Shop Manual 146-5

CEBM016501
Shop
Manual
WB146-5
BACKHOE LOADER
SERIAL NUMBERS WB146-5 A23001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
August 2006 Copyright 2006 Komatsu

Printed in USA DataKom Publishing Division
WB146-5 00-1
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. . . . . . . . . . . . . . . . . . . . . . . Will be issued at a later time
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 WB146-5
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00 00
IMPORTANT SAFETY NOTICE

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 re-
quire the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions ac-
companying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first
consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00 lock all the control levers and hang warning signs on
them.
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully be- 3. When disassembling or assembling, support the ma-
fore operating the machine. chine with blocks, jacks or stands before starting work.
1. Before carrying out any greasing or repairs, read all the 4. Remove all mud and oil from the steps or other places
precautions given on the decals which are fixed to the used to get on and off the machine. Always use the
machine. handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is im-
2. When carrying out any operation, always wear safety possible to use the handrails, ladders or steps, use a
shoes and helmet. Do not wear loose work clothes, or stand to provide safe footing.
clothes with buttons missing.
PRECAUTIONS DURING WORK 00
● Always wear safety glasses when hitting parts with a

hammer. or when grinding parts with a grinder, etc. 1. When removing the oil filler cap, drain plug or hydrau-
lic pressure measuring plugs, loosen them slowly to pre-
3. If welding repairs are needed, always have a trained, ex-
vent the oil from spurting out. Before disconnecting or
perienced welder carry out the work. When carrying out
removing components of the oil, water or air circuits,
welding work, always wear welding gloves, apron,
first remove the pressure completely from the circuit.
glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more 2. The water and oil in the circuits are hot when the engine
workers, always agree on the operating procedure be- is stopped, so be careful not to get burned. Wait for the
fore starting. Always inform your fellow workers before oil and water to cool before carrying out any work on
starting any step of the operation. Before starting work, the oil or water circuits.
hang UNDER REPAIR signs on the controls in the oper-
3. Before starting work, remove the leads from the battery.
ator's compartment.
ALWAYS remove the lead from the negative (-) termi-
5. Keep all tools in good condition and learn the correct nal first.
way to use them. Decide a place in the repair workshop
4. When raising heavy components, use a hoist or crane.
to keep tools and removed parts. Always keep the tools
Check that the wire rope, chains and hooks are free from
and parts in their correct places. Always keep the work
damage. Always use lifting equipment which has ample
area clean and make sure that there is no dirt or oil on
capacity. Install the lifting equipment at the correct plac-
the floor. Smoke only in the areas provided for smoking.
es. Use a hoist or crane and operate slowly to prevent
Never smoke while working.
the component from hitting any other part. Do not work
PREPARATIONS FOR WORK with any part still raised by the hoist or crane.
00
5. When removing covers which are under internal pres-

1. Before adding oil or making repairs, park the machine
sure or under pressure from a spring, always leave two
on hard, level ground, and block the wheels or tracks to
bolts in position on opposite sides. Slowly release the
prevent the machine from moving.
pressure, then slowly loosen the bolts to remove.
2. Before starting work, lower blade, ripper, bucket or any
6. When removing components, be careful not to break or
other work equipment to the ground. If this is not possi-
damage the wiring, Damaged wiring may cause electri-
ble, insert the safety pin or use blocks to prevent the
cal fires.
work equipment from falling. In addition, be sure to
WB146-5 00-3
FOREWORD SAFETY
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
● When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is
being operated.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 in-
stalled.
10. 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.
11. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
12. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
13. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
14. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the ma-
chine.
00-4 WB146-5
FOREWORD GENERAL
12GENERAL
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.
WB146-5 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00 REVISED EDITION MARK 00
Shop manuals are issued as a guide to carrying out repairs. When a manual is revised, an edition mark ( …) is re-
They are divided as follows: corded on the bottom outside corner of the pages.
Chassis volume: Issued for every machine model REVISIONS 00
Engine volume: Issued for each engine series Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
Electrical volume: Each issued as one to cover all models
SYMBOLS 00
Attachment volume: Each issued as one to cover all models

So that the shop manual can be of ample practical use, im-
These various volumes are designed to avoid duplication of portant places for safety and quality are marked with the fol-
information. Therefore to deal with all repairs for any model, lowing symbols.
it is necessary that chassis, engine, electrical and attachment
be available.
Symbol Item Remarks
DISTRIBUTION AND UPDATING 00 Special safety precautions are
Safety necessary when performing the
Any additions, amendments or other changes will be sent to work.
your distributors. Get the most up-to-date information before
you start any work. Special technical precautions or
other precautions for preserving
★ Caution
FILING METHOD 00
standards are necessary when per-
forming the work.
1. See the page number on the bottom of the page. File the
pages in correct order. Weight of parts or systems. Cau-
tion necessary when selecting
Weight
2. Following examples show how to read the page number: hoisting wire or when working
posture is important, etc.
Example:
Places that require special atten-
10 - 3 Torque tion for tightening torque during
assembly.
Item number (10. Structure and Function) Places to be coated with adhesives
Coat
and lubricants etc.
Consecutive page number for each item
Places where oil, water or fuel
Oil, water
3. Additional pages: Additional pages are indicated by a must be added, and the capacity.
hyphen (-) and numbered after the page number. File as Places where oil or water must be
in the example. Drain drained, and quantity to be
drained.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
00
00
00
00
00
00
00-6 WB146-5
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
WARNING!Heavy parts (25kg 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 symbol.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the

relative parts.
2. Check for existence of another part causing interface

with the part to be removed. 3. Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
WIRE ROPES 00
load.
1. Use adequate ropes depending on the weight of parts to WARNING!Slinging with one rope may cause turn-
be hoisted, referring to the table below: ing of the load during hoisting, untwisting of the rope,
or slipping of the rope from its original winding posi-
Wire ropes, standard “Z” or “S” twist ropes without tion on the load, which can result in a dangerous acci-
galvanizing dent
Rope diameter Allowable load 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
mm kN tons two or more ropes, the force subjected to each rope will
10 9.8 1.0 increase with the hanging angles. The table below
shows the variation of allowable load (kg) when hoist-
11.2 13.7 1.4 ing is made with two ropes, each of which is allowed to
12.5 15.7 1.6 sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
14 21.6 2.2 total weight can be suspended. This weight becomes
16 27.5 2.8 1000 kg when two ropes make a 120° hanging angle. On
the other hand, two ropes are subject to an excessive
18 35.3 3.6 force as large as 4000 kg if they sling a 2000 kg load at a
20 43.1 4.4 lifting angle of 150°
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 00
can result. Hooks have maximum strength at the middle

portion.
WB146-5 00-7
FOREWORD QUICK DISCONNECT COUPLER
12
QUICK DISCONNECT 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 pressure from
hydraulic tank.
WARNING!Even if the residual pressure is released from the hy-

draulic tank, some hydraulic oil flows out when the hose is dis-
connected. Accordingly, prepare an oil receiving container.
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 hy-
draulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the 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 in-
dicate an abnormality.
00-8 WB146-5
12
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 WB146-5
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) con-
tacts surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body
(2) in straight until the slide prevention ring (1) contacts surface a
of the hexagonal portion at the male end to connect it.
00
00-10 WB146-5
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 cush-
LT-1A 790-129-9030 150 g Tube
ions and cork plugs from coming out
● Used in places requiring an immediately ef-
fective, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 ● Used for plastics (except polyethylene,
(2 pes.) container
polypropylene, tetrafluoroethylene, and vi-
nyl chloride), rubber, metal and non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant purposes
container
for bolts and plugs.
790-129-9060 Adh : 1 kg
(Set of adhe- Hardening ● Used as adhesive or sealant for metal, glass
LT-3 Can
sive and hard- agent: or plastic.
ening agent) 500 g
Adhesives
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.
3 Bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals, rubbers,
plastics and woods.
● Quick hardening type adhesive.
Aron-al- ● Quick cure type (max. strength after 30 min-
Polyethylene
pha 790-129-9130 50 g utes).
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 temper-
648-50 container
ature.
● 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 WB146-5
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
LG-5 790-129-9080 1 kg joints, flanges. for tapered plugs, elbows,
container
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.
3 Bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
Molybdenum
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
Grease SYG2-350CA
● Used for normal temperature, light load
G2-CA SYG2-400CA-A Various Various bearing at places in contact with water or
steam.
SYG2-160CA
SYG2-160CNCA
Molybdenum
disulphide
lubricant
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-12 WB146-5
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm N•m lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm N•m lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
00-13 WB146-5
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque

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

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

mm mm N•m lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-14 WB146-5
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 - N•m (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 - N•m (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.
Tightening torque - N•m (lbf ft) Taper seal Face seal

Nominal Width
Thread size Nominal thread Root diameter (mm)
hose size across flats Range Target
(mm) size - TPI (Reference)
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 WB146-5
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross section Applicable circuit
number (mm) rating (A)
strands strand (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 Charging Ground Starting Lighting Instrument Signal Other
Classification
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 WB146-5
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from .
B. Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .
C. Take the point where the two lines cross as . This point gives the value when converting from millimeters 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.
Millimeters to inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-17 WB146-5
12
Millimeters to Inches 1 mm = 0.03937 in

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

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 WB146-5
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

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

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WB146-5 00-19
12
N•m to lbf. ft. 1 N•m = 0.737 lbf. ft.

0 1 2 3 4 5 6 7 8 9
0 0 0.737 1.474 2.211 2.948 3.685 4.422 5.159 5.896 6.63
10 7.37 8.107 8.884 9.581 10.318 11.055 11.792 12.259 13.266 14.003
20 14.74 15.477 16.214 16.951 17.688 18.425 19.126 19.899 20.636 21.373
30 22.11 22.847 23.584 24.321 25.058 25.795 26.532 27.269 28.006 28.743
40 29.48 30.217 30.954 31.691 32.428 33.165 33.902 34.639 35.376 36.113
50 36.85 37.587 38.324 39.061 39.798 40.535 41.272 42.009 42.746 43.483
60 44.22 44.957 45.694 46.431 47.168 47.905 48.642 49.379 50.116 50.853
70 51.59 52.327 53.064 53.801 54.538 55.275 56.012 56.749 57.486 58.223
80 58.96 59.697 60.434 61.171 61.908 62.645 63.382 64.119 64.856 65.593
90 66.33 67.067 67.804 68.541 69.278 70.015 70.752 71.489 72.226 72.963
100 73.7 74.437 75.174 75.911 76.648 77.385 78.122 78.859 79.596 80.333
110 81.07 81.807 82.544 83.281 84.018 84.755 85.492 86.229 86.966 87.703
120 88.44 89.177 89.914 90.651 91.388 92.125 92.862 93.599 94.336 95.073
130 95.81 96.547 97.284 98.021 98.758 99.495 100.232 100.969 101.706 102.443
140 103.18 103.917 104.654 105.391 106.128 106.865 107.602 108.339 109.076 109.813
150 110.55 111.287 112.024 112.761 113.498 114.235 114.972 115.709 116.446 117.183
160 117.92 118.657 119.394 120.131 120.868 121.605 122.342 123.079 123.816 124.553
170 125.29 126.027 126.764 127.501 128.238 128.975 129.712 130.449 131.186 131.923
180 132.66 133.397 134.134 134.871 135.608 136.345 137.082 137.819 138.556 139.293
190 140.03 140.767 141.504 142.241 142.978 143.715 144.452 145.189 145.926 146.663
00-20 WB146-5
12
N•m to lbf. inf 1 N•m = 8.85 lbf. inf

0 1 2 3 4 5 6 7 8 9
0 0 8.85 17.7 26.55 35.4 44.25 53.1 61.95 70.8 79.65
10 88.5 97.35 106.2 115.05 123.9 132.75 141.6 150.45 159.3 168.15
20 177 185.85 194.7 203.55 212.4 221.25 230.1 238.95 247.8 256.65
30 265.5 274.35 283.2 292.05 300.9 309.75 318.6 327.45 336.3 345.15
40 354 362.85 371.7 380.55 389.4 398.25 407.1 415.95 424.8 433.65
50 442.5 451.35 460.2 469.05 477.9 486.75 495.6 504.45 513.3 522.15
60 531 539.85 548.7 557.55 566.4 575.25 584.1 592.95 601.8 610.65
70 619.5 628.35 637.2 646.05 654.9 663.75 672.6 681.45 690.3 699.15
80 708 716.85 725.7 734.55 743.4 752.25 761.1 769.95 778.8 787.65
90 796.5 805.35 814.2 823.05 831.9 840.75 849.6 858.45 867.3 876.15
100 885 893.85 902.7 911.55 920.4 929.25 938.1 946.95 955.8 964.65
110 973.5 982.35 991.2 1000.05 1008.9 1017.75 1026.6 1035.45 1044.3 1053.15
120 1062 1070.85 1079.7 1088.55 1097.4 1106.25 1115.1 1123.95 1132.8 1141.65
130 1150.5 1159.35 1168.2 1177.05 1185.9 1194.75 1203.6 1212.45 1221.3 1230.15
140 1239 1247.85 1256.7 1265.55 1274.4 1283.25 1292.1 1300.95 1309.8 1318.65
150 1327.5 1336.35 1345.2 1354.05 1362.9 1371.75 1380.6 1389.45 1398.3 1407.15
160 1416 1424.85 1433.7 1442.55 1451.4 1460.25 1469.1 1477.95 1486.8 1495.65
170 1504.5 1513.35 1522.2 1531.05 1539.9 1548.75 1557.6 1566.45 1575.3 1584.15
180 1593 1601.85 1610.7 1619.55 1628.4 1637.25 1646.1 1654.95 1663.8 1672.65
190 1681.5 1690.35 1699.2 1708.05 1716.9 1725.75 1734.6 1743.45 1752.3 1761.15
WB146-5 00-21
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 WB146-5
01 GENERAL
SPECIFICATIONS ................................................................................................................................................................ 01-2

WEIGHT TABLE .................................................................................................................................................................. 01-3
FUEL COOLANT AND LUBRICANTS .............................................................................................................................. 01-4
WB146-5 01-1
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
ITEM UNIT WB146-5 A23001 and UP
Minimum
Operating weight kg
Maximum
GP w/BOCE 0.95
Loader
MP w/BOCE 0.99
305 mm Edge 0.07

Bucket
457 mm Edge m³ 0.12
capacity
Backhoe 609 mm Edge 0.18
762 mm Edge 0.23
915 mm Edge 0.29
Model S4D102LE-2
Diesel engine Max power kW 69
Max torque N•m 407
Alternator V 12
Output A 95
Electrical system Ground --- NEG
Battery Ah @ V 100
Starter kW 3.2
Forward 1st 6.3
Forward 2nd 11.4
Forward 3rd 21.3
Forward 4th 37.8

Travel speeds km/h
Reverse 1st 6.3
Reverse 2nd 11.4
Reverse 3rd 21.3
Reverse 4th 37.8
Front 3.26 - 3.36

Front tire pressure kg/cm²
Rear 1.83 - 1.93
01-2 WB146-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This table is a guide for use when transporting or handling components.
Unit: kg
Component WB146-5 A23001 and UP
WB146-5 01-3
GENERAL FUEL COOLANT AND LUBRICANTS
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 - °C Capacity

Kind of
Reservoir
fluid
-30 -20 -10 0 10 20 30 40 50 Specified Refill
SAE 5W-30
SAE 10W
SAE 20W-20
Engine oil
SAE 30 11 L 13 L
pan
Oil API CI-4
SAE 40
SAE 10W-30
SAE 15W-40
SAE 5W*
SAE 10W
Hydraulic 150 L 92 L
SAE 30
system
SAE 10W-30+
HEES 150 L 92 L
Front axle
6.5 L 6.5 L
diff
Oil API CI-4
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
Diesel D975 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.
01-4 WB146-5
GENERAL FUEL COOLANT AND LUBRICANTS
12
Note 1:
For axle oil, use only the recommended oil as follows.
SHELL ..................................................................DONAX TD
CALTEX ...............................................................RPM TRACTOR HYDRAULIC FLUID
CHEVRON ...........................................................TRACTOR HYDRAULIC FLUID
TEXACO ..............................................................TEXTRAN TDH OIL
MOBIL..................................................................MOBILFLUID 422 or 424
API ................................ American Petroleum Institute

