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KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER Operation & Maintenance Manual (CEAM010800) – PDF DOWNLOAD
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- KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER Operation & Maintenance Manual
- PUBLICATION NUMBER:CEAM010800
- SERIAL NUMBERS:
WB140PS-2N A40001 and UP
WB150PS-2N A70001 and UP
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Description
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER Operation & Maintenance Manual (CEAM010800)
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER OPERATION & MAINTENANCE MANUAL (CEAM010800) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER Operation & Maintenance Manual (CEAM010800)
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local Komatsu distributor or for the latest available information on your machine or for questions regarding information in this manual.
- This manual may contain attachments and optional equipment that are not available in your area. Consult your local Komatsu distributor or for those items that you may require.
TABLE OF CONTENTS:
KOMATSU WB140PS-2N WB150PS-2N BACKHOE LOADER Operation & Maintenance Manual (CEAM010800)
MAIN MENU.............................................................. 0 COVER.................................................................. 1 INTRODUCTION........................................................... 7 FOREWARD........................................................... 8 SAFETY INFORMATION................................................. 9 APPROVED AND NON-APPROVED USES..................................... 10 NON-APPROVED................................................... 10 PRODUCT INFORMATION................................................ 11 MAIN FEATURES.................................................. 11 BREAK IN PERIOD................................................ 11 SYNTHETIC, BIODEGRADABLE OIL............................... 11 PRODUCT IDENTIFICATION............................................. 12 MACHINE SERIAL NUMBER.......................................... 12 MACHINE IDENTIFICATION PLATE................................... 12 ENGINE SERIAL NUMBER AND EMISSION LABEL........................ 13 FRONT AXLE SERIAL NUMBER....................................... 13 REAR AXLE SERIAL NUMBER........................................ 13 TRANSMISSION SERIAL NUMBER..................................... 14 CAB SERIAL NUMBER.............................................. 14 CANOPY SERIAL NUMBER........................................... 14 SERIAL NUMBERS AND DEALER INFORMATION.............................. 15 MODEL: WB140PS-2/WB150PS-2..................................... 15 CONTENTS............................................................... 16 SAFETY................................................................. 25 GENERAL SAFETY RULES AND PRECAUTIONS............................... 26 GENERAL SAFETY RULES........................................... 26 SAFETY FEATURES................................................ 27 PERSONAL PROTECTIVE EQUIPMENT.................................. 27 UNAUTHORIZED MODIFICATIONS..................................... 27 LEAVING OPERATOR'S COMPARTMENT................................. 28 ENTERING AND EXITING THE MACHINE............................... 29 CHECKING THE REAR VIEW MIRROR.................................. 29 FIRE PREVENTION FOR FUEL AND OIL............................... 30 PREVENTING BURNS............................................... 30 CAB STRUCTURE PRECAUTIONS...................................... 30 OPTIONAL EQUIPMENT PRECAUTIONS................................. 30 DUST HAZARD PRECAUTIONS........................................ 31 CRUSH OR PINCH POINT DANGERS................................... 31 FIRE EXTINGUISHER AND FIRST AID KIT............................ 31 INSIDE THE OPERATOR'S COMPARTMENT.............................. 32 PRECAUTIONS BEFORE STARTING ENGINE................................. 33 PREOPERATIONAL CHECKS.......................................... 33 WALK AROUND CHECK OF MACHINE............................... 33 UNDER THE HOOD............................................. 33 IN THE OPERATOR'S CAB...................................... 34 START UP CHECKS............................................ 34 ROOM VENTILATION............................................... 34 STARTING WORK OPERATIONS........................................... 35 WORK HAZARDS................................................... 35 WORKING CLEARANCES............................................. 36 ROAD TRAVEL.................................................... 37 TRAVELING IN REVERSE........................................... 39 TRAVELING ON ICY OR SNOW COVERED SURFACES...................... 39 WORKING ON LOOSE OR UNSTABLE GROUND............................ 39 VISIBILITY..................................................... 39 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT................. 39 TRAVEL POSITIONS............................................... 40 TRAVELING ON SLOPES........................................ 41 BUCKET PRECAUTIONS............................................. 43 PARKING THE MACHINE................................................ 44 PARKING ON LEVEL GROUND........................................ 44 PARKING FOR LONG PERIODS OF TIME........................... 44 PARKING ON AN INCLINE.......................................... 45 SAFETY LOCK USAGE.................................................. 46 FRONT END LOADER CYLINDER LOCK................................. 46 BACKHOE LOCKS.................................................. 47 TRANSPORTING THE MACHINE........................................... 49 LOADING AND SECURING THE MACHINE............................... 49 EMERGENCY RECOVERY................................................. 51 MOVING THE MACHINE............................................. 51 PRECAUTIONS DURING MAINTENANCE..................................... 52 WARNING TAGS................................................... 52 EQUIPMENT STORAGE.............................................. 