KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (WEAD002202) – PDF DOWNLOAD

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KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (WEAD002202)

KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (WEAD002202) – PDF DOWNLOAD:

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KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (WEAD002202)

• This manual has been carried out by Komatsu in order to supply their customers with all the necessary information on the machine and the safety regulations related to it, together with the use and maintenance instructions that enable the operator to exploit the capacity of the machine with optimal results and to keep the machine efficient over time.
• The operation manual, together with the spare parts catalogue, is an integral part of the machine and must accompany it, even when it is resold, until the nachine’s final disposal.
• The manual must be handled with the greatest care and always kept on board the machine, so that it can be consulted at any moment; it must be placed in the appropriate compartment behind the seat, where also the ownership documents and the logbook are usually kept (see “14.9 TECHNICAL DOCUMENTATION”).
• This manual must be given to the persons who have to use the machine and carry out the routine maintenance
operations; they must read the contents carefully more than once, in such a way as to clearly understand what are the correct operating conditions and the dangerous conditions that must be avoided. In case of loss or damage, request a new copy from Komatsu or your Komatsu Dealer.
• The illustrations contained in this manual may rapresent machine configurations available on request. Continuing improvements in the design of the machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.
• Punctual periodic annotations regarding the maintenance operations that have been carried out are important to have a clear prospect of the situation and to know exactly what has been done and what has to be done after the next maintenance interval. Therefore, consult the hour meter and the maintenance plan frequently.
• This manual may contain attachments and optional equipment that are not available in your area. Consult your Komatsu distributor for those items you may require.
• The table included in this manual (page 9) must be filled in with the machine data, which is the data that must always be indicated to the Dealer when requiring assistance and ordering spare parts.

TABLE OF CONTENTS:

KOMATSU WB140PS-2 WB150PS-2 POWER-SHIFT BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (WEAD002202)

MAIN MENU............................................................................................................................................  0
COVER................................................................................................................................................  1
TABLE OF CONTENTS....................................................................................................................................  2
FOREWORD............................................................................................................................................. 10
INFORMATION ON SAFETY................................................................................................................................ 11
INTRODUCTION......................................................................................................................................... 13
	Intended Uses.................................................................................................................................... 13
	Improper or Unauthrozied Uses.................................................................................................................... 13
	Main Characteristics............................................................................................................................. 14
	Running-In....................................................................................................................................... 14
	Product Identification........................................................................................................................... 15
	Machine Serial Number............................................................................................................................ 15
	Machine Identification Plate..................................................................................................................... 15
	Engine Serial Number and Emission Label.......................................................................................................... 16
	Front Axle Serial Number......................................................................................................................... 16
	Rear Axle Serial Number.......................................................................................................................... 16
	Transmission Serial Number....................................................................................................................... 17
	Cab Serial Number................................................................................................................................ 17
	Canopy Serial Number............................................................................................................................. 17
	Serial Numbers and Dealer's Address.............................................................................................................. 18
SAFETY AND ACCIDENT PREVENTION....................................................................................................................... 20
	1.   General Precautions......................................................................................................................... 21
		1.1   General Safety Rules................................................................................................................... 21
		1.2   Safety Devices and Guards.............................................................................................................. 21
		1.3   Clothing and Personal Protection Items................................................................................................. 21
		1.4   Unauthorized Modifications............................................................................................................. 22
		1.5   Leaving the Operator's Seat............................................................................................................ 22
		1.6   Getting On and Off the Machine......................................................................................................... 23
		1.7   Checking the Rear-View Mirror.......................................................................................................... 23
		1.8   Preventing Fires Due to Fuel and Oil................................................................................................... 24
		1.9   Preventing Burns....................................................................................................................... 24
		1.10   Preventing Damage Due to Asbestos Powder.............................................................................................. 25
		1.11   Preventing Damage Caused by the Work Equipment........................................................................................ 25
		1.12   Fire Extinguishers and First Aid Kit.................................................................................................. 26
		1.13   Precautions Concerning the Cab Structure.............................................................................................. 26
		1.14   Precautions Concerning the Equipment.................................................................................................. 26
PRECAUTIONS.......................................................................................................................................... 28
