Komatsu WB97S-2 Backhoe Loader Operation & Maintenance Manual (97SF11205 and up) – WEAM000704

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the Komatsu WB97S-2 Backhoe Loader (SN: 97SF11205 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-2 Backhoe Loader
Serial Numbers : 97SF11205 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 : WEAM000704
Total Pages : 296

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 USES
1.3.3 MAIN CHARACTERISTICS
1.3.4 RUNNING-IN
1.4 PRODUCT IDENTIFICATION
1.4.1 MACHINE SERIAL NUMBER
1.4.2 MACHINE IDENTIFICATION PLATE
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
1.4.4 FRONT AXLE SERIAL NUMBER
1.4.5 REAR AXLE SERIAL NUMBER
1.4.6 TRANSMISSION SERIAL NUMBER
1.4.7 CAB SERIAL NUMBER
1.4.8 CANOPY SERIAL NUMBER (if provided)
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 WHEN WORKING
2.4.1 STARTING THE ENGINE
2.4.2 RULES FOR ROAD TRAVEL
2.4.3 CHECKS FOR TRAVELLING IN REVERSE
2.4.4 MOVING THE MACHINE
2.4.5 WORKING ON SLOPES
2.4.6 PREVENTING ELECTROCUTION
2.4.7 VISIBILITY
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.4.10 WORKING ON LOOSE GROUND
2.4.11 PARKING THE MACHINE
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.5.1 LOADING AND UNLOADING THE MACHINE
2.5.2 THE ROUTE
2.6 BATTERY
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES
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 PARTS THAT ARE CRITICAL FOR SAFETY
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
2.8.10 RULES FOR REFUELLING AND ADDING OIL
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR
2.8.12 USING LAMPS
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
2.8.14 PRECAUTIONS CONCERNING THE STARTER
2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT
2.8.16 HANDLING HIGH-PRESSURE PIPES
2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL
2.8.18 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
2.8.19 COOLING FAN AND FAN BELT
2.8.20 WASTE MATERIALS
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES
2.8.22 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE
2.8.23 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES
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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
3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version)
3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request)
3.3 INSTRUMENTS AND CONTROLS
3.3.1 FRONT INSTRUMENTS
3.3.2 SIDE INSTRUMENTS
3.3.2.1 SIDE INSTRUMENTS (Standard version)
3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request)
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER
3.3.4 ELECTRICAL ACCESSORIES
3.3.5 MACHINE CONTROLS
3.3.5.1 MACHINE CONTROLS (Standard version)
3.3.5.2 MACHINE CONTROLS (Version with servo controls available upon request)
3.4 FUSES AND RELAYS
3.4.1 EQUIPMENT FUSES AND RELAYS
3.4.1.1 FUSES
3.4.1.2 RELAYS
3.4.2 ENGINE LINE FUSES AND RELAYS
3.4.2.1 FUSES
3.4.2.2 RELAYS
3.4.3 SIDE DASHBOARD RELAYS
3.4.4 SIDE DASHBOARD RELAYS AND FUSES (Only with servo controls)
3.4.4.1 RELAYS
3.4.4.2 FUSES
3.5 GUARDS, CAB AND DRIVER’S SEAT
3.5.1 ENGINE HOOD
3.5.2 CANOPY (if provided)
3.5.3 CAB
3.5.4 VENTILATION AND HEATING
3.5.5 AIR CONDITIONER (if installed)
3.5.6 SEAT
3.5.6.1 SEAT (STANDARD)
3.5.6.2 SEAT (OPTIONAL)
3.5.7 SAFETY BELT
3.5.8 FIRE EXTINGUISHER
3.5.9 FIRST AID KIT
3.5.10 TECHNICAL DOCUMENTATION
3.5.11 ADDITIONAL TOOL BOX (if provided)
3.6 USE OF THE MACHINE
3.6.1 CHECKS BEFORE STARTING THE ENGINE
3.6.1.1 VISUAL CHECKS
3.6.1.2 DAILY CHECKS
3.6.1.3 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 ENGAGING THE FOUR-WHEEL DRIVE
3.6.5.2 MOVING ON SLOPES
3.6.5.3 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 IN THE WARM SEASON
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 TO 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
3.13.5 CHANGING THE BACKHOE BUCKET
3.14 LONG PERIODS OF INACTIVITY
3.14.1 BEFORE THE PERIOD OF INACTIVITY
3.14.2 DURING THE PERIOD OF INACTIVITY
3.14.3 AFTER THE PERIOD OF INACTIVITY
3.15 TROUBLESHOOTING
3.15.1 HOW TO REMOVE THE MACHINE
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED
3.15.3 IF THE BATTERY IS DEPLETED
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 ELECTRICAL 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 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS
4.4 DRIVING TORQUES FOR SCREWS AND NUTS
4.4.1 STANDARD DRIVING TORQUES
4.4.2 SPECIFIC DRIVING TORQUES
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 rapid couplings)
4.5.4 LUBRICATION DIAGRAM (Telescopic arm)
4.5.5 LUBRICATION DIAGRAM (Offset device)
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY
4.6.1 CRITICAL PARTS FOR SAFETY
4.7 MAINTENANCE PLAN
4.7.1 WHEN REQUIRED
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER
4.7.1.c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER (only for machines with air conditioner)
4.7.1.d BLEEDING THE BRAKING CIRCUIT
4.7.1.e CLEANING THE WATER SEPARATOR
4.7.1.f CHECKING AND ADJUSTING THE WHEEL TOE-IN
4.7.1.g CHECKING AND ADJUSTING THE PARKING BRAKE
4.7.1.h CHECKING THE BRAKING EFFICIENCY
