WB142 5 PDF

CEBM018901
Shop
Manual
WB142-5
BACKHOE LOADER
SERIAL NUMBERS WB142-5 A13001 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 improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2008 Komatsu

Printed in U.S.A.
Komatsu America Corp.
May 2008
FOREWORD CONTENTS
12
CONTENTS 00
00 FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20 STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 b WB142-5
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 b 01-3 ● 10-21 b ● 10-50 b
● 00-2 b ● 01-4 b ● 10-22 b 10-51
❍ 00-2-1 b 01-5 ● 10-23 b 10-52
❍ 00-2-2 b ● 01-6 b ● 10-24 b ● 10-53 b
❍ 00-2-3 b 01-7 10-25 ● 10-54 b
❍ 00-2-4 b 01-8 10-26 10-55
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00-5 ● 10-29 b 10-58
00-6 10-1 ● 10-30 b 10-59
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00-22 ● 10-17 b 10-46 ● 30-1 b
10-18 ● 10-47 b 30-2
01-1 10-19 ● 10-48 b 30-3
● 01-2 b 10-20 ● 10-49 b 30-4
WB142-5 WB142-5 00-2-1 b

FOREWORD
30-5 40-7 50-9 50-42
30-6 40-8 ● 50-10 b 50-43
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30-8 40-10 ● 50-12 b 50-45
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30-10 40-12 ● 50-14 b 50-47
● 30-11 b 40-13 ● 50-15 b 50-48
30-12 40-14 ● 50-16 b 50-49
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● 30-14 b 40-16 50-18 50-51
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40-6 50-8 50-41 50-74
00-2-2 b WB142-5
FOREWORD
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50-107 ● 50-140 b 50-173 50-206
WB142-5 00-2-3 b
FOREWORD
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● 50-208 b 50-241 50-274 ● 50-307 b
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50-213 50-246 ● 50-279 b ● 50-312 b
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● 50-215 b 50-248 50-281 90-1
● 50-216 b 50-249 50-282 90-2
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50-221 50-254 50-287 90-7
50-222 50-255 50-288 90-8
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50-224 ● 50-257 b 50-290 90-10
50-225 50-258 50-291 90-11
50-226 50-259 ● 50-292 b 90-12
50-227 50-260 ● 50-293 b 90-13
50-228 50-261 ● 50-294 b 90-14
50-229 50-262 ● 50-295 b 90-15
50-230 50-263 ● 50-296 b 90-16
50-231 50-264 ● 50-297 b 90-17
50-232 ● 50-265 b ● 50-298 b 90-18
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● 50-234 b ● 50-267 b ● 50-300 b
50-235 ● 50-268 b ● 50-301 b
50-236 50-269 ● 50-302 b
50-237 50-270 ● 50-303 b
50-238 50-271 ● 50-304 b
50-239 50-272 ● 50-305 b
00-2-4 b WB142-5
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair procedures
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00
Mistakes in operation are extremely costly and dangerous. 1. Before adding oil or making repairs, park the machine
Read the OPERATION & MAINTENANCE MANUAL on hard, level ground, and block the wheels or tracks to
carefully BEFORE operating the machine. prevent the machine from moving. Lower all work
implements to the ground and remove ignition key
1. Before carrying out any greasing or repairs, read all the
precautions given on the decals attached to the machine. 2. Before starting work, lower blade, ripper, bucket or any
other work equipment to the ground. If this is not possi-
2. When carrying out any operation, always wear proper ble, insert the safety pin or use blocks to prevent the
safety equipment specified for the operation you are work equipment from falling. In addition, be sure to
performing. Do not wear loose fitting work clothes, or lock all the control levers and hang warning signs on
clothes with buttons missing. them.
● Always wear safety glasses when striking parts with a
hammer. 3. When disassembling or assembling, support the
● Always wear safety glasses when grinding parts with a machine with blocks, jacks or stands before starting
grinder, etc. work.
4. Remove all mud and oil from the steps or other places
3. If welding repairs are needed, always have a trained,
used to get on and off the machine. Always use the
experienced welder carry out the work. When carrying
handrails, ladders or steps when getting on or off the
out welding operations, always wear welding gloves,
machine. Never jump on or off the machine. If it is
apron, glasses, cap and other clothes suited for welding
impossible to use the handrails, ladders or steps, use a
work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or hydrau-
before starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to pre-
work, lock and tag all controls in the operator's compart- vent the oil from spurting out. Before disconnecting or
ment. removing components of the oil, coolant or air circuits,
first relive the pressure completely from the circuit.
5. Keep all tools in good condition.
2. The coolant and oil in the systems are hot when the
6. Decide on a place in the repair workshop to keep tools engine is stopped, so be careful not to get burned. Wait
and removed parts. Always keep the tools and parts in for the oil and coolant to cool before carrying out any
their correct places. Always keep the work area clean work on the oil or coolant systems.
and make sure there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.
WB142-5 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Never use flammable liquids to clean parts, always use approved non-flammable solvents to clean parts.
9. Be sure to assemble all parts in their original locations. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, be sure that they are not twisted. Damaged tubbing dangerous, be extremely careful
when installing tubes for high pressure circuits. Also make sure parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques and sequences. When installing
protective parts such as guards, or parts that may vibrate or rotate at high speeds, be particularly careful to check their
installation carefully.
12. When aligning two holes, never insert your fingers or hand. Use appropriate tools to align parts.
13. When measuring hydraulic pressure, be sure the measuring tool is correctly assembled before taking any measurements.
14. Take care when removing or installing the tracks on track-type machines. When removing the track, the track separates
suddenly, never let anyone stand at either end of the track.
15. When making repairs or adjustments on electronically controlled engines, avoid any physical contact with the injection
systems wiring harness while the engine is running. Due to the high voltage and amperage in this system, serious injury
may occur.
16. Never use a welder or machine with a higher voltage to jump-start or supply voltage to a machine with a lower voltage
system, damage to the machines electrical system or a fire or explosion may result. Always stay within the same voltage
range as the machine.
00-4 WB142-5
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
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
completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this
section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
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.
WB142-5 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00
Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
Shop manuals are issued as a guide to carrying out repairs.
They are divided as follows: SYMBOLS 00
Chassis volume: Issued for every machine model So that the shop manual can be of ample practical use,
Engine volume: Issued for each engine series important places for safety and quality are marked with the
following symbols.
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
Symbol Item Remarks
These various volumes are designed to avoid duplication of Special safety precautions are
information. Therefore to deal with all repairs for any model, Safety necessary when performing the
it is necessary that chassis, engine, electrical and attachment work.
be available.
Special technical precautions or
other precautions for preserving
DISTRIBUTION AND UPDATING ★ Caution
00
standards are necessary when

performing the work.
Any additions, amendments or other changes will be sent to
your distributors. Get the most up-to-date information before Weight of parts or systems.
you start any work. Caution necessary when selecting
Weight
hoisting wire or when working
FILING METHOD 00
posture is important, etc.
Places that require special
Tightening
1. See the page number on the bottom of the page. File the attention for tightening torque
torque
pages in correct order. during assembly.
2. Following examples show how to read the page number:
Example: Places to be coated with adhesives
Coat
and lubricants etc.
10 - 3
Places where oil, water or fuel
Oil, water
must be added, and the capacity.
Item number (10. Structure and Function)
Places where oil or water must be
Consecutive page number for each item Drain drained, and quantity to be
drained.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (j …) is

recorded on the bottom outside corner of the pages.
REVISIONS 00
00-6 WB142-5
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load dur-
WIRE ROPES 00 ing hoisting, untwisting of the
rope, or slipping of the rope
1. Use adequate ropes depending on the weight of parts to from its original winding posi-
be hoisted, referring to the table below: tion on the load, which can
result in a dangerous accident
Wire ropes
(Standard “Z” or “S” twist ropes without galvanizing) 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
Rope diameter Allowable load
two or more ropes, the force subjected to each rope will
mm kN tons increase with the hanging angles. The table below
shows the variation of allowable load (kg) when
10 9.8 1.0
hoisting is made with two ropes, each of which is
11.2 13.7 1.4 allowed to sling up to 1000 kg vertically, at various
hanging angles. When two ropes sling a load vertically,
12.5 15.7 1.6
up to 2000 kg of total weight can be suspended. This
14 21.6 2.2 weight becomes 1000 kg when two ropes make a 120°
hanging angle. On the other hand, two ropes are subject
16 27.5 2.8
to an excessive force as large as 4000 kg if they sling a
18 35.3 3.6 2000 kg load at a lifting angle of 150°
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WB142-5 00-7
FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1. Standard size and tolerance

• To be accurate, the finishing size of parts is a little
different from one to another.
• To specify a finishing size of a part, a temporary standard
size is set and an allowable difference from that size is
indicated.
• The above size set temporarily is called the “standard size”
and the range of difference from the standard size is called
the “tolerance”.
• The tolerance with the symbols of + or – is indicated on
the right side of the standard size
Example.
Standard size Tolerance

-0.022
120
-0.126
★ The tolerance may be indicated in the text and a table as

[standard size (upper limit of tolerance/lower limit of toler-
ance)].
Example) 120 (–0.022/–0.126)
● Usually, the size of a hole and the size of the shaft to be fitted
to that hole are indicated by the same standard size and
different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance.
● Indication of size of rotating shaft and hole and relationship drawing of them
Standard size Tolerance

Shaft Hole
60 -0.030 +0.046
-0.076 0
2. Standard clearance and standard value

• The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range
from the minimum clearance to the maximum clearance.
• When some parts are repaired, the clearance is generally adjusted to the standard clearance.
• A value of performance and function of new products or equivalent is called the “standard value“, which is indicated
by a range or a target value.
• When some parts are repaired, the value of performance/function is set to the standard value.
3. Standard interference
• When the size of a hole is smaller than the size of a shaft because of the standard size and tolerance, the difference
between these sizes is called the “interference”.
• The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole
to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard inter-
ference”.
• After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in
the standard range.
00-8 WB142-5
FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
4. Repair limit and allowable value
• The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the
“repair limit”.
• If a part is worn to the repair limit must be replaced or repaired.
• The performance and function of a product lowers while it is used. A value below which the product can be used
without causing a problem is called the “allowable value”.
• If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated
from various tests or experiences in most cases, however, it must be judged after considering the operating condition
and customer's requirement.
5. Clearance limit
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts can-
not be used is called the “clearance limit”.
• If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
6. Interference limit
• The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called
the “interference limit”.
• The interference limit shows the repair limit of the part of smaller tolerance.
• If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
00-9 WB142-5
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
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals,
1735
rubbers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket seal- ● Used as sealant for flange surfaces and bolts
ant at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-10 WB142-5
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 joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket seal- ● Features: Silicon based, resistant to heat,
ant cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to
LM-G 09940-00051 60 g Can
Molybdenum
prevent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

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

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-11 WB142-5
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 Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-12 WB142-5
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5
00-13 WB142-5
FOREWORD CONNECTING PUSH-PULL TYPE COUPLER.
12
CONNECTING PUSH-PULL TYPE COUPLER. 00
WARNING! Before carrying out the following work, loosen the oil filler cap of the hydraulic tank grad-
ually to release the residual pressure from the hydraulic tank
WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Accordingly, prepare an oil receiving container.
★ Type 1
1. Disconnection
A. Hold adapter (1) and push hose joint (2) into mating
adapter (3). (Fig. 1)
• The adapter can be pushed in about 3.5 mm.

• Do not hold rubber cap portion (4).
B. After hose joint (2) is pushed into adapter (3), press rubber
cap portion (4) against adapter (3) until it clicks. (Fig. 2)
C. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3)
• Since some hydraulic oil flows out, prepare an oil

receiving container.
2. Connection
A. Hold hose adapter (1) or hose (5) and insert it in mating
adapter (3), aligning them with each other. (Fig. 4)
• Do not hold rubber cap portion (4).

B. After inserting the hose in the mating adapter perfectly,
pull it back to check its connecting condition. (Fig. 5)
• When the hose is pulled back, the rubber cap portion

moves toward the hose about 3.5 mm. This does not
indicate abnormality, however.
00-14 WB142-5
★ Type 2
1. Disconnection
A. Hold the tightening portion and push body (7) straight
until sliding prevention ring (6) contacts contact surface
(a) of the hexagonal portion at the male end. (Fig. 6)
B. While holding the condition of Step 1), turn lever (8) to

the right (clockwise). (Fig. 7)
C. While holding the condition of Steps 1) and 2), pull out

whole body (7) to disconnect it. (Fig. 8)
2. Connection
• Hold the tightening portion and push body (7) straight
(a) of the hexagonal portion at the male end. (Fig. 9)
00-15 WB142-5
★ Type 3
1. Disconnection
A. Hold the tightening portion and push body (9) straight
(b) of the hexagonal portion at the male end. (Fig. 10)
B. While holding the condition of Step 1), push cover (10)

straight until it contacts contact surface (b) of the
hexagonal portion at the male end. (Fig. 11)
C. While holding the condition of Steps 1) and 2), pull out

whole body (9) to disconnect it. (Fig. 12)
2. Connection
• Hold the tightening portion and push body (9) straight
until the sliding prevention ring contacts contact surface
(b) of the hexagonal portion at the male end. (Fig. 13)
00-16 WB142-5
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 j, then draw a horizontal line from j.
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
j
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
WB142-5 00-17
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 WB142-5
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
WB142-5 00-19
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-20 WB142-5
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
WB142-5 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 WB142-5
01 GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
SERVICE REFILL CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
TOTAL MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
STANDARD BUCKET CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 01-7
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
FUEL REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
WB142-5 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
SPECIFICATIONS
MACHINE DIMENSIONS AND WEIGHTS
A Maximum height 4080mm (13’5”) M Transport length 7060mm (23’2”)

B Hinge pin height 3255mm (10’8”) N Dumping height (SAE) 3600mm (11’10”)
C Overall height, ROPS Canopy 2820mm (9’4”) O Maximum digging height 5210mm (17’1”)
D Maximum dumping height 2615mm (8’7”) P Digging depth (2’ level bottom) 4276mm (14’0”)
Reach at maximum height
E 910mm (3’0”) Q Reach at maximum height 2640mm (8’8”)
and 45o dump angle
F Dumping angle 45o R Maximum reach 5580mm (18’4”)
G Rollback angle 45o S Maximum digging depth 4318mm (14’2”)
H Digging depth 100mm (4’0”) T Digging reach 2380mm (7’10”)
I Bucket reach (transport) 1900mm (6’3”) U Rear tread 1680mm (5’6”)
J Ground clearance 380mm (1’3”) V Front tread 1780mm (5’10”)
K Wheel base 2175mm (7’2”) W Overall width (with bucket) 2180mm (7’2”)
L Backhoe swing center distance 1175mm (3’10”) X Backhoe transport height 3660mm (12’0”)
01-2 1 WB142-5
GENERAL SPECIFICATION DRAWING
BACKHOE ARM
01-3 WB142-5
GENERAL MACHINE SYSTEMS SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS
ENGINE
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu 4D102LE-2

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water-cooled, in line 4-cycle
Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 x 138 mm (4.02 x 5.43 Inches)
Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ltr (275 in3)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18:1
• Horsepower rating @ 2200 rpm (WB142-5)
Gross horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kW 80 HP
Net horsepower (SAE J 1349). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 kW 76 HP
Max. torque @ 1300 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Nm (221 ft lbs)
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with safety element
• Lubrication system
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow
• Cooling system
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator water cooled system
• Starting system
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric motor with air pre-heating system for cold climate
ELECTRICAL SYSTEM
Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah (860 CCA)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95A
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0kw
SERVICE REFILL CAPACITIES

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ltr (2.4 US.gal)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 ltr (3.7 US. gal)
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 ltr (31.7 US. gal)
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 ltr (10.8 US. gal)
Hydraulic system capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 ltr (25.6 US. gal)
Front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 ltr (1.9 US. gal)
Rear axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 ltr (3.8 US. gal)
Gearbox oil, Power Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.0 ltr (4.8 US. gal)
01-4 1 WB142-5
GENERAL MACHINE SYSTEMS SPECIFICATIONS
TRANSMISSION
The transmission is operated through a torque converter and a power shift reversing shuttle; the mechanical 4- speed gearbox
is synchronized
Calculated with standard tires and engine at 2200 rpm.
FORWARD REVERSE
Gears 1st 2nd 3rd 4th 1st 2nd 3rd 4th
km/h 5.2 8.5 18.5 37.0 5.2 8.5 18.5 37.0
m/h 3.2 5.3 11.5 23.0 3.2 5.3 11.5 23.0
TOTAL MASS
Maximum total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,298 kg(16090 lb)
STANDARD BUCKET CAPACITY

Bucket breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,150 kg (11,351 lb)
Arm breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,550 kg (7,670 lb)
Front bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAE) 0.77 m (3 1.0 yd3)
Backhoe bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAE) 0.20 m (3 0.24 yd3)
LOADER
Standard bucket width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,180 mm (7ft 2in)
Standard bucket capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.77m3 (6,00 yd3)
Standard bucket weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410 kg (904 lb)
Lifting capacity at maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,870 kg (6,325 lb)
Lifting capacity at ground level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,670 kg (8,089 lb)
Breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,590 kg (10,116 lb)
WB142-5 01-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
★ This Weight Table is for reference when handling components or when transporting the machine.
Unit: kg (lbs)
Machine model WB142-5
Engine assembly - Muffler and exhaust pipe 400 (882)
Radiator 37 (82)
Hydraulic oil tank (empty) 10 (22)
Fuel tank (empty) 62 (137)
Front counter weight 170 (375)
Engine hood 32 (71)
Canopy (without seat) 580 (1,279)
Seat 23 (51)
Engine - transmission - pump 682 (1,504)
Hydraulic pump 31.5 (69.4)
Transmission 232 (511)
Front axle 262 (578)
Rear axle 430 (948)
Front wheel (complete with rim) 52 (115)
Rear wheel (complete with rim) 126 (357)
Work equipment (front loader) 1,100 (2,425)
Boom 313 (690)
Bucket 436 (961)
Bucket cylinder (mono-link) 13x1
Boom cylinder 46x2
2-spool control valve 24 (53)
Backhoe work equipment 750 (1,653)
Backhoe boom cylinder 248 (547)
Backhoe arm cylinder 305 (672)
Backhoe swing frame 162.5 (358.3)
Outriggers 39x2
Boom cylinders 87.5 (193)
Arm cylinders 67 (148)
Bucket cylinders 52.5 (116)
Outrigger cylinders 27.5x2
Swing cylinders 34x2
Bucket 158 (348)
01-6 1 WB142-5
GENERAL FUEL, COOLANT, AND LUBRICANTS
FUEL, COOLANT, AND LUBRICANTS
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE
Ambient Temperature Capacity

Type of
Reservoir
fluid -22 -4 14 32 50 68 86 104 122°F
Specified Refill
-30 -20 -10 0 10 20 30 40 50° C
SAE 5W-30 11 liter 13 liter

Engine oil (11.6 US gal) (13.7 US gal)
SAE 10W 30
pan Aspirated Aspirated
SAE 15W-40 engine engine
SAE 5W*
Hydraulic Oil API SAE 10W 150 liter 92 liter

system CI-4 SAE 30 (39.6 US gal) (24.3 US gal)
SAE 10W-30
Hydraulic
system with 150 liter 92 liter
See page 3-12
biodegradable (39.6 US gal) (24.3 US gal)
oil
Front axle: 6.5 liter 6.5 liter

Differential (1.7 US gal) (1.7 US gal)
Final
1 liter 1 liter
reduction gear
(0.26 US gal) (0.26 US gal)
(ea.) (See Note 1)
Rear axle: 14.5 liter 14.5 liter
Differential (3.8 US gal) (3.8 US gal)
Final
1.5 liter 1.5 liter
reduction gear
(0.4 US gal) (0.4 US gal)
(ea.)
Hydraulic 20 liter 17 liter

transmission GM (5.3 US gal) (4.5 US gal)
DEXRON
Brake II D 0.8 liter 0.8 liter
system (0.2 US gal) (0.2 US gal)
ASTM
Diesel D975 No. 130 liter
Fuel tank 1 -
fuel (34.4 US gal)
ASTM D975 No. 2
Cooling 14 liter
Coolant -
system (3.7 US gal)
OPTION FOR VERY COLD AREAS: If the temperature exceeds 10° C (50° F), contact your Komatsu Dealer for advise
on the type of oil to be used.
WB142-5 01-7
GENERAL FUEL, COOLANT, AND LUBRICANTS
GREASE
Lubrication Points Consistency Type
Articulations, grease fittings NLGI 2 (See note 2)
Note 1:For axle oil, use only the recommended oil as follows.
SHELL: DONAX TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TEXTRAN TDH OIL
MOBIL: MOBILFLUID 422 or 424
Note 2: The recommended lubricating grease is No.2 multi-purpose lithium grease with 3% molybdenum disulfide
(Lithio EP + MoS2).
FUEL REMARKS
• When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this
manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil in engine

Fuel sulphur content
oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
• When starting the engine in an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil of SAE10W,
SAE20W-20 and SAE10W-30, even though an atmospheric temperature goes up to 10°C (18°F) more or less in the day
time.
• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 10W-40), but be sure to add single
grade oil that matches the temperature in the table.
• Use Komatsu genuine oil which has been specifically formulated and approved for use in the engine, hydraulic work
equipment, transmission, axles, and brakes.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
01-8 WB142-5
GENERAL HOMOLOGATED (HEES) SYNTHETIC LU-
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS

Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils
indicated in the following table is authorized and recommended:
Supplier HEES Synthetic Biodegradable Oil
KOMATSU ---
AGIP ARNICA S 46
ARAL HEF 46 vitam
AVIA SYNTOFLUID N 46
BP BIOHYD SE-S 46
CONDAT CONDAT D 46 K
ELF HYDRELF BIO 46
ESSO HYDRAULIKOIL HE 46
FINA BIOYIDRAN TMP 46 SE 46
FUCHS PLANTOHYD S 46
KENDALL SYNTH NATURA 46 HV
KUWAIT PETROLEUM K8 HOLBEIN 46
MOBIL EAL SYNDRAULIC
MOBIL (USA) ENVIROSYN 46 H
PAKELO GEOLUBE HYDRAULIC EP-46
PANOLIN HLP SYNTH 46
SHELL NATURELLE HFE-46
TAMOIL GREEN HYDRO SAFETY 46
TEXACO HYDRA 46
TOTAL EQUIVIS BIO 46
VAVOLINE UNISYN HLP 32/68
• It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when the
temperature increases insoluble compounds are generated, which are deposited on the filters and clog them (the
maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).
• The synthetic biodegradable oil can be used only in the hydraulic system; it cannot be used for the endothermic
motor, the transmissions, the braking system, etc.
• Before introducing the synthetic biodegradable oil in the hydraulic system, empty the system completely,
disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new
one. Start the engine and let it idle without using the work equipment, wait until the oil reaches a temperature of at
least 40°C (104°F), then start moving the equipment, so that all the parts of the system are filled with oil. Stop the
engine and check the oil level.
WB142-5 01-9
GENERAL LUBRICATION DIAGRAMS
12
LUBRICATION DIAGRAMS
GENERAL VIEW
Remark
Use only recommended oil and grease.
01-10 WB142-5
10 STRUCTURE, FUNCTION AND
12
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
4 WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
TRANSMISSION COMPONANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
CONVERTER AND TRANSMISSION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
TRANSMISSION INTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
GEAR SHIFTER AND FILTERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
CLUTCH PACKS AND DRIVEN GEAR SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
4 WHEEL DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
CONTROL VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
TRANSMISSION CASE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
INTERNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
GEAR SHIFTER AND COMPONANTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
FINAL DRIVE END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
AXLE CARRIER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
AXLE END SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
STEERING UNIT CYLINDER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
AXLE END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
AXLE CARRIER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
AXLE END SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
LOCK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
LOADER 3 - SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
LOADER SPOOL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
BACKHOE SPOOL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
(ST1 VALVE LOCK - DIFFERENTIAL LOCK - BACKHOE BOOM LOCK) . . . . . . . . . . . . . . . . . . . . . 10-44
MASTER CYLINDER (BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
LOADER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
ARM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
ARM CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
BUCKET CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
WB142-5 10-1
STRUCTURE, FUNCTION AND
BOOM cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
ARM cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
BUCKET SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
OUTRIGGER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
BOOM SWING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
BOOM CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
ARM CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
BUCKET CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
BOOM SWING CYLINDER TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
OUTRIGGERS TOLERANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
PIN AND BUSHING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
LOADER WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
BACKHOE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
10-2 WB142-5
MAINTENANCE STANDARD POWER TRAIN
12
POWER TRAIN
SYSTEM OVERVIEW
DESCRIPTION
• The driving power for the engine (1) is transmitted through the flywheel to the converter (2). The converter (2) uses
hydraulic oil to convert the torque transmitted by the engine (1) into driving power. The converter (2) transmits motion to
the drive shaft of the transmission (3) and to the drive shaft of the hydraulic pump (4).
• The transmission (3) has two hydraulically-activated clutches that can be selected by an electrically controlled gear
selector. It also has manual gear selection (four forward gears and four reverse gears).
• The driving power is transmitted from the transmission flanges (3) to the front (5) and rear (6) axles through the drive
shafts (7 and 8).
• The driving power transmitted to the front (5) and rear (6) axles is reduced by the differentials and then transmitted to the
planetary gear through the differential shafts.
WB142-5 10-3
12
4 WHEEL DRIVE SYSTEM
Front axle Rear axle

Gears
Transmission Differential Planetary Total Transmission Differential Planetary Total
1st gear 7.004 96.988 5.603 134.472
2nd gear 4.350 60.239 3.480 83.520
2.308 6.000 3.750 6.400
3rd gear 1.980 27.419 1.584 38.016
4th gear 0.991 13.727 0.793 19.032
1. Diesel engine 4. Hydraulic pump 7. Front and rear drive shafts

2. Torque converter 5. Front axle 8. Rear wheels
3. Transmission 6. Rear axle 9. Front wheels
10-4 WB142-5
TRANSMISSION COMPONENTS
1. Diesel engine 4. Transmission 7. Rear yolk

2. Torque converter 5. Reverse clutch 8. 4WD engagement device
3. Forward clutch 6. Hydraulic pump 9. Front yolk
WB142-5 10-5
12
CONVERTER AND TRANSMISSION CIRCUIT DIAGRAM
1. Converter pressurization valve 7. Max. pressure valve: 23bar (334 psi) 13. Pressure control
2. Converter 8. Spin-on filter 14. 4WD engagement solenoid
3. Diesel engine 9. Pump 15. Control valve group
4. Oil cooler 10. Suction filter 16. Oil flow divider/pressure regulator
valve.
5. Forward clutch 11. 4WD engagement solenoid
6. Reverse clutch 12. Check valve
10-6 WB142-5
MAINTENANCE STANDARD TRANSMISSION
12
TRANSMISSION
CASE
1. Gear shift lever 4. Oil temperature sensor 7. Y203 Reverse gear command solenoid valve
2. Torque converter 5. Suction filter 8. Y108 Forward gear command solenoid valve
3. Filter 6. 4th gear selecting sensor
a. From the oil cooler

b. To the oil cooler
WB142-5 10-7
12
TRANSMISSION INTERNAL VIEW
1. Hydraulic pump drive shaft 7. Rear yolk 13. 4WD engagement device
2. Transmission drive shaft 8. 3rd. gear driven gear 14. Front output shaft
3. Reverse clutch 9. 4th. gear driven gear 15. Front yolk
4. Forward clutch 10. 4WD drive gear 16. 2nd. gear driven gear
5. Reverse gear idler shaft 11. 1st. gear driven gear 17. Rear output shaft
6. Drive shaft 12. 4WD driven gear
10-8 WB142-5
12
GEAR SHIFTER AND FILTERING SYSTEM
1. Gear shift lever 7. 3rd. and 4th. selector rod 13. Spin-on filter
2. Spring 8. 1st. and 2nd. selector rod 14. Valve
3. Spring 9. 4th. gear selector sensor 15. Spring
4. Ball 10. 3rd. and 4th. selector fork 16. Ball
5. 3rd. and 4th. selector fork 11. 1st. and 2nd. selector fork 17. Spring
6. 1st. and 2nd. selector fork 12. Suction filter 18. Selector rod
WB142-5 10-9
12
CLUTCH PACKS AND DRIVEN GEAR SET
CLUTCH PACK
a. Port command reverse clutch b. Port command forward clutch c. Lubrication port
1. Reverse gear clutch 3. Forward clutch piston 5. Shoulder ring
2. Forward gear clutch 4. Reverse clutch piston 6. Driven shaft
DRIVEN GEAR SET
1. 2nd. gear 4. 4th. gear 7. Shoulder ring

2. 1st. gear 5. 3rd. gear 8. Synchronizers
3. 4WD driven gear 6. Rear output shaft
10-10 WB142-5
12
4 WHEEL DRIVE SHAFT
a. 4WD disengagement command port 3. Cylinder

1. Front output shaft 4. Spring
2. 4WD gear driven 5. Disk
WB142-5 10-11
12
CONTROL VALVE BLOCK
1. Ball 9. Valve
2. Spring 10. Piston rod
3. Piston 11. Spring
4. Spring 12. Spool return spring
5. Spring 13. Spool
6. Spring-guide pin 14. Forward gear command solenoid
7. Valve 15. Reverse gear command solenoid
8. Spring
10-12 WB142-5
12
TRANSMISSION CASE SPECIFICATIONS
TORQUE VALUES
No. N·m lbf•ft

1 30 22.1
2 23 17.0
WB142-5 10-13 1
12
INTERNAL SPECIFICATIONS
TORQUE VALUES
No. N·m lbf•ft

1 50 37
2 23 17
3 40 30
4 23 17
5 136 100.3
(a) Use Loctite 518
10-14 1 WB142-5
GEAR SHIFTER AND COMPONENTS SPECIFICATIONS
TORQUE VALUES
No. N·m lbf•ft

1 23 17
2 80 59
3 25 18.4
4 50 37
5 30 22
6 26 - 30 19 - 22
(a) Use Loctite 542
WB142-5 10-15 1
12N·m
TORQUE VALUES
No. N·m lbf•ft

1 9 - 11 7 - 8.1
2 7 - 10 5.2 - 7.4
3 21.5 - 24.5 16 - 18.1
4 5-8 4.0 - 6.0
5 22 16.2
6 23 17.0
10-16 1 WB142-5
12
TORQUE VALUES
No. N·m lbf•ft

1 100 74
2 23 17
3 50 37
4 30 22
5 30 22
(a) Use Loctite 270

(b) Use Loctite 638
(c) Use Loctite 542
WB142-5 10-17 1
MAINTENANCE STANDARD FRONT AXLE ASSEMBLY
12
FRONT AXLE ASSEMBLY
DIFFERENTIAL
1. Axle gears 10. Pinion seal

2. Ring gear 11. Pinion yolk
3. Spider gears 12. Cover
4. Ring nut 13. Pinion nut
5. Axle shaft 14. Bearing
6. Lock pin 15. Pinion gear
7. Carrier housing 16. Pin
8. Crush sleeve 17. Oil refill plug
9. Bearing
10-18 WB142-5
12
FINAL DRIVE END
1. Planetary gear 13. Bearing

2. Planetary 14. Joint
3. Ring gear 15. Pin
4. Ring gear carrier 16. Protector
5. Wheel hub 17. Seal
6. Seal 18. Bearing
7. Pin 19. Snap ring
8. Shim 20. Pin
9. Protector 21. Stud bolt
10. Bushing 22. Plug
11. Seal 23. Sun gear
12. Axle body 24. Snap ring
WB142-5 10-19
12
STEERING CYLINDER
[Port a] From steering unit [L Port] [Port b] From steering unit [R Port] 5. Adjustment screw
1. Steering cylinder 3. Oil drain plug 6. Nut
2. Oil refill plug 4. Nut 7. Bushing
10-20 WB142-5
12
AXLE CARRIER SPECIFICATIONS
1. Carrier bearings 2. Pinion gear 3. Pinion shaft
TORQUE VALUES
No. N·m lbf•ft

