Komatsu WB150AWS-2 Backhoe Loader Workshop Repair Service Manual PDF - Operation & Maintenance, Shop Manual, Wiring Diagrams - MKMTSWB150AWS.zip
A full-service repair guide, complete with electrical wiring diagrams, for the Komatsu WB150AWS Backhoe Loader — packed with the technical detail needed to service, troubleshoot, fix, and overhaul the machine the way professional technicians do.
This workshop service and repair manual for the Komatsu WB150AWS Backhoe Loader 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.
WEAM003700 - Backhoe Loader WB150AWS-2 Operation & Maintenance Manual.pdf
WEBM003301 - Backhoe Loader WB150AWS-2 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 774 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM003700 - Backhoe Loader WB150AWS-2 Operation & Maintenance Manual...1
COVER...2
TABLE OF CONTENTS...3
FOREWORD...11
INFORMATION ON SAFETY...12
INTRODUCTION...14
INTENDED USES...14
IMPROPER OR UNAUTHORIZED USES...14
MAIN CHARACTERISTICS...15
RUNNING-IN...15
PRODUCT IDENTIFICATION...16
MACHINE SERIAL NUMBER...16
MACHINE IDENTIFICATION PLATE...16
ENGINE SERIAL NUMBER AND EMISSION LABEL...17
FRONT AXLE SERIAL NUMBER...17
REAR AXLE SERIAL NUMBER...17
TRANSMISSION SERIAL NUMBER...18
CAB SERIAL NUMBER...18
CANOPY SERIAL NUMBER...18
SERIAL NUMBERS AND DEALER'S ADDRESS...19
SAFETY AND ACCIDENT PREVENTION...21
1. GENERAL PRECAUTIONS...22
1.1 GENERAL SAFETY RULES...22
1.2 SAFETY DEVICES AND GUARDS...22
1.3 CLOTHING AND PERSONAL PROTECTION ITEMS...22
1.4 UNAUTHORIZED MODIFICATIONS...23
1.5 LEAVING THE OPERATOR'S SEAT...23
1.6 GETTING ON AND OFF THE MACHINE...24
1.7 CHECKING THE REAR-VIEW MIRROR...24
1.8 PREVENTING FIRES DUES TO FUEL AND OIL...25
1.9 PREVENTING BURNS...25
1.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...26
1.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...26
1.12 FIRE EXTINGUISHERS AND FIRST AID KIT...27
1.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...27
1.14 PRECAUTIONS CONCERNING THE EQUIPMENT...27
PRECAUTIONS...29
2. PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...30
2.1 SAFETY ON THE WORK SITE...30
2.2 FIRE PREVENTION...30
2.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...30
2.4 ROOM VENTILATION...31
2.5 CLEANING WINDOWS, MIRRORS AND LIGHTS- CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...31
3. PRECAUTIONS TO BE TAKEN WHEN WORKING...32
3.1 STARTING THE ENGINE...32
3.2 RULES FOR ROAD TRAVEL...32
3.3 CHECKS FOR TRAVELING IN REVERSE...33
3.4 MOVING THE MACHINE...34
3.5 WORKING ON SLOPES...34
3.6 PREVENTING ELECTROCUTION...35
3.7 VISIBILITY...36
3.8 WORKING ON ICY OR SNOW-COVERED SURFACES...36
3.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...36
3.10 WORKING ON LOOSE GROUND...36
3.11 PARKING THE MACHINE...37
4. TRANSPORTING THE MACHINE ON OTHER VEHICLES...38
4.1 LOADING AND UNLOADING...38
4.2 THE ROUTE...38
5. THE BATTERY...39
5.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES...39
5.2 STARTING THE ENGINE WITH JUMP LEADS...39
6. PRECAUTIONS FOR EMERGENCY RECOVERY...40
7. PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...41
