Komatsu WB97S-5E0 Backhoe Loader Workshop Repair Service Manual PDF - MMKMTSWB97SE0.zip
A full factory-style service and repair guide, complete with Electrical Wiring Diagrams, for the Komatsu Backhoe-Loader WB97S-5E0 — containing every technical detail needed to service, troubleshoot, fix, and overhaul the machine just as trained dealership technicians would.
The Komatsu Backhoe-Loader WB97S-5E0 workshop service repair manual contains:
* 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.
WEAM009001 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM011704 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM011707 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM015502 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEBM008400 - Backhoe-Loader WB97S-5E0 Shop Manual.pdf
WEBM008402 - Backhoe-Loader WB97S-5E0 Shop Manual.pdf
WETT001308 - Backhoe-Loader WB91R-5EO, WB93R-5EO, WB97R-5EO, WB93S-5EO, WB97S-5EO Basic Technical Training.pdf
PRODUCT DETAILS:
Total Pages: 2,834 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM009001 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...1
WEAM011704 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...295
1.1 FOREWORD...297
1.2 INFORMATION ON SAFETY...298
1.2.1 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...301
1.2.2 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...302
1.2.3 GUIDE WHEN WORKING IN AREAS WHERE AIR POLLUTION...303
1.3 INTRODUCTION...304
1.3.1 INTENDED USES...304
1.3.2 DEMOLITION WORK...304
1.3.3 IMPROPER OR UNAUTHORIZED USE...305
1.3.4 MAIN CHARACTERISTICS...306
1.3.5 RUNNING-IN...306
1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE...307
1.3.6.1 WHEN OPERATING THE LOADER OR TRAVELLING...307
1.3.6.2 WHEN OPERATING THE BACKHOE...308
1.4 PRODUCT IDENTIFICATION...309
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...309
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...309
1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)...310
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...311
1.4.4 FRONT AXLE SERIAL NUMBER...311
1.4.5 REAR AXLE SERIAL NUMBER...312
1.4.6 TRANSMISSION SERIAL NUMBER...312
1.4.7 CAB SERIAL NUMBER...312
1.4.8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...313
1.4.9 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)...313
1.5 KOMTRAX SYSTEM...314
1.5.1 GENERAL PRECAUTIONS...314
TABLE OF CONTENTS...315
2.1 SAFETY, NOISE AND VIBRATION PLATES...326
2.1.1 POSITION OF THE SAFETY PLATES...326
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...328
2.2 GENERAL PRECAUTIONS...342
2.2.1 GENERAL SAFETY RULES...342
2.2.2 SAFETY DEVICES AND GUARDS...342
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...342
2.2.4 UNAUTHORIZED MODIFICATIONS...343
2.2.5 LEAVING THE OPERATOR’S SEAT...343
2.2.6 GETTING ON AND OFF THE MACHINE...344
2.2.7 CHECKING THE REAR-VIEW MIRRORS...344
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...345
2.2.9 LIFTING OF PERSONNEL PROHIBITED...345
2.2.10 PREVENTING BURNS...345
2.2.11 ASBESTOS DUST HAZARD PREVENTION...346
2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...346
2.2.13 DETERGENT FOR THE WINDOWS...346
2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT...347
2.2.15 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...347
2.2.16 CAUTIONS RELATED TO ROPS...348
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT...348
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...349
2.3.1 SAFETY ON THE WORK SITE...349
2.3.2 FIRE PREVENTION...349
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...349
2.3.4 ROOM VENTILATION...350
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...350
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...351
2.4.1 WHEN STARTING THE ENGINE...351
2.4.2 RULES FOR TRAVELLING ON ROADS...351
2.4.3 REGULATIONS FOR ROAD TRANSFER (TUV approval)...352
2.4.4 HAND SIGNALS...354
2.4.5 CHECKS FOR TRAVELLING IN REVERSE...359
2.4.6 MOVING THE MACHINE...359
2.4.7 WORKING ON SLOPES...360
2.4.8 PROHIBITED OPERATIONS...360
2.4.9 PREVENTING ELECTROCUTION...361
2.4.10 VISIBILITY...362
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...362
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...362
2.4.13 WORKING ON LOOSE GROUND...362
2.4.14 PARKING THE MACHINE...363
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...364
2.5.1 LOADING AND UNLOADING THE MACHINE...364
2.5.2 TRANSPORT...364
2.6 BATTERY...365