ASTM............................ American Society of Testing and Materials
NLGI ............................. National Lubricating Grease Institute
SAE ............................... Society of Automotive Engineers
Specified Capacity ........ Total amount of oil including oil for components and piping.
Refill Capacity .............. Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20°C. Consult your Komatsu distribu-
tor for your specific needs.
NOTE Use only diesel fuel. The engine mounted in this machine employs electronic control and a high pres-
sure fuel injection device to obtain good fuel consumption and good exhaust characteristics. For this
reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lu-
bricating ability is used, there will be a significant drop in durability.
WB146-5 01-5
GENERAL
12
MEMORANDA
01-6 WB146-5
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12
POWER TRAIN ...................................................................................................................................................... 10-3
DESCRIPTION..................................................................................................................................................... 10-3
POWER FLOW .................................................................................................................................................... 10-3
TRANSMISSION DIAGRAM................................................................................................................................ 10-5
TRANSMISSION .................................................................................................................................................... 10-7
COMPLETE ASSEMBLY ................................................................................................................................... 10-7
FORWARD REVERSE CLUTCH..................................................................................................................... 10-11
1ST THROUGH 4TH SPEED SHAFT .............................................................................................................. 10-11
4WD SHAFT ...................................................................................................................................................... 10-12
FRONT AXLE....................................................................................................................................................... 10-13
COMPLETE ASSEMBLY ................................................................................................................................. 10-13
REAR AXLE ......................................................................................................................................................... 10-16
COMPLETE ASSEMBLY ................................................................................................................................. 10-16
DIFFERENTIAL ................................................................................................................................................ 10-17
PLANETARY..................................................................................................................................................... 10-18
WORK BRAKES................................................................................................................................................ 10-19
DIFFERENTIAL LOCK .................................................................................................................................... 10-20
HYDRAULIC PUMP ............................................................................................................................................ 10-21
MAIN PUMP ...................................................................................................................................................... 10-22
DELIVERY CONTROL VALVE ...................................................................................................................... 10-26
MAIN CONTROL VALVE .................................................................................................................................. 10-32
CLSS ...................................................................................................................................................................... 10-39
DESCRIPTION................................................................................................................................................... 10-39
OPERATING PRINCIPLES .............................................................................................................................. 10-40
STEERING UNIT.................................................................................................................................................. 10-55
TECHNICAL DATA.......................................................................................................................................... 10-55
OPERATION ...................................................................................................................................................... 10-55
PPC VALVE.......................................................................................................................................................... 10-56
LOADER ............................................................................................................................................................ 10-56
OUTRIGGER ..................................................................................................................................................... 10-61
BACKHOE ......................................................................................................................................................... 10-65
SOLENOID VALVE ............................................................................................................................................. 10-67
HYDRAULIC CONTROLS W/O MP BUCKET .............................................................................................. 10-67
HYDRAULIC CONTROLS WITH MP BUCKET............................................................................................ 10-68
LOADER CYLINDERS........................................................................................................................................ 10-69
BOOM................................................................................................................................................................. 10-69
BUCKET............................................................................................................................................................. 10-70
MP BUCKET...................................................................................................................................................... 10-71
WB146-5 10-1
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TABLE OF CONTENTS
BACKHOE CYLINDERS..................................................................................................................................... 10-72
BOOM................................................................................................................................................................. 10-72
ARM ................................................................................................................................................................... 10-73
BUCKET............................................................................................................................................................. 10-74
TELESCOPIC ARM CYLINDER ..................................................................................................................... 10-75
SWING ............................................................................................................................................................... 10-76
OUTRIGGER ..................................................................................................................................................... 10-77
WORK EQUIPMENT ........................................................................................................................................... 10-78
LOADER ............................................................................................................................................................ 10-78
BACKHOE ......................................................................................................................................................... 10-80
AIR CONDITIONING .......................................................................................................................................... 10-83
10-2 WB146-5
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
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 uses hydraulic oil
to convert the torque transmitted by the engine into driving power. The converter transmits motion to the drive shaft of the
transmission d and to the drive shaft of the hydraulic pump e.
● The transmission d has two hydraulically activated clutches that can be selected by an electrically controlled gear selector.
The same switch also controls the four speed clutch packs.
● The driving power is transmitted from the transmission flanges to the front f and rear g axles through the drive shafts h
and i. The driving power transmitted to the front f and rear g axles is reduced by the differentials and then transmitted to
the planetary gear through the differential shafts.
POWER FLOW
Front Axle
Gear Transmission Differential Planet Total
1st 5.533 81.722
2nd 3.36 49.627
2.462 6
3rd 1.532 22.627
4th 0.81 11.963
Rear Axle
Gear Transmission Differential Planet Total
1st 5.533 97.338
2nd 3.36 59.136
2.75 6.4
3rd 1.532 26.963
4th 0.81 14.256
WB146-5 10-3
MAINTENANCE STANDARD POWER TRAIN
12
b Engine F Front Axle j Rear Tires

c Convert G Rear Axle 1) Front Tires
d Transmission H Front Drive Shaft
e Hydraulic Pump I Rear Drive Shaft
10-4 WB146-5
MAINTENANCE STANDARD TRANSMISSION DIAGRAM
12
TRANSMISSION DIAGRAM
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
WB146-5 10-5
MAINTENANCE STANDARD TRANSMISSION DIAGRAM
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
10-6 WB146-5
MAINTENANCE STANDARD TRANSMISSION
12
TRANSMISSION
COMPLETE ASSEMBLY
B Shift Lever F Suction Strainer J 4WD Solenoid

C Torque Converter G 4th Gear Sensor a From Oil Cooler
D Spin On Filter H Reverse Solenoid b To Oil Cooler
E Oil Temperature Sender I Forward Solenoid
WB146-5 10-7
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 1* Torque Converter
10-8 WB146-5
12
B Gear Shift Lever H 3rd & 4th Selecting Rod 1# Spin On Filter
C Centering Spring I 1st &2nd Selecting Fork 1$ Cold Oil Relief Valve
D Return Spring J 4th Selecting Sensor 1% Return Spring
E Check Ball 1) 3rd & 4th Selector 1^ Return Spring
F 3rd & 4th Selecting Fork 1! 1st & 2nd Selector 1& Return Spring
G 1st & 2nd Selecting Rod 1@ Suction Strainer
WB146-5 10-9
12
B Forward Reverse Solenoid H Valve 1# Spool

C 4WD Solenoid I Return Spring 1$ Forward Solenoid
D Piston J Valve 1% Reverse Solenoid
E Return Spring 1) Rod 1^ Check Ball
F Return Spring 1! Return Spring 1& Return Spring
G Spring Guide Pin 1@ Spool Return Spring
10-10 WB146-5
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
WB146-5 10-11
12
4WD SHAFT
B Front Output Shaft E Cylinder a 4WD Pressure Port

C 4WD Driven Gear F Spring
D Thrust Ring G Disc
10-12 WB146-5
MAINTENANCE STANDARD FRONT AXLE
12
FRONT AXLE
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 -0.039 50.19 0 --- --- Replace
WB146-5 10-13
12
DIFFERENTIAL
B Side Gear F Adjustment Lock Nut J Bearing Spacer 1# Bearing Lock Nut
C Ring Gear G Axle Shaft 1) Outboard Bearing 1$ Inboard Bearing
D Dowel Pin H Dowel Pin 1! Lip Seal Ring 1% Pinion Gear
E Driven Gear I Differential Housing 1@ Lip Seal Ring Cover 1^ Oil Drain Plug
Unit : mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1& Axle Clearance --- ---
1* Ring and Pinion Gear Backlash 0.18 to 0.28 0.28
Adjust
1( Pinion Preload - w/o lip seal 92 to 137 N•m
2) Ring and Pinion Gear Preload - w/o lip seal 129.5 to 194.5 N•m
10-14 WB146-5
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
I Adjustment Shim 1^ Belleville Washer
Unit:mm
2# Hub Rotation Torque ---

Adjust
2$ Axle Shaft Clearance ---
WB146-5 10-15
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
10-16 WB146-5
12
DIFFERENTIAL
B Tapered Roller Bearing F Differential Housing J Bearing Lock Nut 1# Pinion Gear
C Side Gear G Bearing Lock Nut 1) Lip Oil Seal 1$ Differential Housing
D Rotating Gear H Axle Shaft 1! Input Flange
E Ring Gear I Tapered Roller Bearing 1@ Bearing Spacer
Unit:mm
Criteria
Check Item Remedy
Standard Clearance Clearance Limit
1% Axle Clearance --- ---
1^ Ring And Pinion Gear Backlash 0.21 to 0.29 mm 0.29 mm
Adjust
1& Pinion Gear Preload - w/o seal ring 115 to 138 N•m
1* Pinion Ring Gear Preload - w/o seal ring 148 to 188 N•m
WB146-5 10-17
12
PLANETARY
B Stud Bolt F Axle Shaft J Tapered Roller Bearing

C Planet Gear G Pressure Plate 1) Oil Seal
D Wheel Hub H Retaining Ring 1! Wheel Flange
E Sun Gear I Ring Nut
Unit : mm
Check Item Criteria Remedy
1@ Hub Rotation Torque ---
Adjust
1# Axle Shaft Clearance ---
10-18 WB146-5
12
WORK BRAKES
B Bleed Screw E Middle Plate H Bushing

C Brake Piston F Outer Plate I Parking Brake Control Caliper
D Friction Disc G Belleville Washer J Set Screw
Unit : mm
Check Item Criteria Remedy
1) Hub Rotation Torque --- Adjust
WB146-5 10-19
12
DIFFERENTIAL LOCK
B Engagement Pin E Piston h Fork

C Sleeve F Bushing i Spacer
D Cover G Control Rod a Diff Lock Port
10-20 WB146-5
MAINTENANCE STANDARD HYDRAULIC PUMP
12
HYDRAULIC PUMP
COMPONENTS Ps From Hydraulic Tank Ps Oil Intake

b Hydraulic Pump P1L From Control Valve Pp P1L Pump Delivery Pressure Input
c Delivery Control Valve PLS From Control Valve LS P1C QD For Pump Delivery Pressure
d Oil Refil Plug PM From EV1 Solenoid Valve Pd2 Drain Plug
PORT CONNECTIONS PORT FUNCTIONS Pen Delivery Control Pressure Check
P1 To Loader Valve P1 Pump Delivery PLS LS Signal Input
Pd To Hydraulic Tank Pd Drain PM Operarting Mode Control Signal
WB146-5 10-21
12
MAIN PUMP
PORT FUNCTIONS Pe Delivery Control Signal Pd5 Drain

Pa Delivery Control Group Feed Pd4 Drain PM2 Operating Mode Signal
10-22 WB146-5
12
B Bearing G Piston 1! Control Piston

C Input Shaft H Cylinder Block 1@ Spring
D Pump Housing I Swash Plate 1# Seal Ring
E Swash Plate J Cover 1$ Ball
F Shoe 1) Shoe Guide
WB146-5 10-23
12
FUNCTION
The rotation and torque transmitted to the pump shaft is converted into
hydraulic energy and pressurized oil is delivered according to the load
requirements.
The amount of oil delivered can be modified by changing the angle of

the swash plate.
STRUCTURE
● Groove a supports and makes the cylinder block B an integral part of

the shaft c. The shaft is supported by front d and rear e bearings.
● The end of piston f is a concave ball, and the shoe g is staked to it to

form one unit. The piston and shoe form a spherical bearing.
● The swash plate h is supported by the pump body i and ball j,

and has a flat surface A. The shoe g remains in contact with the
swash plate and slides in a circular movement. Pressurised oil is
introduced between the shoe and swash plate forming a static
bearing that allows the shoes to slip.
● The pistons f perform their relative movements in an axial direction,

inside the cylindrical chambers fashioned in the cylinder block B.
● The rotation of the cylinder block B pressurises the oil inside the
chambers of the block; pressure is adjusted by the valve plate 1). The
surface of the swash plate is so designed that the oil pressure always
remains within acceptable limits. The oil in each chamber is drawn in
and discharged through holes in the valve plate.
OPERATION
Pump Operation
1. The cylinder block B rotates with the shaft c, and the shoe g
slides on the flat surface A. When this happens, the swash plate h
rotates on the ball j, and the angle a between the axis of the cylin-
der block and the axis X of the swash plate changes. The angle a is
known as the swash plate angle.
10-24 WB146-5
2. When the axis X of the swash plate h retains the angle a in relation
12
to the axis of the cylinder block B, flat surface A acts as a cam for
the shoe g. This is why the piston f slides inside the cylinder
block, creating a difference between volumes E and F and there-
fore causing the suction and delivery of oil in a quantity that is
equivalent to the difference between those volumes (F – E = deliv-
ery). When the cylinder block rotates, chamber F decreases in vol-
ume causing oil to be delivered to the circuits, while chamber E
increases in volume causing oil to be suctioned. The illustration
shows the state of the pump when suction at chamber F and deliv-
ery at chamber E are complete.
3. When the center line X of the swash plate h and the center line of
the cylinder block B are perfectly aligned, the swash plate angle a
= 0, the difference between the volumes E and F within the cylin-
der block becomes 0 and the pump does not take in or deliver any
oil. The angle of the swash plate a is proportional to pump deliv-
ery.
Control of Delivery
1. When angle a of the swash plate increases, the difference between

volumes E and F increases too, and this makes delivery Q increase
accordingly. Angle a of the swash plate is varied by the servo pis-
ton 1!.
2. The servo piston 1! moves in a reciprocating linear motion caused

by pressure signals from the PC and LS valves. The linear motion
is transmitted to the swash plate h. The swash plate is supported by
the pump body i through the ball j, and this is the reason why the
swash plate moves in a semicircular alternate motion.
WB146-5 10-25
12
DELIVERY CONTROL VALVE
PORT FUNCTIONS P1 Delivery Control Group Feed PE Delivery Control Signal Output
T Drain Pd4 Drain PM Operating Mode Signal Input
10-26 WB146-5
12
COMPONENTS i Gasket PORT FUNCTION

b Lever j Piston T Drain
c Spring 1) Spool PA Pump Delivery Pressure
d Retainer 1! Plug PM Operating Mode Signal Output
e Seal 1@ Seat PPL Delivery Control Signal Input
f Spool 1# Spring PE Delivery Control Signal
g Sleeve 1$ Nut PLS LS Signal Input
h Piston 1% Plug PPLS LS Pump Signal Input
WB146-5 10-27
LS VALVE FUNCTION
12
● The LS valve controls the pump delivery according to the stroke of

the control valve lever, the function of the delivery demands made by
the actuators.
● The LS valve detects the actuator’s delivery needs by means of the

differential pressure UPLS existing between pressure PPLS, con-
trol valve input pressure, and pressure PLS, control valve output
pressure. The sensing of this differential pressure permits control of
the main pump delivery Q. PPLS, PLS and UPLS are, respec-
tively, the pump pressure, the Load Sensing pressure, and the differ-
ence in pressure between these two values.
● The LS valve detects the pressure difference UPLS generated by

the passage of the oil flow through the surface freed by the control
valve spool, and controls the pump delivery Q so as to keep the pres-
sure drop constant. It can therefore be assumed that the pump deliv-
ery is proportional to the demands made known by the control valve.
● Pump pressure PPLS, pump pressure at control valve input, and

pressure PLS, Load Sensing pressure, are introduced into the LS
valve. The relation between differential pressure UPLS and pump
delivery varies as shown in the diagram on the right.
PC VALVE FUNCTION
● The PC, Power Control, valve performs an approximate power

check, and ensures that the hydraulic horsepower absorbed by the
pump does not exceed the horsepower delivered by the endothermal
engine.
● This is achieved by limiting the pump delivery Q function of the de-

livery pressure PPLS, even if the LS valve requests an increase in
delivery Q due to the larger section freed by the control valve spool,
in the presence of high pressure pump delivery.
● When during operation the delivery Q increases and the delivery

pressure PPLS also increases simultaneously, the PC valve reduces
the pump delivery Q. When the delivery pressure PPLS decreases,
the PC valve increases the pump flow.
● As pressure PC increases, the relation between pressure PA and de-

livery Q is switched in accordance with the force applied by pressure
PC.
● When the force applied by pressure PC is added to the force applied

by the pump's delivery pressure against the spool f, the relation be-
tween pump delivery pressure and delivery is switched from b to in
accordance with increment X.
10-28 WB146-5
12
PC VALVE OPERATION
Spring Operation
● PC valve spring loading d is defined by swash plate position.
● If control piston g moves to the right, spring d is compressed by the

lever c and the spring load increases.
When Pump Pressure PA is Low
● The force applied by the pressure against the spool e decreases, and
the spool f shifts slightly to the right. At the same time, a connection
opens between ports C and D, and pressurised oil from valve LS is
sent for discharge, PT.
● Simultaneously, ports F and G on valve LS are interconnected, and

pressure at port J is sent for relief, PT; the control piston c shifts to
the left. Pump delivery increases as a result.
● When the control piston c moves, the lever d moves to the left, and
the spring b expands, thereby reducing its load on the spool f. Con-
sequently, the spool moves to the left and stops the oil flow between
ports C and D, and a passage opens between ports B and C. The
pressure at port C increases, and the control piston stops.
WB146-5 110-29
12
When Pump Pressure PA Is High
● The force applied by the pressure against the spool e increases, and
the spool f shifts slightly to the left. At the same time, a connection
opens between ports C and B, and the pressure of the oil sent to
valve LS becomes equivalent to the pump's delivery pressure, PA.
● Simultaneously, ports F and G on valve LS are interconnected, and

pressure at port J becomes equivalent to the pump's delivery pres-
sure, PA, and the control piston c shifts to the right. Pump delivery
decreases as a result.
● When the control piston c moves, the lever d moves to the right,
and the spring b compresses, thereby increasing its load on the spool
f. Consequently, the spool moves to the right and stops the oil flow
between ports C and B, and a passage opens between ports D and C.
The pressure at port C decreases, and the control piston c stops.
10-30 1 WB146-5
12
When Equilibrium Has Been Reached
● The equilibrium between the force applied by pressure PA against

spool e and the force applied by spring b against spool f is what
determines the position at which the control piston c, pump stops.
WB146-5 110-31
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
10-32 1 WB146-5
12
A1 B8 PA6 Solenoid Valve EV1, A1 Port

