Komatsu WB97R Backhoe Loader Workshop Repair Service Manual PDF WB97R-2 WB97R-5 WB97R-1 - MMKMTSWB97R.zip
A full-service repair guide featuring Electrical Wiring Diagrams for the Komatsu WB97R Backhoe-Loader, packed with every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way professional technicians do.
Inside the Komatsu WB97R Backhoe-Loader workshop service and repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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PRODUCT DETAILS:
Total Pages: 3,812 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM000604 - Backhoe-Loader WB97R-2 avance Operation & Maintenance Manual...1
1.1 FOREWORD...3
1.2 INFORMATION ON SAFETY...4
1.3 INTRODUCTION...6
1.3.1 INTENDED USES...6
1.3.2 IMPROPER OR UNAUTHORIZED USES...6
1.3.3 MAIN CHARACTERISTICS...7
1.3.4 RUNNING-IN...7
1.4 PRODUCT IDENTIFICATION...8
1.4.1 MACHINE SERIAL NUMBER...8
1.4.2 MACHINE IDENTIFICATION PLATE...8
1.4.3 ENGINE SERIAL NUMBER...9
1.4.4 FRONT AXLE SERIAL NUMBER...9
1.4.5 REAR AXLE SERIAL NUMBER...10
1.4.6 TRANSMISSION SERIAL NUMBER...10
1.4.7 CAB SERIAL NUMBER...10
1.4.8 CANOPY SERIAL NUMBER (if provided)...10
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS...11
TABLE OF CONTENTS...13
2.1 SAFETY, NOISE AND VIBRATION PLATES...22
2.1.1 POSITION OF THE SAFETY PLATES...22
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...24
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...28
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...29
2.2 GENERAL PRECAUTIONS...30
2.2.1 GENERAL SAFETY RULES...30
2.2.2 SAFETY DEVICES AND GUARDS...30
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...30
2.2.4 UNAUTHORIZED MODIFICATIONS...31
2.2.5 LEAVING THE OPERATOR’S SEAT...31
2.2.6 GETTING ON AND OFF THE MACHINE...32
2.2.7 CHECKING THE REAR-VIEW MIRRORS...32
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...32
2.2.9 PREVENTING BURNS...33
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...33
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...34
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...34
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...34
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...34
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...35
2.3.1 SAFETY ON THE WORK SITE...35
2.3.2 FIRE PREVENTION...35
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...35
2.3.4 ROOM VENTILATION...36
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...36
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...37
2.4.1 STARTING THE ENGINE...37
2.4.2 RULES FOR ROAD TRAVEL...37
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...38
2.4.4 MOVING THE MACHINE...38
2.4.5 WORKING ON SLOPES...39
2.4.6 PREVENTING ELECTROCUTION...40
2.4.7 VISIBILITY...41
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES...41
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...41
2.4.10 WORKING ON LOOSE GROUND...41
2.4.11 PARKING THE MACHINE...42
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...43
2.5.1 LOADING AND UNLOADING...43
2.5.2 TRANSPORT...43
2.6 BATTERY...44
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...44
2.6.2 STARTING WITH BOOSTER CABLES...44
2.7 PRECAUTIONS FOR THE REMOVAL...45
2.8 PRECAUTIONS FOR MAINTENANCE...46
2.8.1 WARNING PLATES...46
2.8.2 TOOLS...46
2.8.3 PERSONNEL...46
2.8.4 EQUIPMENT...47
2.8.5 WORKING UNDER THE MACHINE...47
2.8.6 CLEANING THE MACHINE...47
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS...48
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...48
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...49
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...50
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...50
2.8.12 USING LAMPS...50
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...51
2.8.14 PRECAUTIONS CONCERNING THE STARTER...51
2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT...52
2.8.16 HANDLING HIGH-PRESSURE PIPES...52
2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...52
2.8.18 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...53