4 95 70
5 13 10
6 60 44.3
7 169 125
(a) Use Loctite 270 (b) Use Loctite 510 (c) Use Loctite 638
WB142-5 10-21 1
Unit: mm (in)
Check item Criteria Remedy
Standard clearance Clearance limit
Axle clearance
⎯ ⎯
Backlash of ring gear and pinion 0.18 - 0.28 (0.01 - 0.011) 0.28 (0.011)
Pinion rotational force
(without sealing ring) Adjust
91.8 - 137.6 N (2.0 - 31.0 lbf)
As measured on pinion ∅ 34.8 (1.4)
Pinion crown rotational force
(without sealing ring) 136 - 197.2 N (31.0 - 44.3 lbf)
TORQUE VALUES
No. N·m lbf•ft

1 169 125
2 60 44.3
3 266 196
10-22 1 WB142-5
AXLE END SPECIFICATIONS
Unit: mm (in)
Hub rotational torque ⎯ Adjust
Drive shaft clearance ⎯ Replace
TORQUE VALUES
No. N·m lbf•ft

1 70 52
2 95 70
3 120 89
4 8 6
5 25 18.4
6 80 59
(a) Use Loctite 270
WB142-5 10-23 1
STEERING UNIT CYLINDER SPECIFICATIONS
Unit: mm (in)
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit Replace
Clearance between bushing and
1 bushing
pin
50.19±0.04 and pin
50 (2.0) ⎯ ⎯ ⎯
(2.1±0.02)
TORQUE VALUES
No. N·m lbf•ft

2 120 89
3 300 221
4 165 122
5 150 111
10-24 1 WB142-5
MAINTENANCE STANDARD REAR AXLE ASSEMBLY
12
REAR AXLE ASSEMBLY
DIFFERENTIAL
1. Bearing 6. Ring nuts 11. Yolk flange

2. Axle gears 7. Axle shaft 12. Crush sleeve
3. Ring gear 8. Bearings 13. Pinion gear
4. Spider gears 9. Pinion nut 14. Differential housing
5. Carrier 10. Seal
WB142-5 10-25
12
AXLE END
1. Stud bolt 7. Snap ring

2. Planarity gear 8. Ring nut
3. Wheel hub 9. Bearing
4. Planetary gear 10. Gasket
5. Half-axle 11. Flange
6. Ring gear
10-26 WB142-5
12
MEMORANDUM
WB142-5 10-27
12
AXLE CARRIER SPECIFICATIONS
10-28 WB142-5
12
Unit: mm (in)
Standard
Clearance limit
1 Axle clearance clearance
⎯ ⎯
2 Backlash between ring gear and pinion 0.21 - 0.29 (0.01 - 0.011) 0.29 (0.011)
Pinion rotational force Adjust
3 (without sealing ring) 2.0 - 2.4 N·m (1.5 - 2.0 lbf/ft)
Pinion-crown rotational force
4 (without sealing ring) 2.58 - 3.27 N·m (2.0 - 2.4 lbf/ft)
TORQUE VALUES
No. N·m lbf•ft

5 10 7.4
6 169 125
7 80 59
8 155 144.3
9 25 18.4
(a) Use Loctite 270

(b) Use Loctite 638
(c) Use Loctite 542
WB142-5 10-29 1
12
AXLE END SPECIFICATIONS
Unit: mm (in)
Hub rotational torque ⎯ Adjust
Drive shaft clearance ⎯ Replace
TORQUE VALUES
No. N·m lbf•ft

1 500 369
2 70 52
3 8 - 12 6-9
4 1000 738
5 79 58.2
6 226 667
7 60 44.3
(a) Use Loctite 270
10-30 1 WB142-5
MAINTENANCE STANDARD REAR BRAKES
12
REAR BRAKES
1. Bleed screw 6. Pressure disc

2. Piston 7. Bushing
3. Brake disc 8. Parking brake control caliper
4. Intermediate disc 9. Screw
5. Pressure disc
WB142-5 10-31
MAINTENANCE STANDARD REAR BRAKES
12
BRAKE SPECIFICATIONS
Unit: mm (in)
Standard thickness Minimum thickness
1 Disc thickness Replace
6.73 - 0.1 (0.3 - 0.004) 5.8 (0.23)
TORQUE VALUES
No. N·m lbf•ft

2 16 12
10-32 1 WB142-5
MAINTENANCE STANDARD DIFFERENTIAL LOCK
12
DIFFERENTIAL LOCK
1. Pin 5. Bushing
2. Sleeve 6. Control rod
3. Cover 7. Fork
4. Piston 8. Spacer
a. From servo control solenoids valve group EV1 (Port B2)
WB142-5 10-33
MAINTENANCE STANDARD DIFFERENTIAL LOCK
12
LOCK SPECIFICATIONS
TORQUE VALUES
No. N·m lbf•ft

1 180 133
10-34 1 WB142-5
MAINTENANCE STANDARD HYDRAULIC SYSTEM
12
HYDRAULIC SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
WB142-5 10-35 1
HYDRAULIC PUMP
Port P2 - To the loader control valve (Port P1) Pump

LS port - From the steering unit (LS Port) P1 P2
Port S - From hydraulic tank Displacement 39.6 cc/rev. 22.0 cc/rev.
EF port - To the distributors Operating pressure 207 ± 7 bar 207 ± 7 bar
Port CF - To the steering unit (Port P) Max. pressure 300 bar 3120 bar
10-36 WB142-5
12
DESCRIPTION
This pump is a double gear pump with priority valve. The function of the priority valve is to distribute the oil flow between the
steering circuit and the work equipment circuit.
OPERATION
• The oil flow generated from the pump is distributed by the priority valve to the steering unit (Port CF) and all the other
hydraulic components (Port EF).
• Distribution is determined by the position of the valve in the priority valve function:
A. Of LS signal from the steering unit (LS port)
B. Of pump discharge
C. From steering system pressure
D. From hydraulic circuit connected pressure

• The position of the valve is such as to guarantee that delivery to the steering unit will always correspond to the actual
need.
WB142-5 10-37
12
LOADER 3 - SPOOL VALVE
(WITH FLOAT AND RETURN TO DIG)
a. Port D - To the steering unit (Port P)

b. LS port - To the pump (X2 Port)
c. B3 port - To auxiliary equipment (Left side)
d. Port A2 - To the bucket cylinder (Gland side)
e. Port C2 - To the raise cylinders (Bottom side)
f. Port T - To the hydraulic tank
g. P port - From the pump (B port)
h. B1 port - To the raise cylinders (Head side)
i. Port B2 - To the bucket cylinder (Bottom side)
l. B3 port - To the auxiliary equipment (Right side)
10-38 WB142-5
12
LOADER SPOOL VIEW
1. Plug 8. Bucket dump control spool

2. Spool raise control 9. Spool return spring
3. Spool return spring 10. Solenoid
4. Spring 11. Optional attachments control spool
5. Ball 12. Spring
6. Ball 13. Check valve
7. Compensator
WB142-5 10-39
12
BACKHOE CONTROL VALVE
(7 - SPOOL VALVE)
a. P port - from the pump (B port) l. Port A6 - To the boom cylinder (Gland side)
b. Port T - To hydraulic tank m. Port A5 - To the bucket cylinder (Gland side)
c. B1 port - To the arm cylinder (Gland side) n. A4 port - To the LH outrigger cylinder (Gland side)
d. B2 port - To the boom cylinder (Bottom side) o. A3 port - To the RH outrigger cylinder (Gland side)
e. B3 port - To the RH outrigger cylinder (Bottom side) p. A2 port - To the right boom cylinder (Bottom side)
f. B4 port - To the LH outrigger cylinder (Bottom side) q. A1 port - To the arm cylinder (Bottom side)
g. Port B5 - To the bucket cylinder (Bottom side) r. Port T1 - To hydraulic tank
h. B6 port - To the boom cylinder (Bottom side) s. LS port - To the pump (X2 Port)
10-40 1 WB142-5
12
BACKHOE SPOOL VIEW
1. Ball 6. Compensator
2. Solenoid valve plate lock 7. Bucket control spool
3. Anti-shock/anti-cavitation valve 8. Anti-cavitation valve
4. Spool (boom control) 9. Outriggers control spool
5. Spool return spring 10. Spool (boom swing control)
WB142-5 10-41
12
1. Ball 7. Check valve

2. Solenoid (Arm control) 8. Valve
3. Spool return spring 9. Spring
4. Anti-shock/anti-cavitation valve 10. Plug
5. Compensator 11. Pressure cut-off valve
6. Spring 12. Unloading valve
10-42 WB142-5
12
MEMORANDUM
WB142-5 10-43 1
MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
(ST1 VALVE LOCK - DIFFERENTIAL LOCK - BACKHOE BOOM LOCK)
1. EV3 - Differential lock P, T Not used

2. EV4 - Backhoe boom cylinder lock a. T port - To transmission (Discharge) b. 1 port - Boom cylinder lock
c. Port 2 - To rear axle d. Port P - Of the transmission (delivery)
10-44 WB142-5
MAINTENANCE STANDARD MASTER CYLINDER (BRAKES)
12
MASTER CYLINDER (BRAKES)
1. Hydraulic plunger 7. Spring 13. Gasket

2. Main piston 8. Check valve 14. Gasket
3. Gasket 9. Ball 15. Ball
4. Differential piston 10. Gasket 16. Spring
5. Spring 11. Pin 17. Gasket
6. Pump spring 12. Gasket
SPECIFICATIONS
Stroke: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 mm (1.4 in)
Displacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/28 cc
Maximum pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 bar (2,176 psi)
WB142-5 10-45
MAINTENANCE STANDARD LOADER CYLINDERS
12
LOADER CYLINDERS
ARM CYLINDERS
1. Bushings 4. Four piece piston packing 7. Gland nut

2. Cylinder 5. Cylinder piston 8. Piston stop
3. Nut 6. Cylinder rod
BUCKET CYLINDER
1. Bushings 4. Cylinder barrel 7. Gland nut

2. Four piece piston packing 5. Cylinder piston 8. Piston stop
3. Nut 6. Cylinder rod
SPECIFICATIONS
Cylinders Arm mm (in) Loader bucket mm (in)

Piston rod diameter 50 (2.0) 50 (2.0)
Internal cylinder diameter 70 (3.0) 85 (3.3)
Piston stroke 900 (35.4) 675 (27.0)
Maximum cylinder length 2,120 (83.5) 980 (38.6)
Minimum cylinder length 1,220 (84.0) 305 (12.0)
Key size for piston safety nut 33 (1.3) 36 (1.4)
10-46 WB142-5
MAINTENANCE STANDARD LOADER CYLINDERS
ARM CYLINDER TOLERANCE
BUCKET CYLINDER TOLERANCE
Unit: mm (in)
Criteria
No. Check item Cylinder Standard Tolerance Standard Clearance Remedy
size Shaft Hole Clearance limit
-0.030 (-0.001) +0.162 (+0.01)

Lifting 50 (2.0) 0.035 (0.001) 0.238 (0.01)
Tolerance between -0.076 (-0.003) +0.005 (+0.0002)
1 Replace
piston rod and gland -0.025 (-0.001) +0.141 (+0.006)
Dumping 50 (2.0) 0.029 (0.001) 0.205 (0.01)
-0.064 (-0.003) +0.004 (+0.0002)
-0.060 (-0.002) +0.174 (+0.01)
Lifting 45 (1.7) 0.160 (0.01) 0.280 (0.011)
2
bushing and pin -0.050 (-0.002) +0.142 (+0.01)
Dumping 60 (2.4) 0.130 (0.005) 0.231 (0.01) Replace
-0.089 (-0.004) +0.080 (0.003)
pin and
-0.060 (-0.002) +0.174 (+0.01) bushing
Lifting 50 (2.0) 0.160 (0.01) 0.280 (0.011)
3
bushing and pin -0.050 (-0.002) +0.142 (+0.001)
Dumping 60 (2.4) 0.130 (0.005) 0.231 (0.01)
-0.089 (-0.004) +0.080 (+0.003)
TORQUE VALUES
No. N·m (lbf ft) No. N·m lbf•ft

4a 1250 ± 130 (922 ± 96) 4b 1670 ± 170 1232 ± 125
5a 569 ± 57 (420 ± 24) 5b 637 ± 63.5 470 ± 47
WB142-5 10-47 1
MAINTENANCE STANDARD BACKHOE CYLINDERS
12
BACKHOE CYLINDERS
BOOM CYLINDER
1. Bottom bushing 5. Piston 9. Bottom bushing

2. Cylinder rod 6. Packing 10. Dowel
3. Gland 7. Guide ring 11. Bearing (no. 10)
4. Cylinder 8. Cushion plunger
ARM CYLINDEr
1. Bottom bushing 5. Brake bushing 9. Nut

2. Cylinder rod 6. Packing 10. Bottom bushing
3. Gland 7. Guide ring
4. Cylinder 8. Piston
10-48 1 WB142-5
12
BUCKET CYLINDER
1. Bottom bushing 4. Cylinder 7. Guide ring

2. Gland 5. Piston 8. Nut
3. Cylinder rod 6. Packing 9. Bottom bushing
OUTRIGGER CYLINDERS
1. Bushing and cylinder rod 4. Packing 7. Nut

2. Gland 5. Guide ring
3. Cylinder 6. Piston
WB142-5 10-49 1
12
BOOM SWING CYLINDERS
1. Retaining ring 5. Bushing 9. Guide ring

2. Restriction ring 6. Gland 10. Packing
3. Cylinder rod 7. Bottom bushing 11. Spacer
4. Cylinder 8. Piston 12. Cushion plunger
SPECIFICATIONS
Cylinders Boom mm (in) Arm mm (in) Bucket mm (in)

Piston rod diameter 60 (2.4) 60 (2.4) 55 (2.2)
Internal cylinder diameter 120 (5.0) 115 (4.5) 90 (3.5)
Piston stroke 850 (33.4) 700 (27.5) 765 (30.1)
Maximum cylinder length 2,160 (85.0) 1,765 (69.5) 1,850 (73.0)
Minimum cylinder length 1,310 (51.6) 1,065 (42.0) 1,085 (43.0)
Key size for piston safety nut ⎯ 55 (2.2) 55 (2.2)
Outriggers mm (in) Boom swing mm (in)
Piston rod diameter 50 (2.0) 50 (2.0)
Internal cylinder diameter 100 (4.0) 100 (4.0)
Piston stroke 515 (20.3) 230 (9.2)
Maximum cylinder length 1,365 (53.7) 3,19.5 (13.0)
Minimum cylinder length 850 (33.5) 89.5 (3.5)
Key size for piston safety nut 39 (1.5) ⎯
10-50 1 WB142-5
12
MEMORANDUM
WB142-5 10-51
12
BOOM CYLINDER TOLERANCE
ARM CYLINDER TOLERANCE
BUCKET CYLINDER TOLERANCE
10-52 WB142-5
BOOM SWING CYLINDER TOLERANCE
Unit: mm (in)
Criteria
-0.030 (-0.001) +0.051 (+0.002)

Boom 60 (2.4) 0.035 (0.001) 0.227 (0.01)
-0.076 (-0.003) +0.005 (+0.0002)
-0.030 (-0.001) +0.046 (+0.002)
Arm 60 (2.4) 0.030 (0.001) 0.132 (0.005)
Tolerance between -0.076 (-0.003) 0 (0)
1 Replace
piston rod and gland -0.030 (-0.001) +0.051 (+0.002)
Bucket 55 (2.2) 0.035 (0.001) 0.227 (0.01)
-0.076 (-0.003) +0.005 (+0.0002)
-0.030 (-0.001) +0.164 (+0.01)
Swing 50 (2.0) 0.037 (0.001) 0.240 (0.01)
-0.076 (-0.003) +0.007 (+0.0002)
-0.060 (-0.002) +0.174 (+0.01)
Boom 60 (2.4) 0.160 (0.01) 0.280 (0.011)
-0.106 (-0.004) +0.100 (+0.004)
-0.050 (-0.002) +0.142 (+0.01)
Arm 50 (2.0) 0.130 (0.005) 0.231 (0.01)
Tolerance between -0.089 -(0.004) +0.080 +(0.003)
2
bushing and pin -0.050 (-0.002) +0.142 (+0.01)
Bucket 45 (1.7) 0.130 (0.005) 0.231 (0.01)
-0.089 (-0.004) +0.080 (+0.003)
Replace
-0.060 (-0.002) +0.174 (+0.01)
Swing 55 (2.2) 0.160 (0.01) 0.280 (0.011) pin and
-0.106 (-0.004) +0.100 (+0.004)
bushing
-0.060 (-0.002) +0.174 (+0.01)
Boom 60 (2.4) 0.160 (0.01) 0.280 (0.011)
-0.106 (-0.004) +0.100 (+0.004)
3 Arm 60 (2.4) 0.160 (0.01) 0.280 (0.011)
bushing and pin -0.106 (-0.004) +0.100 (+0.004)
-0.050 (-0.002) +0.142 (+0.001)
Bucket 45 (1.7) 0.130 (0.005) 0.231 (0.01)
-0.089 (-0.004 +0.080 (+0.003)
TORQUE VALUES
No. N·m lbf•ft No. N·m lbf•ft

4a 981 ± 98 724 ± 72 4c 1176 - 1372 867 - 1012
4b 961 ± 96.1 709 ± 71 4d 297 ± 29.4 219 ± 22
5a 2740 - 2840 2021 ± 2095 5c 785 ± 78.5 579 ± 58
5b 1670 ± 170 1232 ± 125 6e 44.1 ± 53.9 33 ± 40
(5a) Use Loctite 262
WB142-5 10-53 1
OUTRIGGERS TOLERANCE
Unit: mm (in)
Criteria
Tolerance between -0.025 (-0.001) +0.064 (+0.05))

1 Outriggers 50 (2.0) 0.050 (0.04) 0.114 (0.1) Replace
piston rod and gland -0.050 (-0.04)) +0.025 (+0.02))
TORQUE VALUES
No. N·m lbf•ft No. N·m lbf•ft

2 785 ± 78.5 579 ± 58 3 2160 ± 220 1593 ± 162
10-54 1 WB142-5
OUTRIGGERS TOLERANCE
Unit: mm (in)
Criteria
Tolerance between -0.025 (-0.001) +0.064 (+0.05))

1 Outriggers 50 (2.0) 0.050 (0.04) 0.114 (0.1) Replace
piston rod and gland -0.050 (-0.04)) +0.025 (+0.02))
TORQUE VALUES
No. N·m (lbf ft) No. N·m (lbf ft)

2 785 ± 78.5 (579 ± 58) 3 2160 ± 220 (1593 ± 162)
10-54 WB142-5
MAINTENANCE STANDARD PIN AND BUSHING CLEARANCES
12
PIN AND BUSHING CLEARANCES
LOADER WORK EQUIPMENT
WB142-5 10-55
12
10-56 WB142-5
12
Unit: mm (in)
Criteria
No. Check item Standard Tolerance Standard Remedy
Clearance limit
size Shaft Hole Clearance
Clearance between -0.010 (-0.0001) +0.146 (+0.01) 0.105 (0.004)

1 75 (2.9)
bushings and cylinder bosses -0.005 (-0.0001) +0.100 (+0.004) 0.206 (0.008)
2 50 (2.0)
bushing and boom mount -0.089 (0.004) +0.240 (+0.01) 0.329 (0.013)
Clearance between +0.100 (+0.004) +0.200 (+0.01) -0.200 (-0.01)
3 52 (2.1)
bushing and boom mono-link +0.400 (+0.016) +0.300 (+0.012) -0.200 (-0.01)
4 45 (1.7)
bushing and mono-link pin -0.089 (0.004) +0.240 (+0.01) 0.329 (0.013)
Clearance between
5 ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
bushing and boom mono-link
Clearance between -0.050 (-0.002) +0.080 (+0.003) 0.130 - 0.329
6 45 (2.0)
bushing and bucket mounting pin -0.089 (-0.004) +0.240 (+0.01) (0.005 - 0.013)
7 60 (2.4)
bushing and link mounting pin -0.089 (-0.004) +0.240 (+0.01) (0.005 - 0.013)
8 45 (1.7)
bushing and link mounting pin -0.106 -(0.01) +0.197 (+0.01) (0.006 - 0.012)
WB142-5 10-57 1
12
BACKHOE WORK EQUIPMENT
10-58 WB142-5
12
WB142-5 10-59
12
Unit: mm (in)
Criteria
No. Check item Standard Tolerance Standard Remedy
Clearance limit
size Shaft Hole Clearance
80.059 to 80.089 80.00 to 80.054 0.005 to 0.089

1 Top Bushing in Main Frame 80 (3.1)
(3.152 to 3.153) (3.15 to 3.152) (0.0002 to 0.004)
64.894 to 64.94 65.19 to 65.264 0.25 to 0.37
2 Pin to Bushing 65 (2.6)
(2.555 to 2.555) (2.567 to 2.569) (0.01 to 0.015)
50.034 to 50.05 50.0 to 50.025 -0.009 to -0.05
3 Inner Bushing on Cylinder Stud 50 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.0004 to 0.002)
75.043 to 75.062 75.0 to 75.03 -0.013 to -0.062
4 Outer Bushing in Bracket 75 (3.0)
(3.0 to 3.0) (3.0 to 3.0) (-0.0005 to 0.002)
59.894 to 59.94 60.06 to 60.09 0.12 to 0.196
5 Inner Bushing in Outer Bushing 60 (2.4)
(2.4 to 2.4) (2.4 to 2.4) (0.005 to 0.01)
6 Outer Bushing in Frame
54.894 to 54.94 55.137 to 55.197 0.257 to 0.303
(2.2 to 2.2) (2.2 to 2.2) (0.01 to 0.012)
80.059 to 80.089 80.0 to 80.03 -0.029 to -0.089
8 Bottom Bushing in Swing Frame 80 (3.1)
(3.152 to 3.153) (3.15 to 3.15) (-0.001 to -0.001)
64.894 to 64.94 65.19 to 65.264 0.25 to 0.37
(2.555 to 2.555) (3.0 to 3.0) (0.01 to 0.015)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
10 Pin to Rod Bushing 45 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
11 Pin to Head Bushing 45 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
54.985 to 55.015 55.0 to 55.03 -0.015 to 0.045
12 Bushing in Stabilizer 55 (2.2)
(2.2 to 2.2) (2.2 to 2.2) (-0.001 to 0.002)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
75.137 to 75.197 75.0 to 75.03 -0.107 to -0.197
14 Bushing in Boom 75 (3.0)
(3.0 to 3.0) (3.0 to 3.0) (-0.004 to -0.01)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
59.95 to 60.15 60.0 to 60.03 -0.08 to -0.15
16 Bushing in Boom 60 (2.4)
(2.4 to 2.4) (2.4 to 2.4) (-0.003 to -0.01)
59.894 to 59.94 60.137 to 60.197 0.197 to 0.303
(2.4 to 2.4) (2.4 to 2.4) (0.01 to 0.012)
52.10 to 52.40 52.0 to 52.03 -0.07 to -0.40
18 Bushing in Bucket Lever 52 (2.0)
(2.1 to 2.1) (2.05 to 2.05) (-0.003 to -0.02)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
20 Pin to Cylinder Bushing 45 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
52.2 to 52.23 52.10 to 52.40 -0.13 to -0.20
21 Lever Bushing in Arm 52 (2.0)
(2.1 to 2.1) (2.1 to 2.1) (-0.005 to -0.01)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
52.10 to 52.40 52.0 to 52.03 -0.07 to -0.40
23 Bushing in Bucket Lever 52 (2.0)
(2.1 to 2.1) (2.0 to 2.0) (-0.003 to -0.02)
44.911 to 44.95 45.08 to 45.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
10-60 WB142-5
56.45 to 58.05 57.20 to 57.23 -0.85 to 0.78

25 Bucket Bushing in Arm 57 (2.2)
(2.22 to 2.3) (2.3 to 2.3) (-0.03 to 0.03)
49.911 to 49.95 50.08 to 50.24 0.13 to 0.329
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.013)
59.894 to 59.94 60.10 to 60.174 0.16 to 0.28
27 Pin to Boom Rod Bushing 60 (2.4)
(2.4 to 2.4) (2.4 to 2.4) (0.01 to 0.01)
Pin to Boom & Arm Head 59.894 to 59.94 60.10 to 60.174 0.16 to 0.28
28 60 (2.4)
Bushing (2.4 to 2.4) (2.4 to 2.4) (0.01 to 0.01)
49.911 to 49.95 50.08 to 50.142 0.13 to 0.231
29 Pin to Arm Rod Bushing 50 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.01)
44.911 to 44.95 45.08 to 45.142 0.13 to 0.231
30 Pin to Bucket Head Bushing 45 (2.0)
(2.0 to 2.0) (2.0 to 2.0) (0.005 to 0.01)
31 Pin to Jig Head Bushing Not used Not used Not used Not used
32 Pin to Jig Rod Bushing Not used Not used Not used Not used
WB142-5 10-61
12
MEMORANDUM
10-62 WB142-5
This Page Intentionally left Blank
20 STANDARD VALUE TABLES
STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
WB142-5 20-1
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR ENGINE
12
STANDARD VALUE TABLE FOR ENGINE
Machine Model WB142-5
Engine 4D102LE-2
Standard Value
Service Limit
Cat. Item Measurement Conditions Unit For New
Value
Machine
Type 4-cycle water cooled diesel engine
Aspiration Natural
Engine overview
Combustion ⎯ Direct injection

⎯
Compression ratio 18:1
Number of cylinders 4
Piston displacement l (in3) 4.5 (275)
• Engine coolant temperature within

Max. 2,460 ± 50 2,350 - 2,450
operating range.
Engine specs. (without load)
Accelerator • Engine oil temperature within

pedal operating range. Min. 1,050 ± 50 1,000 - 1,100
• Measurement taken on drive shaft
pulley with stroboscope rev/counter Rated speed 2,200 2,100
rpm
• Engine coolant temperature within Max. 2,200 ± 50 2,100 - 2,200
operating range.
Throttle • Engine oil temperature within
lever operating range. Min. 1,050 ± 50 1,000 - 1,100
• Measurement taken on drive shaft
pulley with stroboscope rev/counter Rated speed 2,200 2,100
Gross @ 2,200 rpm 60 (80)

kw (hp)
Net @ 2,200 rpm (SAE J 1349) 57 (76)
⎯
N•m
Maximum torque @ 1300 rpm 298 (221)
(lbf•ft)
• Operating temperatures. 22 - 23 Max. 23

Boost • 2,200 rpm in-Hg {566 - 587} {Max. 587}
pressure • 99 HP {mmNg}
22 - 23 Max. 23
• Torque @ 230 Nm (236 ft/lbs) {566 - 587} {Max. 587}
Engine rating
Max. 0.6 Max. 0.6

Exhaust gas
• Bosch index %
color Min. 1.4 Min. 1.4
Intake valve (at operating temperatures) 0.254 0.254

Valve
mm
clearance Exhaust valve (at operating temperatures) 0.508 0.508
Compression • Oil temperatures: 40 - 60oC (104 - 140oF) 2413 2068

pressure • Cranking speed: 250 rpm. (350) (300)
At idle kPa Min. 69 Min. 69

Oil pressure speed (psi) (Min. 10) (Min. 10)
• Coolant temperature at operating
(SAE5W-30)
range.
(SAE15W-40) At rated Min. 345 Min. 345
speed (Min, 50) (Min, 50)
20-2 1 WB142-5
STANDARD VALUE TABLES STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Standard Value
Service Limit
Unit
Cat. Item Measurement Conditions For New
Value
Machine
a b c a b c
Boom swing, outriggers.