B5
Arm Cylinder Rod Loader Boom Cylinder Rod

A2 Swing Cylinder Head B9 Right Outrigger Cylinder Rod PA7 Solenoid Valve EV2, A2 Port
A3 Loader Bucket Cylinder Head B10 Left Outrigger Cylinder Rod PA8 Loader PPC Valve, P3 Port
A4 Backhoe Boom Cylinder Head LS Hydraulic Pump, PLS Port PA9 Outrigger PPC Valve, P1 Port
A5 Backhoe Bucket Cylinder Rod P Hydraulic Pump, P1 Port PA10 Outrigger PPC Valve, P3 Port
A6 Mp Bucket Cylinder Head D Steering Unit, P Port PB1 Left Backhoe PPC Valve Port 1
A7 Jig Arm Cylinder Head DLS Steering Unit, LS Port PB2 Left Backhoe PPC Valve Port 2
A8 Loader Boom Cylinder Head PP Hydraulic Pump, P1L Port PB3 Loader PPC Valve, P1 Port
A9 Right Outrigger Cylinder Head T Drain PB4 Right Backhoe PPC Valve Port 1
A10 Left Outrigger Cylinder Head TS Drain PB5 Right Backhoe PPC Valve Port 2
B1 Arm Cylinder Head PPPC Solenoid Valve EV1, P Port PB6 Solenoid Valve EV1, B1 Port
B2 Swing Cylinder Rod PA1 Left Backhoe PPC Valve Port 3 PB7 Solenoid Valve EV2, B2 Port
B3 Loader Bucket Cylinder Rod PA2 Left Backhoe PPC Valve Port 4 PB8 Loader PPC Valve, P4 Port
B4 Backhoe Boom Cylinder Rod PA3 Loader PPC Valve, P2 Port PB9 Outrigger PPC Valve, P1 Port
B5 Backhoe Bucket Cylinder Head PA4 Right Backhoe PPC Valve Port 3 PB10 Outrigger PPC Valve, P4 Port
B7 Mp Bucket Cylinder Rod PA5 Right Backhoe PPC Valve Port 4
WB146-5 110-33
12
B ACV - Jig Arm Extend 1) ASCV - Loader Bucket Curl 1( Backhoe Boom Spool
C ACV - Backhoe Bucket Curl 1! ACV - Backhoe Boom Lower 2) Loader Bucket Spool
d ASCV - Backhoe Boom Raise 1@ ACV - Backhoe Bucket Dump 2! Backhoe Swing Spool
e ACV - Loader Bucket Dump 1# ACV - Jig Arm Retract 2@ Backhoe Arm Spool
f ASCV - Backhoe Left Swing 1$ ACV - MP Loader Bucket Dump 2# Priority Valve Spool
g ACV - Backhoe Arm Out 1% Loader Boom Arm Spool 2$ Unloading Valve
h Safety Valve 1^ Jig Arm Spool 2% LS By Pass Plug
i ACV - Backhoe Arm In 1& MP Bucket Spool
j ASCV - Backhoe Right Swing 1* Backhoe Bucket Spool
ACV - Anti-Cavitation Valve ASCV - Anti-Shock/Cavitation Valve
10-34 1 WB146-5
12
Unit : mm
Spring Criteria
Standard Size Repair Limit Remedy
Check Item Free Length Installed Length Installed Load Free Length Installed Load
2^ Backhoe Arm In Spool Spring 24.2 23.7 30.4 N -- 24.3N
2& Backhoe Arm Out Spool Spring 27.2 26.7 30.38 N -- 24.3 N
2* Prioroty Valve Spring 56.8 48.5 29.6 N -- 23.7 N
2( Unloading Valve Spring 25.5 18.0 121.5 N -- 97.2 N
3) Backhoe Swing Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3! Loader Bucket Spool Spring 42.3 40.5 54.9 N -- 43.9 N
3@ Backhoe Boom Spool Spring 41.1 40.5 34.3 N -- 27.4 N Replace
3# Backhoe Bucket Spool Spring 41.1 40.5 34.3 N -- 27.4 N
3$ MP Bucket Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3% Backhoe Jig Spool Spring 29.0 28.5 22.5 N -- 18.0 N
3^ Loader Boom Raise Spool Spring 27.1 26.7 14.7 N -- 11.8 N
3& Loader Boom Lower Spool Spring 38.7 27.6 355.7 N -- 284.5 N
3* Loader Boom Float Spool Spring 19.4 19.0 14.7 N -- 11.8 N
Unit : mm
Spring Criteria
2* PDV Tension Spring 15.4 8.0 7.44 N -- 5.96 N
2( PDV Tension Spring 31.4 21.8 63.7 N -- 51.0 N
3) PDV Tension Spring 18.9 15.0 15.7 N -- 12.5 N
3! PDV Tension Spring 37.1 24.0 34.3 N -- 27.4 N
Replace
3@ PDV Tension Spring 20.0 15.0 4.32 N -- 3.45 N
3# Check Valve Spring 27.2 21.0 4.7 N -- 3.76 N
3$ Check Valve Spring 27.2 22.0 3.92 N -- 3.14 N
3% Check Valve Spring 21.9 15.8 1.96 N -- 1.57 N
WB146-5 110-35
12
Pressure Reducing Valve Delivery Control Valve 1* Check Valve

B Loader Boom j Backhoe Arm 1( Check Valve
C Backhoe Jig Arm 1) Backhoe Swing 2) Check Valve
d MP Bucket 1! Loader Bucket 2! Check Valve
e Backhoe Bucket 1@ Backhoe Boom 2@ Check Valve
f Backhoe Boom 1# Backhoe Bucket 2# Check Valve
g Loader Bucket 1$ MP Bucket 2$ Check Valve
h Backhoe Swing 1% Backhoe Jig Arm 2% Check Valve
i Backhoe Arm 1^ Loader Boom 2^ LS By Pass Plug
1& Main Relief Valve 2& LS, DLS Pressure Check Valve
10-36 1 WB146-5
12
b Backhoe Right Outrigger Spool e Backhoe Swing Spool H Backhoe Boom Spool
c Backhoe Left Outrigger Spool f Loader Boom Spool
d Loader Bucket Spool g Backhoe Bucket Spool
Unit : mm
Spring Criteria
i Outrigger Spool Outer Spring 18.0 17.5 39.2 N -- 31.4 N
Replace
j Outrigger Spool Inner Spring 20.2 10.4 30.4 N -- 24.3 N
WB146-5 110-37
12
b PPC Maximum Pressure Valve e Blow Out Plug H Arm Spool

c Maximum Pressure Valve Spool f Unloading Valve
d Sequential Reducing Valve g LS By Pass Plug
Unit : mm
Spring Criteria
i Outrigger Spool Outer Spring 18.0 17.5 39.2 N -- 31.4 N Replace
10-38 1 WB146-5
MAINTENANCE STANDARD CLSS
12
CLSS
DESCRIPTION
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 ma-

noeuvres.
● 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.
WB146-5 110-39
12
OPERATING PRINCIPLES
PUMPING PLATE CONTROL ANGLE
● The angle of the swash plate and the pump delivery, is controlled in
such a way that the differential pressure UPLS between the delivery
pressure PP of the pump and the pressure PLS at the outlet of the con-
trol valve towards the actuator is maintained at a constant value. UPLS
= pump delivery pressure PP minus pressure PLS of delivery to the ac-
tuator.
● If the differential pressure UPLS becomes lower than the set pressure
of the LS valve, the angle of the swash plate increases, delivery in-
creasing.
● If the differential pressure UPLS increases, the angle of the swash plate
decreases.
10-40 1 WB146-5
12
PRESSURE COMPENSATION CONTROL
● The pressure compensation valves are installed downstream from the

control valve in order to balance the differential pressure between the
loads. When two or more movements, cylinders, are activated simulta-
neously, the pressure differences UP between the delivery at the con-
trol valve inlet and outlets of the control valve are compensated by
these valves. This will obtain the distribution of the pump flow in
proportion to the areas of passage S1 and S2 of each valve.
WB146-5 110-41
12
MAIN CONTROL VALVE
1. Unloading Valve Pressure ................................. LS + 28.02 kg/cm²
2. Main Pressure Relief Valve........................................222.14 kg/cm²
3. Safety Valve ...............................................................275.13 kg/cm²
4. Check Valve
5. Anti Shock/Cavitation Valve......................................219.08 kg/cm²
8. Pressure Compensation Valve
9. Priority Valve
10. PPC Reducing Vave
10-42 1 WB146-5
12
UNLOADING VALVE
Neutral Position
FUNCTION
● When the control valve is in NEUTRAL position, pump delivery Q,

resulting from the swash plate being at its min. angle, is sent into the
tank circuit. When this happens, the pump's delivery pressure PP is reg-
ulated at 28 kg/cm² by means of the spring c inside the valve. LS signal
with PLS pressure = 0 kg/cm² .
OPERATING
● Pump pressure PP acts on spool b on surface S1, and on surface

S2, whereas PLS pressure acts on surface S2. Since no LS signal
with PLS pressure is generated when the control valve is in NEU-
TRAL position, the only pressure acting on spool in this condition is
the pump's delivery pressure PP as regulated by spring compression
c.
● As the pump's delivery pressure PP increases and the resulting force

equals spring loading c, the spool b shifts to the right. The pump's de-
livery circuit PP is then connected to the tank circuit T by means of the
holes in spool. This ensures that the pump delivery pressure PP stays
regulated at 28 kg/cm².
PP .................................................................................Pump circuit
PLS ................................................................. Load Sensing circuit
T..................................................................................... Tank circuit
WB146-5 110-43
12
Control Valve Fine Control
FUNCTION
● When the actuators' delivery needs during fine control are within the
delivery values related to the minimum angle of the swash plate, the
pump's delivery pressure PP is regulated by pressure PLS at +28 kg/
cm². Since the unloading valve opens when the differential pressure
between the pump's delivery pressure PP and pressure PLS of the
LS equals spring load c, 28 kg/cm², the differential pressure UPLS be-
comes 28 kg/cm².
OPERATING
● When fine controls are performed at the control valve, a PLS pres-
sure is generated. This pressure acts on surface S3 on the right hand
side of the spool b. Since pressure PLS of LS is low, because the
control valve passage is small, the difference with the pump's deliv-
ery pressure PP is great.
● When the differential pressure between the pump's delivery pressure

PP and pressure PLS of the LS equals spring loading c 28 kg/cm²,
the spool b shifts to the right and, in turn, the pump circuit PP con-
nects to the tank circuit T.
● The pump's delivery pressure PP is regulated by the combination of

the pressure from the spring, 28 kg/cm², and the pressure PLS of the
LS, when the differential pressure UPLS reaches a value of 28 kg/
cm².
10-44 1 WB146-5
12
Control Valve Is In Use
FUNCTION
● When the request for oil flow from the actuators exceeds the mini-
mum delivery of the pump during use of the control valve, the con-
nection to the tank circuit is eliminated and the entire pump delivery
Q is sent to the actuators.
OPERATING
● When the control valve spool is caused to perform a longer travel,

this generates a pressure PLS of the LS, which acts on the right side
of the spool b. Since the control valve passage is wide, the difference
between the pressure PLS of the LS and the pump's delivery pres-
sure PP is small.
● For this reason, since the differential pressure between the pump's de-
livery pressure PP and the pressure PLS of the LS fails to reach the
spring loading pressure value of spring c 28 kg/cm², the spool b is
pushed to the left by the spring.
● The result is that the connection between the pump delivery circuit
PP and the tank circuit T is excluded and the entire pump delivery Q
is sent to the actuators.
WB146-5 110-45
12
LS PRESSURE
Function
● LS pressure is the actuator's pressure at control valve output. This

pressure actually reduces the pump's PP pressure ñ via the pressure
compensation group reducing valve D to the same A pressure of the
actuator circuit and then sends it into the PLS circuit of the LS. In
the outriggers control valve, the actuator's pressure A is introduced
directly into circuit PLS of the LS.
Operation w/o Outriggers

● When the spool B is operated, pump pressure PP starts flowing into
the circuit of actuator A from the delivery control valve C and from
the notch a via the duct b. At the same time, the pressure reducing
valve D moves to the right making the pump's pressure PP drop as it
flows through the bottleneck c, and causing the pressure to flow into
the circuit PLS of the LS and into the chamber of spring PLSS. At
this point, the PLS circuit of the LS is connected to the tank circuit
T by means of the by pass plug E.
● The pressure acting on the left side of the reducing valve D is pres-
sure PA of the actuator, and the pressure acting on the right hand side
is the reduced pressure PP of pump delivery. The reducing valve bal-
ances out when pressure PA of the actuators and pressure PLSS of
the spring chamber are balanced. This in turn allows the pressure PP,
now reduced by the bottleneck c, to be introduced into the PLS cir-
cuit of the LS at the same pressure A as the actuator's circuit.
10-46 1 WB146-5
Operation w/o Outriggers
● When the spool b is operated, pump pressure PP starts flowing into

the circuit of actuator A through the duct a.
● At the same time, pressurised oil is introduced into the PLS circuit of
the LS through holes b.
★ The outriggers circuit differs from the working equipment cir-

cuit in that the operating pressure of ctuator A is introduced
directly into the PLS circuit of the LS.
WB146-5 110-47
12
LS BY PASS PLUG
Description
● The LS by pass plug unloads residual pressure from the load sens-
ing's PLS circuit.
● This makes the increment rate of load sensing's PLS pressure

smoother. By eliminating oil, through the bottleneck, a loss of pres-
sure is generated in the flow that is controlled by the spool, and sta-
bility is increased as a result, thereby reducing the actual differential
pressure LS.
Operation
● Pressurised oil in the Load Sensing PLS circuit flows through filter
a, through orifice b and into the tank circuit T.
10-48 1 WB146-5
12
PRESSURE COMPENSATION VALVES
Function
● Pressure compensation occurs during simultaneous operation of sev-

eral movements, specifically when the pressure of an actuator be-
comes lower than the pressure of the actuator on the opposite side,
and pump delivery is on the verge of being increased. In this case, the
right actuator withstands a higher pressure than the left actuator.
Operation
● During operation together, when right actuator pressure increases,

delivery in circuit A of the left actuator tends to increase. The PLS
pressure of the LS for the right actuator acts on chamber PLS1 of
the spring and pushes the pressure reducing valve b and the delivery
control valve c to the left. The delivery control valve produces a bot-
tleneck between the pump's delivery PP circuit and the PPA circuit
upstream of the control valve spool. This bottleneck generates a pres-
sure loss between circuits PP and PPA.
● The delivery control valve c and the pressure reducing valve b are
balanced out at a point where the differential pressure between PA
and PLS, these two acting on both surfaces of the pressure reducing
valve, equals the loss of pressure between PP and PPA, these two
acting on both surfaces of the delivery control valve.
● The differential pressure between the upstream pressure PPA and

the downstream pressure of both spools in the control valves con-
cerned in the movement together are equalised, and pump delivery is
distributed proportionally to the sections a that are responsible for
opening the notches of each spool.
WB146-5 110-49
12
PRESSURE COMPENSATION VALVE
Function
● In order to equalize the characteristics of each actuator, the pressure

compensation valve will determine the compensation characteristics
by performing a micrometer adjustment of the surface ratio S1/S2.
This is the ratio of area S1, delivery control valve c end, to area S2,
pressure reducing valve b end.
S1 surface of delivery control valve c minus surface of piston d.
S2 surface of pressure reducing valve b minus surface of piston d.
Compensation Characteristics
● When the ratio is 1.00 : Pump pressure PP minus pressure PPA up-
stream of spool ≅ load sensing PLS pressure - actuator PA pressure
(= A). Delivery is distributed proportionally to the opening surfaces
of the spool.
● When the ratio is > 1.00: PP - PPA > PLS - PA (= A). Delivery
distribution is lower than the proportion of the opening surfaces of
the spool.
● When the ratio is < 1.00: PP - PPA < PLS - PA (= A). Delivery
distribution is higher than the proportion of the opening surfaces of
the spool.
10-50 1 WB146-5
12
PRIORITY VALVE
Function
● The purpose of the priority valve is to feed pressurised oil to the