2.8.19 COOLING FAN AND BELT...53
2.8.20 WASTE MATERIALS...53
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES...54
2.8.22 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAIL PIPE...54
2.8.23 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...55
3.1 SAFETY LOCKS...58
3.1.1 FRONT LOADER LOCKS...58
3.1.2 BACKHOE LOCKS...60
3.2 GENERAL VIEWS...61
3.2.1 FRONT GENERAL VIEW...61
3.2.2 BACKHOE GENERAL VIEW...62
3.2.3 CAB INSIDE GENERAL VIEW...63
3.3 INSTRUMENTS AND CONTROLS...64
3.3.1 FRONT INSTRUMENTS...64
14 - AVAILABLE FOR OPTIONAL EQUIPMENT SWITCH...67
3.3.2 SIDE INSTRUMENTS...68
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...73
3.3.4 ELECTRICAL ACCESSORIES...74
3.3.5 MACHINE CONTROLS...75
KOMATSU SYSTEM CONTROLS...93
ISO STANDARD CONTROLS...94
“X” SYSTEM CONTROLS...95
3.4 FUSES AND RELAYS...97
3.4.1 EQUIPMENT FUSES AND RELAYS...97
3.4.1.1 FUSES...98
3.4.1.2 RELAYS...99
3.4.2 ENGINE FUSES AND RELAYS...99
3.4.2.1 FUSES...100
3.4.2.2 RELAYS...101
3.5 GUARDS, CAB AND DRIVER’S SEAT...102
3.5.1 ENGINE HOOD...102
3.5.2 CANOPY (if provided)...102
3.5.3 CAB...103
3.5.4 VENTILATION AND HEATING...105
3.5.5 SEAT...106
3.5.6 SAFETY BELT...107
3.5.7 FIRE EXTINGUISHER...107
3.5.8 FIRST AID KIT...107
3.5.9 TECHNICAL DOCUMENTATION...107
3.5.10 ADDITIONAL TOOL BOX (if provided)...108
3.6 USE OF THE MACHINE...109
3.6.1 CHECKS BEFORE STARTING THE ENGINE...109
3.6.1.1 VISUAL CHECKS...109
3.6.1.2 DAILY CHECKS...109
3.6.1.3 OPERATIONAL CHECKS...110
3.6.2 STARTING THE ENGINE...111
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...111
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...112
3.6.3 WARMING THE ENGINE...113
3.6.4 HEATING THE HYDRAULIC OIL...113
3.6.5 HOW TO MOVE THE MACHINE...114
3.6.5.1 LOCKING THE DIFFERENTIAL...115
3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE...115
3.6.5.3 WORKING ON SLOPES...116
3.6.5.4 MAXIMUM IMMERSION DEPTH...117
3.7 PARKING THE MACHINE...118
3.7.1 PARKING ON LEVEL GROUND...118
3.7.2 PARKING ON SLOPES...119
3.8 STOPPING THE ENGINE...120
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...121
3.9.1 LOADING AND UNLOADING THE MACHINE...121
3.9.2 TRANSPORT...122
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...123
3.10.1 FUEL AND LUBRICANTS...123
3.10.2 COOLANT...123
3.10.3 BATTERY...123
3.10.4 OTHER PRECAUTIONS...124
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...124
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...125
3.12 USING THE MACHINE AS A LOADER...126
3.12.1 BUCKET POSITION INDICATOR...126
3.12.2 ORGANIZING THE WORK AREA...126
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...127
3.12.2.2 LOADING OPERATIONS ON SLOPES...128
3.12.3 CHANGING THE STANDARD FRONT BUCKET...128
3.13 USING THE MACHINE AS AN EXCAVATOR...129
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...129
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...130
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...131
3.13.4 DIGGING METHOD...132
3.13.5 CHANGING THE BACKHOE BUCKET...133
3.14 LONG PERIODS OF INACTIVITY...134
3.14.1 BEFORE THE PERIOD OF INACTIVITY...134
3.14.2 DURING THE PERIOD OF INACTIVITY...136
3.14.3 AFTER THE PERIOD OF INACTIVITY...136
3.15 TROUBLESHOOTING...137
3.15.1 HOW TO REMOVE THE MACHINE...137
3.15.2 AFTER THE FUEL HAS RUN OUT...137
3.15.3 IF THE BATTERY IS DOWN...138
3.15.3.1 STARTING WITH BOOSTER CABLES...139
3.15.4 OTHER TROUBLES...140
3.15.4.1 ELECTRICAL CIRCUIT...140
3.15.4.2 HYDRAULIC SYSTEM...140
3.15.4.3 BRAKING SYSTEM...141
3.15.4.4 CONVERTER...141
3.15.4.5 ENGINE...142
4.1 GUIDE TO MAINTENANCE...144
4.2 MAINTENANCE NOTES...146
4.2.1 NOTES REGARDING THE ENGINE...146
4.2.1.1 ENGINE OIL...146
4.2.1.2 COOLANT...146
4.2.1.3 FUEL...147
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...147
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM...148
4.2.4 NOTES REGARDING LUBRICATION...148
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...149
4.3 FUEL, COOLANT AND LUBRICANTS...150
LUBRICATION WITH GREASE...151
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...152
4.4 DRIVING TORQUES FOR SCREWS AND NUTS...153
