards the front of the transmission and install the
snap ring 4@ on the bearing.
30-168 1 WB140-2N WB150-2N

34. Lubricate the o-ring of the pump 4# and, using a guide stud A, in-
12
stall the pump.
35. Take out the guiding stud bolt and secure the pump with the screws
4$.
Pump bolts .............................................................. 23 N•m
36. Using tool F2, install the seal ring 4% in the cover 4^.
★ Pay careful attention to the direction of assembly.
37. Install the seal ring 4& on the shaft 4*.
★ The ring is secured by hooking up the two extremities.
WB140-2N WB150-2N 30-169 1

12
38. Use a press to install the bearing 4( on the shaft 4*.
39. Install the snap ring 5).
40. Lubricate the sealing rings and install the complete shaft 4* in the
housing 4^.
41. Install the housing 4^ on the transmission g and bottom it.
42. Install the screws 5! and secure the housing b.
Housing bolts .......................................................... 50 N•m
30-170 1 WB140-2N WB150-2N

12
EXTERNAL GROUP
WB140-2N WB150-2N 30-171 1

12
1. Insert the o-ring a in the flange b and install flange on the shaft.
2. Install the washer c.
3. Screw the bolt d in by hand.
4. Install two long bolts in the flange b. Hold the flange steady, tight-
en the bolt d.
Flange bolt ............................................................ 139 N•m
5. Install the flange e of the secondary shaft.
6. Install the o-ring f.
7. Install the washer g and bolt h. Screw the bolt in by hand.
8. Install two long bolts in the flange e. Holding the flange steady,
tighten the bolt h.
Flange bolt ............................................................ 139 N•m
30-172 1 WB140-2N WB150-2N

12
9. Install the o-ring i in the rear housing.
O-ring lube.......................................................ASL800050
10. Lubricate the levers and the shift lever j end.
Shift lever.........................................................ASL800040
11. Install the shift and the bolts 1).
12. Secure the shift housing.
Shift housing bolts .................................................. 23 N•m
13. Install the priority valve 1!.
14. Install the spring 1@.
15. Install the spool 1#.
16. Install and tighten the element fitting 1$.
Element fitting ........................................................ 50 N•m
WB140-2N WB150-2N 30-173 1

12
17. Lubricate the gasket with clean trans oil and install a new filter 1%.
18. Install the gasket 1^.
19. 4WD; Install the 4WD valve 1& and secure it with the bolts 1*.
Valve bolts .............................................................. 23 N•m
20. 2WD; Install the cover plate 1& and secure it with the bolts 1*.
Cover plate bolts ..................................................... 23 N•m
21. Install the gasket 1(.
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12
22. Install the plate 2).
23. Attach the plate 2) with the bolts 2!, use an alternating cross pattern
method for tightening.
Plate bolts ............................................................... 23 N•m
24. Install the gasket 2@ of the control valve in position.
25. Place the control valve 2# in position and secure it with the bolts 2$.
26. Tighten the bolts 2$ starting in the center and moving towards the
outside, use an alternating cross pattern method.
Control valve bolts.................................................. 23 N•m
WB140-2N WB150-2N 30-175 1

12
27. Insert the filter 2% complete with o-ring 2^.
28. Install the cover 2& and secure it with the bolts 2*.
30-176 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION TORQUE CONVERTER
12
TORQUE CONVERTER

nect switch a.
REMOVAL
1. Lower all work equipment to the ground and turn the electrical sup-
ply off a. Release any pressure from the systems.
2. Remove the piston pump, see PISTON PUMP. Remove the trans-
mission, see TRANSMISSION.
3. Carefully slide the converter b off the transmission c input shaft.
WB140-2N WB150-2N 30-177 1

REMOVAL AND INSTALLATION TORQUE CONVERTER
12
INSTALLATION
★ Engage the two shafts, primary and secondary, by slowly rotating the
body of the convertor.
When installing the converter on to the input shaft, rotate the con-
verter to the right then left while holding it square with the shaft un-
til it slides in place. Be sure it is seated in the flywheel housing. Do
not force the converter into the housing, damage to the front pump
may result. Once the converter is in place, retain it in place to keep
it from falling out.
1. Refill the tank with hydraulic oil up to maximum level.
Hydraulic oil .................................................................92 l
★ Fill the pump body and the pump, bringing the tank up to pres-
sure, see TESTING AND ADJUSTMENTS.
2. Refill the transmission.
Transmission oil............................................................16 l
3. Start the engine to circulate the oil in all circuits. Check that there
are no leaks.
AND ADJUSTMENTS.
5. Stop the engine, check the levels and top them off.
30-178 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION STEERING VALVE
12
STEERING VALVE
nect switch a.
WARNING! Do not dump any system down the drain, on

to the ground or into a body of water, doing so is in viola-
tion of the law.
REMOVAL
1. Lower all work equipment to the ground and release all residual hy-
draulic pressure from the system. Turn the battery disconnect
switch a to the off position.
2. Position a suitable drain pan under the valve. Disconnect the lines
c at the steering valve b. Quickly cap or plug any openings.
★ Tag or mark line locations as they relate to the valve.
3. Remove the lower instrument panel cover d.
4. Raise the column boot e and separate the connectors f and g
WB140-2N WB150-2N 30-179 1

REMOVAL AND INSTALLATION STEERING VALVE
12
5. Disconnect the relays h and i.
6. Remove the steering column bolts j and remove the complete

steering unit 1).
INSTALLATION
★ Bleed the air from the Load Sensing circuit, see TESTING AND
ADJUSTMENTS.
★ Start the engine and perform several complete steering rotation in
both directions, to bleed the air out of the steering system.
30-180 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION COLUMN CONTROL SWITCHES
12
COLUMN CONTROL SWITCHES
nect switch a.
REMOVAL
1. Turn the battery disconnect switch a to the off position.
2. Raise the column boot b and disconnect the wiring c and d.
3. Remove the cover e that hold the switches f and g.
4. Disconnect clamp h that holds the switches in place.
WB140-2N WB150-2N 30-181 1

REMOVAL AND INSTALLATION COLUMN CONTROL SWITCHES
12
5. Remove the center button i, then the steering wheel nut and wash-
er j.
6. Remove the steering wheel 1).
7. Remove each switch f and g with their protective sleeve.
INSTALLATION
★ Check that the dowel pin 1! enters fully into the steering col-
umn and that the transmission unit is attached to the steering
column.
Steering wheel nut .................................................. 40 N•m
30-182 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION MASTER BRAKE CYLINDER
12
MASTER BRAKE CYLINDER
nect switch a.
REMOVAL
1. Turn the battery disconnect switch a to the off position.
2. Remove the cap b from the reservoir c and siphon the brake fluid
out.
3. Disconnect the wiring d.
4. Remove the reservoir c.
5. Remove the retaining clip e that holds the brake lines f in place.
6. Disconnect the lines f from the master cylinder g.
7. Remove four mounting bolts h and carefully remove master cylin-

ders (6).
★ If only one master cylinder is to be removed, disconnect pres-

sure equalizing line i.
INSTALLATION
JUSTMENTS.
★ Adjust pedal rods j to allow full return of the master cylinder

piston. Be sure the pedal adjustments 1) are set equally, see
TESTING AND ADJUSTMENTS.
WB140-2N WB150-2N 30-183 1

REMOVAL AND INSTALLATION MASTER BRAKE CYLINDER
12
Pipe fitting .............................................................. 20 N•m
30-184 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION LOADER CONTROL VALVE
12
LOADER CONTROL VALVE
nect switch a.
REMOVAL
1. Lower all work equipment to the ground and release all residual hy-
draulic pressure from the system. Turn the battery disconnect
switch a to the off position.
2. Remove floor mat B and slide lever boots C, D, and E up.
3. Remove bolts F and trim panel G.
4. Disconnect control rod i from control valve h.
WB140-2N WB150-2N 30-185 1

REMOVAL AND INSTALLATION LOADER CONTROL VALVE
12
5. Disconnect the front equipment tubes j, control valve supply and
delivery lines 1), 1!, load sensing line 1@, and steering line 1#. Cap
or plug all openings.
★ Be sure to tag or mark the line locations and valve body loca-
tions for reassembly.
6. Remove the four control valve retaining bolts. Remove the control
valve h.
INSTALLATION
1. Start the engine to circulate the oil, and check that there are no
leaks.
2. Bleed the air from all circuits, see TESTING AND ADJUSTMENTS.
3. Stop the engine and check the oil level in the tank.
30-186 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION 2WD FRONT AXLE
12
2WD FRONT AXLE
REMOVAL
1. Start the engine and use the front bucket to raise the machine and
front wheels. Place two stands a and some blocks beneath the
chassis. Slowly lower the machine onto the blocks, checking that
the wheels remain at least 5 cm above the ground. Engage the park-
ing brake.

nect switch a.
2. Remove the front wheels b.
Front wheel ................................................................ 65 kg
3. Remove the front guard c, see COUNTERWEIGHT.
4. Utilizing a suitable drain pan, disconnect the lines f from the steer-
ing cylinder and plug open ports.
5. Disconnect the lube lines g for the axle oscillation pin.
6. Position a rolling floor jack and some blocks beneath the axle d.
Raise the jack until the blocks are under axle arms.
★ Lower the jack 10 cm in order to disengage axle from the ful-

crum supports.
WB140-2N WB150-2N 30-187 1

12
7. Remove the retaining bolt i and nut of the axle pivot pin h. Install
an eyebolt into the hole of the pin and extract.
8. Lower the jack until the axle is free of the frame. Remove the entire
axle.
Front axle ....................................................................... kg
INSTALLATION
Front wheel nuts ................................................... 350 N•m
Front close bolts.................................................... 300 N•m

ADJUSTMENT.
Axle pivot pin and bushing..............................ASL800050
★ Check the oil level in the tank and start the engine. Perform a few
steering turns in both directions to bleed air from the steering cir-
cuit.
DISASSEMBLY
STEERING CYLINDER
1. Loosen the link arm b lock nut a until the pin threads are protected
in the lock nut. Bang on the nut A with a hammer in order to dis-
lodge the link arm b from the swivel housing c.
★ Do not beat on the end of the pin threads. This is a destructive

operation for the nut.
2. Remove the guide rod link b by unloosing the jam nut d, then
threading out from the swivel joint e.
3. Remove the swivel joints e from the cylinder rod.
4. Remove the cylinder g gland bolts f.
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12
5. Slide the gland h off the rod j. Remove the seals i from inside
the gland and discard.
6. Pull the rod j out of the body 1). Remove the seals 1! from the rod
piston and discard.
7. Remove the seals 1@ from inside the end of the body 1) and discard.
8. Replace all the seals with the seal kit.
WHEEL HUB
1. Position a suitable drain pan under the wheel hub. Place the wheel
hub b with the plug a up. Loosen it slowly to eliminate any inter-
nal pressure. Rotate the wheel hub over the drain pan. Remove the
plug.
Wheel hub........................................................... 1.3 l each
2. Drain the oil completely.
3. Remove the fastening screws c and stud bolts d from the cover e.
Remove the cover from the wheel hub. Remove and discard the o-
ring f.
4. Remove the bolts g, bushings h and retainer plate i from the

wheel hub j.
5. Using at least two of the removed bolts g in the hub j jack screw
holes, evenly draw out the hub to unseat the bearings 1) from the
steering knuckle. Remove the hub.
6. Position the hub j on a flat surface and remove the seal ring 1!.
This is a destructive operation for the seal ring.
7. Remove the bearing cups on both sides of the hub, using a hammer
and suitable driver. Remove the bearing cone from the knuckle, us-
ing a suitable extractor.
WB140-2N WB150-2N 30-189 1

12
STEERING KNUCKLE
1. Remove the bolts A from the upper B and lower C king pins.
★ Before removing the king pins, attach a hoist the steering

knuckle.
2. Remove the king pins B and C.
3. Remove the steering knuckle D from the axle housing.
4. Remove the belleville washers e and f from the king pin housings
in the axle housing. Remove spacer g from the upper part of axle
housing.
5. Remove the upper h and lower i bushings out of the king pin
housings in the axle housing.
AXLE HOUSING
1. Remove the seal rings a from the pivot with a suitable tool.
★ This is a destructive operation for the seal rings.
2. If required, replace the bushings b.
30-190 1 WB140-2N WB150-2N

12
3. Remove the bolts c and the rear cover/cylinder support D.
REASSEMBLY
★ Before matching two surfaces make sure they are perfectly clean.
Degrease and clean with the appropriate cleaner.
1. Spread a film of sealant on the contact surface between the axle
housing and the rear cover a. Place the cover on the axle housing.
Install and tighten bolts b.
Cover sealant .................................................... Loctite 510
Mounting bolts...................................................... 169 N•m
2. Install two new bushings c respectively, longer bushing to the rear,

and two new seal rings d in the central pivot using tools D12 and
D13.
3. Install the upper king pin bushing e on the axle housing with the
special tool D14 and a hammer.
4. Install the lower king pin spherical bearing f on the axle housing
with the special tool D14 and a hammer.
★ Freezing the bearing will ease the assembly.
WB140-2N WB150-2N 30-191 1

12
5. Position the lower king pin on a workbench and install the cone of
the spherical bearing f with the special tool D19.
6. Place the spacer g under the belleville washer h on the upper part.
★ Liberally grease the king pin housings parts.
7. Position the belleville washers h on the king pin housing and retain
with clean grease.
STEERING KNUCKLE
1. Secure the steering knuckle A with a hoist. Assemble to the axle

housing.
2. Install the two king pins, the lower B and the upper c, and secure
the bolts d.
King pin bolts ....................................................... 190 N•m
★ Make sure that the belleville washers remain in their position.
WHEEL HUB
★ If the tapered roller bearings d have been replaced, verify that the
measure A, B and C are within the limits.
★ A measurement ........................................17.950 to 18.000 mm
★ B measurement ........................................64.275 to 64.325 mm
★ C measurement ........................................23.070 to 23.172 mm
1. Position the wheel hub A on a work bench and drive both cups of
the tapered roller bearing b in position and bottom with the special
tool D20.
2. Install the seal ring c flush into the wheel hub A using special tool
D21.
30-192 1 WB140-2N WB150-2N

12
3. Install the cone of the tapered roller bearing d on the steering
knuckle end.
4. Install the wheel hub a on the steering knuckle and fit the other
cone of the tapered roller bearing d in place.
5. Force all the hub dowel bushings e with the special tool D1 and a
hammer. Install the retaining plate f and secure with the bolts g.
Retaining plate bolts ............................................. 230 N•m
6. Install a new o-ring h to the hub cover i. Install the cover onto the
hub over the studs being careful not to damage the o-ring.
7. Install the two special stud bolts j.
Stud bolts .......................................................... Loctite 542
Stud bolts ................................................................ 70 N•m
8. Screw in the fastening screws 1) and secure.
Fastening screws..................................................... 80 N•m
9. Position the drain/fill hole up. Fill the wheel hub with clean lubri-
cant. Install the drain plug 1!.
Wheel hub....................................................................1.3 l
WB140-2N WB150-2N 30-193 1

12
STEERING CYLINDER
1. Install a new seal kit a to the cylinder gland b, to the piston rod c
and to the cylinder body d.
2. Slide the rod into the cylinder body.
3. Fit the swivel joints e to the ends of the cylinder rod and tighten.
Swivel joint........................................................... 300 N•m
4. Install the steering cylinder to the central body and secure with the
bolts f.
Cylinder bolts ....................................................... 120 N•m
5. Install the lock nut g loose and guide rod h to the swivel joint so
that the ball joint can be inserted into the steering knuckle.
6. Insert the ball joint of the guide rod h into the steering knuckle.
30-194 1 WB140-2N WB150-2N

12
7. Install the lock nut i.
Lock nut ................................................................ 220 N•m

★ Screw in the lock nut g of the guide rod h only when the toe
in adjustment has been carried out.
TOE IN ADJUSTMENT
1. Put two 1 m linear bars A on the wheel sides and lock them with
two nuts on the wheel hub stud bolt. Align the two bars.
★ The two bars should be fixed on their center so that they are
perpendicular to the supporting surface and parallel to the
mounting pin axis.
2. Measure the distance M between the bar ends with a tape line.
★ Keep the minimum value, swing the measurement point.
3. Check that the difference of the measurements between the wheel

hubs diameters ends is within the tolerance range.
WB140-2N WB150-2N 30-195 1

12 ★ The nominal toe in A value is referred to as the top to bottom

distance of the wheel hubs flange. The measured toe in value
M at the bar ends is the front to rear value of the bar and flange
distance.
A - Nominal toe in ........................................................ 0 to < 2 mm
M - Measured toe in...................................................... 0 to < 5 mm
4. If toe in is incorrect, use two wrenches on the swivel joints screw-

ing in and out equally till the toe in is within the requested toler-
ance.
5. After adjusting, tighten the guide rod lock nuts.
Lock nuts .............................................................. 250 N•m
STEERING ANGLE ADJUSTMENT
1. Use the same bars A assembled for the toe in adjustment and a long
bar over the machined part of the central body, so that the two bars
form an acute angle at the maximum steering.
2. Adjust a inclinometer to a 50° angle and position it on the long bar.