7.1 WARNING PLATES...41
7.2 TOOLS...41
7.3 PERSONAL PRECAUTIONS...41
7.4 EQUIPMENT...42
7.5 WORKING UNDER THE MACHINE...42
7.6 KEEPING THE MACHINE CLEAN...42
7.7 RUNNING THE ENGINE DURING MAINTENANCE...43
7.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...43
7.9 RULES FOR REFUELING AND ADDING OIL...43
7.10 LEVEL OF COOLANT IN THE RADIATOR...44
7.11 USING LAMPS...44
7.12 PRECAUTIONS CONCERNING THE GEARSHIFT...44
7.13 BATTERY AND ALTERNATOR PRECAUTIONS...45
7.14 PRECAUTIONS CONCERNING THE STARTER...45
7.15 PRECAUTIONS REGARDING HIGH PRESSURE HOSES...45
7.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH PRESSURE SYSTEMS...46
7.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...46
7.18 THE RADIATOR COOLING FAN AND FAN BELT...46
7.19 WASTE MATERIALS...47
7.20 PRECAUTIONS FOR INFLATING TIRES...47
7.21 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...47
7.22 PRECAUTIONS FOR THE USE OF THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES...48
8. SAFETY PLATES...49
8.1 POSITION OF THE SAFETY PLATES...49
8.2 POSITION OF THE PICTROGRAMS...64
8.3 PICTOGRAMS AND RELEVANT MEANINGS...66
8.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...70
TECHNICAL SPECIFICATIONS...71
9. TECHNICAL DATA...72
9.1 STANDARD OVERALL DIMENSIONS...72
9.2 TECHNICAL CHARACTERISTICS...73
9.3 LIFTING CAPACITIES...74
THE MACHINE AND ITS OPERATIONS...77
10. SAFETY LOCKS...78
10.1 FRONT LOADER LOCK...78
10.2 BACKHOE LOCKS...80
11. GENERAL VIEWS...81
11.1 FRONT GENERAL VIEW...81
11.2 BACKHOE GENERAL VIEW...82
11.3 CAB INSIDE GENERAL VIEW...83
12. INSTRUMENTS AND CONTROLS...84
12.1 FRONT INSTRUMENTS...84
12.2 SIDE INSTRUMENTS...96
12.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...100
12.4 ELECTRICAL ACCESSORIES...101
12.5 MACHINE CONTROLS...102
13. FUSES AND RELAYS...127
13.1 EQUIPMENT FUSES AND RELAYS...127
13.2 ENGINE FUSES AND RELAYS...129
14. GUARDS, CAB AND DRIVER'S SEAT...131
14.1 ENGINE HOOD...131
14.2 CANOPY...131
14.3 CAB...132
14.4 VENTILATION AND HEATING...134
14.5 SEAT...135
14.6 SAFETY BELT...135
14.7 FIRE EXTINGUISHER...136
14.8 FIRST AID KIT...136
14.9 TECHNICAL DOCUMENTATION...136
14.10 ADDITIONAL TOOL CASE...136
15. USE OF THE MACHINE...137
15.1 CHECKS BEFORE STARTING THE ENGINE...137
15.1.1 VISUAL CHECKS...137
15.1.2 DAILY CHECKS...137
15.1.3 OPERATIONAL CHECKS...138
15.2 STARTING THE ENGINE...139
15.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...139
15.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...140
15.2.3 STARTING THE ENGINE IN VERY COLD AREAS...140
15.3 WARMING THE ENGINE...141
15.4 HEATING THE HYDRAULIC OIL...141
15.5 HOW TO MOVE THE MACHINE...142
15.5.1 ENGAGING THE FOUR-WHEEL DRIVE...143
15.5.2 WORKING ON SLOPES...144
15.5.3 MAXIMUM IMMERSION DEPTH...145
16. PARKING THE MACHINE...146
16.1 PARKING ON LEVEL GROUND...146
16.2 PARKING ON SLOPES...147
17. STOPPING THE ENGINE...148
18. TRANSPORTING THE MACHINE ON OTHER VEHICLES...149
18.1 LOADING AND UNLOADING THE MACHINE...149
18.2 TRANSPORT...150
19. PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...151
19.1 FUEL AND LUBRICANTS...151
19.2 COOLANT...151