steering unit and to the other actuators.
● Oil distribution is determined by the position of the spool b of the
priority valve, which is in turn determined by LS signal, pump deliv-
ery, steering circuit pressure, and hydraulic circuit pressure.
● The position of the spool b is determined in such a way as to ensure
that the oil delivered to the steering unit matches the delivery needs
at any time.
WB146-5 110-51
12
PPC REDUCING VALVE
Function
● This valve regulates the PPC feed pressure at 30 kg/cm². When ac-
tuator pressure is low, the sequential valve closes to permit an in-
crease in the pump's delivery pressure PP in order to supply pressure
to the servocontrols.
Neutral Condition
● The spool b of the unloading valve moves, and delivery pressure is

regulated at 30 kg/cm².
● The spool c and valve d reduce the pump's delivery pressure PP to 30

kg/cm². Pressure is then sent to the controls via port PC.
10-52 1 WB146-5
12
Control Valve Operated
● The spool b of the unloading valve moves to the left, and the pump's
delivery pressure exceeds the pressure of the actuator circuit f by an
amount equivalent to LS differential pressure.
● If the pump's delivery pressure PP exceeds 30 kg/cm², valves c and d

reduce pressure PP to 30 kg/cm². The reduced pressure is then sent to
the controls via port PC.
● When this occurs, the sequential reducing valve e stays open.
WB146-5 110-53
12
● When the pump's delivery pressure PP is lower than 30 kg/cm², the se-
quential reducing valve shifts to the right, thereby reducing the flow of
the PP pressure to the actuator circuit f.
● This generates a pressure gap between PP pressure and actuator

pressure. PP pressure is incremented in excess of 30 kg/cm² and is
then reduced to 30 kg/cm² by valves c and d to guarantee pressure
feed to the controls.
10-54 1 WB146-5
MAINTENANCE STANDARD STEERING UNIT
12
STEERING UNIT
a Port L - To Steering Cylinder c Port T - To Hydraulic Oil Tank e Port P - From Control Valve
b Port R - To Steering Cylinder d Port P - To control valve
TECHNICAL DATA
Steering unit type ......................................................... OSPC200LS
Normal flow ............................................................................... 20 .
OPERATION
● The steering unit consists of a control valve and a rotating oil dispens-
er, and is of the hydrostatic type. When the steering wheel is turned,
the control valve sends oil from the pump P2, by means of the rotat-
ing oil dispenser, to one side of the steering cylinder.
● The rotating dispenser ensures that the oil volume upplied to the cyl-
inder is proportionate to the angle of rotation of the steering wheel. In
the event of malfunction, the rotating oil dispenser will function au-
tomatically as a hand pump, thus guaranteeing auxiliary steering.
WB146-5 110-55
MAINTENANCE STANDARD PPC VALVE
12
PPC VALVE
LOADER
10-56 1 WB146-5
12 PORTS B Spool - Ports P1, P2 & P4 I Protective Boot

P1 To Control Valve - PB3 Port C Spool - Port P3 J Electro Detent - Ports P2 & P3
P2 To Control Valve - PA3 Port D Plunger - Ports P2 & P3 1) Lower Spring Retainer
P3 To Control Valve - PA8 Port E Plunger - Ports P1 & P4 1! Center Spring Retainer
P4 To Control Valve - PB8 Port F Adjusting Screw 1@ Upper Spring Retainer
P From EV1 Solenoid Valve G Actuator Disc 1# Mounting Plate
T To Hydraulic Tank H Handle Mount 1$ Valve Housing - Three Section
Unit : mm
Spring Criteria
1% Bottom Outer Spring - Ports P1 30.6 41.2 N
1^ Bottom Outer Spring - Ports P2 31.6 39.1 N
1& Bottom Outer Spring - Ports P3 31.9 38.5 N
1* Bottom Outer Spring - Ports P4 31.6 64.9 N
1( Bottom Inner Spring - Ports P1 23.6 5.3 N
2) Bottom Inner Spring - Ports P2 24.6 5.3 N Replace
2! Bottom Inner Spring - Ports P3 25.3 5.3 N
2@ Bottom Inner Spring - Ports P4 24.9 5.3 N
2# Center Spring - All Ports 21 12.3 N
2$ Top Spring - Ports P1 & P4 11.4 28.4 N
2% Top Spring - Ports P2 & P3 11 13.7 N
OPERATION
Neutral Position
BUCKET PORTION
● Control valve ports A and B and PPC valve ports P1 and P2 are
connected to discharge chamber D by means of the calibrated hole f
in spool b.
WB146-5 110-57
12
BOOM PORTION
● Control valve ports A and B and PPC valve ports P3 and P4 are
connected to discharge chamber D by means of the calibrated hole f
in spool b.
Fine Control, Neutral J Actuator
● When the disk f starts pushing down on piston e and piston 1), the
retainer j moves as a result. This movement will compress the
spring c which will in turn act on the spool b and push it down-
wards.
● As a result of this action, the calibrated hole f will be isolated from

the drain chamber D and at almost at the same time it will be put in
connection with the PP chamber, which is directly connected to the
loader control circuit.
● Pressure in the loader control circuit will flow through the calibrated
hole f and into the circuit thereby increasing the pressure in port P1/
B.
● When pressure P1 increases, spool b is pushed upwards, and cali-

brated hole f is connected back to discharge chamber D thereby com-
pressing the spring c.
● The floating of the spool b will continue until calibrated hole f is

halfway between discharge chamber D and pressure chamber PP,
until the pressure in duct P1, the pressure acting on the section of
stem b, offsets the force applied by the spring c.
● The spring c is compressed proportionally to the movement of the

disk f and pressure at P1 increases in proportion to the travel of the
disk. The equilibrium position is then kept until the position of piston
e is changed.:
1. As long as pressures at ports B and P1 are perfectly balanced;
2. Until pressure in section B/P1, the pressure acting on stem b, is

enough to counteract the force of the spring c.
● This ensures proportionality between control lever position, B/P1

circuit pressure, and main control valve stem displacement.
10-58 1 WB146-5
Fine Control, Actuator J Neutral

12
● When the disk f is released and moved to neutral position, the piston
e is pushed upwards by the spring d acting on the retainer j, and
spool b is thrusted upwards both by the force of spring c and by the
force that the pressure in section B/P1 applies against the stem. This
movement moves the calibrated hole f of spool into the discharge
chamber D, thereby allowing pressure in section B/P1 to be re-
leased.
● If pressure P1 drops too quickly, spool b is pushed downwards by

spring c and the calibrated hole f becomes cut off from the discharge
chamber D; at almost the same time, the calibrated hole f is put in
connection with pressure chamber PP and starts supplying pressure
to section P1 until the pressure corresponding to the control lever
position is balanced.
● When the spool of the control valve returns, oil flows back into
chamber D, through calibrated hole f, and into chamber B of the con-
trol valve spool opposite the operating one. Oil flows through duct
P2 and into chamber B to ensure it is filled properly.
Fine Control, Neutral J Full Stroke
● When the disk f pushes down on the piston e, and the retainer j
pushes down on the spool b, calibrated hole f is put in direct connec-
tion with chamber PP, which is in turn connected to a constantly
pressurised loader control circuit.
● Oil is then allowed to flow directly into section B/P1 thereby push-
ing the stem of the main control valve to the end of its travel. This
causes the main control valve to send the oil contained in chamber
AB towards input P2, through calibrated hole f and into relief
chamber D.
WB146-5 110-59
12
Control Lever To Float Position
● If piston e and piston 1) of the spool controlling the arm, port P4,
are pushed downwards by disk f, the mechanism inside the PPC
valve will start locking the spool halfway along its travel.
● If piston e² is pushed upwards and the solenoid in the PPC valve is

energized, the force generated by the solenoid will retain the piston in
place and the arm float condition will be retained, even if the lever is
released.
● At the same time, the control valve will also be activated and retained
in the arm float position.
Control Lever From Float Position
● The disk f can be moved back to neutral position by applying a force

that exceeds the force applied by the solenoid.
● The floating state can also be cancelled, and the lever can move back
to neutral position, denergizing the solenoid.
10-60 1 WB146-5
12
OUTRIGGER
PORTS P From EV1 Solenoid Valve E Boot

P1 To Control Valve - PA9 Port T To Hydraulic Tank F Mounting Plate
P2 To Control Valve - PB9 Port B Handle Knob G Left Outrigger
P3 To Control Valve - PA10 Port C Stop H Right Outrigger
P4 To Control Valve - PB10 Port D Handle
WB146-5 110-61
12
OPERATION
Neutral Position
● Ports A and B of the main control valve and ports P1 and P2 of the
outrigger valve are connected to the tank circuit, the spool is in neu-
tral position.
10-62 1 WB146-5
Fine Control, Neutral J Actuator

12
● When the lever b is moved in the direction shown by the arrow, the
valves c are rotated and a passage is opened between delivery duct a
and port P1, while port P2 remains conected to the tank circuit.
● Pressure at port P1 increases as the travel of lever b increases. Con-

sequently, the spool of the control valve moves to the left by a dis-
tance that is proportional to the travel of the lever.
WB146-5 110-63
Full Lever, Actuator J Neutral

12
● When lever b is moved fully to the left, the valves c are fully rotat-
ed.
● Port P1 is then connected directly to delivery duct a whereas port

P2 is connected to tank circuit only, and the spool of the control
valve performs its full travel.
10-64 1 WB146-5
12
BACKHOE
LEFT VALVE
PORTS 4 To Swing Left Valve, PA2 Port 1 To Swing Right Valve, PB2 Port
1 To Arm Out Valve, PB1 Port 3 To Arm In Valve, PA1 Port
T To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port
WB146-5 110-65
12
RIGHT VALVE
PORTS 4 To Bucket Dump Valve, PA5 Port 1 To Bucket Curl Valve, PB5 Port
1 To Boom Raise Valve, PB4 Port 3 To Boom Lower Valve, PA4 Port
T To Hydraulic Tank P To EV1 Solenoid Valve, VBH Port
10-66 1 WB146-5
MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
HYDRAULIC CONTROLS W/O MP BUCKET
PORTS VBH To Bakchoe PPC Valves, Port P C Boom Lock Solenoid, Y95
ACC Accumulator VL To Loader PPC Valves, Port P D Backhoe PPC Solenoid, Y90
P1 Pressure Tap PM To Hydraulic Pump, Port PM E Loader PPC Solenoid, Y93
P2 To Outrigger PPC Valve, Port P P From Control Valve, Port PPPC F Ecopower Solenoid, Y91
A2 To Boom Lock Cylinder T To Hydraulic Tank
B2 To Rear Axle B Differential Lock Solenoid, Y94
WB146-5 110-67
MAINTENANCE STANDARD SOLENOID VALVE
12
HYDRAULIC CONTROLS WITH MP BUCKET
PORTS VL To Loader PPC Valves, Port P C Boom Lock Solenoid, Y95

ACC Accumulator A1 To Control Valve, Port PA6 D Backhoe PPC Solenoid, Y90
P1 Pressure Tap B1 To Control Valve, Port PB6 E Loader PPC Solenoid, Y93
P2 To Outrigger PPC Valve, Port P PM To Hydraulic Pump, Port PM f Bucket Open Solenoid, Y98
A2 To Boom Lock Cylinder P From Control Valve, Port PPPC g Bucket Close Solenoid, Y99
B2 To Rear Axle T To Hydraulic Tank h Ecopower Solenoid, Y91
VBH To Bakchoe PPC Valves, Port P B Differential Lock Solenoid, Y94
10-68 1 WB146-5
MAINTENANCE STANDARD LOADER CYLINDERS
12
LOADER CYLINDERS
BOOM
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 i Piston Stop
Unit : mm
Criteria
Size OD ID Clearance Limit
j Piston Rod to Head 36
1) Bushing in Piston Rod 67 67.25 67.2 0.05 Replace
1! Bushing in Barrel 67 67.25 67.2 0.05
CHARACTERISTICS
Unit : mm
Piston Rod Diameter ............................................................................ 50
Max Cylinder Length ....................................................................... 1740
Min Cylinder Length ........................................................................ 1170
Cylinder Barrel Bore ............................................................................ 90
Piston Stroke....................................................................................... 570
Rod Thread for Piston Nut ................................................................M36
WB146-5 110-69
12
BUCKET

C Cylinder Barrel F Cylinder Piston
Unit : mm
Criteria
i Piston Rod to Head 33
52.20 0.05
j Bushing in Piston Rod 52 52.25 52.30 -0.05 Replace
57.20 0.05
1) Bushing in Barrel 57 57.25 57.30 -0.05
CHARACTERISTICS
Unit : mm
Piston Stroke....................................................................................... 745
10-70 1 WB146-5
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 Retaining Nut
Unit : mm
Criteria
h Piston Rod to Head 40 Replace

51.88 52.39 0.51
i Bushing in Piston Rod 50 52.12 52.39 0.27
CHARACTERISTICS
Unit : mm
Max Cylinder Length ......................................................................... 705
Min Cylinder Length .......................................................................... 475
Piston Stroke....................................................................................... 230
WB146-5 110-71
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
1@ Piston Rod to Head 43
1# Bushing in Piston Rod 75 Replace
1$ Bushing in Barrel 75
Unit : mm
Spring Criteria
Check Item Standard Size Repair Limit Remedy
Free Length Installed Length Installed Load Free Length Installed Load
1% Check Valve Spring 35 Replace
CHARACTERISTICS
Unit : mm
Cylinder Barrel Bore .......................................................................... 120
Piston Stroke....................................................................................... 850
10-72 1 WB146-5
12
ARM

C Cylinder Barrel F Cylinder Piston i Piston Spacer
Unit : mm
Criteria
j Bushing in Piston Rod 60
1) Bushing in Barrel 60 Replace
1! Piston Rod 60
CHARACTERISTICS
Unit : mm
Piston Stroke....................................................................................... 700
WB146-5 110-73
12
BUCKET

Unit : mm
Criteria
j Bushing in Piston Rod 55 Replace
1) Bushing in Barrel 55
CHARACTERISTICS
Unit : mm
Piston Stroke....................................................................................... 765
10-74 1 WB146-5
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
47.21 0.01
j Bushing in Piston Rod 47 47.2 47.3 0.1 Replace
47.21 0.01
1) Bushing in Barrel 47 47.15 47.3 0.1
CHARACTERISTICS
Unit : mm
Piston Stroke..................................................................................... 1140
Piston Rod Thread.............................................................................M30
WB146-5 110-75
12
SWING
A Piston Rod Bushing D Cushion Valve G Retaining Screw

B Cylinder Rod E Piston Seal H Cylinder Head
Unit : mm
Criteria
j Piston Rod Bushing 68
Replace
1) Inner Pivot Bushing 50
1! Outer Pivot Bushing 60
CHARACTERISTICS
Unit : mm
Max Cylinder Length ...................................................................... 514.5
Min Cylinder Length ............................................................................. --
Piston Stroke....................................................................................... 230
10-76 1 WB146-5
12
OUTRIGGER
A Piston Rod Bushing E Piston Seal i Piston Retaining Nut