	2.   Precautions to be Taken Before Starting the Engine.......................................................................................... 29
		2.1   Safety on the Work Site................................................................................................................ 29
		2.2   Fire Prevention........................................................................................................................ 29
		2.3   Precautions to be Taken for the Operator's Cab......................................................................................... 29
		2.4   Room Ventilation....................................................................................................................... 30
		2.5   Cleaning Windows, Mirrors and Lights - Checking the Windshield Wiper Blades and the Bulbs.............................................. 30
	3.   Precautions to be Taken When Working........................................................................................................ 31
		3.1   Starting the Engine.................................................................................................................... 31
		3.2   Rules for Road Travel.................................................................................................................. 31
		3.3   Checks for Traveling in Reverse........................................................................................................ 32
		3.4   Moving the Machine..................................................................................................................... 33
		3.5   Working on Slopes...................................................................................................................... 33
		3.6   Preventing Electrocution............................................................................................................... 34
		3.7   Visibility............................................................................................................................. 35
		3.8   Working on Icy or Snow-covered Surfaces................................................................................................ 35
		3.9   Preventing Damage Caused by the Work Equipment......................................................................................... 35
		3.10   Working of Loose Ground............................................................................................................... 35
		3.11   Parking the Machine................................................................................................................... 36
	4.   Transporting the Machine on Other Vehicles.................................................................................................. 37
		4.1   Loading and Unloading.................................................................................................................. 37
		4.2   The Route.............................................................................................................................. 37
	5.   The Battery................................................................................................................................. 38
		5.1   Safety Precautions for Work on Batteries............................................................................................... 38
		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..................................................................................................... 44
		7.10   Level of Coolant in the Radiator...................................................................................................... 44
		7.11   Using Lamps........................................................................................................................... 44
		7.12   Precautions Concerning the Gearshift.................................................................................................. 45
		7.13   Battery and Alternator Precautions.................................................................................................... 45
		7.14   Precautions Concerning the Starter.................................................................................................... 46
		7.15   Precautions Regarding High Pressure Hoses............................................................................................. 46
		7.16   Precautions to be Taken When Working on High Pressure Systems......................................................................... 47
		7.17   Precautions for Maintenance Work Involving High Temperatures and Pressures............................................................ 47
		7.18   The Radiator Cooling Fan and Fan Belt................................................................................................. 47
		7.19   Waste Materials....................................................................................................................... 48
		7.20   Precautions for Inflating Tires....................................................................................................... 48
		7.21   Precautions for the Installation of the Exhaust System Tailpipe....................................................................... 48
		7.22   Precautions for the Use of the Synthetic Biodegradable Oil Type HEES.................................................................. 49
	8.   Safety Plates............................................................................................................................... 50
		8.1   Position of the Safety Plates.......................................................................................................... 50
		8.2   Position of the Pictograms............................................................................................................. 64
		8.3   Pictograms and Relevant Meanings....................................................................................................... 66
		8.4   Vibrations to Which the Operator is Subjected.......................................................................................... 69
TECHNICAL SPECIFICATIONS............................................................................................................................. 70
	9.   Technical Data.............................................................................................................................. 71
		9.1   Standard Overall Dimensions............................................................................................................ 71
		9.2   Techical Characteristics WB140PS-2..................................................................................................... 72
		9.3   Technical Characteristics WB150PS-2.................................................................................................... 73
		9.4   Lifting Capacities..................................................................................................................... 74
			9.4.1   Symbol Table..................................................................................................................... 74
			9.4.2   Lifting Capacity WB140PS-2....................................................................................................... 75
			9.4.3   Lifting Capacity WB150PS-2....................................................................................................... 77
DESCRIPTION AND USE OF THE MACHINE................................................................................................................... 80
	10.   Safety Locks............................................................................................................................... 81
		10.1   Front Loader Lock..................................................................................................................... 81
		10.2   Backhoe Locks......................................................................................................................... 83
	11.   General Views.............................................................................................................................. 84