Arm, bucket, boom 41.5
8 8 ⎯ ⎯ ⎯
(1.6)
Control valve
mm
(in)
4.5
Bucket arm command only 8 8 ⎯ ⎯ ⎯
(0.2)
Raise 75 ± 15 (3.0 ± 1) 75 ± 15 (3.0 ± 1)

Bucket arm control lever Neutral
Lower 75 ± 15 (3.0 ± 1) 75 ± 15 (3.0 ± 1)
Dump 90 ± 15 (3.5 ± 1) 90 ± 15 (3.5 ± 1)

Bucket control lever Neutral
Curl 90 ± 15 (3.5 ± 1) 90 ± 15 (3.5 ± 1)
40 - 60 ± 15
Raise 100 ± 15 (4.0 ± 1)
(1.6 - 2.4 ± 0.6)
Boom backhoe control Neutral
40 - 60 ± 15
Lower 100 ± 15 (4.0 ± 1)
(1.6 - 2.4 ± 0.6)
40 - 60 ± 15
Out 100 ± 15 (4.0 ± 1)
• Engine stopped. (1.6 - 2.4 ± 0.6)
Travel of levers and pedals
Arm backhoe control lever Neutral

• Knob lever: at center and at 40 - 60 ± 15
In 100 ± 15 (4.0 ± 1)
90o. (1.6 - 2.4 ± 0.6)
• Value reading at end of mm 40 - 60 ± 15
working stroke plus half Dump 100 ± 15 (4.0 ± 1)
(in) (1.6 - 2.4 ± 0.6)
Bucket backhoe control lever measured backlash. Neutral
40 - 60 ± 15
• Attachment on the ground. Curl 100 ± 15 (4.0 ± 1)
(1.6 - 2.4 ± 0.6)
• Instrument meter w/mm
divisions. 40 - 60 ± 15
Right 100 ± 15 (4.0 ± 1)
(1.6 - 2.4 ± 0.6)
Boom swing control lever Neutral
40 - 60 ± 15
Left 100 ± 15 (4.0 ± 1)
(1.6 - 2.4 ± 0.6)
25 - 45 ± 10
Up 50 ± 10 (2.0 ± 0.4)
(1 - 1.7 ± 0.4)
Outrigger control lever Neutral
25 - 45 ± 10
Down 50 ± 10 (2.0 ± 0.4)
(1 - 1.7 ± 0.4)
Min. 30 - 50 ± 5
Throttle control lever 50 ± 10 (2.0 ± 0.4)
Max. (1.2 - 2.0 ± 0.2)
Closed 15 (0.6) ± 5 (± 0.2)

Hammer pedal
Delivery 30 (1.2) ± 10 (± 0.4)
WB142-5 20-3 1
12
Standard Service Limit
Cat. Item Measurement Condition Unit Value For New Value
Machine
• Engine stopped Min.
Lever and pedal travel
mm 65 -95
Accelerator pedal • Knob lever: at center and at 90o from to 4 (0.2)
(in) (2.5 - 5.5)
the lever. Max.
• Value reading at the end of working
stroke plus half measured backlash. Right to Left
[3.5 4wd] 3.1 - 3.9
Wheel swing • Attachments on the ground. or rpm
[3.5 2wd] 3.1 - 3.9
Left to Right
• Instrument.
Front loader arm control • Engine speed: min. 2.3 ± 0.5

2.3 (5.1)
lever • Oil temperature within operating range. (5.1 ± 1.1)
• Tool connected at center of knob 80 mm (3.1 in) away
Front loader bucket from handle base. 1.0 - 2.0 ± 0.5
1.8 (4.0)
control lever (0.04 - 0.1 ± 1.1)
• Value reading at the 10 mm (0.4 in) before end of
working stroke. 1.0 - 2.0 ± 0.5
Force for lever, pedal and steering wheel operation
Control lever boom • Instrument force gauge. 1.2 (2.6)

(0.04 - 0.1 ± 1.1)
• Ambient temperature 15 - 35oC (59 - 95oF)
1.2 ± 0.5
Arm control lever 1.2 (2.6)
(2.6 ± 1.1)
1.2 ± 0.5
Bucket control lever 1.2 (2.6)
(2.6 ± 1.1)
kg
Boom swing (lbs) 1.2 ± 0.5
1.2 (2.6)
control lever (2.6 ± 1.1)
2.8 ± 0.5
Outrigger control lever 2.8 (6.2)
(6.2 ± 1.1)
6.5 ± 1.5
Throttle control lever 6.5 (14)
(14 ± 3.3)
2.5 - 5.5
Accelerator pedal 4.0 (8.8)
(5.5 - 12)
Closed
Hammer 4.0 ± 1
to 4.0 (8.8)
pedal (8.8 ± 2.2)
Delivery
20-4 1 WB142-5
12
Standard Value Service Limit
Cat. Item Measurement Conditions Unit For New Machine Value
• Engine speed: 1,050 rpm

• Oil temperature within operating range
• Move arm cylinder to end of stroke and measure the
207 ± 7
Control valve pressure ⎯
(3,002 ± 101)
Main valve pressure
• Instrument: 0 to 600 bar (0 to 8,702 psi) pressure gauge

mounted on the adapters at port on main valve.
• Working mode switch: POWER bar
(psi)
M1 port on loader valve

135 ± 10
Second. pump only • Economy mode ⎯
(1,958 ± 145)
Measure at Max.
175 170 - 185

Steering unit • Engine speed: 1,500 ± 50 rpm
(2,538) (2,466 - 2,683)
Bucket 250 250 -20 +15

(curled) (3,626) (3,626 -290 +218)
• Check for complete range of movement at and near
ground level
Bucket 250 250 -20 +15
(dump) (3,626) (3,626 -290 +218)
Boom 300 300 -20 +15

(raising) (4,351) (4,351 -290 +218)
Secondary valve circuit pressure
Boom 250 250 -20 +15

(lowering) (3,626) (3,626 -290 +218)
Arm bar 250 250 -20 +15

(in) • Engine speed: min. (psi) (3,626) (3,626 -290 +218)
Arm • Check one circuit at a time 250 250 -20 +15
(out) • Instrument: 0 to 600 bar (0 to 8,702 psi) pressure gauge (3,626) (3,626 -290 +218)
mounted on the adapters at port “M” on main valve.
Boom • Working mode switch: POWER. 250 250 -20 +15
(swing) (3,626) (3,626 -290 +218)
Hammer 160 160 -10 +25

(delivery) (2,321) (2,321 -145 +363)
Steering unit 225 225 -5 +20

(safety) (3,263) (3,263 -73 +290)
WB142-5 20-5 1
12
Cat. Item Measurement Conditions Unit For New Value
Machine
• Engine speed: (without load): 2,460±50

With converter • Machine in 3rd gear 1,960 ± 50 ⎯
Engine speed with load
• Working brakes: engaged

• Working mode switch: POWER
Converter
• Engine speed: (without load): 2,460±50 rpm

• Machine in 3rd gear
With converter
• Working brakes: engaged 1,500 ± 50 ⎯
and hydraulic circuit
• Bucket raised bottom of stroke
• Steering held at end of stroke
• Working mode switch: POWER
• In this position check in feedback of each

cylinder and the leakage with applied load on the
All work equipment tip of bucket teeth. 200 400 Max.
(Bucket teeth tip • On level ground. (8.0) (16 Max.)
lowered)
• Bucket: load 1,500 kg (3,307 lbs)
• Engine stopped
• Oil temperature: 45-55 oC (113 - 131oF)
• Check measures as soon as engine stops.
Front bucket
• Check changes every 5 min. and the total change

Loader in 15 min. 35 60 Max.
Raise cylinder (1.4) (2.4 Max.)
(Cylinder in)
Mono link
Work equipment hydraulic drift
25 50
Bucket cylinder
(1.0) (2.0)
(Cylinder out)
mm
• In this position check the extension of each (in)
All work equipment cylinder and the leakage with normal load on the 200 350
(Bucket teeth tip bucket. (8.0) (1.4)
lowered) • On level ground.
• Bucket: load with standard arm: 340 kg
• Bucket load with arm: Fully extend arm
Boom cylinders • Engine stopped 10 20
(Cylinders out) • Oil temperature: 45-55 oC (113 - 131oF) (0.4) (1.0)
• Check measures as soon as engine stops.
Backhoe
• Check changes every 5 min. and the total change

Arm cylinders in 15 min. 10 20
(Cylinders out) (0.4) (1.0)
Bucket cylinders 8 15
(Cylinders in) (0.3) (0.6)
20-6 1 WB142-5
12
Machine model WB142-5
Cat. Item Measurement Conditions Unit For New Value
Machine

• Backhoe balanced on the guides bucket in transport
condition.
• Fully retract arm and bucket cylinder
• Lift the bucket fulcrum pin 1 m (39 in) off the ground
and swing boom to bottom of stroke in either direction.
• Move the machine on a slope of 15o and apply the
parking brake.
• Stop the engine and, after 1 minute, check the inner
cylinder feed back opposite to the boom every 5 min.
15 25
Boom swing for a total of 15 minutes.
(0.6) (1.0)
Hydraulic drift of work equipment
Backhoe
mm
(in)

• Backhoe balanced.
• Boom and arm cylinders in, bucket cylinder out
• Outriggers at maximum extension.
• Engine stopped
• Check the frame lowering for each side every 5 min. for
a total of 15 minutes.
7 15
Outriggers
(0.3) (0.6)
2.0 (0.12)
Front loader
Boom Max. 8.0 (0.5)

[each cylinder]
Mono link
2.5 (0.15) 10 (0.61)
Bucket
• Engine: Max. speed
cc3/min. in3/min.
Cylinder leakage
Boom • Oil temperature: 45-55 oC (113 - 131oF) 3.3 (0.20) Max. 13.5 (1.0)
Arm • Leaking check: on the cylinder opposite side to the 3.0 (0.2) Max. 12.0 (0.7)
pressure one.
Bucket • Check 1 cylinder at a time. 2.4 (0.1) Max. 9.5 (0.6)
Backhoe
• For arm bucket, boom and for swing, check the two
Boom swing cylinders separately. 3.2 (0.2) Max. 13.0 (0.8)
Outriggers 3.3 (0.2) Max. 13.5 (1.0)
Extendable
1.6 (0.1) Max. 6.0 (0.4)
boom
WB142-5 20-7 1
12
Cat. Item Measurement Conditions Unit Value For Value
New Machine
• Engine speed: Max.

Loader • Oil temperature: 45-55 oC (113 - 131oF)
Lifting
arm bucket • Bucket speed 3.6 3.1 - 4.1
button: applied
Cylinders
fully out
↕
Lowering
Bucket on
2.6 2.2 - 3.0
ground level
Loader bucket
• Engine speed: Max.

Mono link • Oil temperature: 45-55 oC (113 - 131oF)
Curl
bucket • Bucket speed 2.5 2.0 - 2.6 ± 0.4
button: applied.
Cylinders
fully out
↕
Cylinders
Dump
fully in 2.0 2.4 -3.2 ± 0.3
• Engine speed: 1700±50 rpm

Work equipment speed
Oil temperature: 45-55 oC (113 - 131oF)

Lifting
•
Boom 2.4 2.4 ± 0.4
• Backhoe balanced
• Power mode ON
Sec.
Cylinders
fully in
↕
Lowering
Bucket
2.0 1.7 - 2.3
on ground
Arm • Oil temperature: 45-55 oC (113 - 131oF)

Out
• Backhoe balanced 2.9 2.9 ± 0.4

• Power mode ON
Backhoe
Cylinders
fully in
↕
Cylinders
3.2 3.2 ± 0.5
In
fully out

Oil temperature: 45-55 oC (113 - 131oF)
Dump
Bucket •
• Backhoe balanced 2.0 2.0 ± 0.3
• Power mode ON
Cylinders
fully in
↕
Cylinders
Curl
2.5 2.5 ± 0.4

fully out
20-8 1 WB142-5
12
Machine Model WB142.5
New Machine
Boom • Oil temperature: 45-55 oC (113 - 131oF)
Right
swing 3.2 2.7 - 3.7
• Arm vertical
• Power mode ON
Backhoe
Right end
of travel
↕
Left
Left end 3.2 2.7 - 3.7
of travel
• Engine speed: min.

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

Work equipment

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

• Place boom at 45o, open
completely with bucket curled.
• Extend arm cylinder and check the
time passing between arm stop at
dead center and restart movement.
Arm 0 Max.2
WB142-5 20-9 1
Machine Model WB142.5

New Machine
● Engine speed: min.
● Oil temperature: 45-55 oC (113 - 131oF)
● Place arm in horizontal position. Tilt back bucket cylinder and then
extend it.
● Check the time passing between bucket stop at dead center and then
restart movement.
Bucket 0 Max.2
Work equipment
Time lag
● Engine speed: min. sec.

● Oil temperature: 45-55 oC (113 - 131oF)
● Boom arm and bucket retracted and centered on machine
● Check the time necessary for the outriggers to raise the machine
from when they lean on level ground.
● ï Check each outrigger at a time.
Outriggers 0 Max.2
20-10 WB142-5
30 TESTING AND ADJUSTING
BLEED AIR FROM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

BLEED AIR FROM BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
RELEASING RESIDUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
ACCELERATOR PEDAL AND THROTTLE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
ACCELERATOR PEDAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
THROTTLE LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
CHECKING LOAD SENSING SIGNAL (LS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
CHECKING COMPENSATED FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
OPERATION OF THE PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
TESTING AND SETTING STEERING SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
CHECKING FOR LEAKS IN THE STEERING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
CLUTCH ENGAGEMENT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
CLUTCH FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
HYDRAULIC DRIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
WB142-5 30-1 B
TESTING AND ADJUSTING BLEED AIR FROM CIRCUITS
12
BLEED AIR FROM CIRCUITS
★ When the hydraulic cylinders or associated tubes have been removed, it is necessary to bleed air before using the machine again. Per-
form 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 engine to low idle speed and make a complete travel of the
cylinder until the pump reaches its maximum pressure.
5. Repeat Steps 2 and 3 for all cylinders, frequently checking the oil level in the tank.
BLEED AIR FROM BRAKING CIRCUIT

★ This operation is to be carried out every time maintenance is made on the
braking circuit to remove or replace a component, or when air entered into
the circuit. Machine must be stopped with attachments on level ground.
1. Make sure that oil in the brake system tank (1) is at maximum level.
Remove safety plugs on the bleed screws (2). Attach a vinyl hose
(3) to catch oil.
2. Push the brake pedal to the bottom and, while keeping it pushed,
loosen the bleed screw (2) of the braking unit that is being bled
until the pedal reaches the end of its stroke. Keeping the pedal at the
end of its stroke, tighten the bleed screw.
3. Release the brake pedal, wait for few seconds and repeat above
operations 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 (2) safety plugs (4).
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.
30-2 WB142-5
TESTING AND ADJUSTING ACCELERATOR PEDAL AND THROTTLE LE-
12
ACCELERATOR PEDAL AND THROTTLE 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 (1) manually.
ACCELERATOR PEDAL TRAVEL

1. Make sure that the accelerator pedal (1) is fully raised and the
accelerator lever (2) is at minimum stroke.
2. Ensure that the accelerator lever (3) contacts the screw (4).
3. Push accelerator pedal until accelerator lever (5) contacts the

injection pump high idling adjusting screw (6).
4. .Adjust the end travel stopper (6) of the accelerator pedal (1) in this
position and lock it with the nut (7).
5. Release the accelerator pedal (1).
WB142-5 30-3
TESTING AND ADJUSTING ACCELERATOR PEDAL AND THROTTLE LE-
12
THROTTLE LEVER TRAVEL
1. Remove the front mat.
2. Remove the metal sheet (1) closing the bottom of the cab and the
upright guard (2).
3. Check that the throttle lever (3) is at end of travel at MIN.
4. Loosen and unscrew the locking nut (4).
5. Start the engine and move the throttle lever (3) to MAX.
6. Tighten the nut (5) to the required speed for throttle lever.
★ Engine idle speed2200±50 rpm

7. Return to engine low idle speed and retain the position of the nut
(5) with the locking nut (4).
8. Check the MAX speed once more by pushing the throttle lever to
the end of travel.
30-4 WB142-5
TESTING AND ADJUSTING BRAKE SYSTEM
12
BRAKE SYSTEM
★ Working condition:
l Set the machine on level surface with attachments on ground
level
l Apply the parking brake and remove the ignition key
l Pedal connection pin (0) inserted.
CONTROL
1. Remove the floor mat.
2. Check the height A between the floor and pedal (1) lower edge.
3. Depress the pedals by hand and check height B to determine slack

G.
Standard clearance3 - 8 mm (0.1 - 0.3 inches)
ADJUSTMENT
1. Remove the front cover (2).
2. Loosen the nuts (3) and adjust the slack using the stoppers (4).
3. When adjustment is complete, secure the stoppers (4).

★ When the stoppers are secured, double check to ensure that slack
G is within the range and that the pedals touch the stoppers
simultaneously.
WB142-5 30-5
12
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 (1) from the tubes (2) 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 (1).
3. Apply the brake pedals until a pressure of 122.2 kg/cm² (1,738 psi)
is reached.
★ Do not exceed the max permitted pressure152.8 ± 5 kg/cm²
(2,173 ± 71psi)
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.
30-6 WB142-5
12
INDIVIDUAL PUMP CHECK
1. Remove the front cover (2).
2. Disconnect the pressure equalizer hose (5) from the brake circuit
pump (4) that is being inspected.
3. Seal the hole of the equalizer plug A.
4. Remove the clamp (6).
5. Disconnect the delivery hoses (7) from the pump that is being tested.
Connect a pressure gauge E2 to the pump during the inspection.
6. Apply the brake pedal corresponding to the pump and pressurize

the circuit to 122.2 kg/cm² (1,738 psi).
★ Do not exceed the max permitted pressure152.8 ±5 kg/cm²
(2,173 ± 71psi)
WB142-5 30-7
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 ASSEMBLY LEAKAGE

1. Disconnect the delivery hose (1) from the braking group that is
being inspected.
2. Connect a suitable tool between the delivery hose (1) and the
braking group.
★ Check to ensure that the pressure tap (1) is installed between the
braking group and the cut out valve (9).
3. Connect a pressure gauge E2 to the tool pressure tap and open the
cut out valve (9).
4. Operate the brake pump and pressurize the circuit to 152.8 ±56 kg/
cm² (2,173 ± 71psi) max.
5. Hold the pressure while simultaneously closing the valve (9) 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 sections and completely change the lubri-
cant.
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.
30-8 WB142-5
TESTING AND ADJUSTING PARKING BRAKE ADJUSTMENT
12
PARKING BRAKE ADJUSTMENT
★ Test conditions:
• Tire pressureWithin the prescribed range
• Machine in operating conditionsW/O load and on level ground
• Working brake pedals connected by a cotter pin
• Remove the screws (1) and parking brake housing (2).
1. Engage the parking brake.
2. Press and hold the micro-switch (3) while engaging 2nd gear and
selecting a direction of movement.
3. Accelerate engine gradually up to 1530 ±50 rpm.
WARNING! If machine moves, release the microswitch to

return to N, Neutral.
4. Rotate the end of the lever (4) by 2 or 3 turns counter clockwise.

★ Direction of rotation is from the operator’s point of view when
sitting in the driver’s seat.
5. 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.
WB142-5 30-9
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT
★ Shown in this section are manual control valves.

INTRODUCTION
★ The machine is equipped with two control valves with mechanical spools performing the following functions:
• Control valve no. 1 (2 or 3 elements): controls front equipment.
• Control valve no. 2 (6, 7, 8 elements): controls rear equipment.
★ Both control valves are protected against overpressure by a maximum-pressure valve (or general valve, called cut-off
valve) with adjustable calibration.
★ The pump flow of pumps P1 and P2 supplies the control valves.
★ Pump P1 delivery is shut by the priority valve (installed on pump) when the steering unit is used for a steering manoeuvre.
30-10 WB142-5
3-SPOOL VALVE
Control Ports
Arm (Lifting-Lowering) A1 - B1
Bucket (Curled-Drain) A2 - B2
Auxiliary equipment (4x1) A3 - B3
7-SPOOL VALVE
Control Ports
Arm (Closing-Opening) A1 - B1
Boom swing (Left-Right) A2 - B2
Left outrigger (Up-Down) A3 - B3
Right outrigger (Up-Down) A4 - B4
Bucket cylinder (Drain-Curl) A5 - B5
Boom cylinders (Lifting-Lowering) A6 - B6
Hammer (Bottom side) A7
WB142-5 30-11 B
12
MAIN RELIEF VALVE
SETTING (PRESSURE CUT-OFF)
• Engine: at operating temperature.
• Hydraulic oil: 45-55 oC (113 - 131 oF)
• Working brakes applied
1. Connect a pressure gauge E3 (400 bar) to the pressure tap (1) on the
backhoe control valve (2).
2. Start the engine, move the hand accelerator lever to full throttle and
check setting pressure for main relief valve by forcing the arm raise
movement to full travel span.
★ Nominal pressure: 207 ± 7 bar (3,002 ± 102 psi)
★ If the main relief valve pressure does not correspond to the nominal pressure value, it must be re-set.
PUMP P2 PRESSURE RELIEF VALVE

CALIBRATION
• Working brakes applied
• Working mode: ECONOMY
1. Connect a pressure gauge (E3) (400 bar) to the pressure tap (1) on
the shovel control valve (2).
2. Start the engine and run at Low idling
3. Operate the bucket dump lever to obtain a full dump.
4. Slowly force the shovel dump motion to cause the pressure to rise
gradually.
5. Measure the maximum pressure reached just before opening the

valve (E3) and then read the pressure drop.
★ Normal relief pressure: 135 ± 10 bar (1,958 psi)
★ If relief valve calibration setting is not within the specified
limits, calibrate using the secondary valve calibration
procedure, making sure that you do NOT change the setting of
the general (cut-off) valve.
30-12 WB142-5
SECONDARY VALVES SETTING

• Parking brake engaged
★ The pressure readings are to be operated from the same check point.
backhoe control valve (2).
2. Start the engine and bring the hand accelerator lever up to 1050
rpm.
3. Set the main relief valve (pressure cut-off) to a value 45 bar higher than the maximum pressure to be tested.
4. Check the pressure in every single motion.

★ The backhoe boom raise secondary valve must be calibrated on a test bench.
WB142-5 30-13
12
Calibration Values For 3-element Control Valve Secondary Valves
Unit: kg/cm² (PSI)

Setting
Cylinder and movement Port
Standard version
Lifting A1 ⎯
Loader arm
Lowering B1 ⎯
Curl A2 254 +15 -20 (3,626 +218 -290)
Bucket
Dump ✤ B2 193 ± 10 (2,755 ± 145)
⎯ A3 254+15 -20 (3,626 +218 -290)
Optional equipment
⎯ B3 254+15 -20 (3,626 +218 -290)
✤ This calibration can be performed without re-calibrating the general value.
Calibration Values For 7-element Control Valve Secondary Valves
Unit: kg/cm² (PSI)

Setting
Cylinder and movement Port
Standard version
Close A1 254 +15 -20 (3,626 +218 -290)
Arm
Open B2 ⎯
Left A2 254 +15 -20 (3,626 +218 -290)
Boom swing
Right B2 254+15 -20 (3,626 +218 -290)
Up A3 ⎯
Right outrigger
Down B3 ⎯
Up A4 ⎯
Left outrigger
Down B4 ⎯
Dump A5 ⎯
Bucket cylinder
Curl B5 254 +15 -20 (3,626+218 -290)
Lift A6 305 +15 -20 (4,351 +218 -290)
Boom cylinder
Lower B6 254 +15 -20 (3,626 +218 -290)
Bottom side ✤ A7 163 +25 -10 (2,321 +363 -145)
Hammer
Right side B7 ⎯
✤ This calibration must be performed on bench test only.

✤ This calibration can be performed without re-calibrating the general valve.
★ If valve calibrations are not within specifications, perform the calibration procedure (Refer to "Checking secondary valves
setting”).
1. Restore the general valve calibration.
30-14 B WB142-5
12
SETTING THE MAIN RELIEF AND REDUCING VALVES
★ General cut-off valve (1)
★ P2 pump pressure relief valve (2)
1. Prepare the machine for calibration as for pressure checking.
2. Loosen lock nut (3).
3. Force any motion to its end of travel.
4. Adjust pressure using the adjusting screw (4).

• To INCREASE pressure rotate in CLOCKWISE direction.
• To DECREASE pressure rotate in COUNTERCLOCKWISE
direction.
5. Lock into position with the nut (3).
6. At the end of adjustment, apply a protection (5) (orange color)

against unauthorized tampering.
WB142-5 30-15 B
SECONDARY VALVES AND P2 PUMP RELIEF

VALVE
★ Prepare the machine for calibration as for pressure checking.
★ This calibration procedure applies to all secondary valves (except
the boom raise valve) and the relief valve.
★ Calibration monitoring is achieved by forcing the respective motion
to end of travel while checking.
1. Loosen lock nut (1).
2. Adjust pressure using the adjusting screw (2).

• To INCREASE pressure rotate in CLOCKWISE direction.
• To DECREASE pressure rotate in COUNTERCLOCKWISE
direction.
3. Lock into position with the nut (1).
Lock nut: 10±1 Nm (7.4 ± 1lbf/ft)
★ At the end of adjustment, apply a protection (3) (orange color)

against unauthorized tampering.
★ Secondary valves only
4. Restore upper (cut-off) valve.
30-16 WB142-5
12
CHECKING LOAD SENSING SIGNAL (LS VALVE)
• Engine: stopped but at working temperature.
• Machine: front equipment on the ground, parking brake
applied and boom and arm fully extended.
• Working mode: POWER
1. Disconnect hose (1) from the Load Sensing line, Install a tee with
pressure tap (2) and reconnect hose (1).
2. Connect differential pressure gauge E5 to pressure taps (2), (3).
3. Start and idle the engine (1050 ± 50 rpm) and, without performing
any movement (lever in neutral position), read the DP pressure.
★ Normal value: 15 ± 1 bar
★ If the DP value is not within the permissible range, set the unloading valve. (For details, see “ADJUSTING THE
UNLOADING VALVE PRESSURE”).
4. Operate and move the boom raise lever to end of travel, then measure the DP pressure value.
★ Normal value: 15 ± 1 bar (218 ± 15 psi)
★ If the DP value is out of specifications, clean and, if necessary, calibrate the unloading valve (4).
UNLOADING VALVE CALIBRATION
1. Remove the plug (5) and take out the spring (6), washers (7) and
valve body (8).
2. Install a shim (9) under the spring (6) and reassemble the valve.
3. Introducing a 1mm shim under the spring will increase the DP

pressure by 3 bar (44 psi).
Plug: 100 Nm (74 lbf/ft)
WB142-5 30-17
12
CHECKING COMPENSATED FLOW VALVE
• Engine: stopped but at working temperature.
• Engine RPM at IDLE: within permissible limits.
• Hydraulic oil: 45 - 55 oC (113 - 131 oF)
• Machine: under safety conditions, parking brake applied.
• Control valve lever in neutral position.
1. Disconnect hose (1) from the Load Sensing line, Install a tee with
pressure tap (2) and reconnect hose (1).
2. Connect differential pressure gauge E5 to pressure taps (2), (3).
3. Start and idle the engine. Without performing any motion, check
the pressure at both taps.
★ Control valve normal pressure (P): 27 ± 3 bar (392 ± 44 psi)
★ Load Sensing (PLS) line normal pressure: 6 ± 2 bar (87 ± 29 psi) (This value is owed to the influence of the back
pressure in the steering circuit).
★ No variation will give rise to concerns as long as a difference of 21 ± 1 bar (305 ± 15 psi) is kept between the two
readings.
4. If difference between the two readings is higher than 21 ± 1 bar

(305 ± 15 psi), stop the engine and release all residual pressure.
5. Thoroughly clean the valve (4) and put it back on.
Valve: 20 Nm (15 lbf/ft)
6. If the 21 ± 1 bar (305 ± 15 psi) difference value is still not reached

after cleaning the valve (4), replace valve.
30-18 WB142-5
12
OPERATION OF THE PRIORITY VALVE
• Engine: operating temperature
• Hydraulic oil: 45 - 55 oC (113 - 131 oF).
• Parking brake engaged.
• Hydraulic pump: ECONOMY MODE
backhoe control valve.
2. Start and operate the engine at 1500 ± 50 RPM.
3. Check the pressure value on the pressure gaugeE2 with the steering
wheel stopped.
4. Engage a slight steering motion and check for an increase in pressure.
5. Continue steering until full steering is obtained and make sure that
the pressure increases to normal value when the steering wheel is
forced.
★ Normal pressure: 175 ± 5 bar (2,538 ± 73 psi)
★ If pressure fails to reach normal value, perform the steering
system pressure calibration procedure.
★ If the pressure displayed on the pressure gauge shows no varia-
tion when turning the steering wheel, and the effort needed to
execute the steering operation is high, clean the priority valve
(2).
WB142-5 30-19
12
TESTING AND SETTING STEERING SYSTEM PRESSURE
• Engine: operating temperature
CONTROL
1. Connect a pressure gauge E3 (400 bar) to the pressure tap on the

backhoe control valve.
2. Start the engine and bring it to idle speed 1500 ± 50 rpm and carry
out a total steering.
3. Forcing the steering wheel at the end of stroke, check pressure.

★ Normal pressure: 175 bar (2,538 psi)
4. Check for the other steering direction too.
SETTING
★ If pressure is not within permissible value, carry out setting acting
on upper valve (1) of the steering unit (2).
1. Remove the plug (3).
2. Insert a wrench of 4 mm and rotate screw (4).

★ To INCREASE pressure rotate in CLOCKWISE direction.
★ To DECREASE pressure rotate in COUNTERCLOCKWISE
direction.
3. Stop the engine and replace the plug (3); ensure that the seal (5) is
in its proper position.
Plug 50 ± 10 Nm (37 ± 7 lbs/ft)
30-20 WB142-5
12
CHECKING FOR LEAKS IN THE STEERING CYLINDERS
• Working brakes: engaged.
• Maximum steering pressure: within permissible limits.
1. Start the engine and fully steer the wheels in either direction.
2. Stop the engine.
3. Disconnect the supply hose (2) from the cylinder (1) on the side
where the rod is fully out (3); plug the hose tightly.
4. Connect a provisional hose to the cylinder (1) to collect any leaking fluid.
5. Start the engine and operate the engine at high idling speed.
6. Force the steering wheel to the end of its travel and retain the position for 30 seconds; measure any leak during the follow-
ing minute.
7. Release the steering wheel, run the engine at low idling, and then stop the engine.
8. Check if leakage is normal.

★ Test cylinder on one side only, as there is only one gasket separating the two chambers.
9. Restore the hydraulic connection, steer the wheel several times in both directions to remove any air from the circuit.
WB142-5 30-21
TESTING AND ADJUSTING POWER TRAIN
12
POWER TRAIN
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 (176 ± 41oF).
3. With the engine at MIN, check the pressure on the pressure gauge
E6.
Idle pressure3.05 kg/cm² (43 psi)
4. Gradually increase engine speed to 2200 rpm; take a new reading
on pressure gauge E6.
Normal pressure . . . . . . . . . . . . . . . . . 3.05 - 9.17 kg/cm² (43 - 130 psi)
5. Bring the engine back to MIN and compare the pressure with the normal value.
Min pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.05 kg/cm² (43 psi)
★ If the pressure value drops to below the permissible lower limit, the power train pump needs an replacement.
CLUTCH ENGAGEMENT PRESSURE

1. Remove the plug P19 and connect the pressure gauge E6.
a temperature of 80 ±5 °C.
3. Bring the engine up to low idle and check the pressure on the pres-
sure gauge E6.
Normal pressureMax. 0.3 kg/cm² (4.3 psi)
30-22 WB142-5
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.
Normal pressure . . . . . . . . . . . . . . . . 13.7 - 16.8 kg/cm² (195 - 239 psi)
5. Bring the engine back to MIN and the transmission in neutral position; compare the pressure with the normal value.
Normal pressure . . . . . . . . . . . . . . . . . . . . . . . Max. 0.3 kg/cm² (4.3 psi)
6. Remove the pressure adapter and replace the plug P19.
7. Repeat the same test for the FORWARD gear, reading the pressure from the orifice protected by the plug P18.
l If the pressures are different for the two travel directions, there is a loss of pressure on the clutch piston with lower
pressure.
WB142-5 30-23
12
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 (1). During the fol-
lowing 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 pedals,
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
completing the tests.
CONTROL
a temperature of 80 ± 5 °C (176 ± 41 oF).
2. With the engine in idling condition, accelerate to MAX. and check

that in this condition the RPM remains within permissible limits.
3. Brake hard and bring the engine up to MAX.
4. Engage the 3rd gear while braking and accelerating as above;

confirm that engine speed decreases to the permissible range
5. Repeat this test in REVERSE gear.

★ If the RPM is high than the permissible limits, the clutches are worn, and must be replaced.
30-24 WB142-5
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 oC (113 - 131 oF).
• 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
(4.0 inches) and in vertical position in relation to the ground.
2. Stop the engine and release the residual hydraulic pressures.
3. Disconnect the tubes (1) and (2) from the lift cylinders (3) and plug
them.
4. Plug the cylinders, base side, and apply a temporary tube, rod side,
to catch any possible oil leakage.
5. Start the engine and curl the bucket until the teeth are in the tilt
position by 10°.
6. Stop the engine and check bucket link position for movement 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
position.
8. Remove from one of the cylinders the plug fitted on the cylinder
bottom side in Step 4.
9. Start the engine and retract the bucket to bring the teeth in a tilt
position of about 10° upwards.
10. Stop the engine and check the loader position for 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.
WB142-5 30-25
12
BUCKET CIRCUIT
1. Put the machine with the loader on level ground and bucket edge
tilted 10°. Put a 1500 kg (3,307 lbs) weight in the bucket.
2. Disconnect the tubes (1) and (2) from both bucket cylinders (3) 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.
30-26 WB142-5
12
BACKHOE
★ Test condition:
★ Backhoe aligned
★ Lifted outriggers
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 (1) and (2) that feed cylinder (3).
4. Plug the two hoses to avoid impurity inlet.
5. Plug the cylinder head side.
6. Apply a temporary tube to tube (4) 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
gaskets.
★ If boom has no lowering movement, drift is due to control
valve.
ARM CIRCUIT
1. Set the machine with the arm fully extended and with the bucket
teeth on ground.
WB142-5 30-27
3. Disconnect the tubes (1) and (2) the tubes from the arm cylinder (3)
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 340 kg (750 lbs) weight in the bucket or fill it
with dirt.
3. Disconnect the bucket cylinder (3) hoses (1) and (2) 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.
30-28 WB142-5
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 TESTING
1. Set the machine with the arm in vertical position and with the
bucket on level ground leaned to the side.
2. Put 20 cm (8 inches) blocks under the outriggers.
3. Without forcing them, lower the outriggers onto the blocks.
5. Disconnect from the cylinders (3), the tubes (1) and (2) after the
lock valve.
6. Plug the cylinders base head tube (1). Add a temporary tubes to the
rod side (2) tube to catch oil leakage.
7. Start the engine, use the boom to raise the machine, and remove the
blocks supporting the outriggers.
WB142-5 30-29
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
cylinders.
★ If there is no lowering, drift is due to control valve.
30-30 WB142-5
40 TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-5
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-5
HANDLING ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS . . . . . . . . . . . . . . 40-11
HOW TO READ ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . 40-14
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-27
WB142-5 40-1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
40-2 WB142-5
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
3. Check before troubleshooting.
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the failure.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of failure.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
WB142-5 40-3
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-4 WB142-5
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for electronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT

1. Handling High Voltage Circuits
A. If the machine is equipped with an electronically controlled

engine, high voltage is used to control fuel injection,
(110 - 130 V) for the fuel injector drive. Never handle the
engine wiring harness while the engine is running, tamper with
or modify this circuit, sever injury may result due to the high
voltage and amps in the circuit. Always use caution when
working around this circuit.
2. Handling Wiring Harnesses And Connectors
A. Wiring harnesses consist of wiring connecting one component

to another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or
tubes used for protecting the wiring. Compared with other
electrical components fitted in boxes or cases, wiring harnesses
are more likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during inspection and
repair operations they are frequently removed and installed
again, so they are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when
handling wiring harnesses.
3. Main Failures Occurring In Wiring Harness
A. Faulty contact of connectors:

(faulty contact between male and female). Problems with
faulty contact are likely to occur because the male connector is
not properly inserted into the female connector, or because one
or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidation of
the contact surfaces.
WB142-5 40-5
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector:

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
if water does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.
E. Oil, grease or dirt stuck to connector:

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, and this will cause
a defective contact.If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.
40-6 WB142-5
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a screw, loosen
the screw fully, then hold the male and female connectors
in each hand and pull apart. For connectors which have a
lock stopper, press down the stopper with your thumb and
pull the connectors apart.
★ Never try to pull apart with one hand
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.
iv. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
WB142-5 40-7
B. Connecting connectors:
i. Check the connector visually.

• Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
• Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
• Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage, replace the
connector.
ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
★ When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
C. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
★ Male connector (1), Female connector (2).
★ Normal locking state (Horizontal): a, b, d
★ Incomplete locking state (Diagonal): c
40-8 WB142-5
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.
iii. Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, spray it with
contact restorer and reassemble.
WB142-5 40-9
HANDLING ELECTRONIC CONTROL UNIT

1. The electronic control unit contains a microcomputer and electronic
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control unit.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control unit in a place where it is exposed to rain.
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
7. Precautions when carrying out arc welding.

★ When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control unit. Attach
the arc welding ground close to the welding point as possible.
40-10 WB142-5
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIR-

CUITS
1. Always turn power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
6. When checking a dual diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
★ When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the Operator’s Manual for the meter you
will be using.
WB142-5 40-11
12
HOW TO READ ELECTRIC WIRE CODE
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric
wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness
and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Type Symbol Material temperature Example of use
range (°C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric –30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
mobile
Heat-resistant Annealed copper for electric
Conductor General wiring in extremely cold dis-
low-voltage appliance
AEX –50 to +110 trict, wiring at high-temperature
wire for auto- Heat-resistant crosslinked poly-
Insulator place
mobile ethylene
40-12 WB142-5
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f
(1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
Cov AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
- AV Standard – – – – – – – 4.6
er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
Diameter of
Conductor strand
Sectional area
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
Cov AVS Standard – – – – – – – – –
- AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible.
WB142-5 40-13
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot
of dust.
2. Disassembly and maintenance work in the field.

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.
3. Seal or cover all openings of disconnected piping.

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.
4. Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.
40-14 WB142-5
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
WB142-5 40-15
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
2. Check for impurities in fuel - Drain
3. Check oil level in hydraulic oil tank - Add oil
Lubricating oil, coolant
4. Check transmission oil level - Add or Replace

5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check engine oil filter condition - Replace
Before Starting Checking Item
10. Check hydraulic oil filter - Replace

11. Check transmission oil filter - Replace
12. Check for abnormal noise or smells - Repair
Hyd. Mech.
13. Check for leaks - Repair

14. Bleed any air from circuit - Bleed air
15. Check effect of braking - Repair or adjust
16 Check condition of steering - Repair or adjust
17. Check battery and cables for looseness or corrosion - Retighten/replace
18. Check alternator wiring - Repair
Electrical equipment
19. Check starter motor wiring - Repair

20. Check operation of instruments - Repair or replace
21. Check battery load condition. - Replace
22. Check wiring condition - Repair or replace
23. Check condition of all fuses - Repair or replace
24. Check operation of starter - Repair or replace
25. Check wiring connectors - Repair
40-16 WB142-5
TROUBLESHOOTING 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.
WB142-5 40-17
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
phases
Blocked half shaft:
l Abnormal functioning of the differential or l Verify assembly of all components
breakage/blockage of control device
l Vehicles with wide steering angle may proceed l 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
40-18 WB142-5
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
WB142-5 40-19
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
40-20 WB142-5
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
WB142-5 40-21
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
40-22 WB142-5
12
Uneven wear of tires
CAUSES REMEDY
Defective axle
phases
Blocked half shaft:
l Abnormal functioning of the differential or break- l Verify assembly of all components
age/blockage of control device.
l Vehicles with wide steering angle may proceed l 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
WB142-5 40-23
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
40-24 WB142-5
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
WB142-5 40-25
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
40-26 WB142-5
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
WB142-5 40-27
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
40-28 WB142-5
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
WB142-5 40-29
40-30 WB142-5
50 DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4

REMOVAL AND INSTALLATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
OVERHAUL OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
PRECAUTIONS WHEN CARRYING OUT AN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-12
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-13
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-14
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-15
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-16
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-18
FRONT GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-19
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
EXHAUST STACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29
OPERATORS SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
SIDE PANEL AND INSTRUMENT GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
LOWER ELECTRICAL GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
DASH BEZEL AND COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-32
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-38
STEERING AND FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-39
FRONT DASH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41
STEERING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
WB142-5 50-1 B
CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-53
HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-66
TRANSMISSION OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-67
PLUGS AND FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-68
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-75
OIL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-79
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80
4 WHEEL DRIVE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-96
TRANSMISSION HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100
CLUTCH PACK (A) AND GEAR SHAFT (D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
GEAR SHAFTS (B) AND (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140
GEAR SHAFT (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-158
SHIFTER TOWER AND FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-168
BACKHOE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-174
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-174
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-175
FRONT AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-177
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-177
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-178
FRONT AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-179
STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-179
FRONT AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-185
AXLE END HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-195
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-198
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-204
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-211
REAR AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-214
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-214
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-216
REAR AXLE OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-217
PARKING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-217
SERVICE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-224
REAR AXLE END PLANETARY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-235
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-244
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-251
CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-257
PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-265
FRONT LOADER CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-271
SOLENOID VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-272
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-272
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-272
FRONT-END LOADER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-273
LOADER BOOM CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-273
50-2 B WB142-5
BUCKET CYLINDER AND MONO-LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-275
LOADER BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-278
LOADER BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-279
BACKHOE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-282
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-282
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-284
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-286
SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-289
BOOM LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-292
BACKHOE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-294
BACKHOE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-295
BACKHOE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-298
BACKHOE SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-300
OUTRIGGER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-301
OUTRIGGER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-303
WORK EQUIPMENT CYLINDER OVERHAUL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-304
LOADER AND BACKHOE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-304
SWING CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-309
WB142-5 50-3 B
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
12
HOW TO USE THIS MANUAL
REMOVAL AND INSTALLATION OF COMPONENTS
REMOVAL
• The REMOVAL Section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the REMOVAL Section are explained and listed below.
This indicates safety-related precautions which must be followed when doing the
WARNING!
work.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows oil or water to be drained.
Weight of a part or component.
INSTALLATION
• Except where otherwise instructed, install parts is the reverse order of removal.
• Marks shown in the INSTALLATION Section stand for the following.
WARNING! This mark indicates safety-related precautions which must be followed when doing the work.
★ This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or coolant to be added.
50-4 B WB142-5
DISASSEMBLY AND ASSEMBLY HOW TO USE THIS MANUAL
12
OVERHAUL OF COMPONENTS
DISASSEMBLY PROCEDURES
• The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water to be drained.
• Various symbols used in the DISASSEMBLY Section are explained and listed below.
Remark This mark gives guidance or precautions when doing the procedure.
This mark shows amount of oil or coolant to be drained.
ASSEMBLY PROCEDURES
• Section titled ASSEMBLY contain procedures, precautions and the know-how for the work, as well as the amount of oil
or water to be added.
• Various symbols used in the ASSEMBLY Section are explained and listed below.
★ This mark gives guidance or precautions when doing the procedure.
This mark stands for a specific coating agent to be used.
This mark indicates the specified torque.
This mark indicates an amount of oil or water to be added.
WB142-5 50-5 B
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT AN
12
PRECAUTIONS WHEN CARRYING OUT AN OPERATION
When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given
below when carrying out the operation.
1.Precautions when carrying out removal work

• If draining a system always dispose of the fluids correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before
removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors. Do not pull the wires.
• Install wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength and always stand clear of what you are
lifting.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from entering
after removal.
★ Precautions When Handling Piping During Disassembly install the following blind plugs into the piping after
disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2. Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3. If the part is not under hydraulic pressure, the following plugs can be used.
Nominal Dimensions (mm)

Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
50-6 WB142-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT AN
4.Precautions when carrying out installation work
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3
drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check to be sure there is no dirt or
damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check to be sure snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eyebolts, check to be sure there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic
equipment removed for repair, always bleed the air as follows:
A. Start the engine and run at low idling.
B. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm
(4.0 in) from the end of its stroke.
C. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
WB142-5 50-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST.
12
SPECIAL TOOL LIST.
Symbol
Qty.
Component Part No. Part Name
1 CA15655 Plunger 1
2 CA119097 Plunger 1
3 CA15360 Plunger 1
4 CA15035 Plunger 1
5 CA15026 Plunger 1
6 CA15077 Plunger 1
Disassembly and assembly of the
D 11 CA15164 Plunger 1
front axle (4WD)
12 CA119030 Ring nut spanner wrench 1
14 CA119099 Closed end wrench 1
17 CA715023 False pinion 1
18 CA119182 False differential box 1
2 CA715902 Removal/installation tool (self adjusting kit) 1
4 CA715901 Bushing 1
Disassembly and assembly of the rear 7 CA715900 Removal/installation tool (ring nut) 1
E
axle 8 CA715391 Plunger 1
11 CA715092 Outer ring installation tool (pinion bearing) 1
12 CA119225 Outer ring installation tool (pinion bearing) 1
13 CA715128 False pinion 1
50-8 WB142-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST.
Symbol
Qty.
Component Part No. Part Name
5 CA715495 Protection + shims 1
7 CA715356 Installer 1
9 CA715358 Installation /assembly tool (clutches) 1
Disassembly and assembly of the
F 10 CA715499 Protection 1
transmission
12 CA715743 Protection + shims (/2-/3-/4) 1
14 CA715745 Installer 1
15 CA715496 Latch for B and C shafts 1
17 CA715493 Removal/installation tool (stop ring) 1
18 CA715257 Protection 1
19 CA715263 Protection 1
WB142-5 50-9
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
CONTACT TERMINAL REMOVAL (HD30 TYPE)
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will hinder wire
removal and may damage the connector or removal tool. Always
use the correct removal tool size for the wire gauge you are
servicing.
3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting removal tool
into the grommet. Damage to the tool or connector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.
50-10 B WB142-5
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
WB142-5 50-11 B
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2mm (1 in) behind the
crimped barrel.
2. Holding connector with rear grommet facing you.
3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environmental
sealing.
50-12 B WB142-5
12
CONTACT TERMINAL REMOVAL (DT TYPE)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
WB142-5 50-13 B
12
CRIMPING CONTACT TERMINAL (DT TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.
50-14 B WB142-5
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2 mm (1in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.
3. Push the contact terminal straight into the connector until a “click”
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.
Remark
As the connector receptacle is shown - use the same procedures for
a plug.
WB142-5 50-15 B
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 -.218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 -.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 -.312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 -.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 -.312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 -.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 -.284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 -.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 -.492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 -.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 -.492)
Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
50-16 B WB142-5
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
12
ENGINE HOOD
REMOVAL
WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a
smooth level surface. Lower all work equipment to the ground, set the parking brake,
chock the wheels and disconnect the battery.
1. Raise the front loader arms fully up and set the lock as shown in
(A).
A. Raise the front end loader unit completely in the air extending
the lifting cylinders rods completely.
B. Remove the cylinder lock assembly small pin (3). Holding on

to the lock unit (1), pull out lock pin (2).
C. Using both hands lower the lock unit (1) down from its
storage position onto the extended lift arm cylinder rod.
D. Once on the cylinder rod, install lock pin (2) and small pin (3)
and slowly lower the loader arms until it rests on the loader
lock (1).
2. Remove the four grill mounting screws (1) and remove the front
grill assembly (2).
WB142-5 50-17
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
3. Fully raise the engine hood (3) and remove the safety pins (4) then
disconnect the gas struts (5) from the chassis.
4. Remove the snap rings (6) and retaining washers (7) from the pivot
pins (8).
5. Remove the pivot pins (8) and carefully lift the hood assembly (3)
off the machine using two people.
Engine hood: 32 kg (71 lbs)
INSTALLATION
★ Installation is done in the reverse order.
★ After installing hood (3) be sure to line up hood latch bracket (9)
when closing the hood.
50-18 WB142-5
DISASSEMBLY AND ASSEMBLY FRONT GUARD
12
FRONT GUARD
REMOVAL
WARNING! Before any disassembly procedures are started, be sure the machine is sitting on a
smooth level surface. Lower all work equipment to the ground, set the parking brake,
chock the wheels and disconnect the battery.
★ Before removing the front guard, the grill and hood assembly must
be removed first. See “ENGINE HOOD” .
1. After the grill and hood are removed, sling the front guard (4) as
shown in the illustration. Lift up slightly to relieve tension on the
mounting bolts (3) before removing them.
Front guard: 110 kg (242 lbs)
2. Carefully remove the four mounting bolts (3) that hold the guard
(4) in place.
WARNING! When doing this procedure be sure to

keep upward tension on the guard frame
(4). When removing the four mounting
bolts (3) be sure to stand clear of the
guard frame (4).
3. Once the four mounting bolts (3) are removed, move guard frame
(4) forward then lift up on frame to remove from machine.
INSTALLATION
Mounting bolts (3): Loctite 242
Bolts (3) torque: 300 N·m (221 lbf/ft)
WB142-5 50-19
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
REMOVAL
★ Before removing the radiator, the grill, hood and front guard assembly must be removed first. See “ENGINE HOOD” and
“FRONT GUARD” .
1. Open the drain valve (3) and drain the engine coolant at the front of
the radiator.
WARNING! Slowly loosen the radiator cap to

release the pressure inside the
cooling system.
A. Set a suitable size container under the engine coolant drain to

catch the coolant that is drained from the cooling system.
B. Place the drain hose into the container and open the drain valve
two to three turns to drain the engine coolant.
Remark
It is a violation of EPA laws to drain coolant on the ground, in rivers or lakes or in a city sewer system.
Coolant must be captured and recycled according to EPA laws. Failure to do so may result in fines or
punishment.
Engine coolant: Approximately 15 liters (4 gal.)
2. Disconnect the connector (4) and remove the horn (5).
3. Disconnect hose (7) from radiator (6) and remove surge tank (8).
50-20 WB142-5
4. Remove the fan guard mounting bolts (9).
5. After the fan guard mounting bolts (9) are removed, carefully lift
the fan guard (10) out of the machine.
6. Partly loosen fittings (11) and (12) to drain the hydraulic oil from
the oil cooler; once the oil is drained, fully disconnect hoses (13),
(14) and plug them to prevent contamination.
Hydraulic oil: Approximately 40 liters (10.5 gal.)
7. Disconnect transmission oil cooler oil hoses (15) and (16) from the
oil cooler and plug them to prevent contamination.
★ Mark the hoses and their respective positions for reconnecting.
WB142-5 50-21
8. Disconnect the upper (17) and lower (18) radiator hoses.
9. Disconnect the fan shroud (19) from the radiator core.
10. Remove the self-locking nuts (21), washers (22) and anti-vibration
dampers (23).
11. Remove the bolts (24) retaining the brackets (25).
50-22 WB142-5
12. Move the radiator (6) to the front of the machine to disengage it
from the cooling fan and lift it off the machine frame.
Radiator : 37 kg (82 lbs)
INSTALLATION
★ To install, reverse removal procedure.
★ Refill the cooling system.
Coolant: 15 liters (4 gal.)
★ Fill the tank with hydraulic oil up to maximum level.
Hydraulic oil: 40 liters (10.5 gal)
★ Ensure that the level of transmission oil is at maximum.

★ Start the engine at low idle to circulate all the fluids and to fill up the systems.
★ Accelerate gradually to 1700 rpm; after about one minute, stop the engine and check or top up the level. Top up all oil
levels.
★ Align radiator (6) with fan, making sure the fan protrudes from fan
shroud by 25 ± 2 mm (1.0 ± 0.1).
WB142-5 50-23
DISASSEMBLY AND ASSEMBLY MUFFLER
12
MUFFLER
WARNING! Be sure the engine and exhaust system have fully cooled down before removing any
exhaust components. Failure to do so may result in a burn injury.
REMOVAL
(A).

storage position on to the extended lift arm cylinder rod.
lock (1).
2. Remove the four exhaust pipe flange bolts (1) and disconnect the
exhaust pipe (2) from the engine manifold.
50-24 WB142-5
3. Disconnect outlet pipe (3) from the muffler (4).
4. Remove the top fire wall faring (4) from the fire wall.
5. Remove the air intake horn (5) from the air cleaner housing.
6. Sling the muffler (4) as shown in the illustration.
WB142-5 50-25
7. Remove mounting bolts (6) and (7) being careful not to lose the
spacers (8) on the left side of the mounting bracket.
8. Lift the muffler assembly (4) off the machine.
Muffler: 30 kg (66 lbs)
INSTALLATION
50-26 WB142-5
DISASSEMBLY AND ASSEMBLY AIR FILTER
12
AIR FILTER
REMOVAL
1. Park the machine on hard, level surface, apply the parking brake,
stop the engine and remove the ignition key.
2. Open engine hood, loosen straps (1) and (2), and disconnect pipe
(3) from pipe (4).
3. Disconnect connector (6) from filter clogging sensor (5).
4. Remove the bolts (7) and remove the filter (8) together with the
filter bracket.
INSTALLATION
WB142-5 50-27
DISASSEMBLY AND ASSEMBLY EXHAUST STACK
12
EXHAUST STACK
REMOVAL
(A).

lock (1).
2. Remove exhaust clamp nuts (1) and clamp (2) from pipe (3).
3. Loosen the bolts (4) on the stack flange and remove one bolt only
for safety to hold stack in place.
50-28 WB142-5
DISASSEMBLY AND ASSEMBLY EXHAUST STACK
4. Remove bolt (5) and lift stack (6) off of the machine after removing
last bolt (4) from flange.
INSTALLATION
WB142-5 50-29
DISASSEMBLY AND ASSEMBLY OPERATORS SEAT
12
OPERATORS SEAT
★ This job requires two people to perform the removal and installation tasks.
REMOVAL
★ Before proceeding with any removal procedures, be sure the seat is locked in position.
1. Unplug connector (1) and remove connector mounting bracket (2).
2. Remove the two right side seat mounting bolts (3).
3. Remove the two left side seat mounting bolts (3).
4. Using two people, lift the seat (4) off the machine.
Seat: 62 kg (136 lbs)
INSTALLATION
50-30 WB142-5
DISASSEMBLY AND ASSEMBLY SIDE PANEL AND INSTRUMENT GROUP
12
SIDE PANEL AND INSTRUMENT GROUP
WARNING! Before proceeding with any electrical work, park the machine on a flat level
surface, lower all work equipment to the ground and disconnect the battery.
★ Before proceeding with any side dash group removal, the operators seat must be removed. See “OPERATORS SEAT” .
LOWER ELECTRICAL GROUP
REMOVAL
1. Remove fasteners (4) and remove the front lower panel (5).
2. Remove four screws (6) and remove PPC valve and parking brake
housing (7).
3. Remove four screws (8).
4. Remove the lower side instrument panel (9).
5. Position the dash panel (9) on the panel (10).
INSTALLATION
WB142-5 50-31
12
DASH BEZEL AND COVER
REMOVAL
1. Remove four screws (11).
2. Remove the upper side gauge panel (12).
3. Disconnect the connector (13) from the gauge panel (12).
4. Disconnect connectors (14) and (15) from the lighter.
5. Remove screws (16) and remove the throttle handle (17).
6. Remove screws (18) from the accelerator cover assembly.
7. Remove the lower screws (21) retaining the lower panel (10).
50-32 WB142-5
8. Remove three screws (22) and screws retaining the upper panel
(10) at the rear.
9. Remove screw (23) and screw (24) and washer.
10. Remove the screw (25) retaining the upper panel (10) and its
washer.
WB142-5 50-33
11. Move the rear part of the panel (10) towards the middle of the cab,
remove pin (26), and disconnect the throttle cable (27).
12. Loosen nut and disconnect cable (28).
13. Disconnect connector (29).
14. Engage the parking brake.
15. Raise cover panel (10) until PPC valve control and parking brake
lever are disengaged; fully remove the cover panel.
INSTALLATION
50-34 WB142-5
DISASSEMBLY AND ASSEMBLY BATTERY
12
BATTERY
WARNING!
Be careful when working around batteries:
• Keep metal tools away from battery if possible.
• Do not set tools or parts on battery tops.
• The battery generates flammable gas and there is danger of explosion. Do not bring fire or
sparks near the battery.
• Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large
amounts of water and consult a doctor.
REMOVAL
1. Remove the three mounting screws (1) and remove the trim cover
(2) from the machine.
2. Remove the step cover mounting bolts (3) and remove top step
cover (4) from machine.
3. Remove wing nut (5) and remove battery hold down brace (6).
WB142-5 50-35
DISASSEMBLY AND ASSEMBLY BATTERY
4. Disconnect battery (-) then (+) terminals (7) and lift out battery (8)
from the compartment.
Battery: 43.3 kg (102 lbs)
INSTALLATION
★ When re-connecting the battery be sure to connect the (+) terminal first.
50-36 WB142-5
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
WARNING! Lower the working equipment completely until it is resting on the ground. Set the parking
brake and chock the wheels. Remove the ignition key and disconnect the battery.
REMOVAL
1. Remove the fuel cap (1) off the fuel tank (2) and remove plug (3) in
order to drain the fuel.
WARNING! Do not remove or install fuel tank with fuel

in it. Tank may become unstable causing
fuel to spill.
Fuel tank: Approximately 150 liters (40 US gal.)
2. Reinstall the fill plug (3) and fuel cap (1).
3. Remove screws (4) and remove the lower left trim panel (5) from
the cab.
4. Disconnect connector (6) from the level gauge sending unit (7).
★ Mark then disconnect the fuel inlet and return hoses (8) and
(9).
★ Plug all pipes and hoses to prevent contamination.
WB142-5 50-37
DISASSEMBLY AND ASSEMBLY FUEL TANK
5. Place a lift under the fuel tank (2); remove four retaining bolts (10)
and washers, then remove the tank.
Fuel tank: 62 kg (137 lbs)
INSTALLATION
Tank retaining bolts: 120 N·m (89 lbf ft)
1. Refill the fuel tank.
Fuel fill: 150 liters (40 gal.)
2. Bleed the air from the fuel circuit.
3. Start the engine.
50-38 WB142-5
DISASSEMBLY AND ASSEMBLY STEERING AND FRONT DASH ASSEMBLY
12
STEERING AND FRONT DASH ASSEMBLY
STEERING WHEEL
★ Before proceeding with any steering wheel or dash removal the
operator’s seat must be removed.
See “OPERATORS SEAT” REMOVAL
1. Use a thin bladed screwdriver placed under each spoke of the

steering wheel to pry away the cover (1).
2. Remove the retaining nut (2) and remove the steering wheel (3).
3. Remove four screw covers (4) and loosen four screws (5) retaining
the instrument panel.
WB142-5 50-39
4. Lift off instrument panel (6) from steering column; disconnect
connectors (7) and (8), and remove instrument panel.
5. Remove screws (9) and (10) and release direction indicator group
(11) and transmission control group (12).
6. Disconnect connectors (13) and (14) and remove (11) and (12).
INSTALLATION
★ Before attempting to tighten the screws, check the anti-rotation stake (15) for proper engagement into the steering column
(16).
50-40 WB142-5
12
FRONT DASH ASSEMBLY
REMOVAL
1. Remove the upper screws (4) retaining the instrument panel (5).
2. Remove the plugs and extract screws (7) at the front trim cover (8).
3. Remove the screws (9) retaining the front trim cover (8).
4. Take out the screws (10) and remove the instrument panel holder
(5).
WB142-5 50-41
5. Slide the front trim cover (8) up to remove it.
6. Remove the cap (12) and draw the brake fluid from the tank (13).
7. Reinstall the cap and disconnect connectors (14) and pressure

switch connectors (15) and (16).
★ Connector (15) left (X54)
★ Connector (16) right (X53)
8. Remove the tank (13).
9. Disconnect the delivery pipes (18) from the master cylinder (17).
10. Take off four nuts (19) and remove the master cylinders.
★ If only one pump is to be removed, disconnect the
pressure equalizing pipe (20) and remove master cylinders
individually.
50-42 WB142-5
INSTALLATION
★ Bleed the air from the braking circuit. For details, see “BLEED
AIR FROM BRAKING CIRCUIT” .
WB142-5 50-43
12
STEERING UNIT
REMOVAL
WARNING! Eliminate residual pressure from all circuits by moving all control levers in all directions.
1. Remove the steering wheel and the direction indicator, transmission

reverse and headlight dipper beam control groups For details, see
“STEERING AND FRONT DASH ASSEMBLY” .
2. Loosen and remove the upper screws (4) retaining the instrument
panel holder (5).
3. Remove the screws (6) retaining the side of the instrument panel
holder.
50-44 WB142-5
4. Slide the instrument panel holder (5) up to remove it.
5. Loosen screw (7) and remove two screws (8); remove the front
guard (9).
6. Mark the respective positions of connectors and disconnect five

pipes (10) from steering unit (13).
★ Plug all pipes to prevent contamination.
7. Loosen the screws (11) fastening the column (12) and steering unit
(13); remove the steering unit.
INSTALLATION
★ Start the engine and perform several complete steering maneuvers in both directions, to bleed the air out of the steering
system.
WB142-5 50-45
DISASSEMBLY AND ASSEMBLY CANOPY
12
CANOPY
WARNING! Lower the backhoe work equipment completely until it is resting on the ground. Set the
parking brake and chock the wheels. Remove the ignition key and disconnect the battery.
REMOVAL
(A).

lock (1).
2. Remove bolts (1) and cover (2) to access steering unit and hoses.
50-46 WB142-5
3. Remove the front seat. See “OPERATORS SEAT” for details on

procedures.
4. Remove the five mounting bolts (3) and lift off floor cover (4).
5. Once floor cover (4) is removed, disconnect brake lines (5), throttle
cable (6) and hose bundle clamp (34) from the mounting bracket.
★ Tag each brake line with reference to Right and Left braking
system.
6. Remove the front dash assembly.

See: “FRONT DASH ASSEMBLY” for details on
procedures.
7. Remove bracket (7) from steering hoses.
8. Remove the throttle linkage relay rod Allen bolts (8) to

disconnect throttle linkage system from floor.
Remark
Keep track of the bearings inserted into the lever blocks
when removing linkage.
WB142-5 50-47
9. Cut wire strap (10) and remove the four bolts (11) and lift off
steering column (12) as well as steering unit (9).
10. Lay steering unit (9) with hoses attached on top of the transmission
as shown in the illustration.
11. Remove the backhoe control lever boots and knobs.
12. Remove the four mounting screws and remove the backhoe control
cover (13) assembly.
50-48 WB142-5
13. Loosen lock nut (14) and remove both backhoe control levers (15)
from their mounting location.
14. Remove the four mounting bolts (16) and remove floor plate (17)
for clearance purposes.
15. Remove the side access cover (18) to access the wiring
connections. See “DASH BEZEL AND COVER” for details on
procedures.
16. Disconnect connectors (19).

★ Two purple multi-connectors.
★ One green multi-connector.
17. Remove solenoid power supply connection (20).
WB142-5 50-49
18. Remove ground connection (21) from floor.
19. Remove loader control and parking brake lever control cover (22)
to access parking brake lever and loader control lever.
20. Disconnect grey connector (23), wire X49 at the control lever.
21. After all wires are disconnected, pull them through the floor access
hole as shown in the illustration.
50-50 WB142-5
22. Disconnect parking brake cable (24) and loosen lock nut (25).
Remove brake cable (24) from brake lever assembly.
23. Remove gear shift lever bolt (26), disconnect electrical connector
(28) and pull out gear shift lever (27) from the machine.
24. Remove loader lever bolts and nuts (29) and remove loader lever
handle (30). Be sure to disconnect lever wiring harness X47 when
removing loader control lever.
25. Remove three screws (31) and remove side trim panels (32) on both
sides of the machine.
WB142-5 50-51
26. Remove the exhaust stack (33). See “EXHAUST STACK” for
details on procedures.
27. Remove the two 19 mm bolts in the top of the canopy and install
two 19mm eye bolts. Using straps, sling the canopy in the manner
shown in the illustration
28. Remove the front and rear mounting hardware on both sides of the
machine canopy.
50-52 WB142-5
29. Carefully lift the canopy off the machine chassis high enough to
clear the side and rear work equipment controls.
Canopy: 422 kg (930 lbs)
INSTALLATION
★ Check and adjust the stroke of the hand and accelerator pedal.
See Section 30 “ACCELERATOR PEDAL AND THROTTLE LEVER” .
★ Adjust the stroke of the parking brake lever. See: Section 30 “PARKING BRAKE ADJUSTMENT” .
★ Bleed the air from the braking circuit. See: Section 30 “HYDRAULIC CIRCUIT” .
★ Bleed the air from the steering circuit. See: Section 30 “BLEED AIR FROM BRAKING CIRCUIT” .
★ Reinstall canopy mounting bolts and torque.
Canopy mounting hardware: 200 N·m (148 lbf ft)
WB142-5 50-53
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL TANK
12
HYDRAULIC OIL TANK
WARNING! Lower the working equipment completely until it rests on the ground. Engage the parking
brake, chock the front and rear wheels. Eliminate all residual pressure from all circuits by
moving all control levers in all directions. Disconnect the cable from battery negative
terminal (-). For details, see “BATTERY”.
REMOVAL
1. Remove the plug (1) and drain the hydraulic oil.
Hydraulic oil: Approximately 40 liters (10.5 US gal.)
2. Remove the operator’s seat. See “OPERATOR’S SEAT” .
3. Remove the steering wheel and remove the transmission control

lever (5) and the direction indicator and headlight control lever (6).
For details, see: “STEERING AND FRONT DASH ASSEMBLY”
4. Remove the upper screws (7) retaining the instrument panel holder
(8).
50-54 WB142-5
5. Remove the screws (12) retaining the front trim cover (11).
6. Slide the front trim cover (11) up to remove it.
7. Take out the screws (10) and remove the instrument panel holder
(5).
8. Remove the fill cap (13) and draw the brake fluid out.
★ Replace cap to prevent contamination.
9. Disconnect oil level and pressure switch connectors (14) and (15).
WB142-5 50-55
10. Disconnect the brake fluid delivery tubes (16) and (17).
11. Loosen mounting bolt (18).
12. Remove bolts (19) and remove the cover (20).
13. Remove five bolts (21) and remove the metal floor cover (22)
off the cab floor.
14. Remove nuts (23) and disconnect the throttle cable (25) from the
relay rod (24).
15. Disconnect rod (26) from the relay rod (24).
16. Disconnect the strap (27) holding the steering unit and brake hoses.
50-56 WB142-5
17. Remove four mounting bolts (35) and washers.
18. Remove the complete bulkhead (36) and move it to the rear of the
machine.
19. Remove the bolts (37) and remove the cover (38).
20. Lift the rubber bulkhead and disconnect the discharge hose (40)
from the tank (39).
★ Plug the pipe to prevent contamination.
21. Disconnect union (41) and pipe (42).