B Barrel Bushing F Cylinder Piston j Detent Ball
C Cylinder Barrel G Cylinder Rod
D Retarder Pin H Cylinder Head
Unit : mm
Criteria
1) Piston Rod to Head 50
1! Bushing in Piston Rod 55 Replace
1@ Bushing in Barrel 55
CHARACTERISTICS
Unit : mm
Min Cylinder Length .......................................................................... 850
Piston Stroke....................................................................................... 515
WB146-5 110-77
MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT
LOADER
10-78 1 WB146-5
12
Unit : mm
Criteria
52.10 52.20 -0.20
b Bushing in Boom 52 to 52.40 to 52.30 to 0.20
44.911 45.08 0.13
c Pin to Bushing 45 to 44.95 to 45.24 to 0.329
52.10 52.20 -0.20
d Bushing in Lever 52 to 52.40 to 52.30 to 0.20
44.911 45.08 0.13
e Pin to Bushing 45 to 44.95 to 45.24 to 0.329
54.85 55.00 -0.15
f Bushing in Lever 55 to 55.15 to 55.046 to 0.196
44.911 45.08 0.13
g Pin to Bushing 45 to 44.95 to 45.24 to 0.329
75.046 75.00 -0.076
h Bushing in Lever and Cylinder 75 to 75.076 to 75.046 to 0.0
Replace
59.894 60.137 0.197
i Pin to Bushing 60 to 59.94 to 60.197 to 0.303
57.2 57.25 -0.05
J Bushing in Cylinder 57 to 57.3 to 57.25 to 0.05
49.911 50.08 0.13
1) Pin to Bushing 50 to 49.95 to 50.24 to 0.329
57.2 57.25 -0.05
1! Bushing in Boom 57 to 57.3 to 57.25 to 0.05
49.911 50.08 0.13
1@ Pin to Bushing 50 to 49.95 to 50.24 to 0.329
67.10 67.2 -0.20
1# Bushing in Cylinder 67 to 67.40 to 67.2 to 0.10
59.894 60.13 0.19
1$ Pin to Bushing 60 to 59.94 to 60.29 to 0.396
WB146-5 110-79
12
BACKHOE
10-80 1 WB146-5
12
Unit : mm
Criteria
80.059 80.00 -0.005
b Top Bushing in Main Frame 80 to 80.089 to 80.054 to -0.089 Replace
64.894 65.19 0.25
c Pin to Bushing 65 to 64.94 to 65.264 to 0.37
50.034 50.0 -0.009
d Inner Bushing on Cylinder Stud 50 to 50.05 to 50.025 to -0.05
75.043 75.0 -0.013
e Outer Bushing in Bracket 75 to 75.062 to 75.03 to -0.062
59.894 60.06 0.12
f Inner Bushing in Outer Bushing 60 to 59.94 to 60.09 to 0.196
g Outer Bushing in Frame to to to
54.894 55.137 0.257
h Pin to Bushing 55 to 54.94 to 55.197 to 0.303
80.059 80.0 -0.029
i Bottom Bushing in Swing Frame 80 to 80.089 to 80.03 to -0.089
64.894 65.19 0.25
j Pin to Bushing 65 to 64.94 to 65.264 to 0.37
44.911 45.08 0.13
1) Pin to Rod Bushing 45 to 44.95 to 45.24 to 0.329
44.911 45.08 0.13
1! Pin to Head Bushing 45 to 44.95 to 45.24 to 0.329
54.985 55.0 -0.015
1@ Bushing in Stabilizer 55 to 55.015 to 55.03 to 0.045
44.911 45.08 0.13
1# Pin to Bushing 45 to 44.95 to 45.24 to 0.329
75.137 75.0 -0.107
1$ Bushing in Boom 75 to 75.197 to 75.03 to -0.197
59.894 60.137 0.197
1% Pin to Bushing 60 to 59.94 to 60.197 to 0.303
59.95 60.0 -0.08
1^ Bushing in Boom 60 to 60.15 to 60.03 to -0.15
49.911 50.08 0.13
1& Pin to Bushing 50 to 49.95 to 50.024 to 0.329
52.10 52.0 -0.07
1* Bushing in Bucket Lever 52 to 52.40 to 52.03 to -0.40
44.911 45.08 0.13
1( Pin to Bushing 45 to 44.95 to 45.24 to 0.329
44.911 45.08 0.13
2) Pin to Cylinder Bushing 45 to 44.95 to 45.24 to 0.329
52.2 52.10 -0.13
2! Lever Bushing in Arm 52 to 52.23 to 52.40 to -0.20
44.911 45.08 0.13
2@ Pin to Bushing 45 to 44.95 to 45.24 to 0.329
52.10 52.0 -0.07
2# Bushing in Bucket Lever 52 to 52.40 to 52.03 to -0.40
44.911 45.08 0.13
2$ Pin to Bushing 45 to 44.95 to 45.24 to 0.329
56.45 57.20 -0.85
2% Bucket Bushing in Arm 57 to 58.05 to 57.23 to 0.78
49.911 50.08 0.13
2^ Pin to Bushing 50 to 49.95 to 50.24 to 0.329
59.894 60.10 0.16
2& Pin to Boom Rod Bushing 60 to 59.94 to 60.174 to 0.28
59.894 60.10 0.16
2* Pin to Boom & Arm Head Bushing 60 to 59.94 to 60.174 to 0.28
49.911 50.08 0.13
2( Pin to Arm Rod Bushing 50 to 49.95 to 50.142 to 0.231
44.911 45.08 0.13
3) Pin to Bucket Head Bushing 45 to 44.95 to 45.142 to 0.231
39.911 40.05 0.10
3! Pin to Jig Head Bushing 40 to 39.95 to 40.10 to 0.189
39.911 40.05 0.10
3@ Pin to Jig Rod Bushing 40 to 39.95 to 40.10 to 0.189
WB146-5 110-81
12
10-82 1 WB146-5
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
10-83 1 WB146-5
MAINTENANCE STANDARD AIR CONDITIONING
12
The compressor b is driven directly by the engine shaft by means of a
belt, and made to rotate by a pulley fitted with an electromagnetically
engaged clutch a. 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.
WB146-5 110-84
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLE ................................................................................................. 20-3

ENGINE............................................................................................................................... 20-3
CHASSIS ............................................................................................................................. 20-4
SPECIAL TOOLS ................................................................................................................... 20-11
ENGINE SPEED ..................................................................................................................... 20-12
ENGINE WITHOUT LOAD............................................................................................. 20-12
VALVE CLEARANCE ........................................................................................................... 20-14
AC COMPRESSOR BELT TENSION ................................................................................... 20-15
BLEED AIR FROM CIRCUITS ............................................................................................. 20-16
BLEED AIR FROM CYLINDERS ................................................................................... 20-16
BLEED AIR FROM BRAKING CIRCUIT ...................................................................... 20-16
RELEASING RESIDUAL PRESSURE............................................................................ 20-16
ACCELERATOR PEDAL AND LEVER ............................................................................... 20-17
ACCELERATOR PEDAL TRAVEL................................................................................ 20-17
ACCELERATOR LEVER TRAVEL................................................................................ 20-18
BRAKE SYSTEM ................................................................................................................... 20-19
CONTROL......................................................................................................................... 20-19
ADJUSTMENT ................................................................................................................. 20-19
CHECKS............................................................................................................................ 20-20
PARKING BRAKE ADJUSTMENT ...................................................................................... 20-23
HYDRAULIC CIRCUIT ......................................................................................................... 20-24
INTRODUCTION ............................................................................................................. 20-24
RELIEF VALVES ................................................................................................................... 20-26
TESTING........................................................................................................................... 20-26
SETTING RELIEF VALVES ................................................................................................. 20-29
MAIN RELIEF VALVE.................................................................................................... 20-29
CIRCUIT RELIEF VALVES ............................................................................................ 20-29
LS DIFFERENTIAL PRESSURE........................................................................................... 20-31
CONTROL......................................................................................................................... 20-31
ADJUSTMENT ................................................................................................................. 20-31
PPC SUPPLY PRESSURE...................................................................................................... 20-32
CHECK .............................................................................................................................. 20-32
ADJUSTMENT ................................................................................................................. 20-32
PC VALVE .............................................................................................................................. 20-33
ADJUSTMENT ................................................................................................................. 20-33
STEERING CONTROL SYSTEM ......................................................................................... 20-34
CONTROL......................................................................................................................... 20-34
SETTING........................................................................................................................... 20-34
STEERING CYLINDER ......................................................................................................... 20-35
POWER TRAIN GROUP........................................................................................................ 20-36
WB146-5 20-1
TESTING AND ADJUSTING TABLE OF CONTENTS
CONVERTER OIL PRESSURE ....................................................................................... 20-36

CLUTCH ENGAGEMENT PRESSURE .......................................................................... 20-36
SUPPLY PRESSURE........................................................................................................ 20-37
TRANSMISSION CLUTCH FUNCTION.............................................................................. 20-38
MACHINE PREPARATION ............................................................................................ 20-38
CONTROL......................................................................................................................... 20-38
HYDRAULIC DRIFT ............................................................................................................. 20-39
LOADER ........................................................................................................................... 20-39
BACKHOE ........................................................................................................................ 20-40
AIR CONDITIONING ............................................................................................................ 20-44
WORK TEMPERATURE ................................................................................................. 20-44
UNIT CHECK ................................................................................................................... 20-45
EMPTYING THE AC UNIT ............................................................................................. 20-46
TROUBLESHOOTING GUIDE ............................................................................................. 20-47
FRONT AXLE................................................................................................................... 20-47
REAR AXLE ..................................................................................................................... 20-52
TRANSMISSION .............................................................................................................. 20-57
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.
20-2 WB146-5
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
STANDARD VALUE TABLE
ENGINE
Machine Model WB146-5
Engine Model S4D102LE-2
Item Measurement Conditions Unit Standard Value Service Limit Value

• High idle 2457 2407 - 2507
Engine speeds • Low idle RPM 1050 1000 - 1100
• Rated speed --- ---
New
• At torque converter stall and 381
Intake air restric- element
full throttle mm H2O
tion Used
• At restriction indicator port 635
element
Lubricating oil
pressure with SAE • Minimum at low idle 0.7
15W-40 oil and kg/cm²
coolant tempera-
ture in operating • Minimum at high idle 2.1
range
New
101
Fuel filter inlet re- • Maximum restriction at high element
mm Hg
striction idle
Used
203
element
• Coolant temperature in operat-
ing range
Blow by pressure • Service Tool orifice size 5.613 mm H2O Max 101.6 Max 431.8
mm
• Full load at rated speed
Exhaust back pres- • Maximum at converter stall

mm Hg 76
sure and full throttle
Coolant tempera- • Maximum coolant operating

°C 105
ture temperature
Valve clearances • Intake valves 0.254

mm
with engine cold • Exhaust valves 0.504
• Deflection when pressed with
Fan Belt Tension finger force of approx. 10 kg
mm 10 10 - 15
WB146-5 20-3
12
CHASSIS
Applicable Model WB146-5
Permissible
Cat. Item Measurement Condition Unit Standard Value
Value
• Engine coolant temperature: Within Max. 2457 2407 - 2507

operation range
Accelerator pedal • Engine oil temperature: Within operation
range
Engine speed
• Measurement taken on drive shaft pulley Min. 1050 ±50 1000 - 1100
with tachometer.
rpm
• Engine coolant temperature: Within
operation range Max. 2200 2150 - 2250
• Engine oil temperature: Within operation
Accelerator fuel range
• Measurement taken on drive shaft pulley
with tachometer. Min. 1050 ±50 1000 - 1100
l a b c l a b c
Control valve
Bucket arm command only

mm - 6 5.5 2 - - - -
Raise 95 80 - 110
Bucket arm control lever Neutral J
Lower 95 80 - 110
Dump 95 80 - 110
Bucket control laver Neutral J
Curl 95 80 - 110
Raise 50 40 - 60
Boon backhoe control Neutral J
Travel of levers and pedals
• Engine stopped Lower 50 40 - 60

• Knob lever: at center and at
90° from the lever. Open 50 40 - 60
Arm backhoe control lever Neutral J
• Value reading at end of work-
Close mm 50 40 - 60
ing stroke plus half measured
backlash Open 50 40 - 60
Bucket backhoe control lever • Attachments on ground Neutral J
• Instrument metric divisions Close 50 40 - 60
Right 50 40 - 60
Boom swing control lever Neutral J
Left 50 40 - 60
Up 35 25 - 45
Outrigger control lever Neutral J
Down 35 25 - 45
Fuel control lever Min J.Max 40 30 - 50
20-4 WB146-5
12
Applicable model WB146-5
Permissible
Cat. Item Measurement condition Unit Standard value
value
• Engine stopped
Levers and pedals
Accelerator pedal • Knob lever: at center and at 90o from Min J Max mm 80 65 - 95
travel
lever.
• Value reading at end of work stroke Right J Left 3.5 3.1 - 3.9
Wheel swing plus half measured backlash rev
• Attachments on ground Left J Right 3.5 3.1 - 3.9
Bucket arm lever 1.5 1.0 - 2.0

Force for lever, pedal and steering wheel operation
Bucket lever • Engine speed: min. 1.5 1.0 - 2.0

• Oil temperature within operating
Boom lever range 1.8 1.3 - 2.3
• Tool connection at center of
Arm lever 1.8 1.3 - 2.3
knob 80 mm away from handle
Bucket lever base.
kg 1.3 0.8 - 1.8
• Value reading at the 10 mm
Boom swing lever before end of work stroke. 1.3 0.8 - 1.8
• Instrument force gauge
Outrigger lever 1.5 1.0 - 2.0
• Ambient temperature 15 - 35oC
Fuel lever 6.0 5.0 - 7.0
Accelerator pedal 4.0 2.5 - 5.5
Steering wheel • Force measured on steering wheel knob at min. RPM −−− −−− −−−
for approx. half a rev under steady motion at a speed of
2.5 per rev.
• Engine speed: 2200 rpm

Main valve pressure
• Oil temperature within operating range

• Move arm cylinder to end of stroke and measure pres-
Control valve sure 249 238 - 264
• Instrument: 0 to 100 kg/cm² pressure gauge mounted kg/cm²
on adapter at port P1C
• Working mode switch: POWER
Steering unit • Engine speed: 1500 ±50 rpm 178 173 - 188
WB146-5 20-5
12
Permissible
value
Bucket curled 274 264 - 284
Bucket dump 244 234 - 259
Bucket open close 274 264 - 284

Pressures of secondary valves circuits
Boom raise 351 323 - 365
Boom lower • Engine speed: 2200 rpm 274 264 - 284
Arm close) • Oil temperature within operating range 274 264 - 284
• Move arm cylinder to end of stroke and measure pres-
Arm out sure kg/cm² 274 264 - 284
• Instrument: 0 to 100 kg/cm² pressure gauge mounted on
Boom swing adapter at port P1C 234 223 - 249
Bucket curl • Working mode switch: POWER 274 264 - 284
Bucket dump −−− −−−
Extenda arm out - in −−− −−−
Hammer delivery 193 183 - 213
Steering unit safety 228 228 - 249
• Engine speed, w/o load: 2400 ±50 rpm

With converter • Machine in 3rd gear 2175 ±50 2125 - 2225
• Work brakes: engaged
• Work mode switch: POWER
Engine speed with load - Converter

• Machine in 3rd gear
With converter and
• Work brakes: engaged 2075 ±50 2025 - 2125
hydraulic circuit rpm
• Bucket raised bottom of stroke
• Steering held at end of stroke

Hydraulic circuit at • Machine in Neutral
600 Min. 600
Low idle • Parking brake: applied
• Bucket dump bottom of stroke
20-6 WB146-5

Permissible
value
• In this position check in feedback of each cylinder and
leakage with applied load on tip of bucket teeth.
Work equipment • On level ground. 150 300
• GP Bucket: load 1800 kg MP Bucket: load 1550 kg
• Engine stopped
• Oil temperature: 45 - 55 °C
• Check measures as soon as engine stops.
Loader
• Check changes every 5 min and total change in 15 min.

Boom cylinder 12 20
Hydraulic drift working equipment
Bucket cylinder 35 50
mm
Working equip-
• In this position check extension of each cylinder and 200 350
ment
leakage with normal load on bucket.
• On level ground.
• Bucket: load with standard arm: 340 kg
• Bucket load with tele arm: 0 kg Fully extend arm
Boom cylinders 10 20
• Engine stopped
Backhoe
• Check measures as soon as engine stops.

• Check changes every 5 min and total change in 15 min.
Arm cylinder 10 20
Bucket cylinder 8 15
WB146-5 20-7
.

Cat. Item Measurement condition Unit Standard value Permissible value
• Backhoe balanced on guides bucket in
• Transport condition.
• Fully retract arm and bucket cylinder Lift
bucket fulcrum pin 1 m off ground and swing
boom to bottom of stroke in either direction.
• Move machine on a slope of 15° and apply
parking brake.
Boom swing • Stop engine and, after 1 minute, check inner 15 15
cylinder feed back opposite to boom every 5
min for a total of 15 minutes.
Hydraulic drift work equipment
Backhoe
mm
• Backhoe balanced.
• Boom and arm cylinders in, bucket cylinder
out
• Outriggers at maximum extension.
• Engine stopped
• Check frame lowering for each side every 5
Outriggers min. for a total of 15 minutes. 7 15
Loader
Boom 2 each Max. 8

Bucket • Engine: Max speed 1.6 each Max. 6
Cylinder Leakage
Boom • Oil temperature: 45 - 55 °C 3.3 Max. 13.5

Arm • Leaking check: on cylinder opposite side to 3 Max. 12
pressure one.
Backhoe
Bucket cm³/min 2.4 Max. 9.5

• Check 1 cylinder at a time.
Boom swing • For loader bucket and boom and for swing, 3.2 Max. 13
Outriggers check the two cylinders separately. 3.3 Max.13.5
Jig arm 1.6 Max 6
20-8 WB146-5
12 Applicable model WB146-5
Standard Permissible
Cat. Item Measurement condition Unit
value value
Arm bucket
• Engine speed:
Lifting
max.
• Oil tempera- 3.6 3.1 - 4.1
ture: 45 - 55 °C
• Bucket speed
Cylinders fully button: applied
out
Lowering
Loader bucket
2.6 2.2 - 3.0
Bucket at ground
level
Bucket • Engine speed:
max.
Curl
2.3 2.0 - 2.6
• Oil tempera-
ture: 45 - 55 °C
• Bucket speed
button: applied
Dump
Cylinders fully
2.8 2.4 - 3.2
out
Work equipment speed
Lifting U
Boom cylinder • Engine speed: 2200 rpm
fully in sec. 2.7 2.3 - 3.1
• Oil temperature: 45 - 55
°C
↕ • Backhoe balanced Lowering
• Power mode ON
2.0 1.7-2.3
Bucket on ground
Arm cylinder
Opening
• Engine speed: 2200 rpm

fully in
• Oil temperature: 45 - 55 °C 2.9 2.5 - 3.4
Backhoe
↕ •
•
Backhoe balanced
Power mode ON
Closing U
Arm cylinder 3.2 2.7 - 3.7

fully out
Bucket cylinder
Dump
fully in • Engine speed: 2200 rpm

2 1.7 - 2.3
• Oil temperature: 45 - 55
°C
↕ • Backhoe balanced
• Power mode ON
Curl
Bucket cylinder 2.5 2.1 - 2.9

fully out
WB146-5 20-9

Standard Permissi-
Cat. Item Measurement condition Unit
value ble value
Right U
Boom swing to
Work equipment speed
3.2 2.7 - 3.7

tight end of travel • Engine speed: 2200 rpm
Oil temperature: 45 - 55 °C
Backhoe
•
↕ • Arm vertical
• Power mode ON
Left U
Boom swing to left
3.2 2.7 - 3.7
end of travel
• Engine speed: min.