		11.1   Front General View.................................................................................................................... 84
		11.2   Backhoe General View.................................................................................................................. 85
		11.3   Cab Inside General View............................................................................................................... 86
	12.   Instruments and Controls................................................................................................................... 87
		12.1   Front Instruments..................................................................................................................... 87
		12.2   Side Instruments...................................................................................................................... 90
		12.3   Push Buttons on the Front Loader Control Lever........................................................................................ 94
		12.4   Electrical Accessories................................................................................................................ 95
		12.5   Machine Controls...................................................................................................................... 96
	13.   Fuses and Relays...........................................................................................................................116
		13.1   Equipment Fuses and Relays............................................................................................................116
		13.2   Engine Fuses and Relays...............................................................................................................118
	14.   Guards, Cab and Driver's Seat..............................................................................................................122
		14.1   Engine Hood...........................................................................................................................122
		14.2   Canopy................................................................................................................................122
		14.3   Cab...................................................................................................................................123
		14.4   Ventilation and Heating...............................................................................................................125
		14.5   Seat..................................................................................................................................126
		14.6   Safety Belt...........................................................................................................................126
		14.7   Fire Extinguisher.....................................................................................................................127
		14.8   First Aid Kit.........................................................................................................................127
		14.9   Technical Documentation...............................................................................................................127
		14.10   Additional Tool Case ( if provided ).................................................................................................127
	15.   Use of the Machine.........................................................................................................................128
		15.1   Checks Before Starting the Engine.....................................................................................................128
			15.1.1   Visual Checks...................................................................................................................128
			15.1.2   Daily Checks....................................................................................................................128
			15.1.3   Operational Checks..............................................................................................................129
		15.2   Starting the Engine...................................................................................................................130
			15.2.1   Starting with Warm Engine or in Temperate Climates ( more than 0 degrees centigrade / 32 degrees fahrenheit )...................130
			15.2.2   Starting with Cold Engine or in Cold Climates ( up to -16 degrees centigrade / 3 degrees fahrenheit )...........................131
			15.2.3   Starting the Engine in Very Cold Areas ( up to -30 degrees centigrade / -22 degrees fahrenheit )................................131
		15.3   Warming the Engine....................................................................................................................132
		15.4   Heating the Hydraulic Oil.............................................................................................................132
		15.5   How to Move the Machine...............................................................................................................133
			15.5.1   Locking the Differential........................................................................................................134
			15.5.2   Engaging the Four-Wheel Drive...................................................................................................134
			15.5.3   Working on Slopes...............................................................................................................135
			15.5.4   Maximum Immersion Depth.........................................................................................................136
	16.   Parking the Machine........................................................................................................................137
		16.1   Parking on Level Ground...............................................................................................................137
		16.2   Parking on Slopes.....................................................................................................................138
	17.   Stopping the Machine.......................................................................................................................139
	18.   Transporting the Machine on other Vehicles.................................................................................................140
		18.1   Loading and Unloading the Machine.....................................................................................................140
		18.2   Transport.............................................................................................................................141
	19.   Precautions to be Taken in the Cold Season.................................................................................................142
		19.1   Fuel and Lubricants...................................................................................................................142
		19.2   Coolant...............................................................................................................................142
		19.3   Battery...............................................................................................................................142
		19.4   Other Precautions.....................................................................................................................143
		19.5   Precautions to be Taken at the End of Work............................................................................................143
	20.   Precautions to be Taken in the Warm Season.................................................................................................144
	21.   Using the Machine as a Loader..............................................................................................................145
		21.1   Bucket Position Indicator.............................................................................................................145
		21.2   Organizing the Work Area..............................................................................................................145