★ Plug the union to prevent contamination.
WB142-5 50-57
22. Disconnect the pump suction pipe (43).
★ Plug the pipe to prevent contamination.
23. Disconnect the vent hose (44) and filter and remove.
24. Remove the screws and remove the fill sleeve (45).
★ Discard the old O-ring.
25. Remove screws (46) and washers and remove the tank's front
holder (47).
26. Remove bolts (48) and washers and remove the tank's rear support
(49).
50-58 WB142-5
27. Remove two bolts (50) and washers to release the complete tank
(39).
28. Remove the tank (39).
INSTALLATION
★ Bleed the air from the braking circuit. For details, see Section 30 “BLEED AIR FROM BRAKING CIRCUIT” .
★ Check and adjust the stroke of the throttle lever.
1. Refill the hydraulic oil.
2. Start the engine and check for leaks.
3. Stop the engine, check the oil level in the tank and, if necessary, top it up.
WB142-5 50-59
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
12
HYDRAULIC PUMP
moving all control levers in all directions. Disconnect the cable from battery negative ter-
minal (-). For details, see “BATTERY”.
REMOVAL
Remove plug (1) and drain the hydraulic oil.
★ Replace plug to prevent contamination.
1. Disconnect rear drive shaft (3) from transmission (2).
2. Disconnect lines (5), (6), (7), and (8) from the pump (4).
★ Cap all hoses and openings to prevent contamination.
50-60 WB142-5
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
3. Disconnect the intake line (9) from the pump.
4. Remove the lower bolt (10) retaining the pump (4) and its washer.
5. Loosen upper bolt (11) but leave it in place.
Remark
Do not remove bolt (11) at this stage.
6. Install a hydraulic jack under the pump until the pump is fully
supported and stable.
7. Remove the upper bolt (11) and remove the pump (4).
Pump: 31.5 kg (70 lbs)
INSTALLATION
Drive shaft bolts: 38 ± 1 N·m (28 ± 1 lbf ft)
Pump bolts: 220 N·m (162 lbf ft)
★ Refill the hydraulic oil.
1. Start the engine and run it at minimum speed to bleed any air.
2. Stop the engine and check the oil level in the tank and top up if necessary.
WB142-5 50-61
DISASSEMBLY AND ASSEMBLY TRANSMISSION
12
TRANSMISSION
moving all control levers in all directions. Disconnect the cable from battery negative ter-
minal (-). For details, see “BATTERY”.
REMOVAL
1. Drain the hydraulic oil.
2. Drain the oil from the transmission.
Transmission oil:
Approximately 20 liters (5.2 US gal.)
3. Remove the pump (1). See “HYDRAULIC PUMP” .
4. Remove the floor panel (2) at the bottom of the cab.
5. Disconnect the connector (3) on the transmission disengagement

button, remove the bolt (4) and remove the control lever (5).
50-62 WB142-5
6. Disconnect rear drive shaft (7) from transmission (6).
7. Remove front drive shaft (8).
8. Disconnect solenoid valve connectors (9), (10), 4th gear sensor

connector (11), and oil temperature sensor connector (12) from
transmission (6).
9. Disconnect the dual-traction engagement solenoid connector (13).
10. Disconnect the feed and discharge hoses (14) and (15) for the
differential lock. Disconnect backhoe boom safety solenoid valve
group from transmission (6).
WB142-5 50-63
11. Disconnect delivery hose (16) to oil cooler and return hose (17)
from transmission (6).
13. Remove the bolts and remove the cover (19) giving access to the
converter coupling flange.
14. Slowly rotate the engine flywheel until the converter retaining bolts
(20) are centred in the hole; remove the four bolts.
15. Remove the bolts (21) and (22) retaining the wiring harness brace
(23).
16. Support the engine (24) with a stand “C” placed under the engine
bell housing.
50-64 WB142-5
17. Disconnect the transmission oil level pipe (25), remove bolt (26)
and remove the complete pipe (25).
18. Remove the nuts (27) on the vibration dampers (28), the bolts (29)
and remove the transmission supports (30).
19. Install the transmission holding tool “B2” to a stand that is capable
of supporting approximately 60 cm (24 inches).
20. Using the holes on the supports, secure the tool “B2” to the
transmission.
21. Loosen and remove the two bolts (31) retaining the transmission (6)
to the engine (24).
WB142-5 50-65
22. Move the transmission assembly (6) towards the rear of the
machine and remove.
Transmission: 232 kg (511 lbs)
INSTALLATION
Transmission: 20 liters (5.3 US gal.)
Hydraulic oil: 40 liters (10.5 US gal.)
Front drive shaft bolts (6): 38 N·m (28 lbf ft)

Flywheel bolts (20): 64 N·m (47 lbf ft)
Support bolts (30): 90 ± 5 N·m (66 ± 4 lbf ft)
Anti-vibration nuts (27): 195 ± 20 N·m (144 ± 15 lbf ft)
Engine-bell-housing (31): 50 ± 5 N·m (37 ± 4 lbf ft)
Gear shift bolt (4): 120 N·m (89 lbf ft)
Flywheel bolts (20): Loctite 242

Support bolts (30): Loctite 262
Engine-bell-housing (13): Loctite 262
1. Tighten the bolts using the alternating crosswise method.
2. Start the engine to circulate the oil. Check that there are no leaks.
3. Bleed the air from the working equipment circuits. For details see Section 30 “HYDRAULIC CIRCUIT” .
4. Stop the engine, check the levels and, if necessary, top them up.
50-66 WB142-5
DISASSEMBLY AND ASSEMBLY TRANSMISSION OVERHAUL PROCEDURES
12
TRANSMISSION OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the transmission is
sitting on a level stable surface. Clean up any oil spills immediately and keep your work
area clean and clear of debris.
TORQUE CONVERTER
REMOVAL
★ Remove the engine and transmission. See “TRANSMISSION” .
1. Remove the converter (1).
INSTALLATION
★ Ensure that the mating surfaces are clean and free of dents.
★ To aid in mating flywheel, engine and transmission, install a
threaded stud “A” as a guide.
Bolts: Loctite 262
Bolts: 39 N·m (29 lbf ft)
WB142-5 50-67
12
PLUGS AND FILTERS
DISASSEMBLY
1. Drain plug 7. Oil filter 13. Priority valve

2. Cap screw 8. O-ring 14. Port plug
3. Cover 9. Cover 15. Vent
4. Oil screen 10. O-ring 16. Temperature sending unit
5. O-ring 11. Spool
6. Cap 12. Spring
50-68 WB142-5
12
1. Remove the drain plug (1) and drain the oil from the transmission.
2. Remove the two cap screws (2) which fasten the cover for the oil
screen.
3. Remove the cover (3).
4. Remove the oil screen (4) and the O-ring (5).
5. Remove the connector for the oil filter (7) and its elements: plugs
(6) and cover (9).
WB142-5 50-69
6. Remove the connector (7) from the cover (9). Remove the O-Ring
(8).
7. Remove O-Ring (10) from cover (9).
8. Remove the spool (11).
9. Remove the spring (12).
50-70 WB142-5
10. Using a puller, remove the priority valve (13).
★ Do not remove or adjust the valve (13). If valve is already
damaged, replace it with a new one.
11. It is not necessary to remove the port plugs (14), the breather (15),
or the oil temperature sensor (16).
WB142-5 50-71
12
ASSEMBLY
1. Assemble the port plugs (14), the breather (15) and the oil
temperature sensor (16).
Sensor: 30 N·m (22 lbf ft)
2. Assemble valve (13).
3. Install the spring (12).
4. Install the spool (11).
50-72 WB142-5
5. Assemble O-Ring (10) on the cover (9).
6. Assemble O-Ring (8) on the connector (7), and the connector on the
cover (9).
7. Assemble the connector (7) and plugs (6).
Union: 50 N·m (37 lbf ft)
8. Assemble filter (4) and O-ring (5) after having washed or replaced
it.
WB142-5 50-73
9. Assemble cover (3) and bolt (2).
Bolt: 23 N·m (17 lbf ft)
10. Install the plug (1).
50-74 WB142-5
12
PUMP
DISASSEMBLY
1. Mounting bolts (4 of them) 3. O-ring

2. Pump 4. Front seal
1. Remove the bolts (1).

★ Reference mark the pump and bell housing before removing
the bolts.
WB142-5 50-75
2. Remove the pump (2) by means of two levers.
3. Remove the oil pump (2).
4. Remove O-ring (3).

★ Inspect the condition of the O-ring (3) and replace if necessary.

★ Inspect the condition of the sealing ring (4) and replace if
necessary.
50-76 WB142-5
12
ASSEMBLY
1. Use the tool F1, assemble the seal ring (2) on the oil pump (2).
2. Assemble O-ring (3).
3. Check oil passage holes between pump (2) and half-case or the
visual marks aligned.
4. Grease the ring to the half boxes to keep it centred with respect to
the shaft slot center line and to make the introduction onto the
pump easier.
WB142-5 50-77
5. Apply a thin coat of grease to the seat of the oil pump (2) and
install.
6. Install the bolts (1).
50-78 WB142-5
12
OIL LINE
REMOVAL
1. Fitting 3. Oil line

2. Fitting 4. Seals
5. Remove banjo fittings (1) and (2) and remove the clutch oil supply
line (3)
★ Replace the seals (4) at each disassembly of the banjo fittings.
ASSEMBLY
1. Install the clutch oil supply line (3) and the banjo fittings (1) and (2).
Fittings (1) and (2): 40 N·m (29.5 lbf ft)
WB142-5 50-79
12
VALVE BODY
DISASSEMBLY
1. Plug 19. O-ring 37. Plate gasket

2. O-ring 20. Nut 38. Outward piston
3. Snap ring 21. Spool 39. Outer spring
4. Piston 22. Washer 40. Middle spring
5. Spring 23. Spring 41. Center spring
6. Plug 24. Solenoid tube 42. Pin
7. O-ring 25. Spring 43. Inward piston
8. Spool 26. Ball 44. O-ring
9. Spring 27. O-ring 45. Plug
10. Washer 28. Solenoid 46. O-ring
11. O-ring 29. O-ring 47. Body housing
12. Cap plug 30. Solenoid 48. Plate bolts
13. Bolt 31. O-ring 49. Gasket
14. Cap plug 32. Nut 50. Plate
15. O-ring 33. Bolts 51. Gasket
16. Cap plug 34. Cap 52. Transmission
17. O-ring 35. Gasket 53. Valve body assembly
18. Solenoid valve 36. Plate
50-80 WB142-5
54. Remove bolts (13) and remove the distributor (53).
55. Remove the gasket (49).
56. Remove plate bolts (48) and remove the plate (50).
WB142-5 50-81
58. Clamp the valve body (53) in a vise.
59. Remove plug (1) and discard the O-ring (2).
60. Push down the piston (4) then remove the snap ring (3).
61. Remove the piston (4), the spring (5) and check the wear conditions
of the components.
62. Remove plug (6) and collect the O-ring (7).
50-82 WB142-5
64. Remove the washer (10).
65. Turn the body housing (47) over and remove the screws (33).
66. Remove the valve cover (34).
WB142-5 50-83
67. Remove the plate gasket (35).
68. Remove the plate (36).
69. Remove the outward piston (38), the springs (39, 40, 41), the pin
(42) and the inward piston (43).
★ Check the wear conditions of removed parts.
50-84 WB142-5
70. Remove the plate gasket (37).
71. Remove the ball (26).
73. Remove the nut (32) and the O-ring (31).
74. Remove the solenoid (30) and remove the O-Ring (29).
WB142-5 50-85
75. Remove the solenoid (28) and remove the O-Ring (27).
76. Unscrew the solenoid tube (24).
77. Remove the cartridge (24) and spool (21).
78. Disassemble the spool (21) from the cartridge (24).
79. Remove the spring (23) and the washer (22).

50-86 WB142-5
80. Remove the nut (20).
81. Remove the O-ring (19), the solenoid valve (18) and the O-ring
(17).
82. Loosen the cartridge (18).
83. Remove the O-Rings (17).

WB142-5 50-87
12
ASSEMBLY
1. Install the O-Rings (17).
2. Install the cartridge (18).
Cartridge: 25 - 30 N·m (18 - 22 lbf ft)
3. Install the O-Ring (17), the solenoid (18) and assemble the O-Ring
(19).
4. Install the nut (20).
Nut: 5 -7 N·m (4 - 5 lbf ft)
50-88 WB142-5
5. Install the cartridge (24) and spring (23) to spool (21), and the
washer (22).
6. Install the cartridge (24) and spool (21) to control valve.
7. Tighten the cartridge (24).
Cartridge: 21.5 - 24.5 N·m (16 - 18 lbf ft)
8. Install O-Ring (27) and the solenoid (28).
WB142-5 50-89
9. Install O-Ring (29) and the solenoid (30).
10. Install O-ring (31) on the plug.
11. Install the nut (32).
Nut: 7 -10 N·m (5 - 7 lbf ft)
13. Install the ball (26).
50-90 WB142-5
14. Install the gasket (37) being careful not to dislodge ball (26).
★ Reassemble the components.
15. Install the outward piston (38), the springs (39, 40, 41), the pin (42)
and the inward piston (43).
16. Install the plate (36).
WB142-5 50-91
17. Install the gasket (35).
18. Assemble the valve cover (34).
Bolts: 9.8 -11.8 N·m (7 - 9 lbf ft)
20. Turn the valve body (47) over.
21. Install the washer (10).
50-92 WB142-5
23. Install O-ring (7) on the plug.
25. Install piston (4) and spring (5).
26. Push down the piston (4) then install the snap ring (3) in its seat.
WB142-5 50-93
27. Install the O-ring (2) on the plug.
29. Install the gasket (51) on the transmission (52).
30. Install the plate (50) and the screws (48).
31. Install the gasket (49).
50-94 WB142-5
32. Install the valve body (53) and the bolts (13).
WB142-5 50-95
12
4 WHEEL DRIVE SOLENOID VALVE
DISASSEMBLY
1. Mounting bolts 4. Gasket 7. Solenoid valve

2. Valve body 5. O-rings 8. Nut
3. Valve 6. Spool valve
1. Remove the bolts (1) and remove the solenoid valve body (2).
50-96 WB142-5
2. Remove the nut (8).
3. Remove the solenoid (7).
4. Remove spool valve (6) from housing.
5. Remove O-rings (5) from the cartridge.
7. Remove the valve (3).
Remark
DO NOT try to disassemble the valve (3). If valve is
already damaged, replace it with a new one.
WB142-5 50-97
12
ASSEMBLY
1. Assemble valve (3) to the housing.
2. Install O-rings (5) into the spool valve (6) in the housing.
Spool valve: 22 N·m (16 lbf ft)
3. Assemble the 4WD solenoid valve (7) and the nut (8).
Nut: 5 - 8 N·m (4 - 6 lbf ft)
4. Install new gasket (4).
50-98 WB142-5
5. Install the housing (2) and bolts (1).
WB142-5 50-99
12
TRANSMISSION HOUSING
DISASSEMBLY
1. Snap ring 16. O-ring 31. Snap ring

2. Bolt 17. Bolt 32. Snap ring
3. Washer 18. Rear housing 33. Bearing
4. O-ring 19. Seal 34. Bolt
5. Yolk flange 20. Pins 35. Bolt
6. Bolt 21. Shift collars 36. Front housing
7. Cover 22. Bolt 37. Bearing
8. O-ring 23. Plate 38. Bearing
9. Seal 24. Balls 39. O-rings
10. Bolt 25. Plugs 40. Bearing
11. Washer 26. Washers 41. Bolt
12. Yolk flange 27. Springs 42. Bolt
13. O-ring 28. Balls 43. O-ring
14. Bolt 29. Snap ring
15. Shift tower 30. Shaft
50-100 B WB142-5
12
1. Remove bearing snap ring (1).
2. Remove yolk flange retaining bolts (2).

★ Use a pry bar and two screws to prevent yolk flange rotation.
4. Remove yolk flange (5) and O-ring (4).
WB142-5 50-101
5. Take out the bolts (6).
6. Remove the cover (7).
7. Remove O-Ring (8) from cover (7).
8. Remove the seal (9) from the cover (7).
50-102 WB142-5
9. Remove yolk flange retaining bolt (10).
★ Use a pry bar and two screws to prevent yolk flange rotation.
11. Remove yolk flange (12) and O-ring (13).
12. Remove out the bolts (14).
WB142-5 50-103
13. Remove the shift tower assembly (15) and the O-ring (16).
★ Replace the O-ring (16) with a new one at each disassembly.
15. Remove the six cap screws (17) and the two cap-screws (42) which
fasten the rear cover (18) to the rear half housing.
16. Use a pry bar to separate the rear cover from the housing.
17. Remove the rear cover (18).
18. Remove the seal (19) from the rear cover.
50-104 WB142-5
19. Use a punch to remove the pins (20) which fasten the shift collars to
the shift rods.
20. Remove the centering pins (41).
21. Remove the shift collars (21).
22. Remove the two screws (22) which hold the plate between the two
shift rods.
23. Remove the plate (23).
WB142-5 50-105
24. Remove the two detent balls (24) from the groove between the two
shift rods.
25. Remove bolts (25) and washers (26).
26. Remove springs (27).
27. Remove balls (28).
50-106 WB142-5
28. Pull the secondary shaft to the rear so that there is clearance
between the snap ring and the rear housing.
29. Remove the snap ring (29).
30. Remove transmission shaft PTO (30) by pushing lightly on the

opposite side.
31. Replace Teflon seal ring (31) by cutting it.
32. Remove snap ring (32).
WB142-5 50-107
33. Use the tool F2 to take the bearing (33) out.
36. Use lever to remove the front half housing (36).

★ Lift the front half housing by means of two hooks.
50-108 WB142-5
37. Remove the outer bearing cups (37) and (38).
38. Remove bearing (40).
★ Inspect the condition of the O-rings (39) and replace if

necessary.
WB142-5 50-109
12
ASSEMBLY
1. Push the secondary shaft toward the rear of the rear housing so that
there is clearance between the snap ring groove and the rear
housing.
2. Install the snap ring (29).
3. Install the O-Rings (39).
★ Apply a thin film of sealant on the edge of the rear half

housing.
Contact surface: Loctite 510
4. Lubricate the bearings (37) and (38) and mount them on the shaft.
50-110 WB142-5
5. Install front half housing (36) to rear half housing.
★ Make sure the bearings on the shafts are correctly positioned in
the front half housing.
★ Press the front half housing onto rear half housing.
★ Use clean transmission oil to lubricate the bearing for the 4WD
shaft.
8. Install the bearing (40) on the 4WD shaft.

★ Use tool F3.
WB142-5 50-111
9. Use the F4 special tool to install a new seal (9) in the cover (7).
★ Push just until the seal stops moving. DO NOT use excessive
force.
10. Fill the cavity under the lip of the seal with high temperature wheel
bearing grease.
11. Assemble O-ring (8).
12. Install the cover (7) in the front housing.
13. Install the three cap screws (6) which fasten the cover to the front
housing.
50-112 WB142-5
14. Install a new O-ring (4) in the four-wheel drive yolk flange.
★ Use clean transmission oil to lubricate the O-ring.
15. Install the four-wheel drive yolk flange (5) on the four-wheel drive
shaft.
17. Tighten the screw (2) using a pry bar to prevent yolk flange
rotation.
WB142-5 50-113
18. Install snap ring (1).
19. Install the ball (28).
21. Install the washer (26) and the bolts (25).
50-114 WB142-5
★ Repeat steps 19 through 21 to install the upper detent ball and
spring.
22. Install bearing (33) on transmission shaft PTO (30).
23. Assemble snap ring (32).

★ Use tools F5 - F6 - F7.
24. For the assembly of the Teflon seal ring (13), see “CLUTCH PACK
(A) AND GEAR SHAFT (D)” .
WB142-5 50-115
25. Insert transmission shaft PTO (30).
26. Grease and install the two detent balls (24).
27. Install the plate (23).
★ Apply sealant to the threads of the Allen head screws (22) and
attach the plate in position.
Bolts: Loctite 542
50-116 WB142-5
28. Install shift collars (21) on the shift rods.
29. Install the pins (20) to fasten the shift collars to the shift rods.
30. Install the centering pins (41).
★ Use the F8 special tool to install a new seal (19) on rear cover.
★ Push until the seal touches the lip in the hole.
31. Position the rear cover (18).

★ Make sure that the pin (41) is correctly installed both in the
rear housing and through the hole in the rear cover.
32. Install the six cap screws (17) and the two cap screws (42) to fasten
the cover to the rear half housing.
Screw: 50 N·m (37 lbf ft)
33. Install the O-ring (43).
WB142-5 50-117
34. Install a new O-ring (16) on the shift tower assembly (15).
★ Use clean oil to lubricate the O-ring and assembly it on the rear
housing.
35. Tighten the bolts (14) to fasten the shift tower assembly to the rear
cover.
36. Install a new O-ring (13) in the output yolk flange (12).
★ Use clean oil to lubricate the O-ring.
50-118 WB142-5
38. Tighten the bolts (10) using a lever to prevent yolk flange rotation.
WB142-5 50-119
12
CLUTCH PACK (A) AND GEAR SHAFT (D)
DISASSEMBLY
1. Teflon seal ring 15. Spring 29. Clutch pack assembly

2. Snap ring 16. Bearing 30. Lock ring
3. Bearing 17. Drive plate 31. Roll pin
4. Spacer 18. Clutch plate 32. Lock spring cover
5. Race 19. Piston 33. Snap ring
6. Gear 20. Outer O-ring 34. Spring
7. Needle bearing cage 21. Inner O-ring 35. Drive plate
8. Spacer 22. Teflon seal rings 36. Clutch plate
9. Roll pin 23. Snap ring 37. Bearing
10. Snap ring 24. Bearing 38. Piston
11. Clutch pack assembly 25. Thrust washer 39. Outer O-ring
12. Needle bearing cage 26. Gear 40. Inner O-ring
13. Lock spring cover 27. Race
14. Snap ring 28. Thrust washer
50-120 WB142-5
12
Shaft A (Clutch Pack)
1. Simultaneously remove shafts A and D.
2. Remove the Teflon seal ring (1).
4. Install a split bearing puller under the gear as shown in the

illustration.
Remark
Do not install the split bearing puller between the gear and
the bearing and do not use the puller on the gear without
the split bearing puller. Doing so will damage the bearing
or the gear.
★ Use a two jaw puller on the split bearing puller.
★ Pull the bearing, gear and spacer until it is free on the shaft.
WB142-5 50-121
6. Remove spacer (4).
7. Remove gear (6).
8. Remove needle bearing cage (7).
50-122 WB142-5
9. Remove spacer (8).
10. Remove roll pin (9).
12. Use pry-bars to lift and to remove the clutch plate lock ring (11)
evenly.
WB142-5 50-123
13. Remove the clutch plates (18) and the drive plates (17).
Remark
After removing the clutches and plates, be sure to keep
them assembled and in order of assembly. Mark the top
and bottom for reassembly order.
14. Place a reference mark below the groove on the clutch housing.
15. Place a mark on each plate lock ring (11), clutch plate (18) and
drive plate (17).
★ These marks will be used for reference during the reassembly
procedure.
16. Use the tool F9 push down lock spring cover (13).
50-124 WB142-5
18. Loosen the handles of the threaded rods to release the tension on
the spring.
19. Remove the top piece of the F9 special tool.
20. Remove lock spring cover (13) and spring (15).
21. Remove sleeve (5).
WB142-5 50-125
22. Using low pressure compressed air into the delivery hole, expel
piston (19).
WARNING! Do not use high pressure air to remove

piston (19), doing so will cause the
piston to fly out of the clutch housing.
23. Remove Teflon seal ring (20) and inner O-ring (21) from piston.
★ To remove the rings it is necessary to cut them.
24. Rotate the shaft.
25. Remove Teflon seal rings (22) by cutting them.
50-126 WB142-5
27. Remove bearing (24) by means of a two jaw puller.
28. Remove bearing (24) and thrust washer (25).
29. Remove gear (26) and needle bearing cage (12).
★ Repeat the procedure described so far to remove the

components of this clutch.
WB142-5 50-127
Gear Shaft D
1. Remove bearing (16) of shaft D by means of a two jaw puller.
2. Remove bearing (37) of shaft D by means of a two jaw puller.
50-128 WB142-5
12
Clutches And Disc Inspections
• Inspect grooves on shafts for wear or damage.
• Replace parts if necessary.
• Inspect output shaft for wear or damage.
• Check oil passages in the output shaft for restrictions or foreign
matter.
• Check all bearings for smooth areas, pits, galling or other damage.
• If the clutch discs are to be used again, keep the clutch packs in the
same previous dismantling order separate and record which clutch
pack goes with each clutch.
• At each disassembly, use a gauge to check the total thickness of
clutch plates to see if they are within the permissible wear limits. If
it is not, replace the clutch plates (18) with new ones.
• Check all clutch plates for burns and inspect the friction material
for damage. Inspect the grooves in the friction material for any
abnormal wear.
• Also inspect the clutch drive plates (17) for warping, overheating
and for pits or scratches.
• If any of the above conditions exists on any of the plates, replace
the clutch pack with a new one.
• If a new clutch pack is to be used, soak it in transmission oil for at
least one hour before installing. See “FUEL, COOLANT, AND
LUBRICANTS” in the Operators manual for fluid type.
• Lubricate the contact surfaces of the clutch drive plates with
transmission oil. See “FUEL, COOLANT, AND LUBRICANTS”
in the Operators manual for fluid type.
• Check the hole on the input shaft entering the rear half housing for
any damage, this may cause leaks when clutch is installed.
• Check the splines on the input shaft for damage caused by steel
plates.
• Replace parts as necessary during installation.
Number of clutch plates (each side) 6

Number of drive plates (each side) 7
Drive plate thickness 2.5 ± 0.05 mm (0.1 ± 0.002 in)
Clutch plate thickness 1.75 ± 0.05 mm (0.1 ± 0.002 in)
Maximum clutch plate wear (each side) 0.2 mm (0.01 in)
WB142-5 50-129
12
ASSEMBLY
Shaft (A) Clutch Pack
1. Install the new Teflon ring (20) and O-rings (21) onto the piston
outer and inner seats.
★ Apply a thin film of Petroleum Jelly or transmission oil on the

sealing rings just inserted. See “FUEL, COOLANT, AND
LUBRICANTS” in the Operators manual for fluid type.
2. Insert clutch piston (19) with special tool F10 as protection of seal
rings (21).
3. Assemble sleeve (5).
50-130 WB142-5
4. Assemble spring (15) and cover (13).
5. Press down on the lock cover (13). Insert lock ring (14).
★ Use tool F9.
6. Remove tool F9 and install roll pin (9).
7. Install thrust washer (8).
WB142-5 50-131
8. Insert needle bearing cage (7).
★ To assemble the clutch pack start with the gear (6) on a bench.
Install the clutch plate lock ring (11) so that the reference mark
on top of the plate made during disassembly is facing towards
the gear.
★ Assemble clutch plates (18) and drive plates (17) on the gear
(6). The assembled clutch pack must contain seven drive plates
and six clutch plates.
9. Install the pack assembly by using two screwdrivers.
50-132 WB142-5
11. Install washer (4).
12. Heat the bearing (3) to 80 -100oC (176 - 212oF) and install using
tool F2.
13. Install the stop ring (2).

★ Measure clearance between clutch plate lock ring and first
drive plate (17).
★ The clutch plate lock ring must be lifted against the stop ring.
★ Distance must be 2.3 - 4.3 mm (0.1 - 0.2 inches).
★ If distance is not within the specified range, the likelihood is
that the clutch has been installed incorrectly.
★ Check clutch for proper operation.
WB142-5 50-133
14. Insert the Teflon seal ring (1) as follows:
A. Install the F5 spacer onto the input shaft with the chamfered
end facing in.
B. Slide the F5 expander/protector onto the input shaft and on the

spacer.
★ The expander/protector will stop in the correct position to
install the seal ring in the groove.
C. Heat the Teflon seal ring to 60 - 80oC (140 -176o F) for 5

minutes.
★ Install the Teflon seal ring onto the expander/protector.
50-134 WB142-5
D. Install the F6 pusher over the expander/protector and slide the
seal ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from
the shaft.
E. Install the end of the seal installer F7 with the chamfer onto the
shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal
installer to slip over the top of the sealing ring and seat the
sealing ring into the groove.
★ Be careful not to damage the seal ring.
★ After the sealing ring is seated in the groove, remove the
seal installer from the shaft.
F. Turn the seal installer around and slide the end with the
narrow chamfer over the shaft and over the seal ring.
★ Leave the seal installer in place for 15 minutes until the
sealing ring has cooled and is properly sized and seated in
the groove.
★ After the sealing ring has cooled, remove the seal
installer from the shaft.
G. Using a feeler gauge between the lock ring (10) and the first
drive plate: Check clutch pack backlash.
★ Standard clearance: 2.3 - 4.3 mm (0.1 - 0.2 inches).
★ If backlash is not within specifications, check for proper
assembly of the clutch packs.
WB142-5 50-135
15. Turn the shaft around and carry out steps A - G for the other clutch.
★ Lubricate the ring (25) with transmission oil. See “FUEL,
COOLANT, AND LUBRICANTS” in the Operators manual
for fluid type. Install the ring (25) so the notch on the inside
rim falls onto the pin.
★ Make sure that the side with the oil grooves is down.
16. Heat the bearing (24) to 80 100 oC (176 to 212 oF).

★ Use driver F11 to drive the bearing (24) onto the input shaft
until the bearing makes contact with the thrust washer.
18. Install the Teflon seal rings (22) as follows:
A. Place the F12a spacer into the F12b expander/protector.
50-136 WB142-5
B. Slide the F12b expander/protector and the spacer onto the
shaft.
★ The expander/protector will stop in the correct position to
install the seal ring in the groove.
C. Heat the Teflon seal ring to 60 - 80oC (140 -176o F) for 5

minutes.
★ Install the Teflon (22) seal ring onto the expander/
protector.
D. Install the F13 pusher over the expander/protector and slide the
seal ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from
the shaft.
E. Install the end of the seal installer F14 with the deep chamfer
onto the shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal
installer to slip over the top of the sealing ring and seat the
sealing ring into the groove. Be careful not to damage the
seal ring.
★ After the sealing ring is seated in the groove, remove the
seal installer from the shaft.
WB142-5 50-137
19. Turn the seal installer around and slide the end with the narrow
chamfer over the shaft and over the seal ring.
20. Leave the seal installer in place for 15 minutes until the sealing ring
has cooled and is properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal installer from the shaft.
★ For the introduction of the other three Teflon rings, repeat the
operations from step 27 to step 31, using the following spacer rings:
• F12/2 for the 2nd Teflon ring,
• F12/3 for the 3rd Teflon ring,
• F12/4 for the 4th Teflon ring.
Gear Shaft D
1. Assemble D shaft bearing (16).

★ Use tool F3.
2. Install D shaft bearing (37).