• Check item necessary to lift
bucket from level ground
Arm bucket 0 Max. 2

Boom • With attachments fully extended, 0 Max 2
lower boom and check necessary sec
time from beginning of lift until
bucket is on level ground
Work equipment

Time lag
• Place boom at 45°, open completely with

Arm bucket curled. Extend arm cylinder and 0 Max 2
check time passing between arm stop at dead
center and restart movement.

• Place arm in horizontal position.
Bucket Tilt back bucket cylinder and then 0 Max.2
extend it. Check time passing
between bucket stop at dead center
and then restart movement
• Boom arm and bucket retracted and
centered on machine
Outriggers 0 Max. 2
• Check time necessary for outriggers to
raise machine from when they lean on
level ground.
• Check each outrigger at a time.
20-10 WB146-5
TESTING AND ADJUSTING SPECIAL TOOLS
12
SPECIAL TOOLS
Measurement Point Symbol Code Name Qty Note
Engine speed A Available Locally Multi scale tachometer 1 20 to 4000 rpm
Valve clearance B Available Locally Feeler gauge 1 –
Oil and coolant temp D 1 Available Locally Digital thermometer 1 -50 to 1200°C
1 Available Locally Pressure gauge 2 Full scale 61 kg/cm²

E
Hydraulic pressure
5
Servo control kit 1 0 to1020 kg/cm²
6
ATR800200
1 Flow meter 1 Delivery 0 to 300 l/min.
F
2 Pipe fitting kit 1 –
Air bleeding G ATR201490 Tank cap 1 Pump air bleeding
Hand brake L Available Locally Spring dynamometer 1 Full scale 20 kg
1 Available Locally Maintenance station 1 For coolant R134a
Air Conditioning unit M 2 Available Locally Thermometer hygrometer 1 Sampling every 15 sec
3 Available Locally Leak detector 1 For coolant R134a
WB146-5 20-11
TESTING AND ADJUSTING ENGINE SPEED
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 with a tachometer A under the following

conditions:
● Engine coolant temperature.........................................68 to 80 °C
● Hydraulic oil temperature............................................45 to 55 °C
ENGINE WITHOUT LOAD

1. Start the engine and check:
Low idle speed without load, accelerator pedal released. High idle
speed without load, accelerator pedal at the travel end.
● Low idle speed....................................................... 1050 ± 50 rpm
● High idle speed ...................................................... 2400 ± 50 rpm
★ If the idle speeds are not within limits, without a load on the engine,
check the accelerator pedal stop and wiring insulation before going
on with other operations.
MACHINE IN POWER MODE AT MIN

1. With the transmission in neutral, idle the engine.
2. Dump the loader bucket and hold the movement; let the engine sta-
bilize and then read the engine speed.
● Normal speed....................................................................600 rpm
● Minimum speed ................................................................600 rpm
WITH CONVERTER STALLED

1. Increase speed to high idle and brake with the foot brakes.
2. Hold the brakes while simultaneously engaging 3rd gear; let the en-
gine stabilize, and read the rpm value.
● Minimum speed ..............................................................2125 rpm
● Maximum speed .............................................................2225 rpm
3. Hold the machine stalled as long as necessary, in any case for not
more than 30 sec., and carry out the tests at least 15 sec one from
the other.
CONVERTER STALLED AND HYDRAULIC PUMP UNDER

LOAD
1. Increase speed to high idle and brake with the working brakes.
2. While holding the brakes:

a. Engage 3rd FORWARD
b. Raise the loader and hold in this position;
c. Steer the wheels fully;
20-12 WB146-5
TESTING AND ADJUSTING ENGINE SPEED
12
3. In the above conditions, let the engine stabilize, then read the en-
gine rpm.
● Minimum speed ..............................................................2025 rpm
● Maximum speed .............................................................2125 rpm
4. Hold the machine stalled as little as necessary, in any case for not
more than 30 sec., and carry out the tests at least 15 sec one from
the other.
ANALYSIS
1. If readings are not within the required interval, check the ENGINE
SHOP MANUAL.
2. If the engine has no conditions, adjust the pump's power absorp-

tion, PC valve.
WB146-5 20-13
TESTING AND ADJUSTING VALVE CLEARANCE
12
VALVE CLEARANCE
1. Park the machine on solid, level ground, apply the parking brake,
and remove the ignition key.
2. Remove the air filter and muffler. For details see Section 30.
3. Release the coolant temperature sensor the wiring harness.
4. Adjust the valve clearance according to the instructions provided in

the ENGINE SHOP MANUAL.
20-14 WB146-5
TESTING AND ADJUSTING AC COMPRESSOR BELT TENSION
12
AC COMPRESSOR BELT TENSION
1. Turn the screw B clockwise to tension the belt C.
2. Apply a 10 kg force halfway between compressor pulley E and en-

gine pulley D.
3. Check the resulting arrow F.

● Normal tensioning .........................................................4 to 6 mm
● New belt................................................................................3 mm
WARNING! Check the belt tension again after 15 minutes

of operation.
WB146-5 20-15
TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS
12
BLEED AIR FROM CIRCUITS
BLEED AIR FROM CYLINDERS
★ When the hydraulic cylinders or associated tubes have been removed, it is
necessary to bleed air before using the machine again. Perform bleeding on
one cylinder at a time.
1. Start the engine and run at high idle for about 5 min. to heat the oil.
2. Reduce speed to low idle and extend and retract the 1st cylinder to
be bled several times.
★ Extend and retract pistons until about 100 mm from their end
of stroke.
3. Stop the engine, check and top off the oil in the tank.
4. Bring again the engine at high idle and repeat Step 2; return the en-
gine to low idle speed and make a complete travel of the cylinder
until the pump reaches its maximum pressure.
5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil
level in the tank.
BLEED AIR FROM BRAKING CIRCUIT

★ This operation is to be carried out every time maintenance is made on the
braking circuit to remove or replace a component, or when air entered into
the circuit. Machine must be stopped with attachments on level ground.
1. Make sure that oil in the brake system tank b is at maximum level.
Remove safety plugs on the bleed screws c. Attach a vinyl hose d
to catch oil.
2. Push the brake pedal to the bottom and, while keeping it pushed,
loosen the bleed screw c of the braking unit that is being bled until
the pedal reaches the end of its stroke. Keeping the pedal at the end
of its stroke, tighten the bleed screw.
3. Release the brake pedal, wait for few seconds and repeat above op-
erations 2 or 3 times until, oil flows out the bleeding screw without
air bubbles.
4. Repeat the same steps for the opposite braking unit.
★ Frequently check the oil level in the tank and refill every time
the level approaches minimum.
5. After bleeding air, apply on screws c safety plugs e.
RELEASING RESIDUAL PRESSURE

1. Put work attachments on level ground, stop the engine.
2. Move all control levers in all directions to fully release cylinder and
PPC circuit residual pressure.
20-16 WB146-5
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR PEDAL AND LEVER
★ Measurement conditions:
● Machine ......................... Shut down with safety features engaged
● Engine................................ Stopped and at operating temperature
● Idle speeds ................................................. Within standard value.
★ In order to check high speed engine idle, push the accelerator pedal
B manually.
ACCELERATOR PEDAL TRAVEL

1. Make sure that the accelerator pedal b is fully raised and the accel-
erator lever c is at minimum stroke.
2. Push the accelerator pedal until the accelerator lever f contacts the
injection pump high idle adjusting screw.
3. Adjust the end travel stopper g of the accelerator pedal b in this

position and lock it with the nut h.
4. Release the accelerator pedal b.
WB146-5 20-17
TESTING AND ADJUSTING ACCELERATOR PEDAL AND LEVER
12
ACCELERATOR LEVER TRAVEL
1. Remove the front mat.
2. Remove the metal sheet b closing the bottom of the cab and the up-
right guard c.
3. Check that the hand accelerator d is at end of travel at MIN.
4. Loosen and unscrew the locking nut e.
5. Start the engine and move the hand accelerator d to MAX.
6. Tighten the nut f to the required speed for hand accelerator.
● Engine idle speed............................................................2200 rpm

7. Return to engine low idle speed and retain the position of the nut f
with the locking nut e.
8. Check the MAX speed once more by pushing the hand accelerator
to the end of travel.
20-18 WB146-5
TESTING AND ADJUSTING BRAKE SYSTEM
12
BRAKE SYSTEM
★ Working condition:
● Set the machine on level surface with attachments on ground
level
● Apply the parking brake and remove the ignition key
● Pedal connection pin a inserted.
CONTROL
1. Remove the floor mat.
2. Check the height A between the floor and pedal b lower edge.
3. Depress the pedals by hand and check height B to determine slack

G.
★ Standard clearance .......................................................3 - 8 mm
ADJUSTMENT
1. Remove the front cover c.
WB146-5 20-19
12
2. Loosen the nuts d and adjust the slack using the stoppers e.
3. When adjustment is complete, secure the stoppers e.

★ When the stoppers are secured, double check to ensure that slack
G is within the range and that the pedals touch the stoppers
simultaneously.
CHECKS
★ Working condition:
● Engine stopped
● Place the vehicle on firm level ground with the equipment raised
and the safety devices activated.
● Independent brake pedals and oil pan at maximum level.
★ The brake system checking procedure consists of two steps:

● Checking the brake pumps and checking the braking groups for
leaks.
LEAKAGE CHECKS
1. Disconnect the hose B from the tubes c connecting to the axle
braking groups. Plug the tube.
● Plug all open tubes and hoses to prevent contamination.
2. Connect a pressure gauge E2 to the hose B.
3. Apply the brake pedals until a pressure of 122.2 kg/cm² is reached.

★ Do not exceed the max permitted pressure .........152.8 ±5 kg/cm²
4. Hold the pressure on the pedal for at least 2 minutes and verify that
the pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside either pump. To confirm whether this is the case, check
the oil. If a leak condition exists, the oil will be stirred.
20-20 WB146-5
12
INDIVIDUAL PUMP CHECK
1. Remove the front lining d.
2. Disconnect the pressure equalizer hose f from the brake circuit

pump e that is being inspected.
3. Seal the hole of the equalizer plug A.
4. Remove the clamp g.
5. Disconnect the delivery hoses h from the pump that is being tested.
Connect a pressure gauge E2 to the pump during the inspection.
6. Apply the brake pedal corresponding to the pump and pressurize

the circuit to 122.2 kg/cm².
★ Do not exceed the max permitted pressure .........152.8 ±5 kg/cm²
WB146-5 20-21
12
7. Hold the pressure on the pedal for at least 2 minutes and verify that
pressure and pedal position remain unchanged.
★ If the position of the pedal needs to be changed in order to hold
the pressure, then the loss of pressure is to be blamed on leaks
inside the pump, and in this case the pump needs to be
changed. To confirm whether this is the case, check the oil. If a
leak condition exists, the oil will be stirred.
8. Repeat for the other pump.
BRAKE GROUP LEAKAGE

1. Disconnect the delivery hose b from the braking group that is be-
ing inspected.
2. Connect a suitable tool between the delivery hose b and the brak-
ing group.
★ Check to ensure that the pressure tap i is installed between the
braking group and the cut out valve j.
3. Connect a pressure gauge E2 to the tool pressure tap and open the
cut out valve j.
4. Operate the brake pump and pressurize the circuit to 152.8 ±56 kg/
cm² max.
5. Hold the pressure while simultaneously closing the valve j to keep

the braking circuit that is being inspected under pressure.
6. Release the brake pedal and monitor the pressure gauge E2 for two
minutes.
★ If the pressure reading changes in the negative, then there is a
brake piston seal failure.
WARNING! Further evidence of leak is an increase in the

level of oil in the axle, and the fact that the oil is stirred as
a result. Replace all sealing rings in the various axle sec-
tions and completely change the lubricant.
7. Repeat the test for the other brake group using the same procedure
as above.
8. Restore the brake circuit to operating condition.
WARNING! When checks and repair are complete, bleed

the air from the braking groups
20-22 WB146-5
TESTING AND ADJUSTING PARKING BRAKE ADJUSTMENT
12
PARKING BRAKE ADJUSTMENT
★ Test conditions:
● Tire pressure ......................................Within the prescribed range
● Machine in operating conditions ...W/O load and on level ground
● Working brake pedals ........................... Connected by a cotter pin
1. Remove the screws b and parking brake housing c.
2. Engage the parking brake.
3. Press and hold the microswitch d while engaging 2nd gear and se-
lecting a direction of movement.
4. Accelerate engine gradually up to 1530 ±50 rpm.
WARNING! If machine moves, release the microswitch to

return to N, Neutral.
5. Rotate the end of the lever e by 2 or 3 turns counterclockwise.

★ Direction of rotation is from the operator’s point of view when
sitting in the driver’s seat.
6. Apply the parking brake and repeat the test.

★ If a normal braking condition is not achieved after 2 attempts
to adjust the lever, check control cable for slackness and brake
disc for wear and replace components as necessary.
WB146-5 20-23
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
INTRODUCTION
b Engine D Hydraulic Pump f LS Safety Valve

c Transmission E Steering Unit g Main Control Valve
INTRODUCTION
1. The machine is equipped with a single control valve with hydrauli-
cally controlled spools. The control valve is protected against over
pressure by a main relief valve, referred to as the LS safety valve,
with an adjustable pressure setting.
2. The full pump delivery supplies the control valve.
3. Pump delivery is shut by the priority valve, inside the control valve,
when the steering unit is used for a steering manoeuvre.
20-24 WB146-5
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
MAIN CONTROL VALVE
Cylinder and Movement Port kg/cm²

Hammer B0 191.02
Open A1 275.13
Backhoe Arm
Close B1 275.13
Right A2 234.37
Backhoe Swing
Left B2 234.37
Dump A3 244.56
Loader Bucket
Curl B3 275.13
Lower A4 275.13
Backhoe Boom
Raise A4 346.02
Dump A5 ---
Backhoe Bucket
Curl B5 275.13
Close A6 275.13
MP Bucket
Open B6 275.13
Out A7 ---
Telescopic Arm
In B7 ---
Raise A8 ---
Loader Arm
Lower B8 ---
Down A9 ---
Right Outrigger
Up B9 ---
Down A10 ---
Left Outrigger
Up B10 ---
WB146-5 20-25
TESTING AND ADJUSTING RELIEF VALVES
12
RELIEF VALVES
TESTING
UNLOADING VALVE
1. Connect a pressure gauge E1 to the tap P1C on the pump. Start
the engine and run at low idle with all levers in neutral position.
2. In this condition, check the pressure in the hydraulic circuit.

★ Normal pressure ..............................................41.8 ±4.1 kg/cm²
★ The unloading valve cannot be reset; replace if necessary.
MAIN RELIEF VALVE

● Engine.................................................. At Operating Temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................. Applied
1. Connect a pressure gauge E3 to the tap P1C of the pump. Start the
engine, move the hand accelerator lever to full throttle and check
setting pressure for main relief valve by forcing the loader arm
raise movement the full travel span.
● Nominal pressure.............................................239.4 - 270 kg/cm²

★ If the main relief valve pressure does not correspond to the nominal pres-
sure value, it must be reset.
SECONDARY VALVES
Boom Swing, Loader Bucket Dump and Hammer
● Hydraulic oil................................................................. 45 - 55 °C
★ The pressure readings are to be operated from the same check point.
1. Connect a pressure gauge E3 to the tap P1C of the pump. Start the
engine and bring the hand accelerator lever up to 2200 rpm.
20-26 WB146-5
12
2. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure.
Cylinder and movement Setting kg/cm²
Hammer 183.4 – 213.9

Right 229.2 – 254.7
Boom swing
Left 229.2 – 254.7
Loader Dump 239.4 – 264.9
Backhoe Boom Raise
● Hydraulic oil................................................................. 45 - 55 °C
1. Set the machine with the arm in the vertical position and the bucket
on level ground.
2. Stop the engine and release the residual hydraulic pressures
3. Disconnect the hose b and connect a tee c with an adapter. Con-

nect a pressure gauge E3 to the adapter.
4. Start the engine, connect a 1500 kg weight to the bucket, and fully
lower the outriggers.
WB146-5 20-27
12
5. Slowly extend the arm and boom and take the pressure when the
boom lowers.
★ Normal pressure ...........................................326 - 366.7 kg/cm²
Arm In, Loader Bucket, Backhoe Bucket, Boom Raise, And

MP Bucket
● Hydraulic oil................................................................. 45 - 55 °C
★ The pressure readings are to be operated from the same check point.
1. Connect a pressure gauge E3 to pressure tap P1C of the pump.
2. Start the engine and bring the hand accelerator lever up to 2200
rpm.
3. Set the main relief valve b to a value 30.5 kg/cm² higher than the
maximum pressure to be tested.
4. Check pressure for each movement, with the control lever at the
end of its travel and at stabilized pressure.
★ Move piston to the end of stroke to check the pressure of the
working equipment.
Cylinder and movement Setting kg/cm²
Arm Close 264.9 – 285.3

Loader bucket Curl 264.9 – 285.3
Boom Left 264.9 – 285.3
Loader Dump 264.9 – 285.3
Close 264.9 – 285.3
Open 264.9 – 285.3
★ If one movement fails to reach the setting pressure, then the

malfunction is in the tested element.
★ If all movements fail to reach the setting pressure, then you

need to pressure set or replace the secondary valve.
20-28 WB146-5
TESTING AND ADJUSTING SETTING RELIEF VALVES
12
SETTING RELIEF VALVES
MAIN RELIEF VALVE
1. Loosen lock nut B.
2. Adjust the pressure using the screw C.