Move a wheel side till it forms, with the two bars, the angle fixed
by the inclinometer.
30-196 1 WB140-2N WB150-2N

12
3. Adjust the steering mechanical retainer, screwing in or out the spe-
cial bolts A on the steering knuckle, locking them with the lock nut
B.
Lock nut ................................................................ 150 N•m

★ Steer completely towards the other side and repeat the same
operations.
WB140-2N WB150-2N 30-197 1

12
4WD FRONT AXLE
REMOVAL
1. Start the engine and use the front bucket to raise the machine and
front wheels. Place two stands a and some blocks beneath the
chassis. Slowly lower the machine onto the blocks, checking that
the wheels remain at least 5 cm above the ground. Engage the park-
ing brake.

nect switch a.
2. Remove the front wheels b.
Front wheel ................................................................ 65 kg
3. Remove the front guard c, see COUNTERWEIGHT.
4. Utilizing a suitable drain pan, disconnect the lines f from the steer-
ing cylinder and plug open ports.
5. Disconnect the drive shaft e from the axle d.
6. Disconnect the lube lines g for the axle oscillation pin.
7. Position a rolling floor jack and some blocks beneath the axle d.
Raise the jack until the blocks are under axle arms.
★ Lower the jack 10 cm in order to disengage axle from the pivot

support.
30-198 1 WB140-2N WB150-2N

12
8. Remove the retaining bolt i and nut of the axle pivot pin h. Install
an eyebolt into the hole of the pin and extract.
9. Lower the jack until axle is free. Remove the entire axle.
Front axle ................................................................. 316 kg
INSTALLATION
Front wheel nuts ................................................... 350 N•m
Front close bolts.................................................... 300 N•m

ADJUSTMENT.
Axle pivot pin and bushing..............................ASL800050
★ Check oil level in the tank and start the engine. Perform a few
steering turns in both directions to bleed air from the steering cir-
cuit.
DISASSEMBLY
STEERING CYLINDER
1. Loosen the link arm b lock nut a until the pin threads are protected
in the lock nut. Tap on the nut A with a hammer in order to dis-
lodge the link arm b from the swivel housing c.
★ Do not beat on the end of the pin threads. This is a destructive

operation for the nut.
2. Remove the guide rod link b by unloosing the jam nut d, then
threading out from the swivel joint e.
3. Remove the swivel joints e from the cylinder rod.
4. Remove the cylinder g gland bolts f.
WB140-2N WB150-2N 30-199 1

12
5. Slide the gland h off the rod j. Remove the seals i from inside
the gland and discard.
6. Pull the rod j out of the body 1). Remove the seals 1! from the rod
piston and discard.
7. Remove the seals 1@ from inside the end of the body 1) and discard.
8. Replace all the seals with the seal kit.
PLANETARY WHEEL HUB
1. Position a suitable drain pan under the wheel hub. Place the wheel
hub b with the plug a up. Loosen it slowly to eliminate any inter-
nal pressure. Rotate the wheel hub over the drain pan. Remove the
plug.
Wheel hub........................................................... 1.3 l each
Drain the oil completely.
2. Remove both fastening screws c and stud bolts d from the cover
e. Remove the cover from the wheel hub. Remove and discard the
o-ring f.
3. Remove the three snap rings g and thrust plate h.
4. Remove the planetary gears i off the shafts.
★ Collect the needle bearings j (30 per shaft), check their condi-
tions. With new planetary gears, is advisable to assemble new
needle bearings.
5. Remove the thrust washers 1).
★ DO NOT remove the shafts from the cover 1!. DO NOT lose the
thrust button 1@ from the cover.
30-200 1 WB140-2N WB150-2N

12
6. Remove the steel lock ring 1# from the axle shaft.
7. Remove the sun gear 1$ and spacer 1% from the axle shaft.
8. Remove the bolts 1^ from the wheel carrier 1&.
9. Install two of the just removed bolts in the threaded extraction

holes of the wheel carrier. Extract and remove the carrier together
with the planetary ring gear.
10. Remove the steel lock ring 1* and the wheel carrier 1& from the
planetary ring gear 1(.
11. Only if necessary, remove the centering bushings 2) of the carrier

with tool D1.
WB140-2N WB150-2N 30-201 1

12
12. Remove the wheel hub 2! and collect the bearing cone 2@.
13. Place the hub on a flat surface and remove the seal ring 2#.
★ This is a destructive operation for the seal ring.
14. Remove the bearing cups out 2@ on both sides of the hub.
15. Remove the bearing cone 2@ from the steering knuckle.
STEERING KNUCKLE
1. Remove the bolts a from the upper b and lower c king pin.
★ Before removing the king pins, sling the steering knuckle to a

support device.
2. Remove the king pins b and c.
3. Remove the steering knuckle d from the axle housing and from the
short shaft e.
30-202 1 WB140-2N WB150-2N

12
4. Place the steering knuckle d on a flat surface and remove the seal
ring f.
5. Turn the steering knuckle over and remove the bushing g.
AXLE HOUSING
1. Remove the U joint a from the axle housing.
2. Remove the seal ring b from the axle housing.
3. Remove the belleville washers c and d from the king pin mounts
in the axle housing.
4. Remove spacer e from the upper part of axle housing.
5. Remove the bushing f from the housing. Examine the bushing be-
fore the removal and replace it only if the wear conditions require
this.
6. Take the upper g and lower h bushings out of the housing and out
of king pin.
7. Remove the seal rings i from the pivot. If necessary, replace the
bushings j.
★ This is a destructive operation for the seal rings.
WB140-2N WB150-2N 30-203 1

12
DIFFERENTIAL CARRIER
1. Remove the bolts a and the nuts b from the flange c. Use a screw-
driver and unclamp the flange and remove.
2. Using a lever to carefully pry out the oil seal cover d from the dif-
ferential carrier.
3. Remove the seal ring e and o-ring f from the oil seal cover. Dis-
card the o-ring and seal ring.
4. Rotate the axle so that the differential carrier g is facing up. Attach
a hoist to the carrier. Remove the bolts, then the differential carrier.
★ Install the differential carrier in an appropriate stand.
5. Remove the bolts h and the ring nut retainers i.
30-204 1 WB140-2N WB150-2N

12
6. Mark the carrier halves j to the differential carrier g with refer-
ence marks to avoid incorrect assembly.
7. Remove the adjuster ring nuts 1) using tool D2.
8. Loosen and remove the bolts 1! and collar halves j.
9. Using a hoist, remove the differential case 1@.
★ Keep the cups with the bearings 1# they were removed with.
DO NOT mismatch the cups and cones bearings if they are not
to be replaced.
★ Check that the bushings 1$ remains in the housing.
WB140-2N WB150-2N 30-205 1

12
PINION GEAR
1. Mount the differential carrier a in a vise.
2. Remove the lock nut b using special tools D3 and D4.
★ This is a destructive operation for the ring nut.
3. Remove the ring nut b and retaining washer c.
4. Tap the shaft with a mallet to remove the pinion gear d.
★ Take care not to drop the pinion gear.
5. Remove the washers e, the collapsible spacer f and the inner cone
of the tapered roller bearing g.
6. Place the differential carrier on a flat surface and remove the outer
cups of the taper roller bearing g using a driver.
30-206 1 WB140-2N WB150-2N

12
7. Remove the inner cone of the tapered roller bearing g from the pin-
ion gear d. Collect the bearing cone and the shim h.
8. Check all pinion components for wear. The ring nut and compres-
sion spacer must be replaced.
DIFFERENTIAL
1. Place the differential a in a vise. Remove the ring gear b bolts c.
★ This will make both differential halves free, so take care not to
drop the internal components.
2. Remove the ring gear.
3. Disassemble the differential halves d. Check the operating and

wear conditions of the components.
4. Remove the bearing e from the differential halves d.
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12
REASSEMBLY
PINION GEAR
1. Place the differential support a on a workbench. Install the outer

cups of the bearings b using the special tool D5.
2. In order to measure the distance, use the kit consisting of the spe-
cial tools called the false pinion gear D6 and false differential
halves D7 and D8.
3. Insert the false pinion gear D6, together with its bearings b and
ring nut c. Using tools D3 and D4, tighten until the backlash is
eliminated.
4. Install special tools D7 and D8 to the differential carrier and bolt

d in the carrier halves e.
5. Use a depth gauge to take the measurement X. Write down the X

measurement.
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6. Make a note of the value V marked on the head of the pinion gear.
12
Calculate the shim thickness S to be installed beneath the pinion,
using the formula:
S = X - V, S is the thickness of the shim.
7. Install the shim f onto the pinion gear g and press the inner bear-
ing b using the tool D9.
★ The chamfer on the inner diameter of the shim must face the
gear teeth.
8. Install to the pinion gear the first washer h, the new spacer i and
the second washer h.
9. Install the pinion gear g into the differential carrier a, from the in-
ternal axle side, and the second bearing cone b into the pinion end,
from the opposite side.
★ In order to seat the second bearing into position, use the special
tool D9.
10. Install the ring nut washer j and new lock ring nut d on the pinion
gear end.
WB140-2N WB150-2N 30-209 1

11. Tighten ring nut, using the wrench for ring nut D3 and for pinion
12
gear D4.
★ The torque setting is given by the preloading measurement on

bearings. Tighten the ring nut gradually.
★ If the tightening is excessive, the elastic spacer must be re-
placed and the procedure repeated. When you check the pre-
loading, it is advisable to bang slightly both pinion ends with a
soft hammer, so as to help set the bearings.
12. Wrap a wire line around the pinion, uniformly and without overlap-
ping. Connect it to a load meter and check the force P required to
rotate the shaft.
★ The force should be that needed for continual rotation. Do not

take into consideration the initial thrust force.
13. Using the wrenches, tighten the nut d taking load measurements at
intervals until force P has been obtained.
★ P force, maximum .................................................. 92 to 137 N

If the max permissible value is exceeded, a new spacer must be
used and the preloading operations must be repeated.
DIFFERENTIAL
1. Assemble the cones of the new taper roller bearings a on the carri-
er halves b, using the special tool D10.
2. After cleaning and after checking operational conditions and wear,

assemble the differential parts.
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12
3. Position a carrier half on a workbench and assemble all its inner
components, sun gears, planetary gears, thrust washers pin and
discs. Join the two carrier halves c.
4. Install the ring gear d and assemble with the bolts e.
Ring gear bolt ................................................... Loctite 270
Ring gear bolt ......................................................... 95 N•m
DIFFERENTIAL CARRIER
1. Install the differential box a, with outer bearing cups b on the dif-
ferential carrier.
Take care not to invert the outer races of the tapered

roller bearings and check that you are working on
the right side of the ring gear.
2. Install the two carrier halves c and bolts d in their seat. Check the
position with the reference marks. Position and snug the bolts.
WB140-2N WB150-2N 30-211 1

12
3. Install the two adjustment ring nuts e in the differential carrier
with tool D2, so as to preload the bearings slightly. Tap lightly with
a soft hammer in order to properly set the bearings in position. Take
care not to reverse the ring nuts.
4. Position a magnetic base dial indicator A on the differential carrier,

so that the indicator feeler touches the surface of one tooth of the
ring gear at a 90° angle.
5. Lock the pinion gear and move the ring gear alternatively and note
the pinion ring gear backlash, measured with the dial indicator. Re-
peat the operation on 2 or more points (teeth), rotating the ring gear,
to obtain an average value.
Permissible backlash ............................................ 0.18 to 0.25 mm
6. If the measured backlash is less than the given tolerance range,

screw in the ring nut from the side opposite to the ring gear and un-
screw the opposite one the same amount.
If the measured backlash is higher than the given tolerance range,

screw in the ring nut from the side of the ring gear and unscrew the
opposite one of the same amount.
★ Before measuring the clearance, tap lightly on the bearing cov-
ers with a soft hammer to ensure that they are securely posi-
tioned.
7. Tighten the bolts d.
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12
8. Using the same method employed to check the pinion gear force,
check the force T required to rotate the ring and pinion gears.
★ Force required:
(P+39 N) < T < (P+59 N)
P = the force found for the pinion gear
★ The force should be that of continual rotation. Do not take the
thrust force into consideration.
9. If the force is not within permissible limits:
Tighten each lock nut to the same extent to increase the force T.
Loosen each lock nut to the same extent to decrease the force T.
The clearance between the ring gear and the pinion
gear must remain within permissible limits.
10. Check the centering of the contact area using the following proce-
dure:
a. Coat both surfaces of the teeth of the ring gear with a marking
substance.
b. Rotate the pinion gear.
If the contact area is excessive near to the edge of the teeth, the ring
gear must be brought closer to the pinion gear. If the contact area is
excessive on the inside of the teeth, the ring gear must be moved
away from the pinion gear.
11. Tighten the carrier half bolts d.
Carrier half bolts ................................................... 266 N•m
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12
12. Once you have completed adjustment operations, fit the adjuster
nut f retainers bolts g.
Retainer bolts .......................................................... 13 N•m
13. Install the seal ring h in the pinion gear cover i with special tool
D11.
14. Install a new o-ring j onto the pinion gear cover i.
15. Assemble the pinion gear cover i with a suitable driver.
★ Do not damage the seal ring h o-ring j.
16. Clean the mating surfaces of the carrier and axle. Degrease and
clean with the appropriate cleaner. Apply Loctite on the contact
surface of the differential carrier.
Differential carrier surface................................ Loctite 510
17. Place the differential carrier 1) on the axle housing. Install the
mounting bolts 1!.
Differential carrier bolts ....................................... 169 N•m
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12
18. Insert the flange 1@ on the pinion gear end. Install the flange bolts 1#
with the relative nuts on the flange.
Flange bolts............................................................. 56 N•m
AXLE HOUSING
1. Assemble two new bushings A respectively, longer bushing from

the pinion gear side, and two new seal rings b in the central pivot
by using special tools D12 and D13.
2. Install the king pin bushings c and d on the axle with the special
tool D14.
3. Install the bushing e on the axle with the special tool D15.
4. Install the seal ring f on the axle with the special tool D16.
★ Fill ¾ of the seal ring cavity with fresh grease.
WB140-2N WB150-2N 30-215 1

12
5. Lubricate the bushing e and the seal ring lip f. Insert the U joint g
inside the axle housing.
★ Be careful not to damage the seal.
STEERING KNUCKLE
1. Drive the bushing a into the steering knuckle b with the special
tool D17.
2. Assemble the seal ring c on the steering knuckle b with the special
tool D18.
★ Fill ¾ of the seal ring cavity with grease.
3. Place the lower king pin d on a workbench and assemble the cone
of the spherical bearing e with the special tool D19 under a press.
Put the spacer f under the belleville washer on the upper part.
★ Liberally grease the king pin housings.
4. Position the belleville washers G on the king pin housings.
5. Secure the steering knuckle b with a hoist.
6. Lubricate the seal ring lip and protect the splined end of the axle
shaft with a thin adhesive tape to avoid damage to the seal ring. Af-
ter assembly, remove the adhesive tape. Assemble the steering
knuckle on the axle housing. Assemble the two king pins, the upper
H and the lower I, and tighten the retaining bolts J.
Retainer bolts ........................................................ 190 N•m

★ Make sure that the belleville washers remain in their position.
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12
WHEEL HUB
★ If the tapered roller bearings B have been replaced, verify that the
measure A, B and C are within the limits.
★ A measurement ........................................17.950 to 18.000 mm
★ B measurement ........................................64.275 to 64.325 mm
★ C measurement ........................................23.070 to 23.172 mm
1. Place the wheel hub A on a work bench and drive both cups of the
taper roller bearings b in place with special tool D20.
2. Install the seal ring c into the wheel hub A with the special tool
D21.
3. Install the taper roller bearing cone B on the steering knuckle end.
4. Place the wheel hub on the steering knuckle and install the other
taper roller bearing cone B in place.
5. Position the wheel carrier D on a bench and drive the bushings E

into the carrier surface level with the special tool D1.
At least two bushings, diametrically opposed, should be set slightly

higher than the carrier surface level to be used as dowels.
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12
6. Preassemble the wheel carrier F planetary gear G and with the
locking ring H.
7. Install the wheel carrier F on the wheel hub using the two project-
ing bushings e as dowel pins. Install the bolts to secure the ring
gear with the wheel hub.
8. Seat all the hub dowel bushings completely with the special tool
D1.
9. Assemble the wheel carrier bolts i and tighten.
Wheel carrier bolts................................................ 230 N•m
10. Slide the spacer J onto the axle shaft, fit the sleeve 1) and install
the lock ring 1! to the end of the splined hub.
11. Repeat this procedure for the remaining side.
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12
PLANETARY CARRIER
1. Place the planetary carrier a on a workbench. Install the outer

thrust washers b and planetary gears c the shafts.
2. At each gear, install 30 needle rollers d between the gear and shaft.
Install the inner trust plate b and secure with the snap rings e to
the shafts.
3. Install a new o-ring g to the carrier.
4. Install planetary carrier to the wheel hub and secure with the fasten-
ing screws h. Coat the stud bolts i and install.
Fastening screws..................................................... 80 N•m
Stud bolts .......................................................... Loctite 542
Stud bolts ................................................................ 70 N•m
5. Repeat this procedure for the remaining side.
AXLE FILL
1. Position the drain/fill hole up. Fill the wheel hub with clean lubri-
cant. Install the drain plug A.
Wheel hub ...................................................................... 1 l
Repeat for the remaining side.
2. Fill the axle housing with clean lubricant. Install the drain plug b.
Axle housing ............................................................... 6.5 l
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12
STEERING CYLINDER
1. Install a new seal kit a to the cylinder gland b, to the piston rod c
and to the cylinder body d.
2. Slide the rod into the cylinder body.
3. Fit the swivel joints e to the ends of the cylinder rod and tighten.
Swivel joint........................................................... 300 N•m
4. Install the steering cylinder to the central body and secure with the
bolts f.
Cylinder bolts ....................................................... 120 N•m
5. Install the lock nut g loose and guide rod h to the swivel joint so
that the ball joint can be inserted into the steering knuckle.
6. Insert the ball joint of the guide rod h into the steering knuckle.
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12
7. Install the lock nut i.
Lock nut ................................................................ 220 N•m

★ Screw in the lock nut g of the guide rod h only when the toe
in adjustment has been carried out.
TOE IN ADJUSTMENT
1. Put two 1 m linear bars A on the wheel sides and lock them with
two nuts on the wheel hub stud bolt. Align the two bars.
★ The two bars should be fixed on their center so that they are
perpendicular to the supporting surface and parallel to the
mounting pin axis.
2. Measure the distance M between the bar ends with a tape line.
★ Keep the minimum value, swing the measurement point.
3. Check that the difference of the measurements between the wheel

hubs diameters ends is within the tolerance range.
WB140-2N WB150-2N 30-221 1

12 ★ The nominal toe in A value is referred to as the top to bottom

distance of the wheel hubs flange. The measured toe in value
M at the bar ends is the front to rear value of the bar and flange
distance.
A - Nominal toe in ......................................................0 to < 2 mm
M - Measured toe in....................................................0 to < 5 mm
4. If toe in is incorrect, use two wrenches on the swivel joints screw-

ing in and out equally till the toe in is within the requested toler-
ance.
5. After adjusting, tighten the guide rod lock nuts.
Lock nuts .............................................................. 250 N•m
STEERING ANGLE ADJUSTMENT
1. Use the same bars A assembled for the toe in adjustment and a long
bar over the machined part of the central body, so that the two bars
form an acute angle at the maximum steering.
2. Adjust a inclinometer to a 50° angle and position it on the long bar.

