Komatsu WB97S-5 Backhoe Loader Operation & Maintenance Manual (F50003 and up) - WEAM007600

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu WB97S-5 Backhoe Loader (SN: F50003 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu WB97S-5 Backhoe Loader
Serial Numbers : F50003 and up


TABLE OF CONTENTS :

SAFETY AND ACCIDENT PREVENTION
DESCRIPTION AND USE OF THE MACHINE
MAINTENANCE
TECHNICAL SPECIFICATIONS
AUTHORIZED OPTIONAL EQUIPMENT


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : WEAM007600
Total Pages : 280


This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.

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1.1 FOREWORD
1.2 INFORMATION ON SAFETY
1.3 INTRODUCTION
1.3.1 INTENDED USES
1.3.2 IMPROPER OR UNAUTHORIZED USE
1.3.3 MAIN CHARACTERISTICS
1.3.4 RUNNING-IN
1.4 PRODUCT IDENTIFICATION
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) (alternatively for some markets)
1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
1.4.5 FRONT AXLE SERIAL NUMBER
1.4.6 REAR AXLE SERIAL NUMBER
1.4.7 TRANSMISSION SERIAL NUMBER
1.4.8 CAB SERIAL NUMBER
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS

TABLE OF CONTENTS

2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
2.2.2 SAFETY DEVICES AND GUARDS
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
2.2.4 UNAUTHORIZED MODIFICATIONS
2.2.5 LEAVING THE OPERATOR’S SEAT
2.2.6 GETTING ON AND OFF THE MACHINE
2.2.7 CHECKING THE REAR-VIEW MIRRORS
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL
2.2.9 PREVENTING BURNS
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
2.3.1 SAFETY ON THE WORK SITE
2.3.2 FIRE PREVENTION
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB
2.3.4 ROOM VENTILATION
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS
2.4 PRECAUTIONS TO BE TAKEN DURING WORK
2.4.1 WHEN STARTING THE ENGINE
2.4.2 RULES FOR TRAVELLING ON ROADS
2.4.3 HAND SIGNALS
2.4.4 CHECKS FOR TRAVELLING IN REVERSE
2.4.5 MOVING THE MACHINE
2.4.6 WORKING ON SLOPES
2.4.7 PREVENTING ELECTROCUTION
2.4.8 VISIBILITY
2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES
2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.4.11 WORKING ON LOOSE GROUND
2.4.12 PARKING THE MACHINE
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.5.1 LOADING AND UNLOADING THE MACHINE
2.5.2 TRANSPORT
2.6 BATTERY
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
2.6.2 STARTING WITH BOOSTER CABLES
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.1 WARNING PLATES
2.8.2 TOOLS
2.8.3 PERSONNEL
2.8.4 EQUIPMENT
2.8.5 WORKING UNDER THE MACHINE
2.8.6 KEEPING THE MACHINE CLEAN
2.8.7 USE OF THE ENGINE DURING MAINTENANCE
2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
2.8.12 USING LAMPS
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
2.8.14 PRECAUTIONS CONCERNING THE STARTER
2.8.15 HANDLING HIGH-PRESSURE PIPES
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
2.8.18 HYDRAULIC ACCUMULATOR
2.8.19 COOLING FAN AND FAN BELT
2.8.20 WASTE MATERIALS
2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS
2.8.22 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES
2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE
2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»