			21.2.1   Loading Heaped and Level Material...............................................................................................146
			21.2.2   Loading Operations on Slopes....................................................................................................146
		21.3   Changing the Standard Front Bucket....................................................................................................147
	22.   Using the Machine as an Excavator..........................................................................................................148
		22.1   Positioning the Bucket According to the Work that Must be Carried Out.................................................................148
		22.2   Positioning the Machine for Digging Operations........................................................................................149
		22.3   Digging Method........................................................................................................................150
		22.4   Changing the Backhoe Bucket...........................................................................................................151
	23.   Troubleshooting............................................................................................................................152
		23.1   How to Remove the Machine.............................................................................................................152
		23.2   If the Fuel has Been Completely Depleted..............................................................................................152
		23.3   If the Battery is Depleted............................................................................................................153
			23.3.1   Starting with Booster Cables....................................................................................................154
		23.4   Other Troubles........................................................................................................................155
			23.4.1   Electrical Circuit..............................................................................................................155
			23.4.2   Hydraulic System................................................................................................................155
			23.4.3   Braking System..................................................................................................................156
			23.4.4   Torque Converter System.........................................................................................................156
			23.4.5   Engine..........................................................................................................................157
MAINTENANCE..........................................................................................................................................158
	24.   Guide to Maintenance.......................................................................................................................159
	25.   Maintenance Notes..........................................................................................................................161
		25.1   Notes Regarding the Engine............................................................................................................161
			25.1.1   Engine Oil......................................................................................................................161
			25.1.2   Coolant.........................................................................................................................161
			25.1.3   Fuel............................................................................................................................162
		25.2   Notes Regarding the Hydraulic System..................................................................................................162
		25.3   Notes Regarding the Electrical System.................................................................................................163
		25.4   Notes Regarding the Lubrication.......................................................................................................163
		25.5   Parts Subject to Wear that Periodically Need Changing.................................................................................164
	26.   Fuel, Coolant and Lubricants...............................................................................................................165
		26.1   Homologated HEES Synthetic Biodegradable Lubricants...................................................................................169
		26.2   Lubrication Diagram...................................................................................................................170
		26.3   Lubrication Diagram ( multipurpose bucket and pallet forks )..........................................................................171
		26.4   Lubrication Diagram ( front bucket rapid couplings )..................................................................................172
		26.5   Lubrication Diagram ( telescopic arm )................................................................................................173
		26.6   Periodical Change of the Components Connected with Safety.............................................................................174
			26.6.1   Critical Parts for Safety.......................................................................................................175
	27.   Nut and Bolt Tightening Torques............................................................................................................179
		27.1   Standard Tightening Torques...........................................................................................................179
		27.2   Specific Tightening Torques...........................................................................................................179
	28.   Maintenance Plan...........................................................................................................................180
		28.1   Checks Before Starting................................................................................................................184
			28.1.a   Various Checks..................................................................................................................184
			28.1.b   Checking the Fuel Level.........................................................................................................184
			28.1.c   Checking the Coolant Level......................................................................................................185
			28.1.d   Checking the Engine Oil Level...................................................................................................185
			28.1.e   Checking the Hydraulic Circuit Oil Level........................................................................................186
			28.1.f   Draining the Water Separator....................................................................................................187
		28.2   Maintenance Every 10 Hours of Operation...............................................................................................187
			28.2.a   Lubricating the Joints..........................................................................................................187
		28.3   Maintenance After the First 50 Hours of Operation ( only for machines in which the synthetic biodegradable oil type HEES is used )....190
			28.3.a Change Hydraulic Oil Drain Filter.................................................................................................201
		28.4   Maintenance Every 50 Hours of Operation...............................................................................................190
			28.4.a  Checking the Radiator Fluid Level................................................................................................190
			28.4.b  Checking the Braking System Oil Level............................................................................................190