★ Use tool F3.
3. Lubricate shaft seat A.
50-138 WB142-5
4. Install shaft assembly D and shaft assembly A.
★ The operation is correctly done if the two shafts are installed at
the same time.
CHECKING CLUTCH FUNCTION
1. Lubrication oil passage 4. Forward gear 7. Reverse gear

2. Forward clutch passage 5. Forward clutch pack 8. Input shaft
3. Reverse clutch passage 6. Reverse clutch pack
• Apply compressed air to the forward clutch passage. Listen to hear the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward gear must not turn on the input shaft. Try to move the reverse gear. The
reverse gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the
problem.
• Apply compressed air to the reverse clutch passage. Listen to hear the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The forward gear must not turn on the input shaft. Try to move the forward gear. The
reverse gear must turn freely on the input shaft. If the clutches do not work correctly, disassemble the clutches to find the
problem.
WB142-5 50-139
12
GEAR SHAFTS (B) AND (C)
DISASSEMBLY
1. Bearing 15. Bearing 29. Sintered ring

2. Thrust washer 16. Stop ring 30. Friction ring
3. Third speed gear 17. Thrust washer 31. Sleeve
4. Third/fourth speed synchronizer 18. Second speed gear 32. Synchronizer
5. Clutch ring 19. Roll pin 33. Block
6. Tapered friction ring 20. Shims 34. Spring
7. Sleeve 21. Spacer 35. Inner hub
8. Plate 22. Synchronizer 36. Spacer
9. Ball 23. Synchronizer assembly 37. First speed gear
10. Spring 24. Steel ring 38. Snap ring
11. Inner hub 25. Sintered ring 39. Bearing
12. Fourth speed gear 26. Friction ring 40. Bearing
13. Snap ring 27. Synchronizer ring 41. Gear shaft (B)
14. 4WD gear 28. Steel ring 42. Shaft
50-140 B WB142-5
1. Remove the shafts B and C using special tool F15.
2. Remove the gear shift forks.
Gear Shaft (C)
1. Install a split bearing puller under the gear as shown in the

illustration and remove bearing (1).
Remark
Do not install the split bearing puller between the gear and
the bearing and do not use the puller on the gear without
the split bearing puller. Doing so will damage the bearing
or the gear.
★ Use a two jaw puller on the split bearing puller.
★ Pull the bearing until it is free on the shaft.
2. Remove thrust washer (2) and third speed gear (3).
WB142-5 50-141
3. Remove third/fourth speed synchronizer assembly (4).
4. Remove the clutch ring (5) from each side of the synchronizer
assembly.
★ The synchronizer assembly component parts are serviced as a
complete unit.
★ The synchronizer assembly may be disassembled for
inspection and cleaning.
★ If any of the parts are damaged, the entire synchronizer
assembly must be replaced.
5. Use a feeler gauge to measure the clearance between the bottom of

the teeth on the synchronizer ring and the edge of the sleeve on the
outside of the synchronizer assembly.
★ This clearance should be approximately 1.0 mm (0.04 inches)
with used parts in good condition.
★ If clearance is equal to or less than 0.5 mm (0.02 inches),
replace the complete synchronizer.
6. Inspect both sides of synchronizer for wear.

★ Thickness must be not less than 1 mm (0.04 inches).
7. Remove the tapered friction ring (6) from each side of the
synchronizer assembly.
★ Do not remove the sleeve (7) from synchronizer hub unless it is
absolutely necessary.
Remark
When removing the sleeve from the hub, be aware that
spring plates, hub pins and hub springs are not attached
to the hub and will be expelled quickly once the hub is
removed.
50-142 WB142-5
★ Do not mix up these parts.
★ The synchronizer hub contains three plates (8), three balls (9),
and three hub springs (10).
8. Remove fourth speed gear (12).
9. Rotate the shaft and remove bearing outer ring (15).
10. Using a puller, remove bearing inner ring (15).
Remark
Do not extract the bearing using the gear as a puller. The
snap ring (16) will prevent removal.
WB142-5 50-143
12. Remove the shims (20) and the thrust washer (17).
13. Remove roll pin (19).
14. Remove second speed gear (18).
50-144 WB142-5
15. Remove the spacer (21).
16. Remove the first/second speed synchronizer assembly (23).
17. Remove synchronizer ring (22).
18. Remove the steel ring (24) and the sintered ring (25).
19. Remove the tapered friction ring (26).
WB142-5 50-145
20. Turn the synchronizer assembly (23) over and remove the
synchronizer ring (27) from the other side.
21. Remove the steel ring (28) and the sintered ring (29).
22. Remove the tapered friction ring (30).
23. Support the sleeve on blocks.
24. Push down on the hub while you use a punch to push the detent
assemblies out of the sleeve and hub.
25. Remove the sleeve (31) from the hub.
50-146 WB142-5
27. Remove first speed gear (37).
29. Remove the 4WD gear (14).
WB142-5 50-147
Gear Shaft B
1. Remove bearing inner race (39) using a puller.
2. Turn shaft (41) around and remove bearing (40).
50-148 WB142-5
12
ASSEMBLY
Gear Shaft C
1. Place shaft on bench so the side with serrated edge is facing

upwards.
2. Install the stop ring (13).
3. Install 4WD gear (14).
5. Install the first speed gear (37).
WB142-5 50-149
6. Install spacer (36).
7. Install the first/second speed synchronizer (23).
8. Install the hub (35) the spring (34), the blocks (33), the balls (32),
and the sleeve (31).
9. Using a punch or screwdriver push in the balls (32) to complete hub

assembly (35).
10. Install the tapered friction ring (30) on the synchronizer assembly.
50-150 WB142-5
11. Use clean transmission oil to lubricate the sintered ring (29) and the
steel ring (28).
12. Install the synchronizer ring (27) as shown.

★ The flat sides of the teeth must be up.
13. Turn the synchronizer assembly over and install the tapered friction
ring (26) on the other side.
14. Use clean transmission oil to lubricate the sintered ring (25) and the
steel ring (24). Install the sintered ring (25) and the steel ring (24).
WB142-5 50-151
15. Install the upper synchronizer ring (22) so the smooth sides of the
teeth are facing upwards.
16. Install the complete first/second speed synchronizer (23).
17. Install the spacer (21) on the second speed gear (18).
18. Install the second speed gear (18).

★ Be sure the spacer (21) and gear (18) make solid contact with
the synchronizer (23).
19. Install the pin (19).
50-152 WB142-5
20. Install thrust washer (17) and shims (20).
21. Install the snap ring (16).
22. Using a feeler gauge, measure distance X between gear (18) and
ring (17).
★ Standard clearance: 0.2 - 0.42 mm (0.007 - 0.02 inches)
23. Use a thickness gauge.
★ If distance X is incorrect, rearrange the shim pack to obtain the

specified clearance using the shims available.
WB142-5 50-153
24. Heat the inner race of the bearing (15) to 80 - 100oC (176 - 212oF)
and use the tools F16 on the shaft.
25. Install the outer race of the bearing (15).
26. Rotate the shaft.
27. Install the fourth speed gear (12).
28. Install the third/fourth speed synchronizer (4).
50-154 WB142-5
29. Install springs (10), blocks (8), balls (9) and sleeve (7) to hub (11).
30. Using a punch or screwdriver, push in the balls (9) to complete

assembly of hub (11).
31. Install the tapered friction ring (6) on each side of the synchronizer
assembly.
32. Lubricate clutch ring (5) with transmission oil and install each side
of the synchronizer assembly.
33. Install the third/fourth speed synchronizer assembly (4) onto the
shaft.
★ Use clean transmission oil to lubricate the thrust washer (2).
WB142-5 50-155
34. Install third speed gear (3) and the thrust washer (2) onto the shaft.
35. Heat the bearing (1) to 80 - 100oC (176 - 212oF).

★ Use the tool F2 to assemble bearing (1).
Gear Shaft B
1. Heat the inner race of the bearing (39) to 80 - 100oC (176 - 212oF)
and use the tools F16 install the ring inside the bearing (39).
2. Rotate shaft (41).
3. Heat the bearing to 80 - 100oC (176 - 212oF). Use the tool F2

assemble bearing (40).
50-156 WB142-5
4. Using tool F16, position and install shafts B and C to half housing.
★ Complete shafts should be installed with pins and forks.
5. Install pre-assembled 3rd and 4th speed forks and 1st and 2nd speed
forks as shown.
6. Position the group with care, paying attention to the location of fork
pins in their seats.
WB142-5 50-157
12
GEAR SHAFT (E)
DISASSEMBLY
1. Snap ring 7. Clutch pipe 13. Cylinder

2. Washer 8. Seal ring 14. Snap ring
3. Spacer 9. O-ring 15. Gear
4. Spring 10. Valve 16. Bearing
5. Sleeve 11. Spring
6. O-ring 12. O-ring
1. Remove the shaft E.
50-158 WB142-5
2. Remove shafts B and C. Remove the four-wheel drive clutch gear
(15).
4. Using tool F17, push down on the spring cover until stop ring is
exposed (1).
5. Remove stop ring (1) from its seat and remove tool F17, then
remove washer (2).
WB142-5 50-159
7. Remove springs (4).
9. Remove the two O-rings (6) and (9) from the shaft.
10. Remove the Teflon sealing rings (8) from the shaft.
50-160 WB142-5
12. Remove cylinder (13).
13. Remove O-rings (12) from cylinder (13).
14. Remove valve (10) and spring (11) from cylinder (13).
WB142-5 50-161
★ Do not remove 4WD clutch pipe (7) from front housing unless
absolutely necessary.
ASSEMBLY
1. Install spring (11) and valve (10) in cylinder (13).
2. Install O-rings (12) on cylinder (13).
3. Install cylinder (13) in the shaft.
50-162 WB142-5
5. Install the O-rings (6) and (9) on the shaft.
6. Install sleeve (5).
7. Install springs (4).
WB142-5 50-163
8. Install spacer (3).
9. Position washer (2) and snap ring (1).
10. Using tool F17, push down on spring cover until the stop ring seat
(1) is exposed and complete the assembly of the stop ring (1).
11. Release tension and remove the tool.
12. Ensure that the stop ring (1) is correctly positioned in the recess of
the spring cover.
13. Place the protector F18 onto the shaft. The expander/ protector will
stop in the correct position to install the Teflon sealing ring in the
groove.
14. Heat the Teflon sealing ring (8) to 60 - 80 oC (140 - 176 oF).
15. Install it onto the expander/protector.
50-164 WB142-5
16. Install the F6 pusher over the expander/protector and slide the seal
ring until it reaches the groove in the shaft.
★ Remove the pusher, expander/protector, and spacer from the
shaft.
17. Install the end of the F7 seal compressor with the deep chamfer
onto the shaft and over the sealing ring.
★ Use a back and forth twisting motion to allow the seal installer
to slip over the top of the sealing ring and seat the sealing ring
into the groove.
★ Be careful not to damage the seal ring.
★ After the sealing ring is seated in the groove, remove the seal
compressor from the shaft.
★ Turn the seal installer around and slide the end with the narrow
chamfer over the shaft and over the seal ring.
★ Leave the seal installer in place for 15 minutes until the sealing
ring has cooled and is properly sized and seated in the groove.
★ After the seal ring has cooled, remove the seal compressor
from the shaft.
18. Install protector F19.

★ Repeat steps 13 -19 to introduce the second Teflon ring.
WB142-5 50-165
12
★ Apply air to 4WD clutch oil passage (see arrow) by plugging the opposite hole with a finger. The sleeve (5) should be
moving when compressing the springs (4). The 4WD gear (15) should move freely on 4WD shaft. Valve (10), if operating
correctly, reaches the end of stroke making a noise. If the operation is incorrect, dismantle to find the problem.
1. Snap ring 7. Clutch pipe 13. Cylinder

2. Washer 8. Seal ring 14. Snap ring
3. Spacer 9. O-ring 15. Gear
4. Spring 10. Valve 16. Bearing
5. Sleeve 11. Spring
6. O-ring 12. O-ring
17. Install bearing (16).
50-166 WB142-5
18. Install gear (15).
19. Install shafts B and C. Assemble shaft E.
20. Reinstall the 4WD clutch pipe (7).
Hose (7): 26 - 30 N·m (19 - 22 lbf ft)
WB142-5 50-167
12
SHIFTER TOWER AND FORKS
DISASSEMBLY
1. Bolts 6. Shift lever 11. Pins

2. Shift tower assembly 7. King pins 12. 2nd and 3rd fork
3. O-ring 8. Stop ring 13. 1st and 2nd fork
4. Clamp 9. Bushing
5. Boot 10. Spring
1. Remove bolts (1).
50-168 WB142-5
2. Remove the shift tower assembly (2) and the O-ring (3).
★ Replace the O-ring at each disassembly.

★ Replace the clamp at each disassembly.
4. Remove the boot (5).
5. Remove the king pins (7).
WB142-5 50-169
6. Remove the steel stop ring (8) from transmission lever.
7. Remove the bushing (9) from transmission lever.
9. Slide the gear shift lever (6) out.
50-170 WB142-5
★ Only if necessary - remove the pins (11) and separate the forks
from the gear control rods.
★ Mark the forks and the shifters to prevent mixing them during
installation.
ASSEMBLY
1. Lubricate the shift lever ball.
2. Install the shift lever (6) in the cover (2).
Ball: ASL 800050
★ The illustration shows the correct position of the control lever (6) in
relation to the gear case (2)
★ Recess A must be facing the curved side B of case.
★ Slots C must be aligned with holes D in the case.
3. Install spring (10) to lever.
WB142-5 50-171
4. Install the bushing (9).
5. Install the stop ring (8) to the shift lever.
6. Insert pins (7) through the holes in the case flange (2) so they
engage into the slots on the shift lever.
7. Install the boot (5) into the case carrier (2) so as to hold the pins (7).
50-172 WB142-5
8. Install a new clamp (4) around the boot (5).
9. Install a new O-ring (3) to case flange.
O-ring: Transmission oil.
10. Tighten the screws (1).
Bolt (1): 23 N·m (17 lbf ft)
11. Install the two pins (11) to lock gear control fork 3rd and 4th speed
(12) and gear control 1st and 2nd speed (13).
WB142-5 50-173
DISASSEMBLY AND ASSEMBLY BACKHOE CONTROL VALVE
12
BACKHOE CONTROL VALVE
REMOVAL
★ Center the backhoe and leave the backhoe plate unlocked.

★ Lower the outriggers to the ground, curl the bucket and allow it to
rest on the ground on its back.
★ Apply the parking brakes, stop the engine and remove the ignition
key.
★ Release all residual pressure by operating the hydraulic controls
(including any optional device pedals) several times in all
directions.
1. Remove screws and remove control pedal for

hammer. (If equipped)
2. Remove the metal floor cover (7) closing off the floor.
3. Disconnect all hoses and hydraulic lines.

★ Ensure that all hoses are marked. Disconnect the hoses from
the control valve starting from the upper hoses (8).
★ Plug all pipes and hoses immediately to prevent contamination.
4. Disconnect connector (10) from solenoid valve (9).
5. Disconnect links (12) from control valve (11).
50-174 B WB142-5
6. Sling the control valve and apply slight tension on the sling.
★ Support control valve by using of two slings connected to a lift
arm through the cab opening, see illustration.
★ Pay special attention to sling routing to prevent damaging the
unions.
7. Remove the four mounting bolts (13) then remove the complete
control valve as an assembly.
7-spool control valve: approx 53 kg (117 lbs)

8-spool control valve: approx. 59 kg (130 lbs)
INSTALLATION
★ Start the machine to circulate the oil; check to ensure that there are no leaks.
★ Bleed the air from the working equipment circuits.
★ Stop the engine, check the hydraulic oil level and top off as necessary.
WB142-5 50-175 B
12
MEMORANDUM
50-176 B WB142-5
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
12
FRONT AXLE ASSEMBLY
REMOVAL
★ Start the engine and force the bucket downwards in order to raise
the machine and the front wheels.
★ Place two stands “A” and some blocks beneath the chassis.
★ Slowly lower the machine onto the blocks, checking to be sure the
wheels remain at least 5 cm (2 inches) above the ground.
★ Remove the front wheels.
Wheel: 52 kg (115 lbs)
1. Disconnect the front drive shaft (4) from the axle (3).
2. Disconnect the lines (5) from the steering cylinder and plug them to
prevent contamination.
3. Disconnect the lubrication tube (6) for the axle pin (7).
4. Position a jack “B” and some blocks “C” beneath the axle. Raise
the jack until the blocks can be forced under the axle arms (3).
★ It should be possible to lower the jack 10 cm (4 inches) in order
to disengage the axle from the supports.
WB142-5 50-177 B
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
5. Remove the nut and remove the retaining bolt (8) from the axle pin
(7).
6. Install a slide hammer into the central hole of the axle pin (7); pull
out the axle pin.
7. Lower the jack until the axle is disengaged.
8. Remove the entire front axle assembly (3).
4WD: approximately 262 kg (130 lbs)
INSTALLATION
Front closing bolts: 300 N·m (221 lbf•ft)

Nuts for front wheels: 370 N·m (273 lbf•ft)
Bolts on transmission side: 38 N·m (28 lbf•ft)
★ Bleed the air from the Load Sensing circuit.
Axle pin - bushings: ASL800050
★ Check the oil level in the tank and start the engine.
★ Perform a few complete steering maneuvers in both directions to bleed the air from the steering circuit.
50-178 B WB142-5
DISASSEMBLY AND ASSEMBLY FRONT AXLE OVERHAUL PROCEDURES
12
FRONT AXLE OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the front axle is sitting on a
level stable surface. Clean up any oil spills immediately and keep your work area clean
and clear of debris.
STEERING CYLINDER ASSEMBLY

DISASSEMBLY
1. Castellated nut 8. Ball joint 15. Gland

2. Tie rod 9. Nut 16. Seal ring
3. Steering knuckle 10. Tie rod 17. Cylinder rod
4. Nut 11. Axel end 18. Seal ring
5. Ball joint 12. Castellated nut 19. Cylinder
6. Bolt 13. Scraper 20. O-ring
7. Cylinder 14. O-ring 21. Scraper
WB142-5 50-179
1. Loosen tie rod end (2) locknut (1) until it is over the end of the
threaded pin.
2. Drive the nut (1) with a hammer in order to loosen the tie rod (2)
from the steering knuckle housing (3).
★ Do not strike the end of the threaded pin, this will damage the
pin.
3. Loosen the nuts (4) and (9) and remove the tie rods (2) and (10).
4. Remove the fastening bolts (6) from the cylinder, then remove the
cylinder (7) from its housing using a rubber hammer.
5. Remove only those parts that need to be overhauled and/or

replaced.
6. Remove the cylinder gland (15) from the cylinder (19).
7. Remove the cylinder gland and the rod (17) from the cylinder case
(19).
★ Replace all sealing rings (16) and (18), O-rings (14) and (20),
and scrapers (21) and (13) in cylinder body (19) and rod (17).
ASSEMBLY
1. Install all new sealing rings (16) and (18), O-rings (14) and (20),
and scrapers (21) and (13) to gland (15), to rod piston (17) and into
cylinder body (19).
50-180 WB142-5
2. Slide the pre-assembled (17) rod into the cylinder body (19).
3. Install ball joints (5) and (8), nuts (4) and (9) and tie rods (2) and
(10) at the rod (17) ends and tighten.
Tie rods: 300 N·m (221 lbf•ft)
4. Install steering cylinder to center body (7) together with tie rods.
5. Assemble and tighten the steering cylinder bolts (6) with torque
wrench.
Bolts: 120 N·m (89 lbf•ft)
6. Align the steering knuckle with the axle (parallel wheel hub).
7. Adjust the ball joint (5) so that the ball joint can be inserted into the
steering knuckle arm.
★ It is important to unscrew the locking nut (9) to carry out this
operation.
WB142-5 50-181 B
8. Insert the tie rod (2) into its own housing on the steering knuckle
(3).
9. Assemble and tighten the lock nut (1) with a torque wrench.
Nut: 220 N·m (162 lbf•ft)
★ Repeat the operation for the opposite side.
10. Install lock nuts (4) and (9) of the tie rods (3) and (10) only when
the toe-in adjustment has been carried out.
Checking Toe-in
1. Install 2 one-meter-long linear “A” bars that are identical to each

other to the wheel flanges; lock them into position by tightening
two nuts onto the wheel hub studs.
2. Position the bars so they are centered in relation to the middle of the
wheel axle, then check to ensure that they are perfectly resting
against the hub.
★ Ensure that the piston is centered in relation to the cylinder.
3. Using a tape measure, measure the distance in mm “M” from the

farthest bar ends, and tighten or loosen the tie rods until the distance
is the same on both sides.
★ Keep the minimum value, swinging the measurement point.
50-182 B WB142-5
4.Check the difference of the measurements between the wheel hubs
diameter ends to be sure it is within the requested tolerance range.
★ The nominal toe-in (A) value is referred to the external diameter of
the wheel hubs flange, therefore the measured toe-in value (M) at
the bars ends must be related to the ratio between length of the bar
and flange diameter.
★ Nominal toe-in = A 2 mm (0.1 inches)
★ Measured toe-in = M 5 mm (0.2 inches)
5. If toe-in is incorrect, adjust with two wrenches the tie rods nuts in
or out to set the tie rods equally until the toe-in is within the
required tolerance.
6. Once adjustment is complete, tighten the retaining nuts on the tie

rods.
Nuts: 250 N·m (184 lbf•ft)
WB142-5 50-183 B
Camber Angle Adjustment
1. Use the same bars “A” for the toe-in adjustment and a long bar to
extend over the machined part of the central body (pinion side), so
that the two bars form an acute angle at the maximum steering.
★ Adjust the angle of 65o and position it on the long bar.

★ Move a wheel side until it forms the angle.
2. Adjust the steering angle retainer, bolt in or out using the bolts in
the housing body, locking them with a locknut.
Lock nut: 150 N·m (111 lbf•ft)
3. Steer completely towards the other side and repeat the same
operations.
50-184 B WB142-5
12
FRONT AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1. Screw 5. Bearings 9. Snap ring

2. Plug 6. Gear 10. O-ring
3. Carrier 7. Bearings
4. Pin 8. Thrust washer
★ Before draining the oil, position the axle end (3) with the plug (2) on the upper part and loosen it in order to eliminate any
possible inner pressure, then remove it completely.
1. Turn the hub upside-down till the drain hole (2) is at its lowest
point.
2. Drain the oil completely.
WB142-5 50-185 B
3. Remove the screws (1).
4. Remove the planetary carrier (3) from the epicyclic reduction gear
and remove the O-ring (10).
Removing The Planetary Gears (If Necessary)
1. Remove snap ring (9) from each pin (4).
2. Remove the gears (6) from the pins.
3. Recover the rollers (7) and (5) and inspect their condition.
4. Remove the thrust washers (8).

★ When new planetary gears are used it is advisable to install
new roller bearings.
ASSEMBLY
★ Reinstall all epicyclic reduction gear components: the planetary
gears carrier (3), the gears (6), the needle bearings (5) and (7),
washer (8) and the snap rings (9) of every pin (4).
★ With new gears, it is advisable to install new needle rollers.
50-186 B WB142-5
1. Insert the needles (5) and (7) into the gears (6).
2. Grease the needles (5) and (7).
3. Insert the gears (6) with assembled needles in the planetary carrier
pins.
4. Install a new O-ring (10).
5. Install planetary gear carrier (3) to epicyclic reduction gear.
6. Install retaining screws (1).
Screws: 25 N·m (18 lbf•ft)
★ Use recommended oil in epicyclic reduction gear and axle

body.
7. Install plug (2) to axle end.
Plug: 80 N·m (60 lbf•ft)
WB142-5 50-187 B
12
AXLE END HUB ASSEMBLY
DISASSEMBLY
1. Snap ring 10. Stud 19. Bolt

2. Washer 11. Hub 20. Nut
3. Washer 12. Bearing cup 21. Bolt
4. Ring gear 13. Seal ring 22. Bushing
5. Screw 14. Steering knuckle 23. Seal
6. Bushing 15. Bearing cone 24. Axel shaft
7. Carrier 16. Lower king pin 25. Beveled washer
8. Retaining ring 17. Bolt 26. Axle housing
9. Bearing cone 18. Upper king pin 27. Beveled washer
50-188 B WB142-5
12
WARNING! Before disassembling the wheel hub, it is advisable to secure it with a belt or a sling on a
hoist or any other supporting device, in order to avoid its accidental fall that could dam-
age either the technician or the wheel hub group.
1. Insert a lever between the steering knuckle (14) and the axle beam
and fit it into the double U-Joint. With the lever push the double U-
Joint in the direction of the wheel hub to allow the lock ring (1)
removal.
★ Do not damage the double U-Joint.
2. Remove the lock ring (1) from the double U-Joint shaft and collect
the washers (2) and (3).
3. Remove the bolts (5) from the wheel carrier (7) group.
★ In order to remove the wheel carrier group (7) from its

housing, insert two of bolts (5) in the threaded extraction holes.
WB142-5 50-189 B
4. Extract and remove the hub-lock ring gear (7) together with the
epicyclic ring gear (4).
5. Remove the hub-lock ring gear (8) from the epicyclic ring gear (4).
★ Check the wear conditions of the components.
Only If Necessary
1. Remove the centering bushings (6) of the hub lock ring gear with a
hammer and special tool D1.
2. Remove the hub (11), using levers and a hammer to facilitate the
operation.
★ Collect the bearing (9) cone.
3. Position unit on a flat surface and remove the seal ring (13) with a
pry-bar.
★ This is a destructive operation for the seal ring.
4. Take the bearing cups (9) and (12) out on both sides of the hub,
using a hammer and a suitable tool.
5. Remove the bearing cone (12) from the steering knuckle using a
suitable, commercially available puller.
6. Remove bolts (19) from the upper (18) and (17) lower (16) king
pin.
★ Before removing the king pins, secure the steering knuckle
with a hoist or other supporting device.
7. Remove the king pins (18) and (16) and collect the bevelled
washers (25) and (27).
50-190 B WB142-5
8. Remove the steering knuckle (14) from the axle beam and from the
shaft (24).
9. Lay the steering knuckle (14) on a flat surface and remove the seal
ring (23) with a pry-bar.
10. Turn the steering knuckle (14) and take the bush (22) out, using a
driver and a hammer.
WB142-5 50-191
12
ASSEMBLY
1. Install bushing (22) into the steering knuckle (14) with the special
tool D2. and a hammer or a press.
2. Assemble the seal ring (23) into the steering knuckle (14) with the
special tool D3 and a hammer.
3. Lubricate the ring with grease ASL800050.
4. Position the lower king pin (16) on a workbench and assemble the
cone of the spherical joint (15) with the special tool D4 using a
press. Grease the king pin housings with grease ASL800050.
5. Install the beveled washers (25) and (27) on to the king pin
housings (16) and (18).
6. Secure the steering knuckle (7) group using a sling.
7. Lubricate the seal ring lip and protect the splined end of the axle
shaft by wrapping it in adhesive tape to avoid damage to the seal
ring. After assembly, remove the adhesive tape. Assemble the
steering knuckle on the axle beam.
8. Install the two king pins, the upper (16) and the lower (18), and
tighten the retaining screws (17) and (19).
Screw: 190 N·m (140 lbf•ft)
★ Make sure the beveled washers (25) and (27) remain in their
position.
★ If bearings (9) and (12) need to be replaced, make sure the distances
“A”, “B” and “C” are within the permissible range.
★ A = 5.900 - 5.905 mm (0.232 - 0.232 inches)
★ B = 52.229 - 52.279 mm (2.1 - 2.1 inches)
★ C = 23.072 - 23.173 mm (1.0 - 1.0 inches)
50-192 B WB142-5
9. Place the wheel hub (11) on a workbench and install both cups of
the taper roller bearings (9) - (12) in position using a special tool
D5 under a press or with a hammer.
10. Insert the seal ring (13) into the wheel hub (11) with the special tool
D6 and a hammer.
11. Install the cone of the tapered roller bearing (12) on the steering
knuckle end (14).
12. Install the wheel hub (11) on the steering knuckle (14) and place the
other cone of the taper roller bearing (9) in position.
13. Position the wheel carrier (7) on a workbench and install the bush-
ings (6) to the carrier surface level with the special tool D1.
★ At least two bushes (diametrically-opposed) should be set
slightly higher than the carrier surface level to be used as
dowel pins.
14. Preassemble the wheel carrier - (7) epicyclic ring gear group (7)
and (4) with the special locking ring (8) shown in figure.
WB142-5 50-193
15. Install the wheel carrier group on to the wheel hub using the two
projecting bushes (6) as dowel pins.
16. Install the relative bolts (5) in order to attach the ring bevel gear
with the wheel hub.
17. Install all the hub dowel bushes completely using special tool D1
and a hammer.
18. Install the wheel carrier (7) bolts (5) and tighten.
19. Install washers (2) and (3) to the axle shaft and install the stop ring
(1) by pushing it from the end of the serrated hub.
50-194 WB142-5
12
AXLE HOUSING
DISASSEMBLY
1. Axle housing 4. Axle busing 7. Seal

2. King pin bushing 5. Seal 8. Bushing
3. Cup 6. Axle shaft
1. Remove the axle shaft (6) from the axle housing (1).
WB142-5 50-195
2. Remove the seal (5) from the axle (1).
★ This is a destructive operation for the seal rings.
3. Remove the axle bushing (4) from the axle housing.

★ Examine the bushing before removal and replace only if the
wear conditions require this.
4. Remove the upper king pin bushings (2) and cup (3) from the king
pin housings.
★ Examine the bushing and housing before removal and replace
depending on wear conditions.
5. Remove the seal (7) from the axle (1).

★ This is a destructive operation for the seal rings.
★ If necessary, remove the Pivot bushings (8) with a three point
extractor or a suitable driver and a hammer.
★ Do not damage the bushing housing.
50-196 WB142-5
12!
ASSEMBLY
1. Using tool D7 and a hammer, install bushing (2) and cup (3).
★ To make installation easier, allow the bushings and cups to
cool in liquid nitrogen at less than -100oC (-148oF)
2. Install the bushing (4) into the axle beam with tool D9 and a
hammer.
3. Install the seal (5) in the axle with tool D10 and a hammer.
★ Fill 3/4 of the seal ring cavity with grease ASL800050.
4. Lubricate the bushing (4) and the seal ring lip (5). Insert the axle
shaft (6) into the housing.
★ Take care not to damage the sealing ring.
5. Install two new bushings (8) and two new seal rings (7) in the
housing (1) using tools D8 and D11.
WB142-5 50-197
12
DIFFERENTIAL
DISASSEMBLY
1. Differential housing 6. Bolt 11. Bolt

2. Bolt 7. Adjuster ring nut 12. Guide pin
3. Adjuster ring nut 8. Guide pin 13. Carrier
4. Bearing cup 9. Guide pin 14. Axle housing
5. Ring nut retainer 10. Bearing cap
1. Remove bolts (2) on the differential housing (1). Remove the

differential assembly (1) from the axle housing (14).
★ Support the differential carrier with a sling or other appropriate
means when removing.
50-198 WB142-5
2. Remove bolts (6) and remove the two ring nut retainers (5).
★ Before removing bolts, mark mounting caps (10) and the

differential housing with a permanent reference marks to avoid
inverting them when reassembling the unit.
★ Mark the area between the ring (3) and (7) adjusters and the
differential (1) housing as well.
3. Remove the adjuster ring nuts (3) and (7) using tool D12.
4. Remove the four bolts (11) and remove the two caps (10).
★ Ensure that the center bushings (9) remain seated in the
differential housing.
WB142-5 50-199
5. Remove the carrier assembly (13).
★ Take care not to lose the bearings that are removed together
with the differential carrier (13).
★ Do not mismatch the cups (4) if bearings are not to be replaced.
ASSEMBLY
1. Assemble the complete differential carrier (13), with the outer cups
(4) of the tapered roller bearings.
★ Take care not to invert the outer races of the tapered roller
bearings.
2. Place the differential carrier (13) and the two bearing caps (10) and
bolts in their holes.
★ Check the positions of the bushings and caps using the
reference marks on them and on the differential housing (1).
3. Install the caps loosely with their respective bolts (11).
4. Install the two adjustment ring nuts (3) and (7) in the differential
housing using tool D12, so the preload on the carrier bearings is
loght.
★ Tap lightly with a soft hammer in order to properly set the
bearings in position.
50-200 B WB142-5
5. Install a magnetic dial indicator “A” to the differential housing so
that the dial indicator foot is at a right angle with the side of the
gear teeth.
6. Lock the pinion in place and move the ring gear alternatively taking
note the pinion-ring gear backlash.
7. Repeat the operation on two or more points (teeth), rotating the ring
gear, so as to obtain an average value.
8. Check to be sure it is within the requested range: 0.18 - 0.28 mm

(0.010 - 0.011 inches)
9. Adjust the ring nuts (3) and (7) using tool D12.
★ If the measured backlash is less than the given tolerance
range, tighten ring nut (3) and loosen ring nut (7).
★ If the measured backlash is higher than the given tolerance
range, tighten ring nut (7) and loosen ring nut (3).
10. Make sure that the bearings are slightly pre-loaded; if necessary, repeat previous adjustment until the specified conditions
are reached.
11. Once pinion/ring gear backlash is determined, measure total

bearing preload (T) (pinion/ring gear system) using a spring gauge
with the cable wound around the spindle pinion end.
★ The reading should be within the following values:
T=(P+3.75) - (P+5.75) daN where P is the effectively
measured pinion pre-loading.
★ All pre-loadings should be measured without the seal (13) in

place.
WB142-5 50-201
12. If the measurement is not within the required range, check each
component and adjust ring nuts (3) and (7) of the differential carrier
mounting.
A. If total preload is less than the specified values, tighten the

ring nuts (3) and (7) at the same amount, while keeping pinion/
ring gear backlash unchanged.
B. If total preload is greater than the specified values, loosen the

ring nuts (3) and (7) at the same amount, while keeping pinion/
ring gear backlash unchanged.
13. When all adjustments are complete, install the ring nut retainers (5)
and their respective bolts (6), and tighten to the specified torque.
14. Tighten bolts (11).
★ Before installing into housing, make sure they are perfectly clean.
★ Spread a film of adhesive on the contact surface between the axle
housing (14) and the differential housing (1).
Loctite: 510
15. Check the two dowel pins (12) and (8) are in their proper locations.
50-202 WB142-5
16. Tighten the retaining bolts (2) to the proper torque.
17. Refill the tank with oil.
Bolts: 169 N·m (125 lbf•ft)
Pinion Gear Contact Test

★ To check the gear tooth contact between the ring and pinion gear,
paint the ring gear with red lead paint.
★ The marking test should be always carried out on the ring gear teeth
and on both sides.
★ OK - Correct contact: If the pinion gear is properly adjusted,
the mark on the ring gear surfaces will be within specifications.
★ Z - Excessive contact on the tip of the tooth: Move the ring
gear away from the pinion in order to adjust the backlash.
★ X - Excessive contact at the tooth base: Move the pinion away
from the ring gear and then adjust the ring gear to the pinion in
order to reset the backlash.
★ To correct:
★ Move the pinion (1) for X contact adjustment.
★ Move the pinion (2) for Z contact adjustment.
WB142-5 50-203 B
12
PINION
DISASSEMBLY
1. Pinion gear 6. Washer 11. Seal

2. Shim 7. Housing 12. O-ring
3. Bearing 8. Bearing 13. Cover
4. Washer 9. Retaining washer
5. Collapsible spacer 10. Lock nut
1. Remove the cover (13) from the differential housing.
50-204 WB142-5
2. Remove seals (12) and (11) from the cover (13).
★ This is a destructive operation for the seals.
3. Install the differential carrier (1) in a vise.
4. Remove lock nut (10) using special tools D14-D15.