★ To increase pressure..........................................Turn Clockwise
★ To decrease pressure .............................Turn Counterclockwise
3. Lock the nut B.
Lock nut ............................................................29.4 - 39.2 N•m
★ When adjustment is complete, check the setting of the main

relief valve using the procedures used for measurements.
CIRCUIT RELIEF VALVES

ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM
RAISE, AND MP BUCKET
1. Loosen the lock nut B.
A Circuit Relief Valve.......................................... Hammer Circuit

B Circuit Relief Valve...................................................Swing Left
C Circuit Relief Valve.............................................. Loader Dump
D Circuit Relief Valve................................................ Swing Right
E Circuit Relief Valve...........................................................Boom
2. Adjust the pressure using the nut C.

3. Tighten the lock nut B while holding the adjusting nut c.
Lock nut B ..............................................................39 - 49 N•m
WB146-5 20-29
TESTING AND ADJUSTING SETTING RELIEF VALVES
12
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE
1. Loosen the lock nut B.
2. Adjust the pressure using the nut C.

3. Tighten the lock nut B while holding the adjusting nut c.
Lock nut B ..............................................................39 - 49 N•m
20-30 WB146-5
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
12
LS DIFFERENTIAL PRESSURE
CONTROL
★ Engine ..............................Stopped but at working temperature.
★ Hydraulic oil ............................................................ 45 - 55 °C.
★ Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
★ Working mode.............................................................. POWER
1. Disconnect the hose b from the LS line, Install a tee with a pres-
sure tap c and reconnect the hose b.
2. Connect a differential pressure gauge E4 to adaptor c and to tap

P1C on the pump.
3. Start the engine and run it at low idle, 1050 ±50 rpm, and, without
any lever movement, in neutral position, read the U pressure.
★ Normal value......................................................41.7 ±4 kg/cm²
★ If UPLS pressure is not within the permissible range, replace
the control valve unloading valve.
4. Simultaneously perform a boom raise and a backhoe bucket curl

movement to end of travel and then read the U pressure.
★ Normal value......................................................28 ±1.5 kg/cm²
★ If the UPLS value is not within the permissible range, set the
unloading valve.
ADJUSTMENT
★ If the UPLS value is not within the specified range, adjust the LS valve
as follows:
1. Loosen the retaining nut b and turn the adjustment screw c.

★ Each turn of the adjustment screw c will change the pressure
by approx. 13.2 kg/cm².
2. Lock the nut b.
Lock nut B ..............................................................39 - 49 N•m
3. When adjustment is complete, check the setting of the LS valve us-

ing the procedures used for checking.
WB146-5 20-31
TESTING AND ADJUSTING PPC SUPPLY PRESSURE
12
PPC SUPPLY PRESSURE
CHECK
★ Engine ...............................................At operating temperature.
★ Hydraulic oil temperature ......................................... 45 - 55 °C
1. Connect a pressure gauge E1 to the pressure tap b of the solenoid

valve group c.
2. Start the engine and run the engine at low idle with all levers in
neutral position.
3. Check the pressure.

★ Normal pressure ....................................................38 ±3 kg/cm²
ADJUSTMENT
★ If the pressure value is not within the tolerance range, adjust the valve b as
follows:
1. Loosen the retaining nut c and turn the adjustment screw d.

★ Each turn of the adjustment screw d will change the pressure
by approx. kg/cm².
2. Lock the nut c.
Lock nut c .............................................................22 ±2.5 N•m
20-32 WB146-5
TESTING AND ADJUSTING PC VALVE
12
PC VALVE
ADJUSTMENT
★ If pump delivery and LS differential pressure are within permissible val-
ues, but you notice that the engine rpm drops as a result of a change in the
load, or that working equipment is very slow, it is time to adjust the PC
valve b.
1. Loosen the nut c and turn the adjustment screw d.

★ To decrease the pump's torque absorption, turn the adjustment
screw d counterclockwise
★ To increase the pump's torque absorption (i.e. to increase the
speed of working equipment) turn the adjustment screw d
clockwise.
★ Turn the adjustment screw by not more than 180° in relation to
the 0° line, in both directions
★ Adjustment screw position on first installation shown
2. Lock the nut c.
Lock nut c ........................................................27.4 - 34.4 N•m
WB146-5 20-33
TESTING AND ADJUSTING STEERING CONTROL SYSTEM
12
STEERING CONTROL SYSTEM
● Engine........................................................ Operating temperature
● Hydraulic oil................................................................. 45 - 55 °C
CONTROL
1. Connect a pressure gauge E3 to the tap P1C on the main control
valve.
2. Start the engine and bring it to idle speed 1500 ±50 rpm and carry
out a total steering.
3. Force the steering wheel at the end of stroke, check pressure.

★ Normal pressure ........................................178.3 - 188.5 kg/cm²
4. Check the other steering direction.
SETTING
★ If pressure is not within permissible value, set the upper valve b of the
steering unit c.
1. Remove the plug d. Insert a wrench and loosen the screw e.

2. Stop the engine and replace the plug d; ensure that the seal f is in
its proper position.
Plug c .....................................................................40 - 60 N•m
20-34 WB146-5
TESTING AND ADJUSTING STEERING CYLINDER
12
STEERING CYLINDER
● Engine....................................................At operating temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Working brakes................................................................ Engaged
● Maximum steering pressure .................Within permissible limits.
1. Start the engine and full steer the wheels in either direction, then
stop the engine.
2. Disconnect the supply hose c from the cylinder b on the side

where the rod is fully out d; plug the hose tightly.
3. Connect a provisional hose to the cylinder b to collect any leaking

fluid.
4. Start the engine and operate the engine at high idle speed.
5. Force the steering wheel to the end of its travel and retain the posi-
tion for 30 seconds; measure any leak during the following minute.
6. Release the steering wheel, run the engine at low idle, and then stop
the engine.
7. Check if leakage is normal.

★ Test cylinder on one side only, as there is only one gasket sepa-
rating the two chambers.
8. Restore the hydraulic connection, steer the wheel several times in

both directions to remove any air from the circuit.
WB146-5 20-35
TESTING AND ADJUSTING POWER TRAIN GROUP
12
POWER TRAIN GROUP
The power train group can be used to perform pressure tests on the
internal hydraulic circuit. These are useful for identifying malfunctions.
Specifically, the tests involve:
Converter Oil Pressure
Clutch Engagement Pressure
Supply Pressure
★ Test condition:
● Engine............................................................................... Stopped
● Brake pedals ......................................... Connected by a cotter pin
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
● Lower cab closeout........................................................Removed.
CONVERTER OIL PRESSURE

1. Remove the plug P22 and connect the pressure gauge E6.
2. Start the engine and heat the engine and all the fluids up to working
temperature. In particular make sure that the power train oil reaches
a temperature of 80 ±5 °C.
3. With the engine at MIN, check the pressure on the pressure gauge
E6.
★ Idle pressure ............................................................3.05 kg/cm²
4. Gradually increase engine speed to 2200 rpm; take a new reading

on pressure gauge E6.
★ Normal pressure ............................................3.05 - 9.17 kg/cm²
5. Bring the engine back to MIN and compare the pressure with the
normal value.
★ Min pressure ...........................................................3.05 kg/cm²
★ If the pressure value drops to below the permissible lower
limit, the power train pump needs an replacement.
Plug ................................................................................ 30 N•m
CLUTCH ENGAGEMENT PRESSURE

3. Bring the engine up to low idle and check the pressure on the pres-
sure gauge E6.
★ Normal pressure ...............................................Max. 0.3 kg/cm²
20-36 WB146-5
TESTING AND ADJUSTING POWER TRAIN GROUP
12
4. With the working brakes applied, select reverse gear and gradually
increase rev speed up to MAX, then take a new reading from the
pressure gauge E6.
5. Bring the engine back to MIN and the transmission in neutral posi-
tion; compare the pressure with the normal value.
★ Normal pressure ...............................................Max. 0.3 kg/cm²
6. Remove the pressure adapter and replace the plug P19.
Plug ................................................................................ 30 N•m
7. Repeat the same test for the FORWARD gear, reading the pressure
from the orifice protected by the plug P18.
● If the pressures are different for the two travel directions, there is
a loss of pressure on the clutch piston with lower pressure.
SUPPLY PRESSURE
3. Bring the engine up to low idle and check the pressure on the pres-
sure gauge.
4. Gradually increase engine speed to 2200 rpm; take a new reading

on pressure gauge.
★ Min. pressure ..........................................................14.2 kg/cm²
★ If reading drops below minimum, the transmission pump needs
replacing.
Plug ................................................................................ 30 N•m
WB146-5 20-37
TESTING AND ADJUSTING TRANSMISSION CLUTCH FUNCTION
12
TRANSMISSION CLUTCH FUNCTION
● Engine: stopped.
● Brake pedals: connected by a cotter pin.
● Machine: on solid and level ground with the equipment raised
and safety devices engaged.
★ This test must be performed after having checked the pressures
of the power train group.
MACHINE PREPARATION
1. Prepare a tachometer to measure the engine rpm.
WARNING! Make sure that the brake pedals are fastened

together by the cotter pin b. During the following tests,
during the engine acceleration phase with the gear
engaged, the condition of the brake disks can also be
checked If, while force is being exerted on the brake ped-
als, the machine starts to travel, even slowly:
● Release the accelerator immediately and stop the engine.
● Check the wear on the brake disks and change them before com-
pleting the tests.
CONTROL
2. With the engine in idling condition, accelerate to MAX. and check

that in this condition the revs remain within permissible limits.
3. Brake hard and bring the engine up to MAX.
4. Engage the 3rd gear while braking and accelerating as above; con-
firm that engine speed decreases to the permissible range
5. Repeat this test in REVERSE gear.

★ If the revs are high than the permissible limits, the clutches are
worn, and must be replaced.
20-38 WB146-5
TESTING AND ADJUSTING HYDRAULIC DRIFT
12
HYDRAULIC DRIFT
★ If working attachments have a hydraulic drift, it is necessary to check if
reason is due to cylinders gaskets or to control valve.
★ All testing conditions:

● Engine....................................................At operating temperature
● Hydraulic oil................................................................. 45 - 55 °C
● Removal and install tubes only after residual pressure’s removed.
LOADER
BOOM CIRCUIT
1. Put the machine with the bucket edge on blocks A of about 10 cm
and in vertical position in relation to the ground.
2. Stop the engine and release the residual hydraulic pressures.
3. Disconnect the tubes b and c from the lift cylinders d and plug
them.
4. Plug the cylinders, base side, and apply a temporary tube, rod side,
to catch any possible oil leakage.
5. Start the engine and curl the bucket until the teeth are in the tilt po-
sition by 10°.
6. Stop the engine and check bucket link position for movement 5
minutes.
● If the bucket link has no lowering movement, drift is due to the
control valve.
To test the individual cylinders, proceed as follows:
7. Move the bucket to let the edge lean on the ground in vertical posi-
tion.
8. Remove from one of the cylinders the plug fitted on the cylinder
bottom side in Step 4.
9. Start the engine and retract the bucket to bring the teeth in a tilt po-
sition of about 10° upwards.
10. Stop the engine and check the loader position for 5 minutes.
● If the bucket link lowers, drift is due to seal leakage of the
plugged cylinder.
11. Repeat Steps 8 to 10 to check the other cylinder.
WB146-5 20-39
12
BUCKET CIRCUIT
1. Put the machine with the loader on level ground and bucket edge
tilted 10°. Put a 1500 kg weight in the bucket.
2. Disconnect the tubes b and c from both bucket cylinders d and

plug them to prevent contamination.
3. Plug the bucket cylinder, head side, and install a temporary tube on
the rod side to catch oil leakage.
4. Start the engine and raise the loader until the bucket hinge pin is
aligned with boom hinge pin.
5. Stop the engine and check the position of the bucket edge for 5
minutes.
● If the bucket has no movement, drift is due to the control valve.
To test the individual cylinders, proceed as follows:
6. Lower the loader to the ground.
7. Remove from one of the cylinders the plug fitted on the cylinder
head side in Step 3.
8. Start the engine and raise the loader as indicated in Step 4.
9. Stop the engine and check the position of the bucket edge for 5
minutes.
● If the bucket edge turns, the drift is due to seal leakage of the
plugged cylinder.
10. Repeat operation from Steps 6 to 9 to check the other cylinder.
BACKHOE
★ Test condition:
★ Backhoe aligned
★ Lifted outriggers
20-40 WB146-5
12
BOOM CIRCUIT
1. Set the machine with the boom in vertical position and with the
bucket on level ground leaned on the side.
3. Disconnect the hoses b and c that feed cylinder d.
4. Plug the two hoses to avoid impurity inlet.
5. Plug the cylinder head side.
6. Apply a temporary tube to tube e base side to catch oil leakage.
7. Start the engine and extend the arm.
8. Stop the engine and check the boom position for 5 minutes.
● If boom has a lowering movement, drift is due to cylinder gas-
kets.
● If boom has no lowering movement, drift is due to control valve.
ARM CIRCUIT
1. Set the machine with the arm fully extended and with the bucket
teeth on ground.
WB146-5 20-41
12
3. Disconnect the tubes b and c the tubes from the arm cylinder d
and plug them to avoid impurity inlet.
★ If a safety valve is fitted, remove it.
4. Plug the arm cylinder hole on the head side and fit a temporary tube
on the base side to catch oil leakage.
5. Start the engine and raise the boom.
6. Stop the engine and check the arm position for 5 minutes.
● If the arm has a lowering movement, drift is due to the cylinder
seals.
● If the arm has no movement, drift is due to the control valve.
BUCKET CIRCUIT
1. Set the machine with the arm vertical and the bucket at level
ground on the side. Put a 450 kg weight in the bucket or fill it with
dirt.
3. Disconnect the bucket cylinder d hoses b and c and plug them to

avoid impurity inlet.
4. Plug the bucket cylinder port on the base side and fit a temporary
tube on the rod side to catch oil leakage.
20-42 WB146-5
12
5. Start the engine and raise the boom.
6. Stop the engine and check the bucket position for 5 minutes.
● If the bucket has an movement, drift is due to the cylinder seals.
● If the bucket has no movement, drift is due to the control valve.
OUTRIGGERS CIRCUT - W/O LOCK VALVESI

1. Set the machine with the arm in vertical position and with the buck-
et on level ground leaned to the side.
2. Put 20 cm blocks under the outriggers.
3. Without forcing them, lower the outriggers onto the blocks.
5. Disconnect from the cylinders b, the tubes c and d after the lock
valve e.
6. Plug the cylinders base head tube c. Add a temporary tubes to the
rod side d tube to catch oil leakage.
7. Start the engine, use the boom to raise the machine, and remove the
blocks supporting the outriggers.
8. Lower the machine and stop the engine.
9. Check the outriggers position for 5 minutes.