4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE
4.7.1.k ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)
4.7.1.l CHECKING AND ADJUSTING THE STABILIZER SLACK
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER
4.7.2.b CHANGING THE HYDRAULIC OIL
4.7.3 CHECKS BEFORE STARTING
4.7.3.a VARIOUS CHECKS
4.7.3.b CHECKING THE COOLANT LEVEL
4.7.3.c CHECKING THE FUEL LEVEL
4.7.3.d CHECKING THE ENGINE OIL LEVEL
4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL
4.7.3.f DRAINING THE WATER SEPARATOR
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION
4.7.4.a LUBRICATING THE JOINTS
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL
4.7.6.b CHECKING THE BRAKING SYSTEM OIL LEVEL
4.7.6.c LUBRICATING THE PROPELLER SHAFTS
4.7.6.d LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS
4.7.6.e CHECKING THE TYRE PRESSURE
4.7.6.f CHECKING THE ELECTRICAL SYSTEM
4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION
4.7.8.a ADJUSTING THE FAN BELT TENSION
4.7.8.b ADJUSTING THE A/C COMPRESSOR BELT TENSION (Only for machines with air conditioner)
4.7.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL
4.7.8.d CHECKING THE FRONT AXLE OIL LEVELS
4.7.8.e CHECKING THE REAR AXLE OIL LEVELS
4.7.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL
4.7.8.g CHECKING THE WHEEL NUT DRIVING TORQUE
4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti…
4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION
4.7.10.a CHANGING THE ENGINE OIL
4.7.10.b CHANGING THE ENGINE OIL FILTER
4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER
4.7.10.d CHANGING THE FUEL FILTER
4.7.10.e DRAINING THE FUEL TANK
4.7.10.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable …
4.7.10.g CLEANING THE OUTSIDE OF THE RADIATORS
4.7.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (Only for machines with air conditioner)
4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION
4.7.11.a CHANGING THE FRONT AXLE OIL
4.7.11.b CHANGING THE REAR AXLE OIL
4.7.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL
4.7.11.d CHANGING THE HYDRAULIC TRANSMISSION FILTER
4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION
4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER
4.7.12.b CHANGING THE COOLANT
4.7.12.c CHANGING THE BRAKING SYSTEM OIL
4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER
4.7.12.e CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM (Only for machines with air conditioner)
4.7.13 MAINTENANCE EVERY 4000 HOURS OF OPERATION
4.7.13.a CHANGING THE A/C DEHYDRATING FILTER (Only for machines with air conditioner)
4.7.13.a CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air cond…
5.1 TECHNICAL DATA
5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE
5.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE
5.1.3 TECHNICAL CHARACTERISTICS
5.1.4 LIFTING CAPACITIES
5.1.4.1 SYMBOL TABLE
5.1.4.2 LIFTING CAPACITY (STANDARD BOOM)
5.1.4.3 LIFTING CAPACITY (OFFSET BOOM)
6.1 AUTHORIZED OPTIONAL EQUIPMENT
6.1.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES
6.2.1 MANUAL CONTROL QUICK COUPLING
6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET
6.2.3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL…
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 FOR TRAVEL ON ROADS
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
6.5.1.1 VERSION WITH STANDARD CONTROLS
6.5.1.2 VERSION WITH SERVO CONTROLS (if installed)
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 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER
6.6.1 DESCRIPTION AND CONTROL
6.6.1.1 VERSION WITH STANDARD CONTROLS
6.6.1.2 VERSION WITH SERVO CONTROLS (if installed)
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED
FOR A CORRECT USE OF THE HAMMER, IT IS NECESSARY TO:
ALWAYS AVOID THE FOLLOWING INCORRECT USES:
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
OPERATIONS WITH THE HYDRAULIC HAMMER AND COMPACTING TOOLS
6.6.5 MAINTENANCE
6.7 APPLICATION OF THE OFFSET DEVICE
6.7.1 DESCRIPTION AND CONTROL
6.7.1.1 VERSION WITH STANDARD CONTROLS
6.7.1.2 VERSION WITH SERVO CONTROLS (if installed)
6.7.2 MAINTENANCE
6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW
6.8.1 DESCRIPTION AND CONTROL
6.8.1.1 VERSION WITH STANDARD CONTROLS
6.8.1.2 VERSION WITH SERVO CONTROLS (if installed)
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT
6.8.3 MAINTENANCE
6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET
6.9.1 DESCRIPTION AND CONTROL
6.9.1.1 VERSION WITH STANDARD CONTROLS
6.9.1.2 VERSION WITH SERVO CONTROLS (if installed)
6.9.2 INSTALLING THE CLAMSHELL BUCKET
6.9.3 USING THE CLAMSHELL BUCKET
6.9.4 MAINTENANCE
6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER
6.10.1 DESCRIPTION AND CONTROL
6.10.2 CONNECTING AND REMOVING THE HAMMER
6.10.2.1 CONNECTING THE 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 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)
6.12 REAR EQUIPMENT RAPID COUPLING DEVICE
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE
6.12.2 MAINTENANCE
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