★ This operation will damage the lock nut (10).
5. Remove the lock nut (10) and collect its retaining washer (9).
★ Tap the shaft with a soft hammer to remove the pinion gear (1).
★ Be careful not to drop the pinion gear (1).
6. Recover washers (4) and (6), discard spacer (5) and bearing cone
(8).
WB142-5 50-205
7. Place differential housing (7) on a firm flat surface and extract bear-
ing outer bearing cups (3) and (8).
8. To remove bearing cone (3) from pinion gear (1), use a

commercially available puller.
9. Recover bearing cone (3) and the shim (2) under it.
10. Check all pinion components for wear.

★ The lock nut (10) and spacer (5) must be replaced when
reassembling the unit.
50-206 WB142-5
12
ASSEMBLY
1. Place differential support (7) on a work bench.
2. Install bearing cups (3) and (8) into housing using special tool D16
and a hammer.
★ Use the kit consisting of the special tools called “false pinion”
D17 and “false differential box” D18 and D19 and a depth
gauge.
3. Install bearing cones (3) and (8) to their respective seats.
4. Assemble the “false pinion” and nut (10).
5. Tighten nut - but do not overtighten - until backlash is eliminated.
6. Install tool D18, D19 to bearing seats in differential housing (7) and
retain with bearing caps.
WB142-5 50-207
7. Installation method D18, D19:
★ Use a depth gauge to measure distance “X” (distance between
the axis of the differential bearings and the point at which the
pinion head, or base of bearing, is supported).
★ In order to determine the thickness (S) required between the

pinion and the bearing, subtract the value (V), stamped on the
pinion head (Vaguer depth), from the measured value (X).
S=X-V mm
★ Pick the (S) shim (2) from the range of shims available.
Shim Range
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
8. Remove special tool D18, D19 from differential support.
9. Remove nut (10), false pinion, and bearing cones (3) and (8).
50-208 B WB142-5
10. Install the selected shim (2) to the pinion shaft (1) with the chamfer
facing the gear.
11. Install bearing (3) onto the pinion shaft (1) using a press and driver
D20, and ensure that the bearing is fully locked into position.
12. Install shims (4) and (6), and a new collapsible spacer (5).
★ Use only one new spacer.
13. Install pre-assembled pinion gear (1) to the differential housing (7),
and install bearing inner cone (8) to pinion shaft end as shown.
14. To install bearing (8), use driver D20 and a hammer.
15. Insert washer (9) and install a new lock nut (10) on to the pinion
end.
16. Tighten the nut in (10), using the wrench for nut D14 and for pinion
retainer D15.
17. The torque setting is given by the preload measurement on bearings

(3) and (8).
18. Tighten the nut (10) step by step.

★ If it is tightened too much, the spacer (5) should be replaced
and the procedure repeated.
★ When you check the preload, it is advisable to tap both pinion
ends with a soft hammer, so as to help seat the bearings (3) and
(8).
WB142-5 50-209
19. Measure preload P of tapered bearings (3) and (8) using a force
gauge with the string wound around the splined end of pinion (1).
★ Adjustment is carried out by gradually increasing the
tightening torque of the ring nut (10), paying attention not to
overtighten.
★ All pre-loadings should be measured without the seal.
★ P=9.2-13.7 daN
20. Once you have reached the preloading value, stake the lock nut
(10).
★ Do not carry out the steps below until you have completed the
adjustment of preload T.
21. Assemble seals (11) to cover (13) using tool D21 and a hammer.
22. Install a new O-ring (12) to cover (13). Lubricate O-ring (12) and
seal (11).
23. Install cover (13) to differential support.
50-210 WB142-5
12
CARRIER
DISASSEMBLY
1. Bolt 5. Axle gears 9. Spider shaft

2. Bearing 6. Thrust washer 10. Carrier half
3. Carrier half 7. Spider gears 11. Ring gear
4. Counter-discs 8. Pin
1. Lock the carrier in a vise.
2. Remove all bolts (1) on ring gear (11).

★ This will separate both halves (3) and (10), so take care not to
drop the internal components.
3. Remove the gear (11).
WB142-5 50-211
4. Disassemble the differential carrier in two separate halves (3) and
(10), complete with the relevant components.
★ Marl the two half housings with reference marks.
★ Recover the components from both halves.
★ Check the wear conditions of the components.
5. Remove the bearings (2) from the carrier halves (3) and (10), using
a puller.
ASSEMBLY
1. Assemble the cones of the new taper roller bearings (2) on the half
carriers (3) and (10) using the special tool D13 and a hammer.
2. Position the housing (3) on a workbench and assemble all inner

components: locking differential counter-discs (4), axle gears (5),
spider shaft (9), spider gears (7), thrust washers (6), pin (8), as
shown in illustration.
3. Join the two halves, aligning the reference marks made during dis-
assembly.
50-212 B WB142-5
4. Install the ring gear (3) and then tightening the bolts (4).
Bolt: Loctite 270
WB142-5 50-213
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
12
REAR AXLE ASSEMBLY
REMOVAL
★ For added safety, place the backhoe bucket with its back on the
ground while holding the arm in the upright position.
★ Lower the bucket to the ground as well.
1. Lower the backhoe outriggers (1) and force them downwards in

order to raise the rear wheels (2) by approximately 5 cm. (2 inches)
2. Prepare a safety stand “A” approximately 65 cm (26 inches) high,

beneath the backhoe chassis. Pull up the outriggers until the
machine is resting on the stand “A”.
3. Stop the engine and take off the rear wheels (2).
Wheel 163 kg (350 lbs)
4. Remove the rear wheels with jack stands “A” in place and
outriggers (1) in the lowered position as shown in the illustration.
WARNING! Completely lower the machine on to the

jack stands before removing the tires.
Lower the outriggers (1) to the ground
after the machine is resting on the jack
stands for extra safety.
5. Disconnect cable (3) from parking brake (4).
50-214 B WB142-5
6. Disconnect differential lock hose (5).
★ Cap the hose to prevent contamination.
7. Disconnect service brake lines (7) from axle (6).
8. Disconnect lines (7) from hoses (8); loosen and remove clamp (9)
and lines (7).
★ Cap pipes and hoses to prevent contamination.
9. Disconnect the drive shaft (10) from the rear axle.
10. Position a jack “C” beneath the axle.
11. Raise the jack until it can be forced under the axle.
★ It should be possible to lower the jack by approximately 20 am
(8 inches).
WB142-5 50-215 B
12. Remove bolts (11) and (4).
13. Lower the jack until the axle (6) is disengaged from the chassis.
14. Remove the entire axle.
Rear axle: 430 kg (947 lbs)
INSTALLATION
Lug nuts: 500 ± 9.8 N·m (369 ± 7 lbs/ft)
1. Bleed the air from the braking circuits.
2. Adjust the stroke of the parking brake lever.
Drive shaft bolts: 38 N·m (28 lbf•ft)

Axle retaining bolts: 1000 N·m (737 lbf•ft)
Axle retaining bolts: Loctite 262
50-216 B WB142-5
DISASSEMBLY AND ASSEMBLY REAR AXLE OVERHAUL PROCEDURES
12
REAR AXLE OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the rear axle is sitting on a level
stable surface. Clean up any oil spills immediately and keep your work area clean and
clear of debris.
PARKING BRAKE ASSEMBLY

DISASSEMBLY
1. Lock nut 5. Rotor 9. Caliper support

2. Bolts 6. Shim 10. Seal
3. Brake caliper 7. O-ring 11. Differential housing
4. Snap ring 8. Bolt 12. Dowel pin
WB142-5 50-217
1. Loosen nut (1).

★ Proceed with care, in order to avoid damaging the brake pads.
3. Remove the brake caliper (3).
4. Remove snap ring (4) and rotor (5).

★ Collect the shim (6) and the O-ring (7).
5. Remove bolts (8) caliper support (9).
6. Remove the caliper support (9) from the differential housing.
50-218 WB142-5
7. Remove the seal (10) from the differential housing (11) with a
puller.
ASSEMBLY
1. Install a new seal (10) into in the differential housing using special
tool E1.
2. Install dowel pin (12) and the brake caliper support (9) on the
differential housing (11).
3. Tighten bolts (8).
4. Lubricate O-ring (7).
O-ring: ASL800050
5. Insert the shim (6) on the spined pinion end, a new O-Ring (7), the
input flange (5) and the lock ring (4).
WB142-5 50-219
6. Position the brake caliper (3) on the disc (9).
★ Be careful to avoid damaging the brake pads.
7. Install bolts (2) and tighten the nuts (1) to the prescribed torque.
★ Once the nuts are tightened, check to make sure that a 1 ± 0.5
mm gap remains between nuts (1) and the spacers shown.
Nuts: 115 N·m (85 lbf ft)

50-220 WB142-5
12
MAINTENANCE
1. Lever arm 8. Balls plate 15. Sleeve

2. Adjustment bolt 9. Bolt/sleeve 16. Shim
3. Boot 10. Retention spring 17. Shim
4. Cam assembly 11. Shim 18. Sleeve
5. Torque plate 12. Nut 19. Bolt
6. Brake pads 13. Nut 20. Mounting bracket
7. Torque plate 14. Balls
1. Install mounting bolts through sleeves (9) and attach brake mounting locking nuts as far as possible on mounting bolts.
This is not required if brake assembly comes with the sleeve/bolt subassembly. Position the brake over disc gap and align
with mounting holes in mounting bracket.
2. Thread mounting bolts (9) into mounting bracket, adjusting bolts until a 0.5 - 1.5 mm (0.2 - 1.0 inches) exists between the
sleeves and the locking nuts. Tighten the locking nuts to 115 N·m (85 lbf ft) of torque against the bracket.
3. Refer to Adjustment Procedure to set backlash of installed brake assembly.
Brake Pad Adjustment Procedure
1. Loosen adjustment nuts (12 and 13).
2. Tighten inner adjustment nut (12) until firm contact is made with the disc by the linings. Torque to 13 -14 N·m (10 lbf ft).
3. Be sure the control lever is in the brake apply position.
4. Back off inner adjustment nut (12) four to six turns and check that disc is free to move.
WB142-5 50-221
5. Tighten outer locking nut (13) against inner adjustment nut (12) to lock adjustment bolt (2) in place. Tighten at 61 -74
N·m (45 - 55 lbf ft).
Ball And Cam Replacement
1. Remove both adjustment locking nuts (12, 13), thrust, stainless steel and hardened washer (11, 16, 17), lever (11), and
boot (3) from adjustment bolt (2).
2. Remove outer cam (4) and ball assembly (8) from adjustment bolt (2).
3. Use a screwdriver, or similar tool, to gently pry inner cam (4) protrusions on back of cam, loose from torque plate (5), and
remove from adjustment bolt (2). Remove seal (15) from adjustment bolt (2).
4. Install new seal (15) on adjusting bolt (2), inserting it through inner cam (4) until seal (15) bottoms out on torque plate.
5. We recommend lubricating the cams' thrust surfaces before installing the cams (4).
Cam surface: ASL800050
6. Install new cam (4) on adjustment bolt (2), taking care to orient protrusions into holes in torque plates (5).
7. Install ball assembly (8) onto adjusting bolt (2), orienting balls into pockets of inner cam (4). Install outer cam (4) onto
adjustment bolt (2), orienting pockets onto ball assembly (8). Install boot (3) over cam assembly.
8. Install lever (1), using protrusions on back of outer cam (4) and holes in lever (1) to orient lever to proper operating
position.
9. Install remaining washer and nuts and follow adjustment procedures.
10. Check to ensure that the coated side of shim (11) is oriented towards the steel washer (17).
Lining Replacement
1. Loosen two adjustment locking nuts (12, 13) enough to remove each torque plate (5, 7) away from disc far enough to
provide backlash to remove old carrier and lining assemblies and install new ones. (It may be necessary to remove one or
both Nuts)
2. Collapse the two lining retraction springs (10) and remove them from brake head assembly.
3. Remove torque plates (5 and 7) away from disc, move carrier and brake pads (6) out of pockets, and remove the brake
head assembly from the side.
4. Before installing new pads, it is necessary to apply grease between bushings (9) and pad supports (5 and 7).
Bushings: ASL800050
★ Once grease has been applied, slide the supports onto the bushings to distribute grease evenly.
5. Install new carrier and lining assemblies (6) in each torque plate (5 and 7).
6. Install the two lining retention springs (10) into brake head assembly. Be sure spring’s “feet” are positioned properly in
holes in both lining carrier assemblies (6).
7. Adjust brake.
50-222 WB142-5
12
Sleeve Seal Replacement
1. Loosen the two locking nuts on the mounting bolts and remove the mounting bolt/sleeve assembly (9) from the brake.
2. Insert sleeve seals (18) between the torque (5 and 7) and align with the sleeve bores.
3. Lubricate the mounting bolt/sleeve fit before installing.
Bushings: ASL800050.
4. Install the mounting bolt / sleeve assembly through the front pad support (5), the sleeve seals (18) and the rear pad support
(7).
Replacing The Cable Attachment Bracket
1. Remove the bolts (19) from the bracket (20) pad support (5).
2. Remove the bracket (20).
3. Position the bracket (20) in correspondence with the threaded holes of the pad support (5).
4. Attach the bracket (20) to the front torque plate (5) with the appropriate bolts (19).
WB142-5 50-223
12
SERVICE BRAKE ASSEMBLY
DISASSEMBLY
1. Bolt 8. Shouldered bolt 15. Inner cylinder

2. Hub 9. Washers 16. O-ring
3. Axle housing 10. Brake cylinder 17. O-ring
4. Axle half shaft 11. Lock ring 18. O-ring
5. Brake disc 12. Shouldered bolt kit 19. O-ring
6. Brake plate 13. Washers
7. Pin 14. Bushing
1. Drain the oil completely from the differential.
Differential oil: approximately 15 L (4 gal)
50-224 WB142-5
2. Remove all but two of the cap screws (1).
3. Sling the outer hub (2).
4. Insert two dowel rods to enable removal.
5. Remove last two cap screws (1) and separate the hub (2) from the
axle (3).
6. Carefully pull hub (2) away from axle and the half shaft (4), make
sure that brake disks (5) and plates (6) stay with the hub.
7. Stand the hub up, mark the reaction plat (5) that was against the
axle housing (3). Remove the reaction (6) and brake disks (5) and
pins (7).
★ Check friction plate and brake separator condition.
★ If brake discs are to be replaced, soak the new discs (for each
differential) in oil for at least 24 hours.
WB142-5 50-225
8. Remove axle shaft (4) from wheel hub assembly (2).
9. Remove bolts (8) and beveled washers (9) from brake cylinder (10).
★ Check to ensure that shouldered bolts (8) and beveled

washers (9) are not damaged.
10. If brake discs are being replaced, replace bolts and washers with the
new kit.
11. Remove the lock ring (11) and remove the self adjuster (12).
50-226 WB142-5
12. Place self adjuster (12) onto special tool E2 and drive out the spring
clips (13) from the adjuster.
13. Inspect adjuster bushing (14) for wear.

★ Repeat procedure for the remaining two kit self adjust.
14. Use an acceptable flat bar and pry the brake piston (10) up from the
hub.
15. Remove the brake piston (10) and the inner cylinder (15).
WB142-5 50-227
16. Remove O-rings (16) and (17) from the brake piston (10).
17. Remove O-ring (18) from inner cylinder (15).
18. Remove and replace O-ring (19).

★ Replace the O-ring at each disassembly.
50-228 WB142-5
12
ASSEMBLY
1. Install a new O-ring (19) onto hub (2).
2. Install O-ring (18) onto inner cylinder (15).
3. Install O-rings (16) and (17) onto brake piston (10).
4. Lubricate O-rings (16), (17) and (18), and install complete piston
(15) to brake cylinder (10)
O-ring: ASL800050
WB142-5 50-229
★ Use hydraulic oil to lubricate the brake cavity of the hub
housing (2) and mount pins (7).
Cylinder cavity: ASL800050
5. Install the complete brake cylinder (10) and remove pins (7).
6. Place bushing (14) inside calibrated ring E2 with the chamfer

facing upwards.
7. Place pin E2 into brake adjuster (14).
8. Install spring clips (13) taking care to rotate them 90o clockwise
respect to the one mounted before.
50-230 WB142-5
9. Using driver E2, push the rings (13) until solid contact against
calibrated ring E2 is obtained.
★ Repeat procedure for the remaining self adjusts.
10. Insert the adjuster (12) into the brake piston (14), make sure that the
chaffered side is up.
11. Install the snap rings (11) into the self adjuster bore.
★ Check to ensure that spring ring teeth are facing the self adjust
kit as shown in the following illustration.
★ Snap ring (11) orientation and beveled washers (9).
WB142-5 50-231
12. Install bevelled washers (9) to shouldered bolt (8) taking care to
orient them as shown in the previous illustration.
13. Install the shouldered bolts (8) and spring washers (9) and tighten
to the required torque
14. Install the half shaft (4) and brake separator plate pins (7) into the
axle housing.
15. Using the reference mark made during disassembly, place the inner
brake separator plate (5) into the axle housing (3).
50-232 WB142-5
16. Place the inner brake disk (6) and the second brake separator (5).
★ If brake discs (6) are replaced, soak discs (for each differential)
in oil at least 24 hours prior to installation.
17. Install the outer brake disk (6) and make sure the slots of the inner
and outer brake disks are aligned with each other.
18. Sling the hub assembly (2) and guide onto the axle (3).
19. Lift and rotate the half shaft while pushing the hub onto the axle.
20. Install bolts (1) tighten to the required torque
Bolts: Loctite 270
21. Tighten using the alternating crosswise method.
WB142-5 50-233
22. Fill axle with oil.
Differential oil: approximately 15 l (4 gal)
50-234 B WB142-5
12
REAR AXLE END PLANETARY ASSEMBLY
DISASSEMBLY
1. Bolt 6. Snap ring 11. Bearing

2. Planetary gear 7. Roller bearings 12. Hub seal
3. Retaining washer 8. Retainer nut 13. Bearing
4. Retaining washer 9. Axle end housing 14. Race
5. Planetary carrier 10. Wheel flange
1. Loosen bolts (1).

★ Replace bolts with a new set.
WB142-5 50-235
2. Mark planetary gears (2), retaining washer (3) and indexed washer
(4).
3. Remove bolts (1), retaining washer (3) and indexed washer (4).
4. Mark the mounting position of retaining washer (3) and indexed

washer (4) on the planetary carrier (5).
5. Sling the planetary carrier assembly (5).
50-236 WB142-5
6. Locate the snap ring (6) slot and open it while raising the planetary
carrier (5).
7. Only if necessary, remove from the planetary carrier (5) the gears
(2) and their related roller bearings (7) (66 per gear).
★ Keep all the components of each gear together as a set.
8. Using spanner E4, loosen and remove the ring nut (8).
9. Use suitable puller and separate hub housing (9) from wheel end
(10)
WB142-5 50-237
10. Sling the hub housing (9) and remove it from the wheel flange (10).
★ Collect the bearing cone (11).
11. Remove from hub housing (9) the outer race of the bearing (11).
50-238 WB142-5
14. Remove from wheel flange (10) spacer (14).
15. Using an angle grinder, cut the cage and etch the bearing race (13).
16. Use a chisel to cut and remove bearing inner race (13).
Remark
Do not use a cutting torch to remove this bearing, damage
to the axle end may occur.
WB142-5 50-239
12
ASSEMBLY
1. Install bearing outer races (13) and (11) to hub (9) using special tool
E5 and a press. Using special tool E6 install the hub seal (12).
2. Install bearing inner race (13) to wheel flange (10) using a suitable
driver and a press.
3. Install spacer (14) on wheel flange (10)
4. Sling the hub (9) and carefully install it onto wheel flange (10).
★ Clean all sealing surfaces.
★ Take care not to damage the hub seal (12).
50-240 WB142-5
5. Install bearing inner race (11) using a suitable driver and a hammer.
6. Install ring nut (8).
7. Using spanner E4, tighten ring nut (8) to the required torque.
Ring nut: 1000 N·m (738 lbf ft)
8. Apply a light coat of Lithium based grease to the planetary carrier

(5) stud to hold the needle bearings (7) (bearings 33) in place.
Grease: ASL 800050
★ Use all the components corresponding to the marks made during

disassembly.
9. Install the planetary gear (2) and the remaining needle rollers (7)
(bearings 33) into the side gear.
WB142-5 50-241
10. Sling the planetary carrier (5) and lower it into hub (9).
★ During installation the locking ears of the planetary carrier (5)

must engage the ring nut (8) as shown in illustration.
11. In order to simplify the installation, align the hole on the planetary
carrier (5) with the ring nut (8) as shown.
12. Open the snap ring (6) and slowly lower the planetary carrier (5).
50-242 WB142-5
13. Install washers (3) and (4) and tighten bolts (1); apply the specified
sealant and tighten to the required torque.
★ Replace bolts with new ones.
Bolts: Loctite 270
WB142-5 50-243
12
DIFFERENTIAL
DISASSEMBLY
1. Bolt 4. Bolt 7. Carrier

2. Axle housing 5. Ring nut 8. Bearing
3. Differential 6. Ring nut
1. Drain the oil completely from the differential.
Differential oil: approximately 15 L (4 gal)
50-244 WB142-5
3. Separate from axle housing (2) the differential (3) using pry bars in
slots.
4. Sling differential housing (3) and remove it.
5. Remove bolts (4) securing the ring nuts (5) and (6).
WB142-5 50-245
6. Use the tool E7, unscrew the adjuster ring nuts (5) - (6).
7. Remove out the differential case (7). The external rings (8) and (9)
are removed together with the differential housing.
★ Do not mismatch bearings if bearings are not to be replaced.
ASSEMBLY
1. Using driver E8, install bearing outer races (8) and (9) to
★ Do not mismatch bearings if bearings are not to be replaced.
2. Position the complete differential carrier (7) with bearings on the

50-246 WB142-5
3. Insert and tighten adjustment ring nuts (5) and (6) in the differential
support with tool E7, so as to preload the differential bearings
slightly.
★ Tap lightly with a soft hammer in order to properly set the
bearings in position.
4. Place a magnetic dial indicator on the differential support so that

the feeler is at right angles with the side of a tooth from the ring
gear.
A. Lock the pinion and move the ring gear alternatively and note
the pinion-ring gear backlash, measured with the dial indicator.
B. Repeat the operation on two or more points (teeth), rotating the

ring gear, so as to obtain an average value.
C. Check if the measured backlash value to see if it is within the

required range: 0.21 - 0.29 mm (0.08 - 0.11 inches)
5. Adjust by operating the adjuster ring nuts (5) and (6), using tool E7.
6. Adjust the ring nuts (5) and (6) remembering that:

★ If the measured backlash is less than the given tolerance
range, unscrew the adjuster ring nut (6) and screw in the
adjuster ring nut (5) by the same measure.
★ If the measured backlash is greater than the given tolerance
range, unscrew the adjuster ring nut (5) and screw in the
adjuster ring nut (6) by the same measure.
7. Repeat the whole sequence of the above mentioned operations till

the indicated conditions are reached.
WB142-5 50-247
8. Once the pinion-ring gear backlash has been established, measure
the total rotational torque Tr of the bearings (pinion-ring gear sys-
tem), using a torque wrench and special tool E9.
★ Total rotational torque should be measured without pinion
retaining ring.
★ Rotational torque Tr must be within the following range: Tr =
(Pr+0.58) - (Pr+0.87) N·m where Pr is the actual rotational
torque of pinion alone.
9. If the reading is not within the required range, thoroughly check the
assembly of each component and adjuster ring nuts (5) and (6) of
the differential support caps:
★ If total preload is less than the specified value, tighten the
adjuster ring nuts (5) and (6) by the same amount, while
keeping the pinion/ring gear backlash value unchanged.
★ If total preload is greater than the specified value, loosen the
adjuster ring nuts (5) and (6) by the same amount, while keep-
ing the pinion/ring gear backlash value unchanged.
10. To test the tooth contact on the ring gear teeth, paint the ring gear
with red lead paint.
★ The marking test should be always carried out on the ring gear
teeth and on both sides.
Contact
★ OK-Correct contact:
★ If the ring gear is well adjusted, the mark on the teeth surfaces
will be regular.
★ Z - Excessive contact on the tooth tip:
★ Adjust the pinion to the ring gear and then move the ring gear
away from the pinion in order to adjust the backlash.
★ X - Excessive contact at the tooth base:
★ Move the pinion away from the ring gear and then adjust the
ring gear to the pinion in order to adjust the backlash.
50-248 WB142-5
Movements To Correct
A. Move the pinion for type X contact adjustment.
B. Move the pinion for type Z contact adjustment.
11. When all adjustment procedures are complete, lock adjuster ring
nuts (5) and (6) into position with bolts (4). Tighten screws (4) to
the required torque.
Bolts: 10N·m (7 lbf ft)
12. Before matching surfaces, make sure that they are perfectly clean,
degrease and clean them with appropriate detergents. Spread a film
of adhesive on the contact surface between the axle housing (2) and
the differential carrier (3).
Contact surfaces: Loctite 510
13. Assemble the differential (3) to the axle housing.
WB142-5 50-249
14. Tighten all bolts (1) to the required torque.
15. Refill the hydraulic oil.
5 Differential oil: approximately 15 L (4 gal)
50-250 WB142-5
12
DIFFERENTIAL LOCK
DISASSEMBLY
1. Plug 6. Bushing 11. O-ring

2. Fork 7. Spring 12. O-ring
3. Shaft 8. Bushing 13. Snap ring
4. Spring 9. O-ring
5. Snap ring 10. Piston
1. Loosen plug (1) but do not remove it.
WB142-5 50-251
2. Hold the differential lock fork (2) down to release the block inside
of the housing, remove the plug (1).
3. Pull the differential fork lock (2) up, place a flat piece of steel under
the shaft (3) to keep it from moving.
4. Compress spring (4) until snap ring (5) is released.
6. Remove the bushing (6).
50-252 WB142-5
8. Remove shaft (3) from differential housing.
9. Remove fork (2), spring (7) and bushing (8) from the shaft (3).
10. Remove O-ring (9) from plug (1) and O-rings (11) and (12) from
the piston (10).
WB142-5 50-253
12
ASSEMBLY
1. Install new O-rings (11) and (12) on the piston (10) and O-ring (9)
on plug (1). Lubricate the O-rings.
2. Lubricate the shaft (3) with clean hydraulic oil.
3. Install the fork (2) on the shaft (3) as shown in figure.
4. Install bushing (8) and spring (7) onto shaft.

★ Mount the spacer (8) with the chamfer towards the snap ring
(13).
5. Insert in the differential housing the shaft (3).
50-254 WB142-5
7. Place the bushing (6) on the shaft, make sure the chamfer in the
bushing is facing out.
8. Pull the differential lock fork (2) up, place a flat piece of steel under
the shaft (3) to keep it from moving down.
9. Compress the spring (4) using a proper tool and install the snap ring
(5).
★ Remove the piece of steel under the shaft (3).
10. Hold the differential lock fork (2) down to catch a block inside of
the housing, remove the plug (1).
★ Hand tighten the plug (1).
WB142-5 50-255
11. Tighten plug (1) to the required torque.
Plug: 180 N·m (133 lbf ft)
50-256 WB142-5
12
CARRIER
DISASSEMBLY
1. Bearing race 10. Pin 19. Spacer

2. Bearing race 11. Cap screw 20. Spider gear
3. Sleeve 12. Ring gear (not shown) 21. Thrust washer
4. Snap ring 13. Pin 22. Axle gear
5. Housing cover 14. Spider gear 23. Thrust washer
6. Anti-rotation pin 15. Thrust washer 24. Carrier
7. Thrust washer 16. Spider gear 25. Pin
8. Axle gear 17. Thrust washer
9. Plug 18. Pin
★ If differential bearings are to be replaced, remove bearing outer

races (1) and (2).
WB142-5 50-257 B
3. Remove housing cover (5), remove the anti rotation pin (6) and the
thrust washer (7).
4. Remove the axle gear (8).
5. Remove three plugs (9) from the carrier.
50-258 WB142-5
6. Remove the three pins (10) securing the spider pins in the
carrier.
7. Remove the ring gear cap screws (11), remove the ring gear (12).
8. Push the pin (13) towards the flat surface side (14).
★ The pin can be pushed in only one direction.
9. Remove the planetary gear (14) and thrust washer (15).
WB142-5 50-259
10. Push the pin (13) out of the housing and remove the planetary gear
(16) and thrust washer (17).
11. Push the short spider pins (18) out of the spacer (19) by pushing
them through the hole in the spacer (19).
12. Remove pins (18), spider gears (20) and thrust washers (21).
13. Remove axle gear (22) and thrust washer (23) from the housing.
50-260 WB142-5
14. Remove the differential locking pins (25) from the housing (24).
ASSEMBLY
1. Install and lubricate new O-rings (26) on the pins (25).
O-ring: ASL800050
2. Install the pins (25) in the differential housing (24).
3. Lubricate and install sun gear (22) and thrust washer (23).
Gear: differential oil
WB142-5 50-261
4. Lubricate and install planetary gear (20) and its respective thrust
washer (21) and install pins (18) forward enough to support them.
★ Align the flats on the pins facing upward.
Gear and pin: differential oil
5. Install spacer (19) and install pins (18), taking care to align the
holes with those on the differential housing (24).
6. Lubricate and install the spider gear (16) and thrust washer (17).
★ Install pin (13) as far as it will go.
★ Align pin (13) with the flats on the pin facing up.
Gear and pin: differential oil
7. Lubricate and install the spider gear (14) and thrust washer (15)
then install pin (13).
★ Align the hole on the differential housing (24).
Gear and thrust washer: differential oil
50-262 WB142-5
8. Install the differential ring gear (12), apply sealant and tighten cap
screws (11) to the required torque.
Cap screw: Loctite 270
Cap screw: 155 N·m (114 lbf ft)
9. Install pins (10) and tighten plugs (9) to the prescribed torque.
Plugs: 25 N·m (18 lbf ft)
10. Install the planetary gear (8).
11. Apply a thin coat of grease to the cover (5) and install the shoulder
ring (7).
Cover: ASL800050
12. Install anti-rotation pin (6) to cover (5) and install cover (5) to dif-
ferential housing.
WB142-5 50-263
13. Lock cover (5) into position with snap ring (4).
14. Install sleeve (3) and make sure that sleeve fits snugly into position.
★ To make installation easier, rotate the side gear (22).
15. Install bearing outer rings (1) and (2) using driver E8.
★ Do not invert bearings.
50-264 WB142-5
12
PINION
DISASSEMBLY
1. Lock nut 5. Washer 9. Housing

2. Washer 6. Collapsible spacer 10. Thrust washer
3. Pinion gear 7. Bearing
4. Washer 8. Bearing
1. Place the differential carrier (1) in a vise.
2. Remove the lock nut (1) using special tools E9 - E10.