			28.4.c  Lubricating the Propeller Shafts.................................................................................................191
			28.4.d  Lubricating the Front Axle Joints Central Coupling...............................................................................192
			28.4.e  Checking the Tire Pressure.......................................................................................................192
			28.4.f  Checking the Electrical System...................................................................................................193
		28.5  Maintenance After the First 250 Hours of Operation.....................................................................................194
			28.5.a Change Front Axle Oil.............................................................................................................205
			28.5.b Change Rear Axle Oil..............................................................................................................206
			28.5.c Change Hydraulic Transmission Oil.................................................................................................207
			28.5.d Change Hydraulic Transmission Oil Filter..........................................................................................208
			28.5.e Checking and Adjusting Engine Valve Clearance.....................................................................................208
			28.5.f Changing Hydraulic Oil Drain......................................................................................................201
		28.6  Maintenance Every 250 Hours of Operation...............................................................................................194
			28.6.a  Adjusting the Fan Belt Tension...................................................................................................194
			28.6.b  Cleaning the Outside of the Radiators............................................................................................195
			28.6.c  Checking the Battery Electrolyte Level...........................................................................................196
			28.6.d  Checking the Front Axle Oil Levels...............................................................................................197
			28.6.e  Checking the Rear Axle Oil Levels................................................................................................197
			28.6.f   Checking the Hydraulic Transmission Oil Level...................................................................................198
			28.6.g  Checking the Wheel Nut Driving Torque............................................................................................198
		28.7  Maintenance After the First 500 Hours of Operation ( Only for machines in which the synthetic biodegradable oil type HEES is used )....199
			28.7.a  Changing Hydraulic Oil and Cleaning Suction Filter...............................................................................209
		28.8  Maintenance Every 500 Hours of Operation...............................................................................................199
			28.8.a  Changing the Engine Oil..........................................................................................................199
			28.8.b  Changing the Engine Oil Filter...................................................................................................200
			28.8.c  Changing the Hydraulic System Oil Filter ........................................................................................201
			28.8.d  Changing the Fuel Filter.........................................................................................................202
			28.8.e  Draining the  Fuel Tank..........................................................................................................203
			28.8.f  Draining the Hydraulic Oil Tank ( Only for machines in which the synthetic biodegradable oil type HEES is used ).................204
		28.9  Maintenance Every 1000 Hours of Operation..............................................................................................205
			28.9.a  Changing the Front Axle Oil......................................................................................................205
			28.9.b  Changing the Rear Axle Oil.......................................................................................................206
			28.9.c  Changing the Hydraulic Transmission Oil..........................................................................................207
			28.9.d  Changing the Hydraulic Transmission Filter.......................................................................................208
			28.9.e  Checking and Adjusting the Engine Valve Clearance................................................................................208
		28.10  Maintenance Every 2000 Hours of Operation ............................................................................................209
			28.10.a  Changing the Hydraulic System Oil and Cleaning the Suction Filter...............................................................209
			28.10.b  Changing the Coolant............................................................................................................212
			28.10.c  Changing the Braking System Oil.................................................................................................213
			28.10.d  Checking the Alternator and the Starter.........................................................................................213
		28.11  When Required.........................................................................................................................214
			28.11.a  Checking, Cleaning or Changing the Air Cleaner Cartridge........................................................................214
			28.11.b  Checking and Cleaning the Cab Air Filter........................................................................................215
			28.11.c  Bleeding the Braking Circuit....................................................................................................216
			28.11.d  Washing the Cooling Circuit.....................................................................................................216
			28.11.e  Cleaning the Water Separator....................................................................................................218
			28.11.f  Checking and Adjusting the Front Wheel Toe-In...................................................................................218
			28.11.g  Checking and Adjusting the Parking Brake........................................................................................219
			28.11.h  Checking the Braking Efficiency.................................................................................................220
			28.11.j  Checking and Adjusting the Brake Pedal Stroke...................................................................................221
			28.11.k  Adjusting the Automatic Return of the Front Bucket to the Digging Position......................................................221
		28.12  Maintenance Intervals in Case of Use of the Demolition Hammer.........................................................................222
			28.12.a  Changing the Hydraulic Oil Filter...............................................................................................222
			28.12.b  Changing the Hydraulic Oil......................................................................................................222
		29.   Long Periods of Inactivity.............................................................................................................223
			29.1  Before the Period of Inactivity....................................................................................................223
			29.2  During the Period of Inactivity....................................................................................................225
			29.3  After the Period of Inactivity.....................................................................................................225