Move a wheel side till it forms, with the two bars, the angle fixed
by the inclinometer.
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12
3. Adjust the steering mechanical retainer, screwing in or out the spe-
cial bolts A on the steering knuckle, locking them with the lock nut
B.
Lock nut ................................................................ 150 N•m

★ Steer completely towards the other side and repeat the same
operations.
WB140-2N WB150-2N 30-223 1

REMOVAL AND INSTALLATION REAR AXLE
12
REAR AXLE
REMOVAL
1. Lower the outriggers b in order to raise the rear wheels c about 5
cm.
2. Position a safety stand a, 65 cm tall, beneath the backhoe chassis.

Retract the outriggers until the machine is resting on the stand.
3. Stop the engine and remove the rear wheels c.
Rear wheel ............................................................... 163 kg
4. For safety, rest the backhoe bucket with back resting on the ground,
keeping the arm vertical. Also lower front bucket on the ground.
5. Stop engine and completely release any residual pressures from all
the circuits, see TESTING AND ADJUSTMENTS.
6. Disconnect parking brake cable e and differential lock tube f

from rear axle d.
★ Plug and cap all openings to prevent entry of impurities.
7. Disconnect rear drive shaft g from the rear axle.
8. Disconnect brake hoses h and remove bolts i.
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12
9. Partially loosen eight lock nuts j in order to eliminate the torque
and facilitate subsequent dismantling.
★ Loosen lock nuts in a crisscross sequence.
10. Place the jacks and some blocks beneath the axle d. Raise the jack
until the blocks can be positioned under the axle.
★ Loosen the nuts j and plates 1) that secure the axle.

★ It should be possible to lower the jack by 20 cm.
11. Remove the lock nuts j, plates 1), and mounting bolts 1!. Lower
the jack until the axle d is clear of the chassis. Remove the axle.
INSTALLATION
Wheel nuts .......................................................500 ±9 N•m
★ Adjust stroke of the parking brake lever and bleed air from the
brake circuits. For details, see TESTING AND ADJUST-
MENT.
Axle lock nuts ....................................................... 570 N•m

★ Tighten in two stages, using the crisscross method.
• Check the oil level in the tank and start the engine.
DISASSEMBLY
PLANETARY GEARS
1. Position a suitable drain pan under the wheel hub. Before draining
the oil, position the hub with the plug a on top. Loosen it in order
to relieve any residual pressure, then remove it completely. Rotate
the hub down, then drain the oil.
Wheel hub, each...........................................................1.5 l
2. Remove the two fastening screws b of the planetary carrier c with

a wrench.
WB140-2N WB150-2N 30-225 1

12
3. Remove the planetary carrier c from the wheel hub d.
4. Remove and discard the o-ring e.
5. Position the planetary carrier on a table and check its wear condi-
tions.
6. To replace the planetary gears f, remove the bolt g and relevant

washers h and i. Treat the pin j with care.
7. Remove the planetary gear f from its seat, taking care not to lose
the two units of rollers 1) and thrust washer 1! and 1@ inside it.
8. If the pins 1# of the pinion gears are in poor condition, replace the
entire planetary train with prefitted pins.
9. If the thrust button 1$ is worn, replace the entire planetary carrier.
WHEEL HUB
WARNING! Before disassembling the hub, it is advisable

to secure it with a a hoist or any other supporting device
to avoid an accidental fall.
1. Remove the sun gear shaft a with the coupling and snap ring.
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2. Remove the bolts b from the wheel hub lock ring gear c.
3. To remove the hub lock ring gear c from its housing, screw at least
two of the just removed bolts b in the threaded extraction holes A.
4. Remove the hub lock ring gear c together with the planetary ring
gear d.
5. Remove the steel stop ring e and disjoin the hub lock ring gear d
from the planetary ring gear c.
6. If necessary, remove the centering bushings f of the hub lock ring

gear with special tool E1.
WB140-2N WB150-2N 30-227 1

12
7. Remove the hub g. Collect the bearing cone h.
8. Position the hub on a flat surface and remove the seal ring i.
9. Remove the bearing cups h from both sides of the hub. Remove
the bearing cone h from the steering knuckle.
AXLE HOUSING AND BRAKE
1. Drain oil from the axle, remove the breather first, to release the axle
inner pression, then loosen the plug A very carefully.
2. Extract the seal ring b from the axle housing.
3. In order to replace the bushing c inside the axle housing, it has to

be cut and destroyed with a chisel.
★ Do not ruin the bushing seat
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12
4. Put alignment marks on the axle beam body and on the differential
supporting flanges, in order to identify the right side and the left
side with certainty.
5. Position the axle on supports fitted to hold either the central body
or the two housings, even after the split, or secure the three groups
to a hoist.
6. Remove the bolts d to disassemble the axle housings.
7. Spread apart the axle housings. Once the axle housing has been re-
moved, the brake disks are free.
8. Remove the o-ring e from its seat and the oil passage hole and
check the conditions.
9. Remove the long axle shaft f and the sleeve. Remove the snap ring
from the sleeve.
WB140-2N WB150-2N 30-229 1

12
10. Remove the first brake drive plate G.
11. Remove the remaining brake disks h and drive plates i up to the
brake splined sleeve.
12. Remove the brake splined sleeve j, recording the indent position
compared to the brake group.
★ The brake splined sleeve should be reassembled in the same

position as the one before disassembling.
13. Remove the last brake plate 1).
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12
14. Secure the brake flange to a hoist. Remove the lower bolt 1!. Re-
move the differential supporting flange 1@ from the central body, to-
gether with the ring gear backlash adjusting ring nut and the brake
control unit.
★ This operation frees the differential, and must supported.
15. Remove and discard the o-ring 1# from the housing.
16. Remove and discard the o-ring 1$ from the two oil pipe holes.
17. Remove the oil blow by tube 1% from the central body. Remove and
discard the o-rings 1^ from tube.
WB140-2N WB150-2N 30-231 1

12
BRAKE CONTROLS
1. Remove the brake group a and position it on a workbench.
2. Remove the locknut b and adjusting screw on the support bracket

c. Remove the adjusting screw.
3. Remove the lever fastening bolt d at the shaft end e.
4. Remove the washer f.
5. Put an alignment mark on the lever e and shaft g splines for use
during installation and to distinguish between right and left control,
i.e.: you can put two marks on the right and only one on the left.
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12
6. Loosen the lever e to release the tension on the spring.
7. Remove the lever e.
8. Remove the spring h.
9. Remove the washer i and the spacer j.
10. Remove the two bracket c fastening bolts 1).
WB140-2N WB150-2N 30-233 1

12
11. Remove the bracket c.
12. Make an alignment mark on the cam 1! near the set screw 1@. Align
with the top of the roll pin, for use during assembly.
★ Distinguish between right and left sides.
13. Remove the set screw 1@ to free the cam.
14. Unscrew the shaft set screw 1#, being careful the steel ball does not
get lost.
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12
15. Collect the steel ball 1$.
16. Remove the o-ring 1%, taking the shaft 1^ out.
17. Remove the shaft 1^ and collect the cam 1!.
18. Remove the upper bolts 1& of kit brake mechanism return and take
the springs 1* and the bushings out 1(.
WB140-2N WB150-2N 30-235 1

12
19. Remove the lower self adjust kit screws 2) and take the bushings 2!
and the spacers 2@ out.
20. Remove the brake flange 2$ bleed screw 2#. Remove the piston 2%.
21. Using low pressure air, blow through the brake bleeder vent to
move the piston. Cover the port with a clean folded towel to pre-
vent swift ejection of the piston.
22. Remove the o-rings 2^ and 2& from the piston 2% and check their
conditions.
23. Remove the fastening bolt 2* of the ring nut retainer 2(.
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12
24. Remove the ring nut retainer 3).
25. Remove the ring nut 3! with E2 special tool.
26. Remove the bearing cup 3@.
DIFFERENTIAL
★ Place the differential a in a vise.
1. Remove the bolts b of the ring gear c. This will make both differ-
ential halves free, so take care not to drop the infernal components.
WB140-2N WB150-2N 30-237 1

12
2. Disassemble the differential halves d complete with the relative
components.
★ Mark the two halves before splitting them, in order to reassem-

ble them in the same position as the one before disassembling.
3. Disassemble all the components and check the operating and wear
conditions of the components.
★ Remove the bearing e from each differential half.
PINION GEAR
1. From the gear a, remove the snap ring b and slide out the input
flange c.
★ Collect the o-ring d and the shim e.
2. Remove the seal ring f from the central housing.
3. Place the central body on work bench. Remove the ring nut g with
the special tools E3 and E4.
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12
4. Once the ring nut washer h has been removed, take the pinion gear
i out of its housing.
5. Collect the washers j, the elastic spacer 1) and the cones of the
taper roller bearing 1!.
★ When the elastic spacer is removed, it should be replaced by a

new one.
6. Remove the bearing cone 1@ off the pinion gear.
7. Remove the adjusting shim 1# placed under the bearing and check
its wear conditions.
8. Remove the cups of the taper roller bearing out of the central body
1$.
WB140-2N WB150-2N 30-239 1

12
DIFFERENTIAL LOCK
1. Remove one of the cylinder support a bolts, the replace it with one
that is 25 mm longer. Carefully remove the remaining bolt allowing
the longer bolt to collect the spring tension
2. Remove the o-rings and the piston b.
3. Remove the snap ring c, holding the bushing d that is pushed out-
side by the spring e, remove the bushing and the spring from the
shaft f.
4. Repeat Step 1 for the other cover g.
5. Remove off the shaft h by with the o-ring, spring, spacer and snap
ring.
6. Remove the differential lock fork i from the central body.
7. Check the integrity of all components disassembled.
REASSEMBLY
PINION GEAR
1. Position the central body a on a workbench.
2. Install the cups of the taper roller bearings on their housings using
the special tools included in the kit E5.
3. In order to measure the distance, the kit composed of the tools E6

false pinion and E7 false differential, is used.
4. Insert the false pinion with E6, together with its bearings b and
ring nut c. Tighten without exceeding, till the backlash is eliminat-
ed.
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5. Check the positioning of the right and left flanges, using the refer-
ence marks on them and on the central body. Install the each brake
flange d and affix them with two bolts e diametrically opposed.
Flange bolts............................................................. 79 N•m
6. Insert the false differential E7 into the central body to measure the
distance. Check that the false differential is inserted in both brake
flange housings.
7. Carry out the measurement A with a depth gauge through the false
pinion hole and calculate the measurement X.
B measurement.................................................................. 100 mm
C measurement ................................................................... 50 mm
A+C-B=X
8. Note of the value V marked on the head of the pinion gear. Calcu-
late thickness S to be installed beneath the pinion gear, using the
formula:
S = X - V ........................................ S is the shim thickness
WB140-2N WB150-2N 30-241 1

12
9. Remove the false pinion gear, the bearings and the ring nut from
the central body. Disassemble the false differential from the flanges
and then remove the bolts and flanges.
10. Mount the shim f onto the pinion gear g and press the inner bear-
ing b using the tool E8.
★ Always use a new elastic spacer.
11. Insert the pinion gear h into the central body housing and the sec-
ond bearing b cone onto the pinion gear.
★ In order to seat the bearing into position use the special tool
E8.
12. Insert into the pinion shaft h a new ring nut washer i and the ring
nut c retainer.
13. Install the ring nut, using the wrench for ring nut E3 and for pinion
retainer E4.
★ The torque setting is given by the preloading measurement on

bearings.
★ Tighten the ring nut step by step.
★ If it is tightened too much, the elastic spacer should be re-
placed and the procedure repeated.
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14. Carry out the preloading measurement P of the pinion taper roller
12
bearings, using a pull scale whose cord is wound on the diameter of
the pinion spline.
★ The adjustment is carried out by increasing the ring nut torque

setting gradually, being careful not to exceed.
★ All preloads should be measured without the seal ring.
Preload value ................................................... 92 to 138 N
15. Once you’ve achieved the required preload value, stake the ring
nut.
DIFFERENTIAL
1. Assemble the cones of the new taper roller bearings a on the dif-
ferential halves b, using the special tool E9.
2. Position a differential half b on a workbench and assemble all its

inner components; sun gears, planetary gears, thrust washers, pins,
discs and counterdiscs. Join the two differential halves, aligning the
reference marks made upon them.
3. Position the ring gear c, and secure with the bolts d.
Ring gear bolts.................................................. Loctite 270
Ring gear bolts...................................................... 155 N•m
WB140-2N WB150-2N 30-243 1

12
BRAKE FLANGE AND DIFFERENTIAL HOUSING
1. Place the flange on a work bench and seat the cup of the taper roller
bearing a in position, using the special tool E10 with interchange-
able handle E11.
2. Install the elastic pin b into the brake piston c self adjust ports un-
til they are leveled with the piston supporting inner surface.
3. Install the o-rings d and e to the piston and lubricate the piston
flange with a light layer of fresh grease.
4. Apply a light coat of fresh grease on the piston surfaces and espe-
cially on the o-rings already inserted, insert the piston c into the
brake flange f and position the special tool E12 on the piston and
with a lever anchored to an eyebolt, exert a pressure just enough to
insert the piston into the brake flange.
5. Install the components of the self adjust kit to the piston c. Install
the bolts g of the two kits and tighten them.
Adjust kit bolts........................................................ 10 N•m
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12
6. Insert the new o-rings in their relative housings on the central body.
Before assembling, lubricate the o-rings h. Insert new o-rings i in
the oil tube hole housings. Grease the o-rings.
7. Insert the oil blow by tube. Insert the differential lock fork 1) in the
central body.
★ Do not invert the fork position.
8. Insert a new o-ring 1! on the flange. Lubricate the o-ring. Assemble

the left flange on the central body. Tighten the brake cylinder bolts.
Brake cylinder bolts................................................ 79 N•m

★ Check that the reference marks made in the disassembly be-
tween flange and central body match.
9. Before the adjustment of the ring gear bearings preload, fasten the
brake cylinders with two bolts.
Brake fastening bolts - M14x120 ........................... 79 N•m

★ Once the adjustment is made, remove the bolts.
★ Notice the correct assembled side of the differential with its
relative components.
10. Turn over and position the flange central body on a work bench. In-
sert the differential.
11. Assemble the differential locking device as follows.
WB140-2N WB150-2N 30-245 1

12
12. Once the snap ring 1# has been mounted on the shaft 1@ until about
20 mm from the knotched end, insert the shaft in the central body,
on the ring gear side, through the fork 1).
★ Do not put the snap ring in the housing.
13. Insert the spring 1$ and bushing 1% on the shaft 1@. Install into the
central body on the opposite side of the ring gear, then assemble the
snap ring 1^ in its housing.
14. Insert the piston 1* in the cylinder 2!, with new o-rings 1& and 1(.
Assemble a new o-ring 2) in the cylinder, and then insert, with the
piston, into the central body and secure with the bolts 1@.
Cylinder bolts ...................................................... 27.6 N•m

★ Before the assembly lubricate properly the seal rings and the
contact surfaces.
15. Push the lock ring 1# into the housing in the differential locking de-
vice of the shaft 1#. Then let the ring slide along the shaft with a
pipe or a suitable tool. Insert the spacer 2# and spring 2$ on the
shaft. Install a new o-ring 2% in the cap 2^ and lubricate. Install the
cap to the central body at the flatted end of the shaft, tightening the
bolts 2&.
Cap bolts .............................................................. 27.6 N•m
30-246 1 WB140-2N WB150-2N

12
16. Install the right brake flange. Tighten the brake flange bolts.
Brake flange bolts ................................................... 79 N•m

Install the second brake flange on the opposite ring gear side. Insert
and screw the adjusting ring nuts of the pinion ring, using the
wrench with E2 till the bearing backlash is eliminated. Then mea-
sure the ring gear backlash.
17. Assemble the special tool E13 on the pinion end. Move the pinion
end alternatively and note the pinion gear backlash, measured with
a dial indicator, so that the feeler is in contact and at 90° with the
bracket surface on the special tool in correspondence with the refer-
ence mark. Check if the measured backlash value is within the re-
quest range.
★ Backlash...........................................................0.18 to 0.23 mm
Carry out the adjustment by operating on the two ring nuts with the
tool E2.
Adjust the ring nuts remembering that:
If the measured backlash is less than the given tolerance
range, screw the ring nut from the side opposite to the ring gear
and unscrew the opposite one of the same measure.
If the measured backlash is higher than the given tolerance
range, screw the ring nut from the side of the ring gear and un-
screw the opposite one the same measure.
18. Once you have carried out the adjusting of the ring gear backlash,
check also that there is a minimum preload on the differential bear-
ings.
Repeat the whole sequence of above events until the indicated con-
ditions are reached.
19. Once the pinion gear backlash has been established, measure the to-
tal preload T of the ring gear bearings using a pull scale whose cord
is wound on the pinion gear shaft.
★ Force required:
P + 37.3 < T < P + 55.5 N
P = the force found for the pinion
★ The force should be that of continual rotation. Do not take the
initial thrust force into consideration.
WB140-2N WB150-2N 30-247 1

12
20. If the force is not within permissible limits:
A. Tighten both the lock nuts to the same extent to increase the
force T.
B. Loosen both the lock nuts to the same extent to decrease the
force T.
★ The clearance between the ring gear and the pinion gear
must remain within the permissible limits.
21. Check the centering of the contact area using the following proce-
dure:
A. Coat both surfaces of the teeth of the ring gear with a marking
substance.
B. Rotate the pinion.
If the contact area is excessive near to the edge of the teeth, the
ring gear must be brought closer to the pinion. If the contact
area is excessive on the side of the teeth, the ring gear must be
moved away from the pinion.
22. Insert the ring nut retainer 2* turning the ring nut slightly in order to
align it to the retainer. Screw in and tighten the bolt 2( of the ring
nut retainer.
Retainer bolt............................................................ 13 N•m
23. Install the seal ring 3) into the central housing using seal driver
E14.
30-248 1 WB140-2N WB150-2N