★ This operation will irretrievably damage the lock nut (1).
WB142-5 50-265 B
3. Remove the lock nut (1) and collect its retaining washer (2).
4. Tap the shaft with a soft hammer to remove the pinion gear (3).
★ Take care not to drop the pinion gear (3).
5. Recover washers (4) and (5), collapsible spacer (6) and bearing
inner ring (7).
6. Remove bearing outer races (7) and (8) from differential support (9)
using a driver and a hammer.
7. To remove bearing inner bearing (8) from pinion gear (3), use a
commercially available puller.
★ Recover bearing (8) and the shim (10).
50-266 WB142-5
8. Check all pinion components for wear.
★ The ring nut (1) and the collapsible spacer (5) must be
replaced.
ASSEMBLY
1. Place the differential housing (9) on a workbench.
2. Install outer bearing (7) and (8) using special tools E11 - E12 and a
hammer.
3. Insert inner bearing (7) and (8) in the housings.
4. Assemble the false pinion E13 and its lock nut (1).
5. Tighten till the backlash is eliminated.
6. Install special tool E14 to the differential housing (9).
WB142-5 50-267 B
7. Use a depth gauge to measure distance “X” (distance between the
axis of the housing bearings and the point at which the pinion gear
is supported, or base of the bearing).
8. To adjust ring gear/pinion measure the distance “A” with a depth

gauge. Calculate the value “X” as follows:
★ X =(A+C)-B mm where “B” and “C” are known.
9. In order to determine the necessary thickness value (S) between the

pinion and the bearing, subtract the value (V), stamped on the
pinion head (V= requested distance), from the measured value (X).
★ S = (X - V) mm
10. Select the shim with the thickness value (S) from among the range
of available shims (10), and install it onto shaft under the pinion
gear.
★ The chamfer on the ID of the shim (10) must be toward the
pinion gear (3).
Shim Range
Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
50-268 B WB142-5
11. Remove the special tool E14 from housing (9).
12. Remove the lock nut (1), the false pinion E13 and the bearing cones
(7) and (8).
13. Select a suitable shim (10) and install with the chamfer facing the
gear, then install bearing inner ring (8) to pinion (3) with a press
and tool E3, and check to ensure that it fits snugly in place.
14. Install the washers (4) and (5) and a new collapsible spacer (6) on
the pinion gear (3).
★ Always use a new collapsible spacer (6).
15. Install bearing (7) to pinion end.

★ To install bearing (8), use special tool E3 and a hammer.
WB142-5 50-269
16. Insert lock nut washer (2) and install a new lock nut (1) on the pin-
ion end.
17. Install the lock nut (1), using the wrench for lock nut E10 and for
pinion retainer E9.
★ The torque setting is given by the preload measurement on
bearings (7) and (8).
18. Tighten the lock nut (1) step by step.

★ If it is tightened too much, the spacer (6) should be replaced
and the procedure repeated.
★ When you check the preload, it is advisable to tap both pinion
(3) ends with a soft hammer, so as to help setting the bearings
(7) and (8).
19. To measure the rotational torque (Pr) of tapered bearings (7) and
(8), use a torque wrench and tool E9.
★ Adjustment is carried out by gradually increasing the
tightening torque of lock nut (1), paying attention not to
overtighten.
★ All preload settings should be measured without the seal.
★ Rotational torque should be within the following range: Pr =
2.0 - 2.4 N·m (1.5 - 2.0 lbf ft).
20. Once you got the requested preload value, stake the lock nut (1).
50-270 WB142-5
DISASSEMBLY AND ASSEMBLY FRONT LOADER CONTROL VALVE ASSEM-
12
FRONT LOADER CONTROL VALVE ASSEMBLY
REMOVAL
1. Remove screws (1) and remove cover (2) and boot (3).
2. Disconnect control valve links (7) from PPC valve (6).

★ Check to ensure that all hoses are marked with match marks if
necessary.
★ Cap all hoses to prevent contamination.
3. Disconnect all lines (8) (delivery, relief, LS, and actuators) from the
control valve.
★ Mark all hoses to prevent mixing them when they are
reconnected.
4. Disconnect connector (9) from solenoid valve.
5. Remove three screws (10) and remove the control valve (11) by
sliding it off from below.
INSTALLATION
★ Avoid kinking or bending the control rods.
1. Start the engine to circulate the oil and check for leaks.
2. Stop the engine and check the oil level in the tank. Top if necessary
WB142-5 50-271
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE ASSEMBLY
SOLENOID VALVE ASSEMBLY
REMOVAL
1. Disconnect connectors (1) to solenoid valves (2) and (3).

★ Mark the connectors to avoid mixing them up during
installation.
2. Disconnect lines (5) from solenoid valve (4).

★ Mark the lines to avoid mixing them up during reassembly.
3. Remove two bolts (6) and solenoid valve (4).
INSTALLATION
1. Start the engine and perform possible maneuvers to eliminate the air from circuits.
50-272 WB142-5
DISASSEMBLY AND ASSEMBLY FRONT-END LOADER ASSEMBLY
12
FRONT-END LOADER ASSEMBLY
LOADER BOOM CYLINDERS

★ It is advised to do this procedure on a flat level smooth surface.
REMOVAL
1. At rear of boom lift cylinder remove hose support clamps (1) and
disconnect rear hydraulic supply line (2).
2. Remove snap ring (3) and washer (4).
3. At front of boom lift cylinder disconnect front hydraulic supply line

(5) and remove snap ring (6) and washer (7).
4. Sling the cylinder (8) as shown in the illustration.
WB142-5 50-273
5. With the cylinder properly slung, push the front pin in the direction
shown in the illustration and pull the cylinder off the rear pin in the
direction shown in the illustration.
6. Lower the cylinder (8) to pull it off the rear pin in the direction
shown in the illustration above.
★ For safety sake place a block of wood (A) on the front axle to
protect the cylinder from damage if it should tip.
7. Remove the lift cylinder from machine as shown in the illustration.
Boom cylinder: 75.3 kg (166 lbs)
INSTALLATION
★ To install, reverse the removal procedure.
★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idle speed.
WARNING! Do not insert fingers into the holes to

check alignment.
2 Internal bushing: ASL800050
★ Start the engine and bleed the air from the cylinders. For details, see Section 30 “HYDRAULIC CIRCUIT” .
★ After bleeding the air, check the oil level in the tank.
50-274 WB142-5
12
BUCKET CYLINDER AND MONO-LINK
REMOVAL
1. Sling the mono-link cylinder (1) as shown in the illustration before

removing any pins or components.
★ Use a choke hold nylon strap set-up as shown.
2. Remove pin (2) and mounting bolt then remove the leveling rod (3)
from the machine completely.
3. Disconnect hydraulic supply lines (4) from the hoses and tuck them
out of the way.
WB142-5 50-275
4. Starting with the bucket link side, remove snap ring (5) and washer
(6) from pin (7).
5. Drive the pin (7) out of the bucket mounting boss and links (8).
★ Keep in mind each link (8) is independent from each other.
6. Remove snap ring and washer then remove the rod link pin (9) from
bucket boss ends.
7. To remove rear links (10), remove snap ring (11) and washer (12)
and drive pin (13) out.
★ Keep in mind each link (10) is independent from each other.
50-276 WB142-5
8. Once all pins are pulled and the links and rods are free, lift mono-
link assembly out of the machine.
Mono-link cylinder assembly: 99.7 kg (220 lbs)
Remark
Be careful not to damage extended cylinder rod when
handling mono-link.
INSTALLATION
★ To install, reverse the removal procedure. However, it is advised to install the cylinder link first.
★ When aligning the positions between the hole and the pin, you may have to run the engine at a low idling speed.

check alignment.
★ Start the engine and bleed the air from the cylinders. For details, see Section 30 “HYDRAULIC CIRCUIT” .
WB142-5 50-277
12
LOADER BUCKET
★ To remove the loader bucket, the mono-link cylinder assembly must be removed. Fail to do so may damage the machine
or cause injury. See “LOADER BUCKET” .
REMOVAL
1. Remove pin retaining bolts and nuts (1) and drive out the pins on
each side of the loader boom.
2. Once the pins (2) are removed and the bucket is free, back the
machine up.
★ When moving machine without a bucket, it is important to

keep the loader boom arms off the ground.
INSTALLATION

check alignment.
50-278 WB142-5
12
LOADER BOOM ASSEMBLY
★ To remove the loader boom arms, the mono-link cylinder assembly and bucket should be removed. See “BUCKET CYL-
INDER AND MONO-LINK” and “LOADER BUCKET” . Removing these components after the loader arms are
detached from the machine may be difficult or make the loader boom removal unstable.
REMOVAL
1. Remove the machine hood (3). See “ENGINE HOOD” .
2. After removing the front loader bucket and mono-link, rest the front
part of the loader boom ends on wooden blocks (A) for stable
support.
★ Be sure blocks (A) are of equal size and height.
3. Remove the loader boom cylinders (8). See “LOADER BOOM

CYLINDERS” .
WB142-5 50-279 B
4. Sling the loader boom in the manner shown in the illustration.
WARNING! Be sure to place the sling behind the

hydraulic line mounting boss. Failure to
do so may cause the sling to slide off the
loader boom due to the tapered design.
5. Disconnect the loader bucket cylinder hydraulic supply lines (1) on

both sides.
6. Remove bolts and nuts (2) from loader boom oscillation mounting
pins on both sides of the machine.
50-280 WB142-5
7. Using a puller, remove the oscillation pins (3) of the loader boom
(4).
8. Start the engine, put the machine into reverse gear and travel until
the boom is disengaged and clear from the machine.
9. Place two stands in position and lower the boom until it is resting
on them.
Loader boom: 960 kg (2,116 lbs)
INSTALLATION

check alignment.
WB142-5 50-281
DISASSEMBLY AND ASSEMBLY BACKHOE ASSEMBLY
12
BACKHOE ASSEMBLY
BUCKET CYLINDER
REMOVAL
1. Extend the arm (1) completely and fully open the bucket (2).
2. Lower the boom (3) until the arm is resting on a stand (A) and tip of
the arm is on a block (B).
3. Rest the bucket teeth on the ground.
4. Stop the engine and release the pressures in the cylinder (4) by
moving the control lever several times.
5. Place a sling around the bucket cylinder (4).
6. Remove lock-nut (5) and the washer and remove pin (6) from rod
end (7).
★ Do not use a chisel and hammer or a pipe wrench to remove or
install lock nut (5). Use the proper spanner wrench as shown in
the illustration.
50-282 WB142-5
7. Disconnect the bucket supply lines (8) and (9).
8. Remove snap-ring (10) and remove the pin (11).
9. Once free, lift bucket cylinder (4) off the machine.
Bucket cylinder: 49 kg (108 lbs)
INSTALLATION
★ Replace lock-nut (5) with a new one.

check alignment.
★ Start the engine and bleed the air from the cylinders. For details, see Section 30 “BLEED AIR FROM CIRCUITS” .
WB142-5 50-283
12
ARM CYLINDER
REMOVAL
1. Extend the arm (1) partly to make room for cylinder rod (4)
clearance.
2. Rest the bucket and arm completely on the floor.
3. Using blocks (B) to elevate stand (A), lower the boom (2) until the
boom is resting on a stand (A).
★ At this time be sure there will be enough clearance when the

arm cylinder rod end (7) is retracted to clear the arm mounting
bosses.
5. Remove retaining bolt and nut (6).
6. Pull pin (8) out and allow arm cylinder (4) to rest on boom, then
retract the arm cylinder rod (7) completely.
7. Sling the arm cylinder (4) and remove supply lines (9) and (10).
Lift cylinder (4) to see if rod end (7) will clear the arm mounting
bosses then lower cylinder (4) back down to rest on boom.
50-284 WB142-5
8. Support boom cylinder (5) with a block (B) and resling cylinder (4)
to prepare for final removal. Once both cylinders are supported,
remove pin (11).
★ When removing pin (11) from cylinders (4) and (5), be sure to
keep track of shims (12) on each side of the boom mounting
bosses and pivot points.
9. Once pin (11) is removed, lift arm cylinder (4) from the machine.
INSTALLATION
★ It is recommended to install pin (10) and shims (12) first.

check alignment.
★ After bleeding the air, check the oil level in the tank. Top off tank if necessary
WB142-5 50-285
12
BOOM CYLINDER
REMOVAL
1. Extend the arm (1) partly to make room for cylinder rod (4) and (5)
clearance.
2. Rest the bucket and arm completely on the floor.
4. Remove hydraulic supply lines (6) and (7) from boom cylinder (5).
5. Sling cylinders (4) and (5) and remove pin (11). Be sure to place
block (B) under boom cylinder (5) for support.
6. Once pin (11) has been removed, shims (12) can be retrieved.
50-286 WB142-5
7. Rest arm cylinder (4) on the boom and re-sling boom cylinder (5)
for removal.
8. Remove bolt and nut (13) and prepare to remove pin (16) from
cylinder (5).
9. Remove snap ring (14) and washer (15) then carefully almost
completely remove pin (16) being careful not to unseat backhoe
lock springs.
★ Do not remove the pin (16) completely, remove just enough to
free boom cylinder (5) from it’s mounting position.
10. Lift boom cylinder (5) off of the machine.
WB142-5 50-287
12
INSTALLATION
★ It is recommended to install pin (6) first. Be careful when aligning the springs for the lock mechanism.

check alignment.
50-288 WB142-5
12
SWING CYLINDERS
REMOVAL
★ Center the backhoe and leave the backhoe plate unlocked.
★ Lower the outriggers to the ground, curl the bucket and allow it to
rest on the ground on its back.
★ Apply the parking brakes, stop the engine and remove the ignition
key.
★ Release all residual pressure by operating the hydraulic controls
(including any optional device pedals) several times in all
directions.
1. Remove hose bundle clamp bolts (1) and remove hose clamp
assembly.
2. Group the hoses and sling them up out of the way using a sling (A)
to hold them in place as shown in the illustration.
3. Remove two front hydraulic supply hoses (2) and (3) on the
cylinders you will be removing.
WB142-5 50-289
4. Remove one rear hydraulic supply hose (4) on the cylinders you
will be removing.
5. Remove four bolts (5) and prepare to lift top support frame (6) off
of the swing cylinders.
6. Using two people and a pry bar, lift top support frame (6) off of the
swing cylinders.
Top frame bracket: 27.2 kg (60 lbs)
7. Remove nuts and bolts (7) on both swing cylinders to prepare for
removing both pins (8) completely.
★ It is important to remove both pins in order to be able to move
the swing cylinders for removal.
50-290 WB142-5
8. Remove both swing cylinder pins (8) to allow for removal of swing
cylinders.
9. Once the pins are removed, you can swing the cylinders (9) to the
right or left and remove them individually by lifting them out.
10. To remove a swing cylinder, slightly pry up on swing cylinder (9)

and lift it out.
★ It is advised to use two people to lift cylinder (9) out of
machine.
Swing cylinder: 37.2 kg (82 lbs)
INSTALLATION

check alignment.
WB142-5 50-291
12
BOOM LOCK CYLINDER
REMOVAL
1. Center the backhoe with the arm vertical and the back of the bucket
on the ground.
2. Make sure that the safety stop (2) is raised.
4. Remove nut (1) retaining linkage cover (2).
★ Once nut (1) is removed from linkage cover (2), lay linkage (2)
on to the boom cylinder so lock cylinder (3) is exposed.
5. Remove line (4) and remove the four bolts (5) to remove the lock
cylinder.
50-292 B WB142-5
6. To remove boom lock (10) or lock arm linkage (2), remove nut (6)
from bolt (9).
7. Carefully retaining spring (7), slide bolt (9) out of boom lock (10)
and retain spacer (8).
8. Remove snap ring and spacer (11) and slide boom lock arm (10) off
of the boss.
9. Once the boom lock (10) is removed, spring (7) can be removed.
INSTALLATION
1. Start the engine and perform several lock and release maneuvers to fill up and bleed air from the unit.
WB142-5 50-293 B
12
BACKHOE BUCKET
REMOVAL
1. Place the bucket on a level surface, resting on its back.
2. Remove safety pin (1) and remove the connecting pin (2) between
bucket (3) and tie-rods (4).
3. Remove safety pin (5) and remove the pin (6) that attaches the
bucket to the arm (7).
Standard bucket: 158 kg (348 lbs)
INSTALLATION
50-294 B WB142-5
12
BACKHOE ARM
REMOVAL
1. Extend backhoe arm (1) and boom (2) enough to allow

disconnection of arm cylinder (4).
2. Rest the bucket and arm (1) completely on the floor.
★ At this time be sure there will be enough clearance when the

arm cylinder rod end (7) is retracted to clear the arm mounting
bosses.
5. Remove retaining bolt and nut (6).
6. Pull pin (8) out and allow arm cylinder (4) to rest on boom, then
retract the arm cylinder rod (7) completely.
★ Be sure there is enough clearance between arm cylinder (4) rod

end (7) and arm boss (1)
WB142-5 50-295 B
7. Remove hydraulic supply lines (5) from arm cylinder (3).
8. Remove retaining bolt and nut (6) from pin (9).
9. Sling arm (1) with bucket attached as shown in illustration.
10. Remove pin (9) from arm (1). Be sure to retrieve shims (10).
50-296 B WB142-5
11. Once pin (9) is extracted and shims (10) are collected, lift arm (1)
off of boom (2).
Arm, bucket and bucket cylinder: 464 kg (1,022 lbs)
INSTALLATION

check alignment.
Internal bushing: ASL800050
★ After bleeding the air, check the oil level in the tank. Top tank off if necessary
WB142-5 50-297 B
12
BACKHOE BOOM
★ To remove the backhoe boom, the arm, bucket and boom cylinder must be removed. See “ARM CYLINDER” , “BOOM
CYLINDER” and “BACKHOE ARM” before proceeding to remove the backhoe boom.
REMOVAL
1. After arm, bucket and related cylinders are removed from boom
(2), prepare to remove hoses (3).
★ Keep track of what cylinders and positions the hoses are in
before removing them.
2. Remove hose clamp (1) and remove hose bundle (3).
3. Sling the backhoe boom in the manner shown in the illustration.
50-298 B WB142-5
4. Once backhoe boom is properly slung, remove the lower mounting
bolts (4) and pins (5) one on each side.
5. Once lower pins are removed, lift backhoe boom (2) from machine.
Backhoe boom: 267 kg (588 lbs)
INSTALLATION

check alignment.
WB142-5 50-299 B
12
BACKHOE SWING FRAME
REMOVAL
1. Remove the working equipment.
2. Remove bolts (1) and remove pins (2) that connect the swing
cylinders (3).
3. Remove boom safety cylinder (4). For details, see “BOOM LOCK
CYLINDER” .
4. Remove snap ring (7), washer (8) and nut (4).
5. Slide bolt (5) out of linkage (6) and lock lever (9).
6. Remove lock lever (9) from boss pin (10).
7. Remove the swing bracket (8) and the relative shim (13)
adjustments to given clearance.
Bracket: 133 kg (293 lbs)
INSTALLATION
When aligning the positions between the hole and the pin, run the
engine at low idle.

check alignment.

Pin: ASL800050
1. Insert the shims (13).
2. Start the engine and bleed the air from the cylinders. See
“HYDRAULIC CIRCUIT” .
50-300 B WB142-5
12
OUTRIGGER CYLINDERS
REMOVAL
1. Center the backhoe with the arm vertical and the back of the bucket
on the ground.
2. Lower outriggers to the ground and prepare to remove the rear

wheel and cylinder.
Rear wheel (standard size): 133.3 kg (294 lbs)
3. Remove the rear wheel and support the machine as shown in the
illustration using jack stand (A).
4. Sling outrigger cylinder (1) as shown in the illustration.
5. Remove hydraulic supply lines (2) and tag each line as to its
location on the cylinder connection.
WB142-5 50-301 B
6. Remove bolt and nut (3) and extract pin (4) from cylinder and boss.
7. Remove bolt and nut (6) and extract pin (6) from cylinder and boss.
8. After removing pins (4) and (6) lift cylinder off of the outrigger.
Outrigger cylinder: 52.6 kg (116 lbs)
INSTALLATION

check alignment.
★ Install rear wheel
50-302 B WB142-5
12
OUTRIGGER ARMS
★ Before removing outrigger arms, the outrigger cylinder must be removed. See “OUTRIGGER CYLINDERS”
REMOVAL
1. Sling outrigger arm (7) as shown in the illustration.
2. Remove bolt and nut (8) then remove pin (9).
3. Lift outrigger arm (7) from machine.
Outrigger arm: 173.2 kg (382 lbs)
INSTALLATION

check alignment.
WB142-5 50-303 B
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
12
WORK EQUIPMENT CYLINDER OVERHAUL PROCEDURES
WARNING! Before proceeding with any overhaul procedures be sure the cylinder you are
working on is sitting on a level stable surface. Clean up any oil spills immediately and
keep your work area clean and clear of debris.
LOADER AND BACKHOE CYLINDERS

DISASSEMBLY
1. Position cylinder to be disassembled (1) to equipment U1.
2. Using wrench U2 with torque amplifier, fully unscrew the gland nut
(2).
3. Extract the complete piston (3).

★ Place a receptacle to collect the oil.
4. Position the complete piston (3) to equipment U1.
5. Using a wrench U3 with torque amplifier, remove the nut (4)

retaining the piston (5) from the following cylinders:
★ For raising the front bucket.: 55 mm (2.2 inches)
★ For tilting the front bucket.: 55 mm (2.2 inches)
★ Boom: 65 mm (3.0 inches) (remove safety dowel)
★ Arm: 55 mm (2.2 inches)
★ Bucket: 55 mm (2.2 inches)
★ Outriggers: 65 mm (3.0 inches)
50-304 B WB142-5
6. Slide piston (6) and gland nut (2) off rod (5).
Arm Only
★ Note down direction of installation of stop bushing (5a).
Boom Cylinder Rod Only
1. Remove plug (7) and rotate end (8) to let the balls (9) out.
2. Remove end (8).
All Cylinders
1. Remove guide ring (10) and seal (11) from piston (5).
2. Remove O-ring (12) with anti-extrusion ring, O-ring (13), snap ring
(14) and scraper ring (15) from gland.
3. Remove packing (16) and (17).

★ Note down direction for installation of anti-extrusion ring and
position of seal (12).
Boom Gland Nut
1. Remove bushing (18).
WB142-5 50-305 B
ASSEMBLY
1. Lubricate surfaces to prevent damage to the gaskets, seals, O-rings,

scraper, etc.
Surface: hydraulic oil
★ Do not force sealing rings into place; heat them instead in hot
water at 50 - 60oC (122 - 140oF) before installing.
Boom Gland Only
1. Using tool U6, install bushing (18).
All Cylinders
1. Using tool U7, install scraper ring (15) and snap ring (14).
2. Assemble packing (16) and (17).

★ Check direction of installation.
Assemble Piston
1. Using tool U4 expand seal (11) and fit it on the piston.
2. Calibrate seal (11) using calibrator U5.
Boom Cylinder Only
3. Install anti-extrusion rings and O-ring (12).
4. Assemble the guide ring (10).
50-306 B WB142-5
5. Install rod (6), end (8), and ten balls (9); install plug (7).
Plug: Loctite 262
Plug: 23 ± 2 N·m (17 ± 1.5 lbf•ft)
6. Install piston (5) to rod (6).
Arm Cylinder Only

★ Check orientation of brake bushing (5a).
1. Assembly complete piston
2. Install rod (6) to equipment U1.
3. Remove any existing dirt from the rod and install the head (2).
Boom Cylinder Only.
1. Thread piston (5) onto rod (6) and lock into position with wrench
U3 and torque amplifier.
Piston: 280 - 290 N•m (2,025 - 2,098 lbf•ft)
2. Install safety dowel (19) and tighten until snug.
Dowel: Loctite 542
WB142-5 50-307 B
All Cylinders
1. Install gland nut (2) and piston (5); coat piston thread with sealant.
Piston: Loctite 262
2. Install nut (4) and, using wrench U3 with torque amplifier, lock
piston in place using the following torque values:
Front bucket raise: 2845 ± 284 N·m (2,098 ± 209 lbf•ft)

Front bucket tilt: 2845 ± 284 N·m (2,098 ± 209 lbf•ft)
Arm: 2845 ± 284 N·m (2,098 ± 209 lbf•ft)
Bucket: 2845 ± 284 N·m (2,098 ± 209 lbf•ft)
Final Assembly
1. Lubricate piston seals (5) and head gaskets (2) and install piston
into cylinder (1).
2. Position cylinder (1) to equipment U1 and tighten gland nut (2)

using tool U2; tighten to the following torque:
For raising the front bucket: 69 ± 6.9 N·m (499 ± 50 lbf•ft)

For tilting the front bucket: 55 ± 5.5 N·m (398 ± 40 lbf•ft)
Arm: 98 ± 9 N·m (709 ± 65 lbf•ft)
Bucket: 120 ± 140 N·m (868 ± 1,012 lbf•ft)
Outriggers: 95 -100 N·m (687 - 723 lbf•ft)
Boom: 100 ± 10 N·m (723 ± 72 lbf•ft)
3. Loosen to 0 kg (0 lbf), tighten up to 40 kg (289 lbf•ft), and then

tighten angle-wise for 3.5 - 4.5 mm (0.14 - 0.2 inch)
★ When assembly is complete, plug union fitting holes to prevent
contamination.
50-308 B WB142-5
12
SWING CYLINDERS
DISASSEMBLY
1. Cylinder 4. Rod 7. Seal

2. Gland nut 5. Piston 8. Spacer
3. Brake 6. Snap ring 9. Bushing
1. Place the cylinder (1) on the apparatus A1. Engage the fulcrum pins in the suitable support.
2. Using the specially-designed wrench A6, unscrew the gland nut (2) and extract it completely from the cylinder (1).
3. Remove brake cylinder (3).
4. Attach the piston head to the mobile group of the apparatus A1.
5. Extract the piston rod group (4) from the cylinder.
6. Remove the cylinder and the piston rod group.
7. Secure the complete piston rod (4) to the apparatus A1.
8. Raise the part caulked for safety purposes and unscrew the piston using the tool A7.
★ Check the piston (5) carefully. If both safety-staked areas have been used, the piston must be replaced.
9. Remove the snap-ring (6) from the piston and extract the ring (7) and the spacer ring (8).
10. Make a note of the order of assembly of the ring (7).
WB142-5 50-309 B
11. Using a puller remove the swing bushings (9) from the cylinder axle oscillation pins.
12. Dismantle the groups by removing all the seals, the guard rings, the guide rings and the piston fulcrum bushing.
★ The seals, guard rings and guide rings must not be used again.
ASSEMBLY
★ Take great care not to damage the seals and the sliding surfaces.
★ Prepare each individual component before the final assembly.
Assembly Of The Gland Nut
1. Install packing (10) and the packing (11) in the cylinder gland (2).
★ Make sure that the packing lips (11) are turned towards the
inside of the cylinder.
2. Install the scraper ring (12).
3. Install the O-ring (13), the anti-extrusion ring (14) and lastly the O-
ring (15) of the front seal.
Reassembling The Piston
1. Use the tool A9 with the appropriate diameter, install the rubber
ring (16) and the seal ring (17) onto the piston.
2. Remove the tool A9 and mount the anti-extrusion rings (18).
3. Prepare the guide rings (19).
4. Install the O-ring (20) in the internal seating of the piston.
5. Gauge the diameter of the seal (16) of the piston mounting the
group under a press and use the tools A3 for the piston diameter.
50-310 B WB142-5
Reassembling The Piston Rod
1. Using a press and tools A2 with the appropriate diameter, insert the
bushing (21) into the piston rod (4).
2. Insert the ring (8) into the piston rod (4).

★ Check carefully the direction of assembly of the ring (8).
3. Insert the spacer ring (7) and secure the group with the snap-ring
(6).
4. Install the bushing A10 of appropriate diameter on the tip of the

piston rod (4).
5. Lightly lubricate the gland nut packing (2) and slide the gland nut onto the piston rod (4).
Gaskets: ASL800050
6. Lubricate the O-ring seals (22) and screw the piston (5) onto the
piston rod (4) by hand for several turns.
Gaskets: ASL800050
7. Position the group on the tool A1 and tighten the piston with the
round prong wrench A7.
Piston: 932 - 980 N·m (687 - 723 lbf•ft)
WB142-5 50-311 B
12
Reassembling Cylinders
1. Place the cylinder (1) on the apparatus A1. Engage the fulcrum pins in the suitable support.
2. Lubricate the threading and the first part of the cylinder (1).
Gaskets: ASL800050
3. Install the two halves of the tool A11 with the appropriate diameter at the opening of the cylinder (1).
4. Install the piston rod group on the apparatus A1.
5. Center the piston (5) in the tool A11.
6. Install the first guide ring (19) round the piston and insert part of the piston into the tool A11. Install the second guide ring
(19) and fully insert the piston.
7. Insert the piston slowly in order to calibrate the guide rings (19) without overheating them.
★ Insert the cylinder head (2) and screw it in by hand for several turns.
8. Use the special wrench A6 to screw the gland nut in.
Cylinder gland nut: 932 - 980 N·m (687 - 723 lbf•ft)
9. Install the brake cylinder (3) into the cylinder (1).
Brake cylinder: Loctite 270
Brake cylinder: 804 N·m (593 lbf•ft)
10. Remove the cylinder from the equipment A1.
11. Using a press and the appropriate tool A2, install the swing bushings (9).
50-312 B WB142-5
90 OTHERS
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

CONNECTER DISCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
SIDE INSTRAMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
FRONT INSTRAMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
FUSES, SWITCHES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
SWITCHES (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
SWITCHES (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
TRANSMISSION HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
WB142-5 90-1
OTHERS
12
90-2 WB142-5
OTHERS ELECTRICAL SCHEMATIC
12
ELECTRICAL SCHEMATIC
CONNECTOR DESCRIPTION
90-3
12
SIDE INSTRUMENT PANEL
90-5
12
FRONT INSTRUMENT PANEL
90-7
12
FUSES, SWITCHES AND RELAYS
90-9
12
WIRE HARNESS
90-11
12
SWITCHES (1)
90-13
12
SWITCHES (2)
90-15
12
TRANSMISSION HARNESS
90-17

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CEBM018901

SERIAL NUMBERS WB142-5 A13001 and up

Copyright 2008 Komatsu

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

20 STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

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WB142-5 WB142-5 00-2-1 b

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