AUTHORIZED OPTIONAL EQUIPMENT........................................................................................................................226
	30.  Authorized Optional Equipment...............................................................................................................227
		30.1  Precautions Regarding Safety...........................................................................................................227
		30.2  Characteristics of the Optional Equipment for Model WB140PS-2..........................................................................228
		30.3  Characteristics of the Optional Equipment for Model WB150PS-2..........................................................................229
	31.  Front Equipment Quick Coupling Devices......................................................................................................230
		31.1  Manual Control Quick Coupling..........................................................................................................230
		31.2  Hydraulic Control Quick Coupling for Standard Bucket...................................................................................231
		31.3  Hydraulic Control Quick Coupling for Multipurpose Bucket and Optional Equipment with Unidirectional Oil Flow...........................231
	32.  Multipurpose Bucket.........................................................................................................................232
		32.1  Description and Controls...............................................................................................................232
		32.2  Safety Devices.........................................................................................................................232
		32.3  Installing the Multipurpose Bucket.....................................................................................................233
		32.4  Using the Multipurpose Bucket..........................................................................................................234
		32.5  Maintenance............................................................................................................................234
	33.  Pallet Forks................................................................................................................................235
		33.1  Description............................................................................................................................235
		33.2  Safety Devices.........................................................................................................................235
		33.3  Using the Forks........................................................................................................................235
			33.3.1  Preparing the Pallet Forks for Use...............................................................................................236
			33.3.2  Overturning the Forks for Travel on Roads........................................................................................236
		33.4  Removing the Forks.....................................................................................................................237
		33.5  Installing the Forks...................................................................................................................237
		33.6  Maintenance............................................................................................................................237
	34.  Backhoe Telescopic Arm......................................................................................................................238
		34.1  Description and Control................................................................................................................238
		34.2  Safety Devices.........................................................................................................................238
		34.3  Using the Telescopic Arm...............................................................................................................239
		34.4  Maintenance............................................................................................................................239
			34.4.1  Adjusting the Guide Slack........................................................................................................239
	35.  Arrangement for the Installation of the Demolition Hammer...................................................................................241
		35.1  Description and Control................................................................................................................241
		35.2  Use of the Demolition Hammer and Rules to be Observed..................................................................................242
		35.3  Installing and Removing the Demolition Hammer..........................................................................................246
			35.3.1  Installing the Hammer............................................................................................................246
			35.3.2  Removing the Hammer..............................................................................................................248
		35.4  Maintenance............................................................................................................................248
	36.  Arrangement for the Operation of Optional Equipment with Unidirectional Oil Flow............................................................249
		36.1  Description and Control................................................................................................................249
		36.2  Installing and Connecting the Equipment................................................................................................249
		36.3  Maintenance............................................................................................................................250
	37.  Arrangement for the Installation of the Clamshell Bucket....................................................................................251
		37.1  Description and Control................................................................................................................251
		37.2  Installing the Clamshell Bucket........................................................................................................252
		37.3  Using the Clamshell Bucket.............................................................................................................253
		37.4  Maintenance............................................................................................................................253
	38.  Arrangement for the Installation of the Manual Hydraulic Hammer.............................................................................254
		38.1  Description and Control................................................................................................................254
		38.2  Connecting and Removing the Hammer.....................................................................................................255
			38.2.1  Connecting the Hammer............................................................................................................255
			38.2.2  Removing the Connections.........................................................................................................255
		38.3  Using the Hammer.......................................................................................................................256
		38.4  Maintenance............................................................................................................................256
	39.  Load Stabilizer System ( LSS ) (Optional)...................................................................................................257
		39.1  Accumulator of the Load Stabilizer System ( LSS )......................................................................................257
	40.  Air Conditioner.............................................................................................................................258

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