19.3 BATTERY...151
19.4 OTHER PRECAUTIONS...152
19.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...152
20. PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...153
21. USING THE MACHINE AS A LOADER...154
21.1 BUCKET POSITION INDICATOR...154
21.2 ORGANIZING THE WORK AREA...154
21.2.1 LOADING HEAPED AND LEVEL MATERIAL...155
21.2.2 LOADING OPERATIOINS ON SLOPES...155
21.3 CHANGING THE STANDARD FRONT BUCKET...156
22. USING THE MACHINE AS AN EXCAVATOR...157
22.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...157
22.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...158
22.3 DIGGING METHOD...159
22.4 CHANGING THE BACKHOE BUCKET...160
23. TROUBLESHOOTING...161
23.1 HOW TO REMOVE THE MACHINE...161
23.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED...161
23.3 IF THE BATTERY IS DEPLETED...162
23.3.1 STARTING WITH BOOSTER CABLES...163
23.4 OTHER TROUBLES...164
23.4.1 ELECTRICAL CIRCUIT...164
23.4.2 HYDRAULIC SYSTEM...164
23.4.3 BRAKING SYSTEM...165
23.4.4 TORQUE CONVERTER SYSTEM...165
23.4.5 ENGINE...166
MAINTENANCE...167
24. GUIDE TO MAINTENANCE...168
25. MAINTENANCE NOTES...170
25.1 NOTES REGARDING THE ENGINE...170
25.1.1 ENGINE OIL...170
25.1.2 COOLANT...170
25.1.3 FUEL...171
25.2 NOTES REGARDING THE HYDRAULIC SYSTEM...171
25.3 NOTES REGARDING THE ELECTRICAL SYSTEM...172
25.4 NOTES REGARDING LUBRICATION...172
25.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...173
26. FUEL, COOLANT AND LUBRICANTS...174
26.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...178
26.2 LUBRICATION DIAGRAM...179
26.3 LUBRICATION DIAGRAM (MULTIPURPOSE BUCKET AND PALLET FORKS)...180
26.4 LUBRICATION DIAGRAM (FRONT BUCKET RAPID COUPLINGS...181
26.5 LUBRICATION DIAGRAM (TELESCOPIC ARM)...182
26.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY...183
26.6.1 CRITICAL PARTS FOR SAFETY...184
27. NUT AND BOLT TIGHTENING TORQUES...188
27.1 STANDARD TIGHTENING TORQUES...188
27.2 SPECIFIC TIGHTENING TORQUES...188
28. MAINTENANCE PLAN...189
28.1 CHECK BEFORE STARTING...192
28.1.a VARIOUS CHECKS...192
28.1.b CHECKING THE FUEL LEVEL...192
28.1.c CHECKING THE COOLANT LEVEL...193
28.1.d CHECKING THE ENGINE OIL LEVEL...193
28.1.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL...194
28.1.f DRAINING THE WATER SEPERATOR...194
28.2 MAINTENANCE EVERY 10 HOURS OF OPERATION...195
28.2.a LUBRICATING THE JOINTS...195
28.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION...197
28.3.A CHANGE HYDRAULIC OIL DRAIN FILTER...206
28.4 MAINTENANCE EVERY 50 HOURS OF OPERATION...197
28.4.a CHECKING THE RADIATOR FLUID LEVEL...197
28.4.b CHECKING THE BRAKING SYSTEM OIL LEVEL...197
28.4.c LUBRICATING THE PROPELLER SHAFTS...198
28.4.d LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING AND THE REAR AXLE JOINTS...199
28.4.e CHECKING THE TIRE PRESSURE...199
28.4.f CHECKING THE ELECTRICAL SYSTEM...200
28.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...201
28.5.A CHANGE FRONT AXLE OIL...210
28.5.B CHANGE REAR AXLE OIL...211
28.5.C CHANGE HYDRAULIC TRANSMISSION OIL...212
28.5.D CHANGE HYDRAULIC TRANSMISSION OIL FILTER...213