12
24. Coat the lip seal and o-ring 3! with oil. Install to the pinion gear the
shim 3@, o-ring and input flange 3#. Secure the assembled parts with
snap ring 3$.
BRAKE CONTROLS
1. Insert the cam a and the shaft b, on the side you are operating, on
the brake flange c. They can be identified by the match marks pre-
viously left.
2. When the shaft is inserted into the cam, align the reference mark
with the cam set screw d hole.
3. Insert the cam set screw d.
WB140-2N WB150-2N 30-249 1

12
4. Tighten the cam set screw d.
Set screw................................................................. 10 N•m
5. Insert the steel ball e that sets the shaft and the relative set screw
d.
6. Tighten the shaft set screw f.
Shaft set screw ...................................................SILASTIC
Shaft set screw ........................................................ 25 N•m
7. Insert a new o-ring g on the shaft b.
30-250 1 WB140-2N WB150-2N

12
8. Position the supporting bracket h and secure with bolts i.
9. Tighten the bracket bolts i.
Bracket bolts ........................................................... 35 N•m
10. Install the spacer j washer 1) and spring 1! on the shaft end.
11. Install the brake control lever 1@, using the match marks.
BRAKE AND AXLE HOUSING
1. Insert the odd shaped brake plate a, respecting the indicated posi-
tion compared to the cam position.
WB140-2N WB150-2N 30-251 1

12
2. Check that the friction discs and the brake plates do not present any
sign of burning; replace as necessary. Check the friction disc wear
and if necessary replace them.
Friction disc thickness .................................. Min 4.03 mm
3. Reassemble all the components of the brake group, friction discs b,

brake plates c and coupling d, inside the flange as per the se-
quence in the figure.
★ The coupling should be inserted after the first disc and posi-
tioned with the shortest spline against the differential.
★ If new brake discs are installed, before assembling, they should
be dipped in the suitable oil.
★ The friction discs and brake plates are free.
4. Insert the axle shaft e into the axle housing f. Position the snap
ring g on the inner seat of sleeve h. Insert the sleeve on the axle
shaft.
★ The sleeve must be inserted with the inner snap ring resting
against on the axle shaft.
5. Before assembly, check the match marks for the correct positioning
of the axle housings.
6. Drive the bushing i in the seat on the axle housing by means of the
special tool E15.
30-252 1 WB140-2N WB150-2N

12
7. Assemble a new o-ring into the axle housing and into the two oil
blow by holes. Lubricate the o-rings. Assemble the housing on the
flange, being aware of bolt alignment. to the holes alignment.
★ Support the housings properly.
8. Tighten the bolts j of the axle housing.
Housing bolts ........................................................ 176 N•m

★ Assemble the breather and adapter with the notch.
9. Lubricate with care the lip of the new seal ring 1). Insert the new
seal ring in the seat on the axle housing with special tool E16.
10. Insert the short axle shaft 1! into the axle housing and coupling.
11. Set the brakes, putting the system under pressure.
★ Install a pump, with the required brake oil, with teed lines and
gauges at each brake port BP.
Required brake oil........................................................ ATF
Brake set pressure ............................................... 40 kg/cm²
★ The brake system, piston, discs, self adjust kit and brake return
mechanism, should be set, before moving the brake control le-
vers.
WB140-2N WB150-2N 30-253 1

12
12. With the brakes set, install the control levers 1@, setting them at the
start of brake actuation position A.
★ Start of brake actuation position A ............................165.5 mm

★ Lever total range B .......................................................331 mm
★ The lever return springs should not be connected.
13. Measure the distance between the holes at the control lever ends
and check that it is within the lever total range B.
★ If the value is not within the range, correct the lever position:
take them off the shaft and reinstall them shifted one spline.
Repeat the checking and the further adjustment until the value
is reached.
14. Release the brake control levers 1@, secure with bolts 1# and wash-
ers 1$.
15. Tighten the bolt of the control lever.
Control lever bolt.................................................... 35 N•m
16. Hitch the return spring 1% to the brake control lever 1@.
★ Repeat the described operations for the other brake.
30-254 1 WB140-2N WB150-2N

17. Check that, in released position C, the measurement between the

12
lever holes is higher.
★ Brake lever released position C....................................349 mm
18. Assemble the adjusting bolts 1^ on the brackets and thread in until
they contact the levers.
19. Thread in the two bolts equally to be within the brake lever released
position C:
★ Brake lever released position C....................................349 mm

★ About 3 mm between lever and bracket will remain.
20. If the bolt 1^ is not perpendicular to the side surface of the lever 1@,
adjust its position by moving the support bracket.
WB140-2N WB150-2N 30-255 1

12
WHEEL HUB
1. Place the wheel hub a on a work bench and seat the two cups of the
taper roller bearings b in position with special tool E17.
2. Install the seal ring c into the wheel hub with special tool E18.
3. Install the cone of the taper roller bearing b on the housing d end.
4. Install the wheel hub a on the housing d and seat the other cone of
the taper roller bearing b in position.
5. Place the wheel carrier e on a work bench and seat the bushings f
to the carrier surface flush with special tool E1.
★ At least two bushings, diametrically opposed, should be set

slightly higher than the carrier surface level to be used as dow-
el.
6. Assemble the wheel carrier e, planetary ring gear g, with snap

ring h.
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12
7. Install the wheel carrier on the wheel hub a using the two project-
ing bushings f as dowel.
8. Force the hub dowel bushings flush with special tool E1.
9. Install the wheel carrier bolts i and tighten.
Wheel carrier bolts................................................ 230 N•m
10. If the bearings b were replaced, verify that the measurements A, B

and C are in the limits.
A measurement ................................................... 17.950 to 18.000

B measurement ................................................... 64.275 to 64.325
C measurement ................................................... 23.070 to 23.172
PLANETARY GEAR
1. Install the thrust button a to the planetary carrier.
2. Place the planetary carrier on a work bench and install the planet
gears b and bottom washers c on the shafts. Insert two sets of roll-
ers d into the planet gears b.
WB140-2N WB150-2N 30-257 1

12
3. Place the two thrust washers e and f and secure with the bolt g.
★ The first washer e must be aligned with the dowel pin h.
4. Tighten the bolts g.
Planet gear bolts...................................................... 79 N•m
5. Insert a new o-ring on the wheel hub. Fit the planetary carrier to the
wheel hub i. Insert and tighten the screws j.
Hub screws.............................................................. 25 N•m
AXLE FILL
★ For fill procedure refer to the machine OPERATION AND MAIN-

TENANCE MANUAL.
30-258 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION LOADER CYLINDERS
12
LOADER CYLINDERS
BOOM
REMOVAL
WARNING! Stop the machine on level ground, lower all
work equipment to the ground, and shut off the engine.
Then apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
1. Sling the cylinder a, insert blocks b between the boom c and the
lever spacer d.
2. Remove the snap ring and the internal spacer for the rod end.
3. Remove the pin e in order to free the rod f, but leave the lever d
attached.
4. Start the engine and retract the rod. Secure the rod to the barrel with
wire and stop the engine .
Loosen the oil filler cap slowly to release the pres-

sure inside the hydraulic tank. Then operate the
control levers several times to release the remain-
ing pressure in the hydraulic lines.
WARNING! Cut off electrical supply by turning the
battery disconnect switch counterclockwise and re-
move the handle.
5. Disconnect the hydraulic hoses g and h, then plug them to prevent

the entry of dirt.
6. Remove the snap ring i and spacer j, then remove the cylinder a.
Boom cylinder ........................................................... 40 kg
INSTALLATION
WARNING! When aligning the position of the pin

hole use a bar. NEVER insert your fingers in the pin
hole.
★ Start the engine and run at low idle, operate the control levers
and extend the rod to align the pin holes.
Internal bushing ...............................................ASL800050
1. Start the engine and bleed air from the cylinders, see TESTING
AND ADJUSTMENT.
★ After bleeding the cylinders, check the oil level
WB140-2N WB150-2N 30-259 1

12
DISASSEMBLY
1. Place the cylinder A in the tool A1.
2. Using the wrench A4D, unscrew the cylinder gland b from the
cylinder barrel c.
3. Remove the piston rod d from the cylinder. Remove the cylinder
barrel from the tool. Secure the piston rod d in the tool A1.
4. Use the socket wrench A7, 55 mm across the flats, on the piston
nut e and remove. Slide the piston f off the rod. Remove and dis-
card the piston seal g and wear ring h from the piston.
5. From the cylinder gland 1), remove and discard the following
items;
i O-ring
j Back up ring
1! Buffer ring
1@ Rod seal
1# Wiper seal
1$ O-ring
30-260 1 WB140-2N WB150-2N

12
REASSEMBLY
1. Mount the buffer ring a, rod seal b and wiper seal c in the cylin-
der gland d. Use tool A8 to mount the wiper seal.
★ Make sure that the lips are turned towards the inside of the cyl-
inder for the rod seal b and outward for the wiper seal c.
2. Install the o-ring e outside of the cylinder gland. Install the o-ring
f and the back up ring g on the outside of the cylinder gland.
3. Using tool A9 with the appropriate diameter, Install the piston seal
h, external seal i and back up rings j into the piston 1). Install the
wear ring 1!.
4. Gauge the external diameter of the seal h and i of the piston 1)

mounting the group under a press and use the tools A3 for the pis-
ton diameter.
5. Using tools A1 and A2 with the appropriate diameter, insert the

bushing 1@ into the piston rod 1#
WB140-2N WB150-2N 30-261 1

6. Mount tool A10 of the correct diameter onto the end of the rod 1#.
12
7. Lubricate the cylinder gland seals and slide the assembly onto the
rod 1#.
Seal lube...........................................................ASL800050
8. Remove from the end of the piston rod 1#, the bushing A10.
9. Install the piston 1) to the rod 1# and secure with the nut 1$.
Rod and nut threads .......................................... Loctite 262
Piston nut ............................................................ 2900 N•m
10. Position the bushing 1% and mount it in the cylinder barrel 1^ using
tool A2 of the correct diameter.
★ Leave the cylinder in position for subsequent assembly.
11. Lubricate the threads of the first part of the cylinder barrel 1^.
Barrel threads...................................................ASL800050
12. Mount the two halves of the tool A11 with the appropriate diame-
ter at the mouth of the cylinder barrel 1^. Install the piston and rod
in the cylinder up to tool A11. Guide the piston and center it in the
tool. Insert the piston slowly in until inside the barrel in order to
calibrate the guide rings without overheating them. Remove tool
and thread the cylinder gland into the barrel. Tighten the gland with
upgraded tool A4D.
30-262 1 WB140-2N WB150-2N

13. Using upgraded tool A4D, nut welded to spanner wrench, tighten
12
the cylinder gland.
★ Apply applicable weld to the nut to sustain the following

torque valve.
Cylinder gland ...................................................... 980 N•m
R = T x L ÷ (L + C)
T - Torque required 980 N•m
MULTIPLIED BY (x)
L - Wrench length _ _ _ mm
DIVIDED BY (÷)
PLUS (+)
C - Extension length _ _ _ mm
EQUALS (=)
R - Reading on dial _ _ _ N•m
BUCKET
REMOVAL

1. Loosen the clamps a and remove the hose protector b.
2. Disconnect the sensor C and remove the bucket position indicator

D.
WB140-2N WB150-2N 30-263 1

12
3. Place a sling around the cylinder e and insert a block f between
the spacer g of the lever h and link i.
4. Remove the snap ring and spacer of the rod pin j. Remove the pin.
Start the engine and retract the rod 1). Secure the rod to the barrel
with wire and shut off the engine.
WARNING! Loosen the oil filler cap slowly to re-

lease the pressure inside the hydraulic tank. Then
operate the control levers several times to release
the remaining pressure in the hydraulic lines.
WARNING! Cut off electrical supply by turning the
battery disconnect switch counterclockwise and re-
move the handle.
5. Remove the bolt 1! and clamp 1@. Disconnect the hoses 1# and 1$,
and cap and plug the open ports.
6. Remove the snap ring 1% and spacer 1^.
7. Remove the cylinder e.
Bucket cylinder.......................................................... 45 kg
INSTALLATION
• Install the hoses without twisting or interference.
and extend the cylinder rod to align the pin holes.
WARNING! When aligning the pin holes use a bar.

NEVER insert your fingers in the pin holes.
1. Start the engine and bleed air from the cylinders. For details, see
30-264 1 WB140-2N WB150-2N

12
DISASSEMBLY
1. Place the cylinder A In the tool A1.
2. Using the wrench A4C, unscrew the cylinder gland b from the
cylinder barrel c.
items;
i O-ring
j Back up ring
1! Buffer ring
1@ Rod seal
1# Wiper seal
1$ O-ring
WB140-2N WB150-2N 30-265 1

12
REASSEMBLY
wear ring 1!.

ton diameter.

bushing 1@ into the piston rod 1#
30-266 1 WB140-2N WB150-2N

6. Mount tool A10 of the correct diameter onto the tip of the piston
12
rod 1#.
piston rod 1#.
Seal lube...........................................................ASL800050
8. Remove from the tip of the piston rod 1#, the bushing A10.
9. Install the piston 1) to the rod 1# and secure with the nut 1$.
Rod and nut threads .......................................... Loctite 262
Piston nut ............................................................ 2900 N•m
10. Position the bushing 1% and mount it in the cylinder barrel 1^ using
11. Lubricate the threads of the first part of the cylinder barrel 1^.
ter at the mouth of the cylinder barrel 1^. Install the piston and rod
tool. Insert the piston slowly in until inside the barrel.order to cali-
brate the guide rings without overheating them. Remove tool and
thread the cylinder gland into the barrel. Tighten the gland with up-
graded tool A4C.
WB140-2N WB150-2N 30-267 1

13. Using upgraded tool A4C, nut welded to spanner wrench, tighten
12
the cylinder gland.

torque valve.
Cylinder gland ...................................................... 950 N•m
R = T x L ÷ (L + C)
T - Torque required 950 N•m
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
MP BUCKET CYLINDER
REMOVAL

1. Open the jaw a, and attach a sling and hoist. Remove the lock pin
c from the rod pin. Attach the sling and hoist to the cylinder a.
2.

3. Remove the top rod pin d.Disconnect the hoses e, and cap and
plug the open ports.
4. Remove the bottom pin f and cylinder a.
INSTALLATION

hole use a bar, NEVER use your fingers in the hole.
30-268 1 WB140-2N WB150-2N

12
1. Start the engine and at low idle, extend the rod to align the pin
holes.
AND ADJUSTMENT.
DISASSEMBLY
WB140-2N WB150-2N 30-269 1

2. Using the wrench A4A, unscrew the cylinder gland b from the
12
cylinder barrel c.
4. Remove the rear wear ring e. Drive out the slotted spring pin f.
Slide the piston g off the rod. Remove and discard the front wear
ring e, piston seal h with the back up rings i and o-ring j from
the piston.
5. Slide the cylinder gland b off the rod. From the gland, remove and
discard the following items;
1) Wiper seal
1! O-ring
1@ Back up ring
1# Rod seal
6. if necessary, using tools A1 and A2 with the appropriate diameter

- ∅49 mm, remove the bushing 1$ from the piston rod.
30-270 1 WB140-2N WB150-2N

12
REASSEMBLY
1. Mount the rod seal a and wiper seal b in the cylinder gland c. Use
tool A8 to mount the wiper seal.
inder for the rod seal a and outward for the wiper seal b.
2. Install the o-ring d and the back up ring e on the outside of the
cylinder gland.
3. Using tool A9 with the appropriate diameter, install the piston seal
f, back up rings g and FRONT wear ring h into the piston i. In-
stall inner o-ring j.
4. Gauge the external diameter of the piston seal f of the piston i

ton diameter.

bushing 1) into the piston rod 1!.
WB140-2N WB150-2N 30-271 1

6. Mount tool A10 of the correct diameter onto the tip of the piston
12
rod 1@.
7. Lubricate the cylinder gland seals and slide the assembly c onto
the piston rod 1@.
Seal lube...........................................................ASL800050
8. Remove from the tip of the piston rod, the bushing A10.
9. Install the piston i to the rod 1@ and secure with the slotted pin 1#.
Install the remaining REAR wear ring h.
10. Lubricate the threads of the first part of the cylinder barrel 1$.
ter at the mouth of the cylinder barrel 1$. Install the piston and rod
tool. Insert the piston in slowly until its inside the barrel in order to
upgraded tool A4A.
12. Using upgraded tool A4A, nut welded to spanner wrench, tighten
the cylinder gland.

torque valve.
Cylinder gland ....................................................... ~ N•m
30-272 1 WB140-2N WB150-2N

12
R = T x L ÷ (L + C)
T - Torque required ~ N•m
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
~ For wrench dimension and gland torque contact;

LESTER WHALEY @ 803-405-6512
WB140-2N WB150-2N 30-273 1

REMOVAL AND INSTALLATION FRONT EQUIPMENT
12
FRONT EQUIPMENT
WARNING! Position the machine on level ground.
Lower all work equipment a to the ground and shut
off the engine. Apply the parking brake and put
blocks under the wheels to prevent the machine
from moving.
Open the oil filler cap slowly to release the pres-
controls several times to release the remaining
pressure in the hydraulic lines.
BUCKET
REMOVAL
1. Remove the bolts b and pins c and disconnect the lever d.
★ Rest the lever d on the boom.
2. Remove the bolts e and pins f from the bucket.
3. Start the engine, put the machine in reverse gear, and back up to
disengage the boom g.
INSTALLATION
WARNING! When aligning the pin holes use a bar.