3.1 SAFETY LOCKS
3.1.1 FRONT LOADER LOCKS
3.1.2 BACKHOE LOCKS
3.2 GENERAL VIEWS
3.2.1 FRONT GENERAL VIEW
3.2.2 BACKHOE GENERAL VIEW
3.2.3 CAB INSIDE GENERAL VIEW
3.3 INSTRUMENTS AND CONTROLS
3.3.1 FRONT INSTRUMENTS
3.3.2 SIDE INSTRUMENTS
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES
3.3.5 MACHINE CONTROLS
3.3.6 ADJUSTING THE CONTROLS
3.4 FUSES AND RELAYS
3.4.1 CENTRAL UNIT FUSES - RELAYS AND ENGINE LINE
3.4.1.1 FUSES
3.4.1.2 RELAYS
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS
3.4.2.1 FUSES
3.4.2.2 RELAYS
3.5 GUARDS, CAB AND DRIVER’S SEAT
3.5.1 ENGINE HOOD
3.5.2 CAB
3.5.3 VENTILATION AND HEATING
3.5.4 AIR CONDITIONER (if installed)
3.5.5 SEAT
3.5.5.1 SEAT (STANDARD)
3.5.5.2 SEAT (OPTIONAL)
3.5.6 SAFETY BELT
3.5.7 FIRE EXTINGUISHER
3.5.8 FIRST AID KIT
3.5.9 TECHNICAL DOCUMENTATION
3.5.10 STORAGE COMPARTMENT
3.6 USE OF THE MACHINE
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
3.6.1.1 VISUAL CHECKS
3.6.1.2 OPERATIONAL CHECKS
3.6.2 STARTING THE ENGINE
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
3.6.3 WARMING THE ENGINE
3.6.4 HEATING THE HYDRAULIC OIL
3.6.5 HOW TO MOVE THE MACHINE
3.6.5.1 DIFFERENTIAL LOCKING
3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE
3.6.5.3 WORKING ON SLOPES
3.6.5.4 MAXIMUM IMMERSION DEPTH
3.7 PARKING THE MACHINE
3.7.1 PARKING ON LEVEL GROUND
3.7.2 PARKING ON SLOPES
3.8 STOPPING THE ENGINE
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
3.9.1 LOADING AND UNLOADING THE MACHINE
3.9.2 TRANSPORT
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
3.10.1 FUEL AND LUBRICANTS
3.10.2 COOLANT
3.10.3 BATTERY
3.10.4 OTHER PRECAUTIONS
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER
3.12 USING THE MACHINE AS A LOADER
3.12.1 BUCKET POSITION INDICATOR
3.12.2 ORGANIZING THE WORK AREA
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL
3.12.2.2 LOADING OPERATIONS ON SLOPES
3.12.3 CHANGING THE STANDARD FRONT BUCKET
3.13 USING THE MACHINE AS AN EXCAVATOR
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS
3.13.4 DIGGING METHOD
3.13.4.1 CHANGING THE BACKHOE BUCKET
3.14 LONG PERIODS OF INACTIVITY
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY
3.14.4 RESTARTING THE ENGINE
3.14.5 AFTER THE PERIOD OF INACTIVITY
3.15 TROUBLESHOOTING
3.15.1 HOW TO REMOVE THE MACHINE
3.15.2 AFTER THE FUEL HAS RUN OUT
3.15.3 IF THE BATTERY IS DOWN
3.15.3.1 STARTING WITH BOOSTER CABLES
3.15.4 OTHER TROUBLES
3.15.4.1 ELECTRICAL CIRCUIT
3.15.4.2 HYDRAULIC SYSTEM
3.15.4.3 BRAKING SYSTEM
3.15.4.4 CONVERTER
3.15.4.5 ENGINE

4.1 GUIDE TO MAINTENANCE
4.2 MAINTENANCE NOTES
4.2.1 NOTES REGARDING THE ENGINE
4.2.1.1 ENGINE OIL
4.2.1.2 COOLANT
4.2.1.3 FUEL
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM
4.2.4 NOTES REGARDING LUBRICATION
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
4.3 FUEL, COOLANT AND LUBRICANTS
4.3.1 LUBRICATION WITH GREASE
4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”
4.4 DRIVING TORQUES
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS
4.5 LUBRICATION
4.5.1 LUBRICATION DIAGRAM
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)
4.5.4 LUBRICATION DIAGRAM (offset device)
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS
4.6.1 SAFETY RELATED PARTS
4.6.1.1 FUEL SYSTEM
4.6.1.2 DELIVERY HYDRAULIC SYSTEM
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM
4.6.1.4 BACKHOE HYDRALIC SYSTEM
4.6.1.5 OPERATOR’S SAFETY
4.7 MAINTENANCE PLAN
4.8 MAINTENANCE PROCEDURES
4.8.1 WHEN REQUIRED
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES
4.8.1.f LUBRICATING THE CAB DOOR HINGES
4.8.1.g FUSES AND RELAYS - CHECK AND CHANGE
4.8.1.h BLEEDING THE BRAKING CIRCUIT
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN
4.8.1.j CHECKING THE BRAKING EFFICIENCY
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER
4.8.2.b CHANGING THE HYDRAULIC OIL
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
4.8.3.a VARIOUS CHECKS
4.8.3.b CHECKING THE COOLANT LEVEL
4.8.3.c CHECKING THE FUEL LEVEL
4.8.3.d CHECKING THE ENGINE OIL LEVEL
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION
4.8.4.a LUBRICATING THE JOINTS
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL
4.8.6.d LUBRICATING THE PROPELLER SHAFTS
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS
4.8.6.f CHECKING THE TYRE PRESSURE
4.8.6.g DRAINING THE WATER SEPARATOR
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (only for machines with air conditioner)
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION
4.8.10.a CHANGING THE ENGINE OIL
4.8.10.b CHANGING THE ENGINE OIL FILTER
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER
4.8.10.d CHANGING THE FUEL FILTER
4.8.10.e DRAINING THE FUEL TANK
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines with air conditioner)
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION
4.8.11.a CHANGING THE FRONT AXLE OIL
4.8.11.b CHANGING THE REAR AXLE OIL
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER
4.8.12.b CHANGING THE COOLANT
4.8.12.c CHANGING THE BRAKING SYSTEM OIL
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER
4.8.12.e CHANGING THE ALTERNATOR BELT
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY (only for machines with air conditioner)
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION
4.8.14.a CHANGING THE A/C DEWATERING FILTER (Only for machines with air conditioner)
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air conditioner)
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE

5.1 TECHNICAL DATA
5.1.1 STANDARD OVERALL DIMENSIONS
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM
5.1.2 TECHNICAL CHARACTERISTICS
5.1.3 LIFTING CAPACITIES
5.1.3.1 SYMBOL TABLE
5.1.3.2 LIFTING CAPACITIES (STANDARD ARM)
5.1.3.3 LIFTING CAPACITIES (BOOM WITH OFFSET DEVICE)

6.1 AUTHORIZED OPTIONAL EQUIPMENT
6.1.1 PRECAUTIONS REGARDING SAFETY
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES
6.2.1 MANUAL QUICK COUPLING
6.2.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET
6.2.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW
6.3 4in1 BUCKET
6.3.1 DESCRIPTION AND CONTROLS
6.3.2 SAFETY DEVICES
6.3.3 INSTALLING THE 4in1 BUCKET
6.3.4 USING THE 4in1 BUCKET
6.3.5 MAINTENANCE
6.4 PALLET FORKS
6.4.1 DESCRIPTION
6.4.2 SAFETY DEVICES
6.4.3 USING THE FORKS
6.4.3.1 PREPARING THE PALLET FORKS FOR USE
6.4.3.2 OVERTURNING THE FORKS
6.4.4 REMOVING THE FORKS
6.4.5 INSTALLING THE FORKS
6.4.6 MAINTENANCE
6.5 BACKHOE TELESCOPIC ARM
6.5.1 DESCRIPTION AND CONTROL
6.5.2 SAFETY DEVICES
6.5.3 USING THE TELESCOPIC ARM
6.5.4 MAINTENANCE
6.5.4.1 ADJUSTING THE GUIDE SLACK
6.6 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER
6.6.1 DESCRIPTION AND CONTROL
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER
6.6.3.1 INSTALLING THE HAMMER
6.6.3.2 REMOVING THE HAMMER
6.6.4 USING THE HAMMER
6.6.5 MAINTENANCE
6.7 APPLICATION OF THE OFFSET DEVICE
6.7.1 DESCRIPTION AND CONTROL
6.7.2 MAINTENANCE
6.8 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW
6.8.1 DESCRIPTION AND CONTROL
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT
6.8.3 MAINTENANCE
6.9 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET
6.9.1 DESCRIPTION AND CONTROL
6.9.2 INSTALLING THE CLAMSHELL BUCKET
6.9.3 USING THE CLAMSHELL BUCKET
6.9.4 MAINTENANCE
6.10 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER
6.10.1 DESCRIPTION AND CONTROL
6.10.2 INSTALLING AND REMOVING THE HAND HAMMER
6.10.2.1 CONNECTING THE HAND HAMMER
6.10.2.2 REMOVING THE CONNECTIONS
6.10.3 USING THE HAMMER
6.10.4 MAINTENANCE
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)
6.11.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR
6.12 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE
6.12.2 MAINTENANCE

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