4.4.1 STANDARD DRIVING TORQUES...153
4.4.2 SPECIFIC TIGHTENING TORQUES...153
4.5 LUBRICATION...154
4.5.1 LUBRICATION DIAGRAM...154
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...155
4.5.3 LUBRICATION DIAGRAM (Front bucket rapid couplings)...156
4.5.4 LUBRICATION DIAGRAM (Telescopic arm)...157
4.5.5 LUBRICATION DIAGRAM (Offset device)...158
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY...159
4.6.1 CRITICAL PARTS FOR SAFETY...160
4.7 MAINTENANCE PLAN...164
4.7.1 WHEN REQUIRED...168
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...168
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTERS...169
4.7.1.c BLEEDING THE BRAKING CIRCUIT...170
4.7.1.d WASHING THE COOLING CIRCUIT...170
4.7.1.e CLEANING THE WATER SEPARATOR...172
4.7.1.f CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN...172
4.7.1.g CHECKING AND ADJUSTING THE PARKING BRAKE...173
4.7.1.h CHECKING THE BRAKING EFFICIENCY...174
4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...175
4.7.1.k ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION...175
4.7.1.l CHECKING AND ADJUSTING THE STABILIZER SLACK...176
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...177
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER...177
4.7.2.b CHANGING THE HYDRAULIC OIL...177
4.7.3 CHECKS BEFORE STARTING...178
4.7.3.a VARIOUS CHECKS...178
4.7.3.b CHECKING THE COOLANT LEVEL...178
4.7.3.c CHECKING THE FUEL LEVEL...179
4.7.3.d CHECKING THE ENGINE OIL LEVEL...179
4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL...180
4.7.3.f DRAINING THE WATER SEPARATOR...181
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...182
4.7.4.a LUBRICATING THE JOINTS...182
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...184
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...184
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL...184
4.7.6.b CHECKING THE BRAKING SYSTEM OIL LEVEL...184
4.7.6.c LUBRICATING THE PROPELLER SHAFTS...185
4.7.6.d LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING...186
4.7.6.e CHECKING THE TYRE PRESSURE...186
4.7.6.f CHECKING THE ELECTRICAL SYSTEM...187
4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...188
4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...188
4.7.8.a ADJUSTING THE FAN BELT TENSION...188
4.7.8.b CLEANING THE OUTSIDE OF THE RADIATORS...189
4.7.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL...190
4.7.8.d CHECKING THE FRONT AXLE OIL LEVELS...191
4.7.8.e CHECKING THE REAR AXLE OIL LEVELS...191
4.7.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...192
4.7.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...192
4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti...193
4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...193
4.7.10.a CHANGING THE ENGINE OIL...193
4.7.10.b CHANGING THE ENGINE OIL FILTER...194
4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...195
4.7.10.d CHANGING THE FUEL FILTER...196
4.7.10.e DRAINING THE FUEL TANK...197
4.7.10.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ...198
4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...199
4.7.11.a CHANGING THE FRONT AXLE OIL...199
4.7.11.b CHANGING THE REAR AXLE OIL...200
4.7.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...201
4.7.11.d CHANGING THE HYDRAULIC TRANSMISSION FILTER...202
4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...202
4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...203
4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...203
4.7.12.b CHANGING THE COOLANT...206
4.7.12.c CHANGING THE BRAKING SYSTEM OIL...208
4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER...208
5.1 TECHNICAL DATA...210
5.1.1 STANDARD OVERALL DIMENSIONS...210
5.1.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE...210
5.1.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE...210
5.1.2 TECHNICAL CHARACTERISTICS...211
5.1.3 LIFTING CAPACITIES...212
5.1.3.1 SYMBOL TABLE...212
5.1.3.2 LIFTING CAPACITY (STANDARD BOOM)...213
5.1.3.3 LIFTING CAPACITY (OFFSET BOOM)...214
6.1 AUTHORIZED OPTIONAL EQUIPMENT...216