NEVER insert your fingers in the pin holes.
30-274 1 WB140-2N WB150-2N

12
BOOM
REMOVAL
1. Remove the bucket cylinders, see LOADER CYLINDERS.
2. Disconnect the boom cylinder rod ends c from the boom b and
rest them on wood blocks a on the front axle.
3. Open the front hood d and remove the bolts e that lock the pivot
pins to the boom b. Close the front hood.
4. Sling the boom b, and attach to a hoist. Apply slight tension to the
sling.
5. Using a puller, remove the boom pivot pins f.
6. Start the engine, put the machine into reverse gear, back the ma-
chine up, until the boom is disengaged and clears.
7. Place two stands in position and lower the boom.
Work equipment....................................................... 960 kg
WB140-2N WB150-2N 30-275 1

12
BUSHING REPLACEMENT
Boom at Frame
1. Uses a 57 mm driver to remove the bushing from the boom.
2. Position new bushing, with tapered end in, into the outside boom
arm with the lube hole down and the split side up.
3. Using a 60 mm driver with a 50 mm aligner, install the bushing

flush with the outer wall.
Boom at Bucket
1. Uses a 52 mm driver to remove the bushing from the boom.
2. Position new bushing, with tapered end in, into the outside boom
arm.

Boom at Cylinder
1. Place the spacer tube between the boom ears. Using a 55 mm driv-
er, remove each bushing into the tube spacer.
2. Freeze the bushings. Place the spacer tube between the boom ears.
Position new bushing, with tapered end in, into the outside boom
arm.

Bucket Link
1. At Cylinder;
Place the spacer tube between the boom ears. Using a 55 mm driv-
er, remove each bushing into the tube spacer. Freeze the bushings.
Place the spacer tube between the boom ears. Position new bush-
ing, with tapered end in, into the outside boom arm. Using a 55 mm
driver with a 45 mm aligner, install the bushing flush with the outer
wall.
2. At Bucket;
Uses a 52 mm driver to remove the bushing from the boom. Posi-

tion new bushing, with tapered end in, into the outside boom arm.
Using a 55 mm driver with a 45 mm aligner, install the bushing
30-276 1 WB140-2N WB150-2N

12
INSTALLATION
and extend the cylinder ram to align the pin holes.

hole use a bar. NEVER insert your fingers into the
pin hole.
• Start the engine and bleed air from the cylinders. For details, see
★ After bleeding the cylinders, check the oil level.
WB140-2N WB150-2N 30-277 1

REMOVAL AND INSTALLATION BACKHOE CONTROL VALVE
12
BACKHOE CONTROL VALVE
BACKHOE CONTROL
REMOVAL
1. Swing the backhoe a completely to the right of the machine, rotate

the boom approximately 45° to the right. Lower the outriggers to
the ground, open the bucket and rest the arm on a block, keeping it
perpendicular to the ground. Rest the bucket on the ground, release
the backhoe plate and shut the engine off.

ing pressure in the hydraulic lines
2. Remove the lower window b from the cab, and completely raise
the upper window.
3. Remove the grips c from the control levers of the outriggers.
4. Raise the control lever boots d, remove the bolts e and cover f.
★ If any optional devises have been installed, disconnect the

spool tie rod g, pedal h, and support i.
30-278 1 WB140-2N WB150-2N

12
5. Disconnect the lever command tie rods 1! from the control valve 1).
6. Disconnect hydraulic hoses 1@, top and bottom lines, then cap and
plug the open ports.
★ Mark the hydraulic hoses 1@ before removing, in order to reas-

semble them in the same position as before.
7. Sling the control valve 1), and attach to a hoist. Apply slight tension
to the sling.
8. Remove the mounting bolts 1#, then remove the control valve 1).
6 spool control valve.................................................. 47 kg

INSTALLATION
• Start the engine and bleed air from the load sensing circuits and
from hydraulic circuits of all the actuators. For details, see TEST-
ING AND ADJUSTMENT.
EXCAVATOR CONTROLS
REMOVAL


WB140-2N WB150-2N 30-279 1

12
2. Remove the lower window b from the cab, and completely raise
the upper window.
3. Remove the rear mat c.
4. Remove the screws d and remove the platform e.
5. Disconnect the upper hoses g from the control valve f.
★ Ensure that all hoses are marked and note down bends and
routing pattern. Cap the hoses and the holes to prevent contam-
ination.
★ Lay the hoses inside the cab to gain access to the feed and re-
turn hoses.
30-280 1 WB140-2N WB150-2N

12
6. Disconnect the bottom hoses h from the control valve f.
★ Check that all the hoses are marked and note down the bends
and routing patterns. Cap the hoses and holes to prevent con-
tamination.
★ Lay down the hoses in the cab to gain access to the feed and
exhaust hoses.
7. Disconnect the hoses j from the control valve f.
★ Cap the hoses to prevent contamination.

★ Mark the hoses so as not to mix them up when reassembling.
8. Attach the control valve to a hoist and slightly tension the rods.
9. Remove the fastening screws and then the entire control valve f.
6 Spool control valve ................................................. 47 kg

INSTALLATION
WB140-2N WB150-2N 30-281 1

12
• To install, reverse the removal procedure. For pilot hose connection
and routing, refer to diagrams.
30-282 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION PPC CONTROLS
12
PPC CONTROLS
PPC VALVE
REMOVAL
WARNING! The following removal procedure applies to

both PPC valves.


2. Remove the cab lower window and fully raise the upper window.
3. Raise the top boot b. Loosen and remove the bolts c retaining the
PPC valve d and arm rest e.
4. Raise the arm rest from the rear side and remove the screw f re-
taining the rear guard g.
5. Cut the retaining clamp and lower the bottom boot h.
6. Loosen and remove the screw i and remove the rear guard g.
7. Detach the connector j.
8. Ensure that the hoses are marked 1), then disconnect the hoses from
the PPC valve.
9. Mark the hoses, if necessary. Cap the hoses to prevent contamina-

tion.
WB140-2N WB150-2N 30-283 1

12
10. Remove the PPC valve 1!.
INSTALLATION
★ Carefully inspect the hoses for the proper position when con-
necting them. For more information, see STRUCTURE AND
FUNCTION.
SUPPORT RELEASE CABLES

REMOVAL
1. Lower the outriggers and the mounted equipment a to the ground.

Stop the engine.
2. Remove the rear mat b.
3. Remove the bolts c and platform d.
30-284 1 WB140-2N WB150-2N

12
4. Raise the boot e.
5. Remove the bolts f retaining the PPC valve and the arm rest g.
6. Raise the arm rest from the rear side and remove the bolt h retain-
ing the rear guard i.
7. Cut the retaining clamp and release the lower boot j.
8. Loosen and remove the bolt 1) and remove the rear guard i.
9. Remove the bolts 1! and raise the boot 1@ and retaining edge 1#.
★ Raise until the lower lever and lock fully disengaged.
10. Remove the bolts 1$ from the lock actuating lever 1%.
11. Remove the complete lever 1%.
WB140-2N WB150-2N 30-285 1

12
12. Loosen the nut 1^ and disengage the sheath 1* from the support 1&.
13. Disconnect the cable 2) from the lower lock lever 1(.
14. Loosen the nut 2! and tensioner 2@; disengage the control cable 2)
from the release control lever 1%.
INSTALLATION
1. Using the tensioner 2@, adjust cable tension to obtain safe locking
and friction free unlocking of the column.
2. Lock the nut while holding the tensioner into position 2!.
30-286 1 WB140-2N WB150-2N

12
SUPPORT RETURN GAS SPRING
REMOVAL
1. Lower the outriggers and the mounted equipment a to the ground.

Stop the engine.
2. Remove the rear mat b.
3. Remove the bolts c and platform d.
4. Fully loosen the stop knob e of the PPC valve support f you are
working on.
WB140-2N WB150-2N 30-287 1

12
5. Raise the boot g.
6. Remove the bolts h that retain the PPC valve and arm rest i.
7. Raise the arm rest from the rear side and remove the bolt j retain-
ing the rear guard 1).
8. Cut the retaining clamp to disengage the lower enclosing boot 1!.
9. Remove the bolt 1@ and remove the rear guard 1).
10. Remove the bolts 1# and raise the boot 1$ and the retaining edge 1%.
★ Raise until the gas spring 1( becomes fully disengaged.
11. Loosen the nut 1^ and remove the snap ring 1& and washer 1*.
12. Disconnect the gas spring 1( and remove it.
INSTALLATION
30-288 1 WB140-2N WB150-2N

12
SOLENOID VALVE
REMOVAL
1. Move the backhoe to the right hand side. Lower the outriggers and
the equipment a to the ground; stop the engine.
Eliminate residual pressure in all circuits. For detail

see TESTING AND ADJUSTMENTS.
2. Release the wire harness from the clamps. Detach the connectors c
from the solenoid valves b.
★ Ensure that the connectors are marked to avoid mixing them up

during installation.
3. Disconnect the lower hoses e and the rear hoses f and the front
hose g from the valve d.
★ Mark the position of the hoses to avoid mixing them up during

installation.
4. Remove the bolts h and valve d.
INSTALLATION
WB140-2N WB150-2N 30-289 1

12
SERVO CONTROL FEED VALVE
REMOVAL
1. Position the machine over a pit, lower the outriggers and the equip-
ment a to the ground. Stop the engine.
Eliminate residual pressure in all circuits. For detail

see TESTING AND ADJUSTMENTS.
2. Mark the connectors b and detach them from the solenoid valves.
★ Gather the connectors together and place them in a clean area.
3. Mark the hoses c with the abbreviations for the connections and
then disconnect them from the valve d.
★ Plug and cap the open ports.
4. Loosen the bolts e and remove the valve.
INSTALLATION
1. Start the engine and repeat as many backhoe movements as possi-

ble several times to bleed air from the circuits.
If the valve is replaced or removed, perform the op-

erating pressure calibration procedure, see TEST-
ING AND ADJUSTMENTS.
30-290 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION BACKHOE CYLINDERS
12
BACKHOE CYLINDERS
BOOM
REMOVAL
1. Remove the lube fitting and extension a.
2. Extend the arm b completely and fully open the bucket c.
★ Lower the front equipment until the bucket is resting on the

ground, the arm on a block about 10 cm high, and the joint be-
tween the arm and boom d on a stand, about 70 cm high.
WARNING! Stop the machine on level ground, low-

er all work equipment to the ground, and shut off
the engine. Then apply the parking brake and put
from moving.
3. Sling the boom cylinder e, and attach to a hoist. Apply slight ten-
sion to the sling.
4. Remove the bolt f and pin g.
5. Start the engine and retract the rod. Secure the cylinder rod.

6. Disconnect the hoses i and j, then plug them to prevent entry of

impurities.
7. Remove the bolt and pin.
8. Remove the cylinder e.
WB140-2N Cylinder.................................................. 73 kg
WB150-2N Cylinder.................................................. 78 kg
INSTALLATION

hole with your finger, use a bar. NEVER insert your
fingers into the pin hole.
TESTING AND ADJUSTMENT. After bleeding the cylinders,
check the oil level
WB140-2N WB150-2N 30-291 1

12
DISASSEMBLY
2. Using the wrench A5, unscrew the cylinder gland b from the cyl-
inder barrel c.
4. Remove the set screw e. Use the socket wrench A7, 65 mm across
the flats, on the piston f and remove. Slide the piston off the rod.
Remove and discard the piston seal g, wear ring h and o-ring i
from the piston.
5. Remove the balls j from the rod, then the piston cushion plunger
1).
6. From the cylinder gland 1!, remove and discard the following
items;
1@ O-ring
1# Back up ring
1$ Buffer ring
1% Rod seal
1^ Wiper seal
1& O-ring
30-292 1 WB140-2N WB150-2N

12
7. Remove the plug 1*, gasket 1(, spring 2) and load check poppet 2!
from cylinder barrel.

- ∅56 mm, remove the bushing 2@ from the piston rod.

- ∅56 mm, remove the bushing 2# from the barrel.
REASSEMBLY
WB140-2N WB150-2N 30-293 1

12
wear rings 1!.
4. Install o-ring 1@ inside the piston.

mounting the group under a press and use the tool A3 for the piston
diameter.

bushing 1# into the piston rod.
7. Install the cushion plunger 1$ into the rod. Drop the eleven balls 1%
into the rod to secure the plunger.
30-294 1 WB140-2N WB150-2N

8. Mount tool A10 of the correct diameter onto the end of the rod 1^.
12
9. Lubricate the cylinder gland d seals and slide the assembly onto
the rod.
Seal lube...........................................................ASL800050
10. Remove from the end of the piston rod 1#, tool A10.
11. Install the piston 1# onto the rod and tighten - 65 mm socket.
Piston ..................................................... 1100 to 1300 N•m
12. Install the set screw 1& and tighten.
Set screw........................................................... Loctite 262
Set screw........................................................15 to 20 N•m
13. Position the bushing 1& and mount it in the cylinder barrel using
WB140-2N WB150-2N 30-295 1

12
14. Install the plug 1*, gasket 1(, spring 2) and load check poppet 2! in-
to the cylinder barrel.
15. Lubricate the threads of the first part of the cylinder barrel.
ter at the mouth of the cylinder barrel. Install the piston and rod in
the cylinder up to tool A11. Guide the piston and center it in the
upgraded tool A5.
17. Using upgraded tool A5, nut welded to spanner wrench, tighten the
cylinder gland.

torque valve.
Cylinder gland ......................................... 900 to 1100 N•m
R = T x L ÷ (L + C)
T - Torque required 900 to 1100 N•m
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
30-296 1 WB140-2N WB150-2N

12
ARM
REMOVAL
1. Extend the arm a completely and fully open the bucket b.
★ Lower arm until the joint between the arm and boom c is rest-
ing on stand about 90 cm high, and the tip of arm is resting on
block about 10 cm high. Rest the bucket teeth on the ground.

from moving.
2. Sling the arm cylinder d, and attach to a hoist. Apply slight tension
to the sling.
3. Remove the bolt e and pin f.
4. Start the engine and retract the cylinder rod g.
★ Secure the piston rod with wire.

Stop the engine, loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank. Then
5. Disconnect the hydraulic hoses h and i, then plug them to prevent

6. Remove snap ring j and pin 1).
7. Remove cylinder d.
Arm cylinder.............................................................. 69 kg
INSTALLATION

pin hole.
1. Start the engine and run at low idle, operate the control levers and
extend the rod to align the pin holes.
AND ADJUSTMENT.
WB140-2N WB150-2N 30-297 1

12
DISASSEMBLY
2. Using the wrench A4F, unscrew the cylinder gland b from the cyl-
inder barrel c.
4. Use the socket wrench A7, 55 mm across the flats, on the nut e
and remove. Slide the piston f and spacer g off the rod. Remove
and discard the piston seal h and wear ring i from the piston.
5. From the cylinder gland j, remove and discard the following

items;
1) O-ring
1! Back up ring
1@ Buffer ring
1# Rod seal
1$ Wiper seal
1% O-ring
30-298 1 WB140-2N WB150-2N


12
- ∅51 mm, remove the bushing 1^ from the piston rod.

- ∅51 mm, remove the bushing 1& from the barrel.
REASSEMBLY
wear rings 1!.
WB140-2N WB150-2N 30-299 1

12
diameter.

bushing 1@ into the piston rod.
the rod.
Seal lube...........................................................ASL800050
9. Install the spacer 1#, piston 1) and nut 1$ onto the rod and tighten -
55 mm socket.
Piston nut .......................................................... Loctite 262
Piston nut ...................................................2845 ±284 N•m
30-300 1 WB140-2N WB150-2N

12
upgraded tool A4F.
12. Using upgraded tool A4F, nut welded to spanner wrench, tighten
the cylinder gland.

torque valve.
Cylinder gland ..............................................970 ± 97 N•m
R = T x L ÷ (L + C)
T - Torque required 970 ± 97 N•m
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
BUCKET
REMOVAL
1. Extend the arm a completely and fully open the bucket b.
★ Lower the arm until the joint between the arm and boom is
resting on a stand about 90 cm high, and the tip of the arm is
resting on a block about 10 cm high. Rest the bucket teeth on
the ground.

from moving.
WB140-2N WB150-2N 30-301 1

12
2. Stop the engine and release the pressure in the cylinder D by mov-
ing the control lever several times.
3. Sling the arm cylinder D, and attach to a hoist. Apply a slight ten-
sion to the hoist and sling. Remove the lock nut E, washer, and pin
F.
4. Start the engine and retract the cylinder rod G. Secure the cylinder
rod with wire.

5. Disconnect the hoses H and I, then cap and plug to prevent entry
of impurities. Remove the snap ring J and pin 1).
★ Machines equipped with a telescopic arm, loosen the nut 1!

and remove the pin 1@.
6. Remove the cylinder D.
Cylinder ..................................................................... 49 kg
INSTALLATION

pin hole
★ Tighten locknut completely, then loosen it one half turn.

DISASSEMBLY
1. Place the cylinder A in the tool A1.
30-302 1 WB140-2N WB150-2N

2. Using the wrench A4E, unscrew the cylinder gland b from the
12
cylinder barrel c.
items;
i O-ring
j Back up ring
1! Buffer ring
1@ Rod seal
1# Wiper seal
1$ O-ring
6. If necessary, using tools A1 and A2 with the appropriate diameter

- ∅51 mm, remove the bushing 1^ from the piston rod.
WB140-2N WB150-2N 30-303 1


12
- ∅51 mm, remove the bushing 1& from the barrel.
REASSEMBLY
wear rings 1!.

diameter.
30-304 1 WB140-2N WB150-2N


12
the rod.
Seal lube...........................................................ASL800050
9. Install the piston 1) and nut 1$ onto the rod and tighten - 55 mm
socket.
Piston nut .......................................................... Loctite 262
Piston nut ...................................................2845 ±284 N•m
10. Position the bushing 1% and mount it in the barrel using tool A2 of
the correct diameter.
WB140-2N WB150-2N 30-305 1

12
upgraded tool A4E.
13. Using upgraded tool A4E, nut welded to spanner wrench, tighten
the cylinder gland.

torque valve.
Cylinder gland ....................................... 1108 to 1245 N•m
R = T x L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
TELESCOPIC ARM
REMOVAL
1. Extend the arm b and rest it on a stand about 40 cm high. Extend

the telescopic arm c until it is resting on a block, and rest the buck-
et teeth on the ground.
2. Stop the engine and release the cylinder a pressure by moving the
control several times.
30-306 1 WB140-2N WB150-2N

12
3. Sling the arm cylinder a, and attach to a hoist. Apply slight tension
to the sling.
4. Remove the snap ring d and pin e.
5. Start the engine and retract the cylinder rod. Secure the cylinder rod
with wire.