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...365
2.6.2 STARTING WITH BOOSTER CABLES...366
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...367
2.8 LIFTING OBJECTS WITH LIFTING DEVICE (OPTIONAL EQUIPMENT)...368
2.8.1 SAFETY RULES FOR LIFTING OBJECTS...368
2.9 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...371
2.9.1 WARNING PLATES...371
2.9.2 TOOLS...371
2.9.3 PERSONNEL...372
2.9.4 EQUIPMENT...372
2.9.5 WORKING UNDER THE MACHINE...372
2.9.6 STABILITY...372
2.9.7 REPAIR WELDS...372
2.9.8 KEEPING THE MACHINE CLEAN...373
2.9.9 USE OF THE ENGINE DURING MAINTENANCE...373
2.9.10 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...373
2.9.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...374
2.9.12 BATTERY MAIN SWITCH PRECAUTIONS...375
2.9.13 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...375
2.9.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR...375
2.9.15 USING LAMPS...376
2.9.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...376
2.9.17 PRECAUTIONS CONCERNING THE STARTER...376
2.9.18 HANDLING HIGH-PRESSURE PIPES...377
2.9.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...377
2.9.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...377
2.9.21 HYDRAULIC ACCUMULATOR...378
2.9.22 COOLING FAN AND FAN BELT...378
2.9.23 CHEMICAL HAZARD...378
2.9.24 WASTE MATERIALS...379
2.9.25 SERVICING THE AIR CONDITIONER...379
2.9.26 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...379
2.9.27 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...380
2.9.28 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...380
2.9.29 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...381
2.9.30 FINAL DISPOSAL OF THE MACHINE...381
3.1 SAFETY LOCKS...384
3.1.1 FRONT LOADER LOCKS...384
3.1.2 BACKHOE LOCKS...386
3.2 GENERAL VIEWS...388
3.2.1 FRONT GENERAL VIEW...388
3.2.2 BACKHOE GENERAL VIEW...389
3.2.3 CAB INSIDE GENERAL VIEW...390
3.3 INSTRUMENTS AND CONTROLS...392
3.3.1 FRONT INSTRUMENTS...392
3.3.2 SIDE INSTRUMENTS...397
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...408
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES...410
3.3.5 MACHINE CONTROLS...414
3.3.6 ADJUSTING THE CONTROLS...437
3.4 FUSES AND RELAYS...440
3.4.1 CENTRAL UNIT FUSES - RELAYS AND ENGINE LINE...440
3.4.1.1 FUSES...441
3.4.1.2 RELAYS...443
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS...445
3.4.2.1 FUSES...445
3.4.2.2 RELAYS...445
3.5 GUARDS, CAB AND DRIVER’S SEAT...446
3.5.1 ENGINE HOOD...446
3.5.2 CAB...447
3.5.3 VENTILATION AND HEATING...450
3.5.4 AIR CONDITIONER (if installed)...451
3.5.5 SEAT...453
3.5.5.1 SEAT (Standard mod. CAB SEATING)...453
3.5.5.2 SEAT (Optional mod. CAB SEATING)...455
3.5.5.3 PNEUMATIC SUSPENSION SEAT (optional mod. CAB SEATING)...456
3.5.5.4 SEAT (Standard mod. SEARS SEATING)...457
3.5.5.5 PNEUMATIC SUSPENSION SEAT (optional mod. SEARS SEATING)...458
3.5.6 SAFETY BELT...459
3.5.6.1 STANDARD SAFETY BELTS...459
3.5.6.2 SAFETY BELTS WITH WINDER...459
3.5.7 FIRE EXTINGUISHER...459
3.5.8 FIRST AID KIT...459
3.5.9 TECHNICAL DOCUMENTATION...460
3.5.10 STORAGE COMPARTMENT...460
3.5.11 REFUELLING PUMP (If installed)...461
3.6 USE OF THE MACHINE...463
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...463
3.6.1.1 VISUAL CHECKS...463
3.6.1.2 OPERATIONAL CHECKS...464
3.6.2 STARTING THE ENGINE...465
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...465
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...466
3.6.3 WARMING THE ENGINE...467
3.6.4 HEATING THE HYDRAULIC OIL...467
3.6.5 HOW TO MOVE THE MACHINE...468
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE...469
3.6.5.2 WORKING ON SLOPES...470
3.6.5.3 MAXIMUM IMMERSION DEPTH...471
3.7 PARKING THE MACHINE...472
3.7.1 PARKING ON LEVEL GROUND...472
3.7.2 PARKING ON SLOPES...473
3.8 STOPPING THE ENGINE...474
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...475
3.9.1 LOADING AND UNLOADING THE MACHINE...475
3.9.2 TRANSPORT...476
3.9.3 LIFTING THE MACHINE...477
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...478
3.10.1 FUEL AND LUBRICANTS...478
3.10.2 COOLANT...478
3.10.3 BATTERY...479
3.10.4 OTHER PRECAUTIONS...479
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...479
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...480
3.12 USING THE MACHINE AS A LOADER...481
3.12.1 BUCKET POSITION INDICATOR...481
3.12.2 ORGANIZING THE WORK AREA...481
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...482