28.5.E CHECK AND ADJUST ENGINE VALVE CLEARANCE...213
28.5.F CHANGE HYDRAULIC OIL FILTER DRAIN...201
28.6 MAINTENANCE EVERY 250 HOURS OF OPERATION...201
28.6.a ADJUSTING FAN BELT TENSION...201
28.6.b CLEANING THE OUTSIDE OF THE RADIATORS...202
28.6.c CHECKING THE BATTERY ELECTROLYTE LEVEL...202
28.6.d CHECKING THE FRONT AXLE OIL LEVELS...203
28.6.e CHECKING THE REAR AXLE OIL LEVELS...203
28.6.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...204
28.6.g CHECKING THE WHEEL NUT DRIVING TORQUE...204
28.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION...205
28.7.a CHANGE HYDRAULIC OIL AND CLEAN SUCTION FILTER...214
28.8 MAINTENANCE EVERY 500 HOURS OF OPERATION...205
28.8.a CHANGING THE ENGINE OIL...205
28.8.b CHANGING THE ENGINE OIL FILTER...206
28.8.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...206
28.8.d CHANGING THE FUEL FILTER...208
28.8.e DRAINING THE FUEL TANK...209
28.8.f DRAINING THE HYDRAULIC OIL TANK...209
28.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION...210
28.9.a CHANGING THE FRONT AXLE OIL...210
28.9.b CHANGING THE REAR AXLE OIL...211
28.9.c CHANGING THE HYDRAULIC TRANSMISSION OIL...212
28.9.d CHANGING THE HYDRAULIC TRANSMISSION FILTER...213
28.9.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...213
28.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION...214
28.10.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...214
28.10.b CHANGING THE COOLANT...216
28.10.c CHANGING THE BRAKING SYSTEM OIL...218
28.10.d CHECKING THE ALTERNATOR AND THE STARTER...218
28.11 WHEN REQUIRED...219
28.11.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...219
28.11.b CHECKING AND CLEANING THE CAB AIR FILTERS...220
28.11.c BLEEDING THE BRAKING CIRCUIT...221
28.11.d WASHING THE COOLING CIRCUIT...222
28.11.e CLEANING THE WATER SEPERATOR...224
28.11.f CHECKING AND ADJUSTING THE WHEEL TOE-IN...224
28.11.g CHECKING AND ADJUSTING THE PARKING BRAKE...225
28.11.h CHECKING THE BRAKING EFFICIENCY...226
28.11.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...227
28.11.k ADJUSTING THE AUTOMATIC RETURN OF THE FRONT BUCKET TO THE DIGGING POSITION...227
28.12 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...228
28.12.a CHANGING THE HYDRAULIC OIL FILTER...228
28.12.b CHANGING THE HYDRAULIC OIL...228
29. LONG PERIODS OF INACTIVITY...229
29.1 BEFORE THE PERIOD OF INACTIVITY...229
29.2 DURING THE PERIOD OF INACTIVITY...231
29.3 AFTER THE PERIOD OF INACTIVITY...231
AUTHORISED OPTIONAL EQUIPMENT...233
30. AUTHORIZED OPTIONAL EQUIPMENT...234
30.1 PRECAUTIONS REGARDING SAFETY...234
30.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...235
31. FRONT EQUIPMENT RAPID COUPLING DEVICES...236
31.1 MANUAL CONTROL RAPID COUPLING...236
31.2 HYDRAULIC CONTROL RAPID COUPLING FOR STANDARD BUCKET...237
31.3 HYDRAULIC CONTROL RAPID COUPLING FOR 4 IN 1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...237
32. MULTIPURPOSE BUCKET...238
32.1 DESCRIPTION AND CONTROLS...238
32.2 SAFETY DEVICES...238
32.3 INSTALLING TEH MULTIPURPOSE BUCKET...239
32.4 USING THE MULTIPURPOSE BUCKET...240
32.5 MAINTENANCE...240
33. PALLET FORKS...241