6. Remove the safety pin f.
7. Disconnect the hydraulic hoses G, h, i, and j, then cap and plug

them to prevent entry of impurities.
8. Remove the clamp 1).
9. Remove the bolt 1! and pin 1@.
10. Remove the cylinder a.
Cylinder ..................................................................... 69 kg
INSTALLATION

pin hole
DISASSEMBLY
WB140-2N WB150-2N 30-307 1

2. Using the wrench A4B, unscrew the cylinder gland b from the
12
cylinder barrel c.
4. Use the socket wrench A7, 56 mm across the flats, on the piston e
and remove off the rod. Remove and discard the piston seal f,
wear ring g and o-ring h from the piston.
items;
i O-ring
j Back up ring
1! Buffer ring
1@ Rod seal
1# Wiper seal
1$ O-ring

- ∅46 mm, remove the bushing 1% from the piston rod.
30-308 1 WB140-2N WB150-2N


12
- ∅46 mm, remove the bushing 1^ from the barrel.
REASSEMBLY
3. Using tool A9 with the appropriate diameter, Install the o-ring h,

piston seal i and wear rings j into the piston 1). Install the internal
o-ring 1!.
4. Gauge the external diameter of the seal i of the piston 1) mounting

the group under a press and use the tool A3 for the piston diameter.
WB140-2N WB150-2N 30-309 1


12
the rod.
Seal lube...........................................................ASL800050
9. Install the piston 1) onto the rod 1# and tighten - 56 mm socket.
Piston .........................................................932 to 981 N•m
10. Position the bushing 1$ and mount it in the barrel 1% using tool A2
of the correct diameter.
30-310 1 WB140-2N WB150-2N

12
upgraded tool A4B.
13. Using upgraded tool A4B, nut welded to spanner wrench, tighten
the cylinder gland.

torque valve.
Cylinder gland ...........................................960 to 980 N•m
R = T x L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
OUTRIGGERS
REMOVAL
WARNING! Rest the back of the bucket on the ground,

keeping the arm vertical.
1. Lower the outriggers to the ground and stop the engine.
WB140-2N WB150-2N 30-311 1

12
2. Sling the outrigger cylinder a, and attach to a hoist. Apply slight
tension to the sling.
★ Leave hoses and tubes free.
3. Remove the nut b and bolt c. Then draw out the pin d until the
rod e is disengaged.
4. Start the engine and retract the rod e. Secure the piston rod with
wire.

5. Disconnect the hydraulic hoses f and g, then cap plug to prevent

6. Remove the nut h, bolt i, and pin j, then the cylinder a.
Cylinder ..................................................................... 69 kg
INSTALLATION

pin hole
DISASSEMBLY
2. Using the wrench A4F, unscrew the cylinder gland b from the cyl-
inder barrel c.
30-312 1 WB140-2N WB150-2N

4. Remove the set screw e. Use the socket wrench A7, 65 mm across
12
the flats, on the piston f and remove. Slide the piston off the rod.
Remove and discard the piston seal g, wear ring h and o-ring i
from the piston.
5. Remove the balls j from the rod, then the piston cushion plunger
1).
6. From the cylinder gland 1!, remove and discard the following
items;
1@ O-ring
1# Back up ring
1$ Buffer ring
1% Rod seal
1^ Wiper seal
1& O-ring

- ∅51 mm, remove the bushing 1* from the piston rod.

- ∅51 mm, remove the bushing 1( from the barrel.
WB140-2N WB150-2N 30-313 1

12
REASSEMBLY
wear rings 1!.
4. Install o-ring 1@ inside the piston.

diameter.

30-314 1 WB140-2N WB150-2N

12
7. Install the cushion plunger 1$ into the rod. Drop the eleven balls 1%
into the rod to secure the plunger.
the rod.
Seal lube...........................................................ASL800050
11. Install the piston 1# onto the rod and tighten - 65 mm socket.
Piston ..................................................... 1180 to 1230 N•m
12. Install the set screw 1& and tighten.
Set screw........................................................... Loctite 262
Set screw........................................................15 to 20 N•m
WB140-2N WB150-2N 30-315 1

12
13. Position the bushing 1& and mount it in the cylinder barrel using
upgraded tool A4F.
16. Using upgraded tool A4F, nut welded to spanner wrench, tighten
the cylinder gland.

torque valve.
R = T x L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
30-316 1 WB140-2N WB150-2N

12
SWING
REMOVAL
WARNING! Position the backhoe a with the equipment

centered, arm vertical, and back of the bucket resting on
the ground.
1. Stop the engine and release cylinder pressure by moving the control
several times.
2. Remove the retaining bolts b out of the clamp c.
3. Disconnect the hydraulic hoses e from the cylinder d, then cap and
plug to prevent entry of impurities.
4. Remove the bolts f, then remove the upper support g of the cylin-
der mounting.
5. Remove the bolts h and pin i.
6. Rotate the cylinders to disengage rods from the swing bracket j,

then remove the cylinders d.
Cylinder .................................................................. 32.5 kg
INSTALLATION
1. Mount the cylinders d and upper support g. Secure the support

with bolts f.
Support bolts..................................................... Loctite 262

Support bolts..................................................100 ±10 N•m
2. Connect the four hydraulic hoses e to the cylinders d. Start the en-
gine and swing the boom in order to center one of two pins i. Se-
cure the first pin with bolt h. Repeat this step for the other pin.

hole, use a bar. NEVER insert your fingers into the
pin hole.
TESTING AND ADJUSTMENT. After bleeding the cylinders,
check the oil level
WB140-2N WB150-2N 30-317 1

12
DISASSEMBLY
1. Position the cylinder in fixture A1. Engage the pivot pins into the
suitable support.
2. Remove the set screw a for the gland and barrel.
3. Using special wrench A6, loosen and extract the rod b, gland c
and piston d from the cylinder barrel e.
4. Remove the brake cylinder f.
5. Attach the cylinder rod to the fixture A1.
6. Raise the part staked, then using special tool A7 remove the piston
d.
★ Carefully check the piston. If both staked areas show wear, the
piston must be replaced.
7. Remove the snap ring g from the piston, then remove the collar h
and cushion ring i.
★ Make a note for order of assembly for ring.
8. Using a puller, remove swing bushings from the cylinder pivot

pins.
9. Disassemble the piston d and gland c by removing all the seals,

wear rings and o-rings.
★ Discard the seals, guard rings, and guide rings. They must be
replaced with new.

- ∅59 mm, remove the bushing j from the piston rod.
30-318 1 WB140-2N WB150-2N

12
REASSEMBLY
★ Be extremely careful not to damage the seals and sliding surfaces.

Prepare each component before final assembly.
1. Install the buffer ring a, rod seal b and wiper seal c into the piston
d.
★ Make sure the lips of the rod seal b are face inwards to the in-
side of the cylinder and the lips of the wiper seal c face out-
wards.
2. Install the o-ring e, wear ring f, and the last o-ring g.
3. Using tool A9 with the appropriate diameter, install the inner pis-
ton seal h and outer ring i into the piston j. Remove the tool A9
and install the back up rings 1).
4. Install the wear ring 1!. Install the o-ring 1@ into the internal seat.
5. Gauge the external diameter of the seals of the piston 1) mounting

the group under a press and use the tool A3 for the piston diameter.

WB140-2N WB150-2N 30-319 1

12
7. Install the cushion ring 1% into the rod.
★ Check the direction of assembly for the cushion ring.
8. Insert the collar 1^ and secure with the snap ring 1&.
9. Mount tool A10 of the correct diameter onto the end of the rod 1*.
rod.
Seal lube...........................................................ASL800050
11. Remove from the end of the piston rod, tool A10.
12. Lubricate o-ring and thread the piston assembly onto the rod by
hand several turns.
O-ring...............................................................ASL800050
13. With the rod in tool A1, tighten the piston 1) with tool A7 - 65 mm
socket.
Piston .........................................................810 to 990 N•m
14. Secure the barrel to fixture A1. Engage the pivot pins in the suit-
able support.
upgraded tool A6.
30-320 1 WB140-2N WB150-2N

17. Using upgraded tool A6, nut welded to spanner wrench, tighten the
12
cylinder gland.

torque valve.
R = T x L ÷ (L + C)
MULTIPLIED BY (x)
DIVIDED BY (÷)
PLUS (+)
EQUALS (=)
18. Install the brake cylinder 1( with a new o-ring 2) into the cylinder
barrel.
Brake cylinder................................................... Loctite 270
Brake cylinder................................................78 to 98 N•m
19. Remove the cylinder from fixture A1. Using a press and appropri-
ate tool A2, mount the swing bushings.
BOOM LOCK
REMOVAL
WARNING! Center the backhoe a, rest the back of bucket

on the ground, keeping the arm vertical, lower the outrig-
gers.
WB140-2N WB150-2N 30-321 1

12
1. Make sure that the safety stop b is raised. Stop the engine and re-
lease the residual hydraulic pressure.

2. Remove the cotter pins c, then remove the pin d.
3. Disconnect the hydraulic hose e that feeds cylinder f, then cap

and plug to prevent entry of impurities.
4. Remove the snap ring g, then remove cylinder f.
INSTALLATION
Pin seats ...........................................................ASL800050
★ Install new cotter pins.

1. Start the engine and perform several lock and release manuvers to
fill the safety cylinder and bleed air from the unit. For details, see
DISASSEMBLY
1. Remove the snap ring a.
2. Pull the rod b out with the piston c and gland d.
3. Slide the gland d off, then remove and discard the wiper seal e.
4. Remove and discard the o-ring f from the piston.
REASSEMBLY
• Reassemble the cylinder in reverse order of disassembly.
30-322 1 WB140-2N WB150-2N

REMOVAL AND INSTALLATION BACKHOE WORK EQUIPMENT
12
BACKHOE WORK EQUIPMENT
BOOM TO BUCKET
REMOVAL
1. Extend the arm completely and fully open the bucket. Lower the
equipment until it rests on the ground. Remove the boom cylinder
a, see BACKHOE CYLINDERS.

Stop the engine, loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank. Then operate the
control levers several times to release the remaining pres-
sure in the hydraulic lines.
2. Remove the bracket B located inside the boom. Disconnect the

hoses c from the arm cylinder, then cap and plug to prevent entry
of impurities.
★ Mark the hoses for ease of installation.
3. Remove the bracket d.
★ Mark the hoses for ease of installation.
4. Sling the work equipment e, and attach a hoist. Apply slight ten-
sion to the sling.
5. Remove snap rings and pin f.
6. Slowly remove work equipment e, checking that there is no inter-

ference.
★ Be very careful not to damage any hydraulic hoses.
Work Equipment ...................................................... 850 kg
WB140-2N WB150-2N 30-323 1

12
INSTALLATION

pin hole
1. Pass the cylinder hoses through the inside of brackets g.
• Start the engine and bleed air from the cylinders. For details, see
BUCKET
REMOVAL
WARNING! Place the bucket on a level surface, resting on
its back.
1. Remove the safety pin a and connecting pin b between the bucket
c and linkage d.
2. Remove the safety pin e then the pin f that attaches the bucket c
to the arm g.
INSTALLATION

pin hole.
★ Start the engine and run at low idle, operate the control levers and
extend the ram to align the pin holes.
30-324 1 WB140-2N WB150-2N

12
STANDARD ARM
REMOVAL
1. Remove the bucket, see BUCKET.
2. Remove the bucket cylinder a, see BACKHOE CYLINDERS.
3. Remove the lever b. Remove the lock nut c with washers, pin d
and levers e.
4. Start the engine and bring the arm into a vertical position, then low-
er it to the ground. Stop the engine and release the residual pressure
arm cylinder f.
5. Sling the arm cylinder f to a hoist. Apply slight tension to the

sling. Remove the bolt g and pin h, then rest the cylinder on the
wood block 1!.
6. Start the engine and retract the rod i completely.
★ Secure the piston rod with wire.
7. Sling the arm j to a hoist. Apply slight tension to the sling. Re-
move the bolts and pin 1).
8. Remove the arm j.
WB140-2 arm .......................................................... 213 kg

WB150-2 arm .......................................................... 245 kg
INSTALLATION

pin hole.
★ Tighten the lock nut c, then back off one half turn.
WARNING! Start the engine and run at low idle, op-

erate the control levers and extend the rod to align
the pin holes. When aligning the position of the pin
pin hole.
WB140-2N WB150-2N 30-325 1

12
TELESCOPIC ARM
REMOVAL
1. Remove the bucket, see BACKHOE WORK EQUIPMENT
2. Remove the bucket cylinder a and link b, see BACKHOE CYL-

INDERS
3. Remove the lock nut c with the washer, pin d, then the cylinder
link e.

4. Disconnect the telescopic arm hoses F and G, the bucket cylinder

hoses H and I, then the auxiliary equipment hoses J and 1). Plug
and cap to prevent entry of impurities.
★ Mark the hydraulic hoses before separation, in order to reas-

semble them in the same position as before separation.
5. Remove the clamp 1!.
6. Remove the telescopic arm the same as the standard arm
Telescopic Arm ........................................................ 392 kg
INSTALLATION

pin hole.
★ Completely tighten lock nut c, then back off one half turn.
30-326 1 WB140-2N WB150-2N

12
INNER ARM
REMOVAL
1. Remove the bucket a, see BACKHOE WORK EQUIPMENT
2. Remove the bucket cylinder b and link c, see BACKHOE WORK

EQUIPMENT
3. Remove the telescopic arm cylinder. see BACKHOE CYLINDERS
★ For safety, cap and plug all open ports to prevent entry of im-
purities.
4. Remove the lock nut d with the washer, link pin e, and the arm
links f.
5. Attach chains to the inner arm g, and attach to a hoist.
★ Attach chains to the bucket pin hole and the safety pin holes
6. Start the engine, and maintaining constant tension on the section of

chain connected to the bucket coupling, slowly raise the boom until
both sections of chain are under slight tension.
7. Stop engine and loosen the upper guide adjustment bolts, then the
lower guide adjustment dowel bolts by several turns.
★ Loosen the adjustment bolts on both sides.

8. Slide inner arm g out.
Inner Arm................................................................. 160 kg
INSTALLATION

pin hole.
★ Completely tighten lock nut d, then back off one half turn.
WB140-2N WB150-2N 30-327 1

12
INNER ARM GUIDES
REMOVAL
1. Remove the backhoe bucket, see BUCKET
2. Partially extend the inner arm a.
3. Rest the outer arm b on a stand 80 cm high.
4. Loosen and remove the adjustment bolts c with lock washers d,

then remove the upper guides e.
5. Attach chains to the inner arm a, and attach to hoist.
★ Attach the chains to the bucket pin hole and the safety pin
holes
6. Slowly raise the inner arm b until it rests on the supporting surfac-
es of the upper guides e.
7. Loosen the nuts f, then remove the lower guide adjustment dowel
bolts g.
8. Raise the lower guides h and slide them out.
INSTALLATION
Upper and lower guides ...................................ASL800040
1. Adjust the clearances, keeping the inner arm a aligned with the
outer arm b. For details, see TESTING AND ADJUSTING.
30-328 1 WB140-2N WB150-2N

12
BOOM
REMOVAL
1. Remove the backhoe arm, see BUCKET
2. Remove the backhoe arm cylinder, see BACKHOE WORK

EQUIPMENT
3. Start the engine, lower the boom and rest it on a wooden block on
the ground.
4. Remove the backhoe boom cylinder, see BACKHOE CYLIN-

DERS
5. Remove the bracket a. Disconnect the hydraulic hoses b, then cap

and plug to prevent entry of impurities.
★ Mark the hydraulic hoses b before separation, for ease of as-

sembly.
6. Sling the boom c, and attach to a hoist. Apply slight tension to the
sling.
7. Remove the snap rings and pin d, then lift up and remove the boom
c.
Boom ....................................................................... 323 kg
INSTALLATION

and hole use a bar. NEVER insert your fingers into
the pin hole.
★ Pass the cylinder hydraulic hoses inside the bracket e.
WB140-2N WB150-2N 30-329 1

12
SWING BRACKET
REMOVAL
1. Remove the backhoe work equipment, see BACKHOE WORK

EQUIPMENT
2. Remove the bolts a and pins b that connect the swing cylinder c
rods.
3. Remove the boom lock cylinder d, see BACKHOE WORK

EQUIPMENT
4. Remove the snap e, pin f, and link g.
5. Sling the swing bracket i, and attach to a hoist. Apply slight ten-
sion to the sling.
6. Remove the bolts j and 1), then remove the swing bracket pivot
pins 1! and 1@.
7. Remove the swing bracket i, being careful not to lose or damage

the clearance adjustment shims 1#.
Swing Bracket.......................................................... 133 kg
INSTALLATION

the pin hole.
Pin ....................................................................ASL800050
★ Insert the shims 1#.