3.12.2.2 LOADING OPERATIONS ON SLOPES...483
3.12.3 CHANGING THE STANDARD FRONT BUCKET...483
3.13 USING THE MACHINE AS AN EXCAVATOR...484
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...484
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...485
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...486
3.13.4 DIGGING METHOD...487
3.13.4.1 CHANGING THE BACKHOE BUCKET...488
3.13.5 LIFTING LOADS WITH EQUIPMENT...489
3.13.5.1 LIFTING CAPACITIES...490
3.13.5.2 LIFTING CAPACITIES...491
3.14 LONG PERIODS OF INACTIVITY...492
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...492
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...494
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...494
3.14.4 RESTARTING THE ENGINE...495
3.14.5 AFTER THE PERIOD OF INACTIVITY...495
3.14.6 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE...495
3.15 TROUBLESHOOTING...496
3.15.1 HOW TO REMOVE THE MACHINE...496
3.15.2 AFTER THE FUEL HAS RUN OUT...496
3.15.3 IF THE BATTERY IS DOWN...497
3.15.3.1 STARTING WITH BOOSTER CABLES...498
3.15.4 OTHER TROUBLES...500
3.15.4.1 ELECTRICAL CIRCUIT...500
3.15.4.2 HYDRAULIC SYSTEM...500
3.15.4.3 BRAKING SYSTEM...501
3.15.4.4 CONVERTER...501
3.15.4.5 ENGINE...501
4.1 GUIDE TO MAINTENANCE...504
4.2 MAINTENANCE NOTES...506
4.2.1 NOTES REGARDING THE ENGINE...506
4.2.1.1 ENGINE OIL...506
4.2.1.2 COOLANT...506
4.2.1.3 FUEL...507
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...507
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...508
4.2.4 NOTES REGARDING LUBRICATION...508
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...509
4.3 FUEL AND LUBRICANTS...510
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...512
4.4 DRIVING TORQUES...513
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...513
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...514
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...514
4.5 LUBRICATION...515
4.5.1 LUBRICATION DIAGRAM...515
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...516
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...517
4.5.4 LUBRICATION DIAGRAM (offset device)...518
4.5.5 LUBRICATION CHART (For hydraulically-controlled sliding plate)...519
4.5.6 LUBRICATION DIAGRAM (for telescopic boom)...520
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...521
4.6.1 SAFETY RELATED PARTS...522
4.6.1.1 FUEL SYSTEM...522
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...523
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...524
4.6.1.4 BACKHOE HYDRALIC SYSTEM...525
4.6.1.5 OPERATOR’S SAFETY...526
4.7 MAINTENANCE PLAN...527
4.8 MAINTENANCE PROCEDURES...529
4.8.1 WHEN REQUIRED...529
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...529
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...530
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)...531
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR AND TOPPING UP...531
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES...532
4.8.1.f LUBRICATING THE CAB DOOR HINGES...532
4.8.1.g FUSES AND RELAYS - CHECK AND CHANGE...532
4.8.1.h BLEEDING THE BRAKING CIRCUIT...533
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN...534
4.8.1.j CHECKING THE BRAKING EFFICIENCY...534
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE...535
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...536
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...536
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK...537
4.8.1.o 1st STAGE DECANTER DRAINAGE...538
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...539
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...539
4.8.2.b CHANGING THE HYDRAULIC OIL...539
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...540
4.8.3.a VARIOUS CHECKS...540
4.8.3.b CHECKING THE COOLANT LEVEL...540
4.8.3.c CHECKING THE FUEL LEVEL...541
4.8.3.d CHECKING THE ENGINE OIL LEVEL...541
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...542
4.8.4.a LUBRICATING THE JOINTS...542
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...544
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...544
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...544
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...545
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...545
4.8.6.d LUBRICATING THE PROPELLER SHAFTS...546
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS...547