● If one or both outriggers lower, drift is due to one or both cylin-
ders.
● If there is no lowering, drift is due to control valve.
WB146-5 20-43
TESTING AND ADJUSTING AIR CONDITIONING
AIR CONDITIONING
● Machine on level ground with the working equipment raised and
in safety conditions with the parking brake engaged
WORK TEMPERATURE
1. Connect the maintenance station to the high pressure, HP, valve
and the low pressure, LP, valve.
2. Start the engine and bring it up to a speed of 1500 rpm.
3. Switch on the AC unit using the switch. Select an intermediate ven-

tilation speed inside the cab.
4. Use the thermometer M2 to check that the temperature inside the

cab is equal to or lower than the ambient temperature.
★ If the temperature of the cab is higher than the ambient temper-
ature, open the doors and widows and wait until the cab tem-
perature stabilizes at the outside value.
5. Close the doors and windows and let the AC unit operate in these
conditions for 5 to 10 minutes.
6. 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.
7. Compare the average value of the measured temperatures using the

following table:
Ambient temp °C 20 25 30 35
Outgoing air temp °C 6 -8 8 - 10 8 - 12 9 -14
8. If the average value of the temperature measured does not fall with-
in the values given in the table, it will be necessary to thoroughly
check the unit.
20-44 WB146-5
12
UNIT CHECK
Check the unit after the Steps 1, 2, 3 and 5 of the preceding paragraph.
A diagnosis of faults in the unit is based upon the working pressures.
When the pressures do not fall within the values given in the following
table, the causes must be found by checking the high-pressure and low
pressure gauges.
Unit: kg/cm²
Unit with R134a.
Outside Air Temp °C 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 may be found:
CONDITIONS CAUSES - FAULTS

● Electromagnetic pulley that slips or does not engage correctly
LP high to HP normal or low ● Expansion valve blocked in open position
● Compressor damaged
● Expansion valve blocked in closed position or obstructed
LP low to HP high or normal ● Filter saturated with moisture
● Obstruction in the LP line or in the HP line between the filter and the evaporator.
● Infiltration of hot air into the evaporator group, the pipes or the cab
LP normal to HP normal ● Hot air circulating in the heating group
● Formation of ice on the evaporator
● Normal condition with very high ambient temperature, higher than 43 °C
● Excess coolant, 30 to 35% more
● Overheating of condenser
LP high to HP high
● 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
● Normal condition with very low temperature, lower than 5 °C
● Lack of coolant, 70 to 75% less, probable leakages
LP normal or low to HP low ● Obstruction in the HP line between the compressor and the condenser filler tube before
the measurement point of the HP
● Compressor belt missing
LP roughly equal to HP ● Electromagnetic pulley that slips or does not engage
WB146-5 20-45
EMPTYING THE AC UNIT

1. Connect the maintenance station M1 to service valves b and c
and follow the specific maintenance station instructions relative to
the drainage of the unit.
2. Disconnect the group to be substituted or reconditioned immediate-

ly after switching off the maintenance station. Plug the removed or
disconnected connection tubes tightly and with a minimum of de-
lay.
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.
20-46 WB146-5
TESTING AND ADJUSTING TROUBLESHOOTING GUIDE
12
TROUBLESHOOTING GUIDE
FRONT AXLE
Wheel vibration; front tire resistance; half shaft breakage.

CAUSES REMEDY
Incorrect installation Correct installation
Replace the differential in case it does not survive any of the test
Defective axle
phases
Remove excessive weight and redistribute load following instructions
Overloading incorrect weight distribution
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
Defective axle
phases
Overloading incorrect weight distribution
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
Defective axle
phases
Overloading/incorrect weight distribution
Broken half shaft Replace half shaft
Excess noise
CAUSES REMEDY
Defective axle
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.
WB146-5 20-47
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
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 pneu- vehicle begins to kick.
matic wear on sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
phases
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Defective axle
phases
20-48 WB146-5
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
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
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
WB146-5 20-49
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
Incorrect gear adjustment insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
Prolonged operation at high temperature
Replace bevel gear set. Use correct lubricants, fill to proper levels and
Insufficient lubrication; contaminated oil; improper replace according to the recommended schedule.
lubrication
Pinion teeth pitting
CAUSES 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
Vehicle accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings, use correct lubricants, fill to proper levels and
Normal wear out replace according to the recommended schedule.
Pinion nut loosened
20-50 WB146-5
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
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
Use correct lubricants, fill to proper levels and replace according to the
Insufficient lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm smaller thickness than the new ones
Inner diameter of tapered roller bearing worn out
CAUSES 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-
Insufficient lubrication; contaminated oil ule.
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
WB146-5 20-51
12
REAR AXLE
Wheel vibration; front tire resistance; half shaft breakage.

CAUSES REMEDY
Defective axle
phases
Steering is difficult; vehicle goes straight while trying to turn it.
CAUSES REMEDY
Defective axle
phases
No differential action; jamming while steering.
CAUSES REMEDY
Defective axle
phases
Excess noise
CAUSES REMEDY
Defective axle
phases
20-52 WB146-5
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
phases
Blocked half shaft:
● Abnormal functioning of the differential or break- ● Verify assembly of all components
age/blockage of control device.
● Vehicles with wide steering angle may proceed ● Reduce the steering angle to minimum and decelerate when the
with kicks, have steering difficulty or cause pneu- vehicle begins to kick.
matic wear on sharp turns.
Friction noise
CAUSES REMEDY
Defective axle
phases
Check the condition of the ring gear, pinion gear, bearings, etc.
Damaged or worn out axle parts
Replace when necessary.
Incorrect adjustment of bevel gear set. Parts of the
Replace or adjust as required.
trans worn out transmission gears, U joint, etc.
Vibration during forward drive, intermittent noise
CAUSES REMEDY
Defective axle
phases
WB146-5 20-53
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
heard while decelerating, disappears while increas- Replace
ing speed
Pinion or input flange worn out Adjust
Intermittent noise
CAUSES REMEDY
Ring gear damaged Replace bevel gear set
Differential box bolts loosened Tighten to torque
Constant noise
CAUSES REMEDY
Ring gear teeth or pinion damaged Replace bevel gear set
Worn out bearings Replace
Pinion spline worn out Replace
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
20-54 WB146-5
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
Incorrect gear adjustment, insufficient backlash Replace bevel gear set. Adjust bevel gear set free backlash.
Pinion nut loosened
Pinion or ring gear teeth worn
CAUSES REMEDY
Insufficient lubrication; contaminated oil; improper Replace bevel gear set. Carefully follow the recommended operations
lubrication for the adjustment of the bevel gear set free play. Use correct lubri-
cants, fill to proper levels and replace according to the recommended
Worn out pinion bearings schedule.
Overheated ring and pinion teeth
CAUSES REMEDY
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
Vehicle accident Replace axle beam body
Load bump
Worn out or pitted bearings
CAUSES REMEDY
Insufficient lubrication; contaminated oil
Excessive use Replace bearings. Use correct lubricants, fill to proper levels and
Normal wear out replace according to the recommended schedule.
Pinion nut loosened
WB146-5 20-55
12
Oil leakage from gaskets and seals
CAUSES REMEDY
Oil gasket assembled incorrectly Replace the gasket or seal and matching surface if damaged. Use cor-
rect lubricants, fill to proper levels and replace according to the recom-
Seal lip damaged mended schedule.
Contaminated oil
Excessive wearing out of input flange spline
CAUSES REMEDY
Exhaustive use
Replace the flange. Check that the pinion spline is not excessively
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
Use correct lubricants, fill to proper levels and replace according to the
Lack of lubrication; contaminated oil, improper
recommended schedule. Replace all scratched washers and those with
lubrication
0.1 mm 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-
Insufficient lubrication; contaminated oil ule.
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
20-56 WB146-5
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
WB146-5 20-57
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) Wait for oil to reach operating temperature (stall test)
Overheating See “Overheating”
Damaged hydraulic system Repair/Replace
20-58 WB146-5
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
WB146-5 20-59
12
20-60 WB146-5
90 OTHERS
HYDRAULIC CIRCUIT .......................................................................................................... 90-3

1 OF 4 .................................................................................................................................... 90-3
2 OF 4 .................................................................................................................................... 90-5
3 OF 4 .................................................................................................................................... 90-7
4 OF 4 .................................................................................................................................... 90-9
ELECTRICAL SCHEMATIC ................................................................................................ 90-11
WIRING - 1 OF 7 ................................................................................................................ 90-11
WIRING - 2 OF 7 ................................................................................................................ 90-13
WIRING - 3 OF 7 ................................................................................................................ 90-15
WIRING - 4 OF 7 ................................................................................................................ 90-17
WIRING - 5 OF 7 ................................................................................................................ 90-19
WIRING - 6 OF 7 ................................................................................................................ 90-21
WIRING - 7 OF 7 ................................................................................................................ 90-23
LEGEND FOR WIRING SCHEMATIC............................................................................. 90-25
FUSE AND RELAY PANEL.............................................................................................. 90-27
WB146-5 90-1
OTHERS
12
90-2 WB146-5
OTHERS HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
1 OF 4
WB146-5 90-3
12
90-4 WB146-5
12
2 OF 4
WB146-5 90-5
12
90-6 WB146-5
12
3 OF 4
WB146-5 90-7
12
90-8 WB146-5
12
4 OF 4
WB146-5 90-9
12
90-10 WB146-5
OTHERS ELECTRICAL SCHEMATIC
12
ELECTRICAL SCHEMATIC
WIRING - 1 OF 7
WB146-5 90-11
12
90-12 WB146-5
12
WIRING - 2 OF 7
WB146-5 90-13
12
90-14 WB146-5
12
WIRING - 3 OF 7
WB146-5 90-15
12
90-16 WB146-5
12
WIRING - 4 OF 7
WB146-5 90-17
12
90-18 WB146-5
12
WIRING - 5 OF 7
WB146-5 90-19
12
90-20 WB146-5
12
WIRING - 6 OF 7
WB146-5 90-21
12
90-22 WB146-5
12
WIRING - 7 OF 7
WB146-5 90-23
12
90-24 WB146-5
12
LEGEND FOR WIRING SCHEMATIC
ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION ITEM DESCRIPTION
A6 Machine Function Unit F19 Low Beam Light 15A Fuse S24 Starting Switch X27.s AC Harness Connector
B13 Return To Dig Sensor F20 Main Beam Light 15A Fuse S40 Seat Switch X28.s Heater Connector
B59 Brake Oil Low Level Switch F21 Return To Dig Sensor 10A Fuse S41 Rear Horn Switch X44.p Cab Harness Connector
B97 Rear Horn Switch F22 EC Power 7.5A Fuse S46 Parking Brake Switch X44.s Driver Site Harness Connector
B105 Transmission Oil Temperature Sender F23 Steering Unit 10A Fuse S53 Stop Light Switch X65.p Motor Harness Connector
B111 Fuel Level Sender F24 Flasher 7.5A Fuse S54 Stop 4WD Switch X128.s Driver Site Harness Connector
B112 Thermistor F25 Reverse Buzzer Switch 10A Fuse S57 Steering Column Gear Shift X140 Cab Harness Connector
B113 Air Filter Switch F27 General 175A Fuse S60 Steering Column Light Switch X142 Cab Harness Connector
B115 Engine Oil Pressure Switch S80 Ride Control Switch X166.p Switch Harness Connector
B121 Horn G1 Battery S81 Boom Unlock Switch X166.s Cab Harness Connector
G118 Starter Motor S83 EC Power Switch X177.s Work Light Harness Connector
E136 Right Rear Wok Light G119 Alternator S84 EMPI Solenoid Valve Switch
E138 Left Rear Work Light S85 Rear Horn Switch X30 Cigar Lighter
E143 Right Front Wok Light H17 Buzzer S86 General Light Switch Y48 Float Solenoid
E146 Left Front Work Light S87 4WD Switch Y49 Return To Dig Solenoid
E147 Left Indicator K1 Starter Lock Out Unit S88 PPC Switch Y60 EMPI Solenoid
E148 Beacon Lamp K2 Flasher S89 Warning Switch Y90 Rear PPC Solenoid
E151 Right Indicator K3 Low Beam Light Relay S97 Rear Horn Switch Y91 EC Power Solenoid
E152 Cab Light K4 Main Beam Light Relay S104 4th Speed Switch Y92 Back Up Alarm
E154 Rear Left Light K5 Front Horn Relay S107 Declutch Switch Y93 PPC Solenoid
E155 Left Indicator Light K6 Return To Dig Solenoid Relay S167 Beacon Light Switch Y94 Differential Lock Solenoid
E155 Right Indicator Light K7 Stop Light Relay S168 Front Working Light Switch Y95 Boom Unlock Solenoid
E156 Rear Right Light K8 Starter Relay S169 Rear Working Light Switch Y96 Solenoid
E400 Right Front Work Light K9 Forward Speed Relay Y98 MP Bucket Close Solenoid
E401 Left Front Work Light K10 Reverse Speed Relay X1.s Unit Connector Y99 MP Bucket Open Solenoid
E402 Left Rear Work Light K11 Declutch Relay X2.s Unit Connector Y106 4WD Solenoid
E403 Right Rear Work Light K45 Reheating Relay X3.s Unit Connector Y108 Forward Speed Solenoid
K56 Safety Start Relay X4.s Unit Connector
F1 Front Work Light 15A Fuse K61 Services Relay X5.s Unit Connector
F2 Rear Work Light 15A Fuse K111 X7.p Motor Harness Connector
F3 Right Position Light 3a Fuse X7.s Driver Site Harness Connector
F4 Left Position Light 3a Fuse M42 Rear Window Wiper X8.p Gear Harness Connector
F5 Horn 10A Fuse M55 Window Washer Pump X8.s Driver Site Harness Connector
F6 Rear Work Light 15A Fuse M58 Front Window Wiper X9.p Front Dashboard Harness Connector
F7 Front Window Washer 7.5A Fuse M116 AC Compressor Clutch X9.s Driver Site Harness Connector
F8 Stop Light Switch 7.5A Fuse X10.p Front Dashboard Harness Connector
F9 Front Work Light 15A Fuse P43 Instrument Panel X10.s Driver Site Harness Connector
F10 Front Wiper 10A Fuse P63 Front Control Panel X11.p Solenoid Valve Harness Connector
F11 Optional 7.5A Fuse X11.s Driver Site Harness Connector
F12 Instruments And Buzzer 5A Fuse R114 Preheater X12.p Chassis Harness Connector
F13 Lever Grip 10A Fuse X12.s Driver Site Harness Connector
F14 Light And Optional Switch 10A Fuse S2 EC Power Switch Solenoid Valve X15.p Optional Harness Connector
F15 Safety Starter 10A Fuse S3 MP Bucket Close Switch X25.p Switch Panel Harness Connector
F16 Beacon Light 10A Fuse S4 Declutch Switch X25.s Driver Site Harness Connector
F17 Warning Switch 10A Fuse S5 MP Bucket Open Switch X26.p Switch Panel Harness Connector
F18 Cab Light And Cigar Lighter 10A Fuse S6 Differential Locking Switch X26.s Driver Site Harness Connector
WB146-5 90-25
12
90-26 WB146-5
12
FUSE AND RELAY PANEL
TIER I ENGINE
Position Description
F1 A 15A Light Blue for Low Beam
F1 B 3A Violet for Parking Lights
F1 C 3A Violet for Parking Lights
F2 A 10A Red for Lighter
F2 B 7.5A Brown for Dome Light Radio
F2 C 10A Red for Emergency Power Supply
F3 A 7.5A Brown for Start Enable
F3 B 7.5A Brown for Instruments Switch Lights
F3 C 7.5A Brown for OPT Solenoid
F4 A 7.5A Brown for Diff Lock Solenoid Valve
F4 B 10A Red for Direction Selector
F4 C 15A Light Blue for High Beam
F5 A 15A Light Blue for Heater
F5 B 15A Light Blue for Rear Work Light
F5 C 15A Light Blue for Front Work Light
F6 A 15A Light Blue for Wiper and Beacon
F6 B 7.5A Brown for Dimmer Switch Horn Relay
F6 C 10A Red for Directional Indicators
F7 A 7.5A Brown for Monitor
F7 B 10A Red for Horn
F7 C 7.5A Brown for Alt Excitation Stop Solenoid
K1 Forward Gear Relay

K2 Reverse Gear Relay
K3 Four Wheel Drive Relay
K4 ···
K5 Low Beam Relay
K6 High Beam Relay
K7 Direction Selector Power Supply Relay
K8 Horn Relay
K9 Turn Indicator Relay
K10 Flasher Relay
K11 4th Gear Signaling Relay
WB146-5 90-27
12
90-28 WB146-5

Shop Manual 146-5

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Shop Manual 146-5

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CEBM016501

August 2006 Copyright 2006 Komatsu

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

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

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

IMPORTANT SAFETY NOTICE

● Always wear safety glasses when hitting parts with a

5. When removing covers which are under internal pres-

VOLUMES 00 REVISED EDITION MARK 00

Chassis volume: Issued for every machine model REVISIONS 00

Attachment volume: Each issued as one to cover all models

WARNING!Heavy parts (25kg or more) must be

● If a part cannot be smoothly removed from the machine

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

2. Check for existence of another part causing interface

22.4 54.9 5.6

★ The allowable load value is estimated to be 1/6 or 1/7 of

2. Sling wire ropes from the middle portion of the hook.

can result. Hooks have maximum strength at the middle

WARNING!Before carrying out the following work, release the

WARNING!Even if the residual pressure is released from the hy-

Category Code Part No. Quantity Container Main applications, features

Category Code Part No. Quantity Container Main applications, features

● Used to prevent seizure or scuffing of the

G2-LI SYG2-400LI-A Various Various ● General purpose type

400 g (10 per

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00

Thread diameter of bolt Width across flats

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

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

Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00

Use these torques for split flange bolts.

Thread diameter Width across flat Tightening torque

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.

Thread diameter Width across flat Tightening torque

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

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00

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