30-330 1 WB140-2N WB150-2N

12
OUTRIGGERS
REMOVAL
WARNING! Position the backhoe a with the work equip-
ment centered, with the arm vertical, and the back of the
bucket on the ground.
1. Rest the outrigger on the ground and stop the engine.
2. Sling the outrigger cylinder b, and attach to a hoist. Apply slight

tension to the sling.
3. Remove the nut c, bolt d and pin e.
4. Start the engine and retract the cylinder b rod. Raise the cylinder to
a vertical position and secure it in place with a strap.
5. Sling the outrigger f, and attach to a hoist. Apply slight tension to

the sling.
6. Remove the nut g, bolt h, and pin i.
WB140-2N WB150-2N 30-331 1

12
7. With the hoist, raise the outrigger f until it is in a horizontal posi-
tion. Remove the nut j, bolt 1), and pin 1!, then remove the outrig-
ger.
8. Repeat the same procedure for the other side.
INSTALLATION

the pin hole.
30-332 1 WB140-2N WB150-2N

90 OTHERS
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . 90-3
PPC SYSTEM FOR WB140-2N SHEET 1 OF 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
CAB WIRING SCHEMATIC SHEET 1 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
LEGEND FOR CAB WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
CANOPY WIRING SCHEMATIC SHEET 1 OF 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
LEGEND FOR CANOPY WIRING SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
TIER I ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
TIER II ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
LEGEND FOR TIER I AND II ENGINE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . 90-51
FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
LEGEND FOR FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
LATERAL HARNESS AND SIDE DASHBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
TIER I ENGINE SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
TIER I ENGINE SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
LEGEND FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61
TIER II ENGINE SHEET 1 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63
TIER II ENGINE SHEET 2 OF 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65
LEGEND FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS . 90-67
PPC FRAME AND SIDE DASH BOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . 90-69
FRAME HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-69
SIDE DASH BOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-71
WB140-2N WB150-2N 90-1

OTHERS TABLE OF CONTENTS
LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS . . . . . . . . . 90-73
WORK LIGHT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-75
FUSE AND RELAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-77
LEGEND FOR FUSE AND RELAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-77
90-2 WB140-2N WB150-2N

OTHERS HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
STANDARD CONTROLS FOR WB140-2N SHEET 1 OF 2
WB140-2N WB150-2N 90-3

12
90-4 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-5

12
90-6 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-7

12
90-8 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-9

12
90-10 WB140-2N WB150-2N

12
PPC SYSTEM FOR WB140-2N SHEET 1 OF 3
WB140-2N WB150-2N 90-11

12
90-12 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-13

12
90-14 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-15

12
90-16 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-17

12
90-18 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-19

12
90-20 WB140-2N WB150-2N

12
WB140-2N WB150-2N 90-21

12
90-22 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
ELECTRICAL
CAB WIRING SCHEMATIC SHEET 1 OF 5
WB140-2N WB150-2N 90-23

OTHERS ELECTRICAL
12
90-24 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-25

OTHERS ELECTRICAL
12
90-26 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-27

OTHERS ELECTRICAL
12
90-28 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-29

OTHERS ELECTRICAL
12
90-30 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-31

OTHERS ELECTRICAL
12
90-32 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
LEGEND FOR CAB WIRING SCHEMATIC
ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET
EV1 MP Bucket Open Solenoid 5 of 5 H16 Cab Light 4 of 5 P1 Tachometer 2 of 5 C1 A/C Magnetic Clutch 5 of 5 X67 Seat Sensor, 3 Pin 5 of 5
EV2 MP Bucket Close Solenoid 5 of 5 H17 Front Work Light 4 of 5 P2 Hour Meter 2 of 5 XC1 Lighter Socket 3 of 5 XA Alternator, 2 Pin 5 of 5
EV3 Diff Lock Solenoid 5 of 5 H18 Front Work Light 4 of 5 P3 Fuel Level Gauge 2 of 5 X1 Engine Harness, 11 Pin 2 of 5 XAM Fuel Shutoff Valve, 3 Pin 5 of 5
EV4 Boom Lock Solenoid 5 of 5 H19 Beacon Light 4 of 5 P4 Coolant Temp Gauge 2 of 5 X2 Lights and Gear Shift, 9 Pin 1 of 5 XD1 Light Switch, 9 Pin 1 of 5
F1A Low Beam Fuse, 15A 1 of 5 H20 Rear Work Light 4 of 5 R30 Heating Start 5 of 5 X3 Front Line, 11 Pin 1 of 5 XD2 Gear Shift, 5 Pin 1 of 5
F1B Right Light Fuse, 3A 2 of 5 H21 Rear Work Light 4 of 5 R31 Fuel Level Sender 5 of 5 X4 Not Used, 11 Pin 1 of 5 XM9 Fuel Pump, 2 Pin 5 of 5
F1C Left Light Fuse, 3A 2 of 5 H22 Indicators Warn Light 1 of 5 R32 Coolant Temp Sender 5 of 5 X5 Cab Controls, 11 Pin 3 of 5 XS Instrument Panel, 6 Pin 2 of 5
F2A Fuse, 10A Not Used 2 of 5 H23 High Beam Warn Light 1 of 5 R33 Alternator 5 of 5 X6 Trans Solenoids, 9 Pin 1 of 5 XT1 Fuel Shutoff Timer, 4 Pin 5 of 5
F2B Cab Fuse, 15A 3 of 5 H24 Brake Oil Warn Light 1 of 5 S1 ECO Power Button 5 of 5 X7 Not Used, 9 Pin 3 of 5 XT2 Preheat Timer, 4 Pin 5 of 5
F2C Hazard Fuse, 10A 2 of 5 H25 Diff Lock Warn Light 1 of 5 S2 Boom Unlock Switch 4 of 5 X8 Side Dashboard, 17 Pins 2 of 5 XK12 Seat Unit, 6 Pin 5 of 5
F3A Stp Seat DL Fuse, 7.5A 2 of 5 H28 Right Front Light 2 of 5 S4 Blower Motor Switch 3 of 5 X9 Front Dashboard, 17 Pins 1 of 5 XK13 Stop Light Diff Lock, 6 Pin 4 of 5
F3B Instr. Warn RTD, 10A 2 of 5 H29 Left Front Light 1 of 5 S6 Starting Switch 2 of 5 X10 To Engine Harness, 13 Pin 4 of 5
F3C MPB Declutch Fuse, 7.5A 1 of 5 H36 Rear Left Side Lights 4 of 5 S10 Declutch Button 5 of 5 X11 2 Way Power, 2 Pin 4 of 5
F4A 4WD Ft Washer Fuse, 7.5A 2 of 5 H37 Rear Right Side Lights 4 of 5 S13 Battery Cut Off Switch 5 of 5 X12 Front Cross Over, 2 Pin 4 of 5
F4B F/R BUA Fuse, 10A 1 of 5 H38 Courtesy Light 4 of 5 S15 Hand Brake Switch 3 of 5 X16 AC Clutch, 2 Pin 5 of 5
F4C High Beam Fuse, 15A 1 of 5 HA1 Horn 5 of 5 S16 Brake Oil Level Low Switch 1 of 5 X17 Side Dashboard, 21 Pin 2 of 5
F5A Heater Relay Fuse, 10A 3 of 5 HA2 Buzzer 2 of 5 S17 Brake Pressure Switch 1 of 5 X18 Front Cable, 5 Pin 2 of 5
F5B Rear Work Light, 15A 3 of 5 HA3 Fuel Shut Off Relay 3 of 5 S18 Brake Pressure Switch 1 of 5 X19 Front Dashboard, 9 Pin 2 of 5
F5C Front Work Light, 15A 2 of 5 HA4 Back Up Alarm 3 of 5 S19 Seat Sensor 5 of 5 X20 Blower Motor 3 of 5
F6A Rear Wiper Front Horn, 15A 3 of 5 K01 Starter Relay 5 of 5 S21 Coolant High Temp Switch 5 of 5 X21 Fuel Level Indicator, 3 Pin 5 of 5
F6B Light Sel Horn Relay, 7.5A 1 of 5 K02 Preheat Relay 5 of 5 S22 Air Filter Clogged Switch 5 of 5 X22 Washer Pump, 2 Pin 2 of 5
F6C Direction Lights, 10A 2 of 5 K03 Fuel Shut Off Relay 5 of 5 S23 Lo Eng Oil Pres Switch 5 of 5 X23 Optional, 2 Pin 1 of 5
F7A Fuse, 7.5A Not Used 1 of 5 K04 AC Blower Relay 3 of 5 S24 Fuel Gauge 5 of 5 X24 Front Wiper, 4 Pin 1 of 5
F7B Front Horn Fuse, 10A 1 of 5 K05 Return to Dig Relay 2 of 5 S26 Trans Oil Temp Switch 3 of 5 X25 Blower Motor, 2 Pin 3 of 5
F7C Fuel Shut Off Fuse, 7.5 A 2 of 5 K06 Power ECO Unit 5 of 5 S27 Return to Dig Sensor 3 of 5 X26 Rear Line, 8 Pin 4 of 5
FUG1 Key Switch Fuse, 60A 5 of 5 KC Load Fan Heater Relay 3 of 5 S37 Rear Door Switch 3 of 5 X27 Valve Lines, 6 Pin 5 of 5
FUG2 Preheat Switch Fuse, 80A 5 of 5 K1 Forward Direction Relay 1 of 5 S1A 4WD Switch 1 of 5 X28 Loader Lever, 12 Pin 5 of 5
FUG3 FSO Power Fuse, 40A 5 of 5 K2 Reverse Direction Relay 1 of 5 S1L Rear Work Light Switch 3 of 5 X29 Declutch Button, 2 Pin 5 of 5
FUG4 Heater A/C Fuse, 40A 5 of 5 K3 4WD Relay 1 of 5 S2A Front Wiper/Washer Switch 1 of 5 X30 Transfer Fuel Pump, 2 Pin 5 of 5
G1 Battery 5 of 5 K4 Neutral Position Relay 2 of 5 S2L Rear Wiper/Washer Switch 3 of 5 X31 Cab, 5 Pin 4 of 5
G2 Alternator 5 of 5 K5 Low Beam Relay 1 of 5 S3A Front Work Light 1 of 5 X32 Radio, 2 Pin 3 of 5
H1 Preheat Warn Light 2 of 5 K6 Main Beam Relay 1 of 5 S3L Rotary Beacon Switch 3 of 5 X33 Wiper and Beacon, 7 Pin 3 of 5
H2 Alternator Warn Light 2 of 5 K7 Gear Relay 1 of 5 S4A Warning Switch 1 of 5 X34 Right Front Light, 6 Pin 2 of 5
H3 Coolant Warn Light 2 of 5 K8 Front Horn Relay 1 of 5 S4L Horn Switch 3 of 5 X35 Left Front Light, 6 Pin 1 of 5
H4 Eng Oil Pressure Warn Light 2 of 5 K9 Flasher Unit 1 of 5 S5L Optional Switch 3 of 5 X38 F and R Solenoids, 4 Pin 1 of 5
H5 Air Filter Warn Light 2 of 5 K12 Seat Unit 5 of 5 SM2 Power Button 5 of 5 X39 Proximity, 3 Pin 3 of 5
H6 Hyd Oil Filter Warn Light 2 of 5 K13 Stop Light, Diff Lock Unit 4 of 5 SM3 MPB Grab Button 5 of 5 X40 Flasher Unit, 13 Pin 1 of 5
H7 Opt Warn Light 2 of 5 KT1 Fuel Shut Off Timer 5 of 5 SM4 Converter Declutch Button 5 of 5 X41 4WD Solenoid, 2 Pins 1 of 5
H8 Opt Warn Light 2 of 5 KT2 Preheater Timer 5 of 5 SM5 MPB Open Button 5 of 5 X43 Power Relay, 7 Pin 3 of 5
H9 Coolant Warn Light 1 of 5 M1 Starter Motor 5 of 5 SM6 Differential Lock Button 5 of 5 X45 Power ECO Unit, 5 Pin 5 of 5
H10 Converter Temp Warn Light 1 of 5 M2 Washer Pump 2 of 5 Y0 Fuel Shutoff Solenoid Valve 5 of 5 X46 Rear Wiper, 4 Pin 5 of 5
H11 4WD Warn Light 1 of 5 M3 Windshield Wiper Motor 5 of 5 Y1 Eco Power Solenoid Valve 5 of 5 X47 Beacon Light, 2 Pin 4 of 5
H12 Low Fuel Warn Light 1 of 5 M4 Blower Motor 3 of 5 Y2 4WD Solenoid 1 of 5 X53 AC Interface, 1 Pin 3 of 5
H13 Komatsu Logo Light 1 of 5 M5 Transfer Fuel Pump 5 of 5 Y4 Forward Solenoid 1 of 5 X59 Front Line Cross, 6 Pin 4 of 5
H14 Komatsu Logo Light 1 of 5 M8 Windshield Wiper Motor 1 of 5 Y5 Reverse Solenoid 1 of 5 X60 Optional, 1 Pin 1 of 5
H15 Lighter Light 3 of 5 M9 Fuel Pump 5 of 5 Y6 Return to Dig Magnet 3 of 5 X63 Alternator Resistance, 2 Pin 5 of 5
WB140-2N WB150-2N 90-33

OTHERS ELECTRICAL
12
90-34 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
CANOPY WIRING SCHEMATIC SHEET 1 OF 5
WB140-2N WB150-2N 90-35

OTHERS ELECTRICAL
12
90-36 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-37

OTHERS ELECTRICAL
12
90-38 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-39

OTHERS ELECTRICAL
12
90-40 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-41

OTHERS ELECTRICAL
12
90-42 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WB140-2N WB150-2N 90-43

OTHERS ELECTRICAL
12
90-44 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
LEGEND FOR CANOPY WIRING SCHEMATIC
ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET ITEM DESCRIPTION SHEET
EV1 MP Bucket Open Solenoid 5 of 5 H17 Front Work Light 4 of 5 R33 Alternator 5 of 5 X11 2 Way Power, 2 Pin 4 of 5
EV2 MP Bucket Close Solenoid 5 of 5 H18 Front Work Light 4 of 5 S1 ECO Power Button 5 of 5 X12 Front Cross Over, 2 Pin 4 of 5
EV3 Diff Lock Solenoid 5 of 5 H19 Beacon Light 4 of 5 S2 Boom Unlock Switch 4 of 5 X17 Side Dashboard, 21 Pin 2 of 5
EV4 Boom Lock Solenoid 5 of 5 H20 Rear Work Light 4 of 5 S6 Starting Switch 2 of 5 X18 Front Cable, 5 Pin 2 of 5
F1A Low Beam Fuse, 15A 1 of 5 H21 Rear Work Light 4 of 5 S10 Declutch Button 5 of 5 X19 Front Dashboard, 9 Pin 2 of 5
F1B Right Light Fuse, 3A 2 of 5 H22 Indicators Warn Light 1 of 5 S13 Battery Cut Off Switch 5 of 5 X21 Fuel Level Indicator, 3 Pin 5 of 5
F1C Left Light Fuse, 3A 2 of 5 H23 High Beam Warn Light 1 of 5 S15 Hand Brake Switch 3 of 5 X23 Optional, 2 Pin 1 of 5
F2A Fuse, 10A Not Used 2 of 5 H24 Brake Oil Warn Light 1 of 5 S16 Brake Oil Level Low Switch 1 of 5 X26 Rear Line, 8 Pin 4 of 5
F2B Canopy Fuse, 15A 3 of 5 H25 Diff Lock Warn Light 1 of 5 S17 Brake Pressure Switch 1 of 5 X27 Valve Lines, 6 Pin 5 of 5
F2C Hazard Fuse, 10A 2 of 5 H28 Right Front Light 2 of 5 S18 Brake Pressure Switch 1 of 5 X28 Loader Lever, 12 Pin 5 of 5
F3A Stp Seat DL Fuse, 7.5A 2 of 5 H29 Left Front Light 1 of 5 S19 Seat Sensor 5 of 5 X29 Declutch Button, 2 Pin 5 of 5
F3B Instr. Warn RTD, 10A 2 of 5 H36 Rear Left Side Lights 4 of 5 S21 Coolant High Temp Switch 5 of 5 X30 Transfer Fuel Pump, 2 Pin 5 of 5
F3C MPB Declutch Fuse, 7.5A 1 of 5 H37 Rear Right Side Lights 4 of 5 S22 Air Filter Clogged Switch 5 of 5 X31 Canopy, 5 Pin 4 of 5
F4A 4WD Fuse, 7.5A 2 of 5 H38 Courtesy Light 4 of 5 S23 Lo Eng Oil Pres Switch 5 of 5 X33 Beacon, 7 Pin 3 of 5
F4B F/R BUA Fuse, 10A 1 of 5 HA1 Horn 5 of 5 S24 Fuel Gauge 5 of 5 X34 Right Front Light, 6 Pin 2 of 5
F4C High Beam Fuse, 15A 1 of 5 HA2 Buzzer 2 of 5 S26 Trans Oil Temp Switch 3 of 5 X35 Left Front Light, 6 Pin 1 of 5
F5A Fuse, 10A Not Used 3 of 5 HA3 Fuel Shut Off Relay 3 of 5 S27 Return to Dig Sensor 3 of 5 X38 F and R Solenoids, 4 Pin 1 of 5
F5B Rear Work Light, 15A 3 of 5 HA4 Back Up Alarm 3 of 5 S1A 4WD Switch 1 of 5 X39 Proximity, 3 Pin 3 of 5
F5C Front Work Light, 15A 2 of 5 K01 Starter Relay 5 of 5 S1L Rear Work Light Switch 3 of 5 X40 Flasher Unit, 13 Pin 1 of 5
F6A Rear Wiper Front Horn, 15A 3 of 5 K02 Preheat Relay 5 of 5 S3A Front Work Light 1 of 5 X41 4WD Solenoid, 2 Pins 1 of 5
F6B Light Sel Horn Relay, 7.5A 1 of 5 K03 Fuel Shut Off Relay 5 of 5 S3L Rotary Beacon Switch 3 of 5 X43 Power Relay, 7 Pin 3 of 5
F6C Direction Lights, 10A 2 of 5 K05 Return to Dig Relay 2 of 5 S4A Warning Switch 1 of 5 X45 Power ECO Unit, 5 Pin 5 of 5
F7A Fuse, 7.5A Not Used 1 of 5 K06 Power ECO Unit 5 of 5 S4L Horn Switch 3 of 5 X47 Beacon Light, 2 Pin 4 of 5
F7B Front Horn Fuse, 10A 1 of 5 K1 Forward Direction Relay 1 of 5 S5L Optional Switch 3 of 5 X59 Front Line Cross, 6 Pin 4 of 5
F7C Fuel Shut Off Fuse, 7.5 A 2 of 5 K2 Reverse Direction Relay 1 of 5 SM2 Power Button 5 of 5 X60 Optional, 1 Pin 1 of 5
FUG1 Key Switch Fuse, 60A 5 of 5 K3 4WD Relay 1 of 5 SM3 MPB Grab Button 5 of 5 X63 Alternator Resistance, 2 Pin 5 of 5
FUG2 Preheat Switch Fuse, 80A 5 of 5 K4 Neutral Position Relay 2 of 5 SM4 Converter Declutch Button 5 of 5 X65 Optional Light, 1 Pin 2 of 5
FUG3 FSO Power Fuse, 40A 5 of 5 K5 Low Beam Relay 1 of 5 SM5 MPB Open Button 5 of 5 X66 Optional Light, 1 Pin 3 of 5
FUG4 Fuse, 40A Not Used 5 of 5 K6 Main Beam Relay 1 of 5 SM6 Differential Lock Button 5 of 5 X67 Seat Sensor, 3 Pin 5 of 5
G1 Battery 5 of 5 K7 Gear Relay 1 of 5 Y0 Fuel Shutoff Solenoid Valve 5 of 5 XA Alternator, 2 Pin 5 of 5
G2 Alternator 5 of 5 K8 Front Horn Relay 1 of 5 Y1 Eco Power Solenoid Valve 5 of 5 XAM Fuel Shutoff Valve, 3 Pin 5 of 5
H1 Preheat Warn Light 2 of 5 K9 Flasher Unit 1 of 5 Y2 4WD Solenoid 1 of 5 XD1 Light Switch, 9 Pin 1 of 5
H2 Alternator Warn Light 2 of 5 K12 Seat Unit 5 of 5 Y4 Forward Solenoid 1 of 5 XD2 Gear Shift, 5 Pin 1 of 5
H3 Coolant Warn Light 2 of 5 K13 Stop Light, Diff Lock Unit 4 of 5 Y5 Reverse Solenoid 1 of 5 XM9 Fuel Pump, 2 Pin 5 of 5
H4 Eng Oil Pressure Warn Light 2 of 5 KT1 Fuel Shut Off Timer 5 of 5 Y6 Return to Dig Magnet 3 of 5 XS Instrument Panel, 6 Pin 2 of 5
H5 Air Filter Warn Light 2 of 5 KT2 Preheater Timer 5 of 5 XC1 Lighter Socket 3 of 5 XT1 Fuel Shutoff Timer, 4 Pin 5 of 5
H6 Hyd Oil Filter Warn Light 2 of 5 M1 Starter Motor 5 of 5 X1 Engine Harness, 11 Pin 2 of 5 XT2 Preheat Timer, 4 Pin 5 of 5
H7 Opt Warn Light 2 of 5 M5 Transfer Fuel Pump 5 of 5 X2 Lights and Gear Shift, 9 Pin 1 of 5 XK12 Seat Unit, 6 Pin 5 of 5
H8 Opt Warn Light 2 of 5 M9 Fuel Pump 5 of 5 X3 Front Line, 11 Pin 1 of 5 XK13 Stop Light Diff Lock, 6 Pin 4 of 5
H9 Coolant Warn Light 1 of 5 P1 Tachometer 2 of 5 X4 Not Used, 11 Pin 1 of 5
H10 Converter Temp Warn Light 1 of 5 P2 Hour Meter 2 of 5 X5 Canopy Controls, 11 Pin 3 of 5
H11 4WD Warn Light 1 of 5 P3 Fuel Level Gauge 2 of 5 X6 Trans Solenoids, 9 Pin 1 of 5
H12 Low Fuel Warn Light 1 of 5 P4 Coolant Temp Gauge 2 of 5 X7 Not Used, 9 Pin 3 of 5
H13 Komatsu Logo Light 1 of 5 R30 Heating Start 5 of 5 X8 Side Dashboard, 17 Pins 2 of 5
H14 Komatsu Logo Light 1 of 5 R31 Fuel Level Sender 5 of 5 X9 Front Dashboard, 17 Pins 1 of 5
H15 Lighter Light 3 of 5 R32 Coolant Temp Sender 5 of 5 X10 To Engine Harness, 13 Pin 4 of 5
WB140-2N WB150-2N 90-45

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90-46 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
TIER I ENGINE HARNESS
WB140-2N WB150-2N 90-47

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12
90-48 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
TIER II ENGINE HARNESS
WB140-2N WB150-2N 90-49

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12
90-50 WB140-2N WB150-2N

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LEGEND FOR TIER I AND II ENGINE HARNESSES
TIER I ENGINE TIER II ENGINE
No. Connector Description No. Connector Description
A X10 To Front Line A K03 Fuel Shut Off Relay
b X13 To Front Line b X61 Safety Relays
c XAD Coolant Temperature with Diode c X10 To Front Line
d Ground d X02
e X11 +30 +50 e X63
f Ground f X11 +30 +50
g Ground g Ground
h Ground h Ground
i S23 Oil Temperature i Ground
j XAM Fuel Shut Off j S23 Oil Temperature
1) +30 Starter Motor 1) XAM Fuel Shut Off
1! +50 Starter Motor 1! M9 Fuel Pump
1@ W RPM (Tachometer) Indicator 1@ +50 +50
1# XA Alternator 1# +30 +30
1$ B+ 1$ +30 +30
1% S21 Coolant Temperature 1% W RPM (Tachometer) Indicator
1^ S22 Air Filter Clogged Switch 1^ XA Alternator
1& S22 Air Filter Clogged Switch 1& S21 Coolant Temperature
1* R32 Coolant Temperature 1* S22 Air Filter Clogged Switch
1( X16 AC Magnetic Clutch 1( R32 Coolant Temperature
2) HA1 Horn 2) X16 AC Magnetic Clutch
2! HA1 Horn 2! HA1 Horn
2@ R30 Preheat Grid Block 2@ R30 Preheat Grid Block
2# K02 Preheat Relay 2# GND2 Ground
2$ K02 Preheat Relay 2$ KT2 Preheat Relay
2% K02 Preheat Relay 2% X64 Preheat Start Relay
2^ XT2 Preheat Timer Excitation 2^ XT2 Preheat Timer Excitation
2& XT1 Fuel Shut Off Timer 2& XT1 Fuel Shut Off Timer
2* 80A Fuse 2* 80A Fuse
2( 30A Fuse 2( 30A Fuse
3) 60A Fuse 3) 60A Fuse
3! 30A Fuse 3! 30A Fuse
3@ Fuse Ground 3@ Fuse Ground
3# Matcher 3# Matcher
3$ 12V 70A Relay 3$ 12V 70A Relay
3% Timer 3% Timer
3^ Timer 3^ Timer
3& Relay 3& Relay
3* Control Box 3* Control Box
3( K03 Fuel Shut Off Relay 3( Power Box
4( K01 Starting Relay
WB140-2N WB150-2N 90-51

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90-52 WB140-2N WB150-2N

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12
FRONT HARNESS
WB140-2N WB150-2N 90-53

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12
90-54 WB140-2N WB150-2N

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LEGEND FOR FRONT HARNESS
TIER I ENGINE
No. Connector Description
A X18 Power Box
B X12 Power +30 +50
C X59 To Platform Cable
D X23 Optional
E X35 Front Left Light
F X10 To Engine Harness
G X11 Power +30 +50
H GND Ground
I S18 Stop Light Switch
J S17 Stop Light Switch
1) S16 Brake Oil Level Switch
1! X22 Washer Pump
1@ X34 Front Right Light
1# X1 Electronic Board
1$ X3 Electronic Board
1% X60 Optional
1^ +30 Electronic Board
WB140-2N WB150-2N 90-55

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90-56 WB140-2N WB150-2N

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12
LATERAL HARNESS AND SIDE DASHBOARD
TIER I ENGINE SHEET 1 OF 2
WB140-2N WB150-2N 90-57

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90-58 WB140-2N WB150-2N

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12
TIER I ENGINE SHEET 2 OF 2
WB140-2N WB150-2N 90-59

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90-60 WB140-2N WB150-2N

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LEGEND FOR TIER I ENGINE LATERAL AND SIDE DASH BOARD HARNESS
TIER I ENGINE
A X19 To Front Dash Board 4! Connectors
b +15 Electronic Board 4@ Battery Warning Light
c X8 Electronic Board 4# Preheat Warning Light
d X5 Electronic Board 4$ Engine Oil Pressure Warning Light
e X27 Solenoid Valves 4% Engine Air Filter Warning Light
f X28 Loader Control Lever 4^ Tachometer/Hour Meter
g X39 Return Sender 4& Fuel Level Gauge
h Return Valve 4* Engine Coolant Temperature Gauge
i Ground 4( Buzzer
j X25 Electric Bridge 5) Optional Warning Light
1) K04 Heater Motor Relay 5! Engine Coolant Temp Warning Light
1! K05 Return Relay 5@ Hydraulic Oil Filter Warning Light
1@ K06 Power EC Relay 5# Starting Switch
1# S4 Heater 5$ S3 Beacon Lamp Switch
1$ X31 Cab/Canopy 5% Connectors
1% AC Kit 5^ S2 Optional Switch
1^ X17 Side Dash Board 5& Connectors
1& X15 Starting Switch 5* S1 Work Light Switch
1* S3 Not Used 5( Connectors
1( S2 Relay Valve Switch 6) To Platform Cable
2) S1 Economy Power Button
2! Lighter
2@ X32 Radio
2# X26 Rear Light Cable
2$ Parking Brake Switch
2% Rear Horn
2^ Not Used
2& Back Up Alarm
2* X20 Heater Motor
2( X29 Converter Detach - 2nd Button
3) Economy Power with Diode
3! X30 Fuel Pump
3@ X21 Fuel Float
3# X12 To Front Cable
3$ X14 To Front Cable
3% X43 Wiring Gear Switch
3^ To Platform Cable
3& Wiper Switch
3* Optional Switch
3( Connectors
4) Rear Horn Switch
WB140-2N WB150-2N 90-61

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90-62 WB140-2N WB150-2N

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12
TIER II ENGINE SHEET 1 OF 2
WB140-2N WB150-2N 90-63

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12
90-64 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
TIER II ENGINE SHEET 2 OF 2
WB140-2N WB150-2N 90-65

OTHERS ELECTRICAL
12
90-66 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
LEGEND FOR TIER II ENGINE LATERAL SIDE DASH BOARD HARNESS
TIER II ENGINE
A X19 To Front Dash Board 3( X15 +15 Electronic Board
b X5 Electronic Board 4) X17 To Platform Harness
c X8 Electronic Board 4! Light
d X27 Solenoid Valves 4@ S3L Beacon Light Switch
e X28 Loader Control Lever 4# S2L Front Wiper Switch
f X39 Return to Dig Sensor 4$ S1L Work Light Switch
g Y6 RTD Valve 4% HA Lamp
h Ground 4^ Lamp
i X25 Electronic Bridge 4& Lamp
j K04 3 Speed Fan Relay - AC 4* Fuel Gauge
1) K05 RTD Relay 4( Battery Warning Light
1! KC Load Fan Relay 5) Preheater Warning Light
1@ K12 Not Used 5! Light
1# K06 Power Economy Unit 5@ Engine Air Filter Warning Light
1$ K13 Relay 5# Engine Oil Pressure Warning Light
1% S4 Heater 5$ S4L Switch
1^ X53 AC Kit 5% S5L Switch
1& X31 Cab/Canopy 5^ +15
1* X17 Side Dash Board 5& X33 Cab/Canopy
1( S6 Starting Switch 5* X65 Rear Work Light
2) S3 Not Used 5( X66 Rear Work Light
2! S2 Boom Unlock Switch
2@ S1 Economy Power Switch
2# XC1 Lighter
2$ X32 Radio
2% X26 Rear Work Light
2^ X67 Not Used
2& S15 Parking Brake Switch
2* HA3 Rear Horn
2( Y3 Not Used
3) HA4 Back Up Alarm
3! X20 Heater Motor
3@ X29 Converter Detach - 2nd Button
3# Y1 Economy Power
3$ X30 Fuel Pump
3% X21 Fuel Float
3^ X43 To 4th Gear Relay
3& X12 Power Supply
3* X59 Front Wiring Interface
WB140-2N WB150-2N 90-67

OTHERS ELECTRICAL
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90-68 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
PPC FRAME AND SIDE DASH BOARD HARNESS
FRAME HARNESS
WB140-2N WB150-2N 90-69

OTHERS ELECTRICAL
12
90-70 WB140-2N WB150-2N

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12
SIDE DASH BOARD HARNESS
WB140-2N WB150-2N 90-71

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12
90-72 WB140-2N WB150-2N

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12
LEGEND FOR PPC FRAME AND SIDE DASH BOARD HARNESS
A X55 To Cab/Canopy Wiring
b Y25 Arm Block Solenoid Valve
c GND Ground
d Y14 PPC Solenoid Valve
e Y15 Left Outrigger Down Solenoid Valve
f Y16 Right Outrigger Up Solenoid Valve
g Y22 Telescopic Extend
h Y21 Telescopic Retract
i Y20 Hammer Solenoid Valve
j S43 Hammer Foot Switch
1) Y18 Left Turn Solenoid Valve
1! Y17 Right Turn Solenoid Valve
1@ X57 Left Lever
1# HA3 Horn
1$ HA4 Horn
1% Y19 Not Used
1^ X58 Right Lever
1& Y23 Right Outrigger Down Solenoid Valve
1* Y24 Left Outrigger Up Solenoid Valve
1( X55 From Platform Harness
2) X1 Seat Swivel Switch
2! X3 Backhoe Lock Out Switch
2@ X2 Boom Lock Switch
2# X42c Power Right Outrigger Switch
2$ X42b Up Right Outrigger Switch
2% X42a Down Right Outrigger Switch
2^ X41c Power Left Outrigger Switch
2& X41b Up Left Outrigger Switch
2* X41a Down Left Outrigger Switch
2( X40 Power Economy Switch
3) X10 Telephone Exchange Relay
3! X11 Relay
3@ X9 15A Fuse
3# X4 Power from Key Switch
WB140-2N WB150-2N 90-73

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90-74 WB140-2N WB150-2N

OTHERS ELECTRICAL
12
WORK LIGHT HARNESS

A Ground
B Front Work Light
C Front Work Light
D Rear Work Light
E Rear Work Light
F Rear Relay
G Front Relay
H 25A Fuse
WB140-2N WB150-2N 90-75

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90-76 WB140-2N WB150-2N

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FUSE AND RELAY PANEL
LEGEND FOR FUSE AND RELAY PANEL
TIER I ENGINE TIER II ENGINE
Position Description Position Description
F1 A 15A Light Blue for Low Beam F1 A 15A Light Blue for Low Beam
F1 B 3A Violet for Parking Lights F1 B 3A Violet for Parking Lights
F1 C 3A Violet for Parking Lights F1 C 3A Violet for Parking Lights
F2 A 10A Red for Lighter F2 A 10A Red
F2 B 7.5A Brown for Dome Light Radio F2 B 15A Light Blue for Cab Features
F2 C 10A Red for Emergency Power Supply F2 C 10A Red for Emergency Power Supply
F3 A 7.5A Brown for Start Enable F3 A 7.5A Brown for Stop Lights Differential Lock
F3 B 7.5A Brown for Instruments Switch Lights F3 B 7.5A Brown for Instruments Lights RTD
F3 C 7.5A Brown for OPT Solenoid F3 C 7.5A Brown for Opt Solenoid Trans Disengage
F4 A 7.5A Brown for Diff Lock Solenoid Valve F4 A 7.5A Brown for 4WD Front Wiper
F4 B 10A Red for Direction Selector F4 B 10A Red for Direction Selector
F4 C 15A Light Blue for High Beam F4 C 15A Light Blue for High Beam
F5 A 15A Light Blue for Heater F5 A 10A Red for Heater Motor Power Econ Unit
F5 B 15A Light Blue for Rear Work Light F5 B 15A Light Blue for Rear Work Light
F5 C 15A Light Blue for Front Work Light F5 C 15A Light Blue for Front Work Light
F6 A 15A Light Blue for Wiper and Beacon F6 A 15A Light Blue for Rear Horn Rear Wiper
F6 B 7.5A Brown for Dimmer Switch Horn Relay F6 B 7.5A Brown for Dimmer Switch Horn Relay
F6 C 10A Red for Directional Indicators F6 C 10A Red for Directional Indicators
F7 A 7.5A Brown for Monitor F7 A 7.5A Brown
F7 B 10A Red for Horn F7 B 10A Red for Front Horn
F7 C 7.5A Brown for Alt Excitation Stop Solenoid F7 C 7.5A Brown for Engine Stop Solenoid
K1 Forward Gear Relay K1 Forward Gear Relay

K2 Reverse Gear Relay K2 Reverse Gear Relay Back Up Alarm
K3 Four Wheel Drive Relay K3 Four Wheel Drive Relay
K4 ··· K4 Start Relay
K5 Low Beam Relay K5 Low Beam Relay
K6 High Beam Relay K6 High Beam Relay
K7 Direction Selector Power Supply Relay K7 Direction Selector Power Supply Relay
K8 Horn Relay K8 Front Horn Relay
K9 Turn Indicator Relay K9 Turn Indicator Relay
K10 Flasher Relay K10 4th Gear Signaling Relay
K11 4th Gear Signaling Relay
WB140-2N WB150-2N 90-77

OTHERS ELECTRICAL
12
90-78 WB140-2N WB150-2N

WB 140

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WB 140

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CEBM012701

SERIAL NUMBERS WB140-2N A20637 and up

Copyright 2010 Komatsu

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

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

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

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00-9 10-5 10-33 10-61

00-10 10-6 10-34 10-62

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00-12 10-8 10-36 10-64

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WB140-2N WB150-2N WB140-2N WB150-2N 00-2-1 b

10-75 10-108 20-20 20-53

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10-77 10-110 20-22 20-55

10-78 10-111 20-23 20-56

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10-80 10-113 20-25 20-58

10-81 10-114 20-26 20-59

10-82 10-115 20-27 20-60

10-83 10-116 20-28 20-61

10-84 10-117 20-29 20-62

10-85 10-118 20-30 20-63

10-86 10-119 20-31 20-64

10-87 10-120 20-32 20-65

10-88 20-33 20-66

10-89 20-1 20-34 20-67

10-90 20-2 20-35 20-68

10-91 20-3 20-36 20-69

10-92 20-4 20-37 20-70

10-93 20-5 20-38 20-71

10-94 20-6 20-39 20-72

10-95 20-7 20-40 20-73

10-96 20-8 20-41 20-74

10-97 20-9 20-42 20-75

10-98 20-10 20-43 20-76

10-99 20-11 20-44 20-77