52 WORKING UNDER THE MACHINE...................................... 53 USING DROP LAMPS............................................... 53 KEEPING THE MACHINE CLEAN...................................... 53 ENGINE OPERATION DURING MAINTENANCE............................ 54 REFUELING PRECAUTIONS.......................................... 54 COOLING SYSTEM PRECAUTIONS..................................... 54 GEARSHIFT PRECAUTIONS.......................................... 55 TOOLS.......................................................... 56 BATTERY PRECAUTIONS............................................ 57 STARTER PRECAUTIONS............................................ 58 HIGH PRESSURE HOSES............................................ 59 HIGH TEMPERATURES AREAS........................................ 59 ROTATING PARTS................................................. 60 DISPOSAL OF WASTE MATERIALS.................................... 60 INFLATING TIRES................................................ 60 EXHAUST SYSTEM PRECAUTION...................................... 61 HYDRAULIC OIL ENVIRONMENTAL ESTER SYNTHETIC (HEES)............. 61 CRITICAL PARTS..................................................... 62 VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED.................... 62 SAFETY AND WARNING DECALS.......................................... 63 SAFETY DECAL LOCATIONS......................................... 63 OTHER DECALS....................................................... 79 LOCATION....................................................... 79 DECALS DEFINED................................................. 81 OPERATION.............................................................. 85 GENERAL VIEW OF MACHINE............................................ 86 FRONT VIEW OF MACHINE.......................................... 86 REAR VIEW OF MACHINE........................................... 87 MACHINE CONTROLS................................................... 88 FRONT INSTRUMENTS AND CONTROLS................................. 89 TRANSMISSION OIL TEMPERATURE ALERT......................... 89 ENGINE COOLANT TEMPERATURE ALERT........................... 89 FOUR WHEEL DRIVE INDICATOR................................. 89 LOW FUEL ALERT............................................. 90 DIRECTIONAL SIGNAL INDICATOR............................... 90 HIGH BEAM INDICATOR........................................ 90 PARKING BRAKE/LOW BRAKE FLUID ALERT........................ 90 DIFFERENTIAL LOCK/UNLOCK INDICATOR......................... 90 MULTIFUNCTIONAL DIRECTIONAL SWITCH......................... 90 FOUR WHEEL DRIVE SWITCH.................................... 91 WINDSHIELD WIPER/WASHER SWITCH............................. 91 FRONT WORK LAMPS SWITCH.................................... 91 EMERGENCY/HAZARD SWITCH.................................... 91 OPTIONAL EQUIPMENT SWITCH.................................. 91 ELECTRIC SAFETY VALVE SWITCH............................... 91 SIDE INSTRUMENTS AND CONTROLS.................................. 92 FUEL LEVEL GAUGE........................................... 92 TACHOMETER AND HOUR METER.................................. 93 ENGINE COOLANT TEMPERATURE GAUGE........................... 93 AIR CLEANER RESTRICTION ALERT.............................. 93 ENGINE OIL PRESSURE ALERT.................................. 93 GLOW PLUG PREHEAT INDICATOR................................ 94 ALTERNATOR ALERT........................................... 94 ENGINE COOLANT TEMPERATURE ALERT........................... 94 OPTIONAL EQUIPMENT ALERT................................... 94 AUDIBLE WARNING SYSTEM..................................... 94 REAR WORK LAMPS............................................ 95 REAR WINDSHIELD WIPER/WASHER SWITCH........................ 95 EMERGENCY FLASHING LIGHT SWITCH............................ 95 REAR HORN.................................................. 95 LOAD STABILIZER SWITCH..................................... 95 AIR CONDITIONING SWITCH.................................... 95 IGNITION SWITCH............................................ 96 BLOWER SWITCH.............................................. 96 BACKHOE POWER CONTROL SWTCH................................ 96 BACKHOE BOOM LOCK SWITCH................................... 96 OPTIONAL SWITCH LOCATIONS.................................. 96 LOADER CONTROLS................................................ 97 LOADER DECLUTCH CONTROL.................................... 97 DIFFERENTIAL LOCK.......................................... 97 BUCKET OPEN................................................ 97 BUCKET CLOSE............................................... 97 LOADER SPEED CONTROL....................................... 98 KICKDOWN................................................... 98 GEARSHIFT.......................................................... 99 CONTROLS.......................................................100 STARTING THE ENGINE........................................101 ANTITHEFT..................................................101 DIM BUTTON.................................................102 FOUR WHEEL DRIVE BUTTON....................................102 SHIFTING GEARS WITH SEMIAUTOMATIC LOGIC (SA)...............102 PREVENTING THE ACCIDENTAL SELECTION OF THE FWD/REV GEAR....103 AUTOMATIC LOGIC............................................103 SHIFTING GEARS WITH AUTOMATIC LOGIC........................104 SWITCHING DIRECTION OF TRAVEL..............................104 KICKDOWN...................................................105 DECLUTCH...................................................105 DIAGNOSTIC FUNCTION - MACHINE INOPERATIVE..................106 DIAGNOSTIC FUNCTION - MACHINE OPERABLE....................106 BRAKES AND ACCELERATOR.............................................107 BRAKE PEDALS...................................................107 PARKING BRAKE..................................................107 ACCELERATOR PEDAL..............................................108 HAND THROTTLE..................................................108 THROTTLE OPERATING TIPS....................................108 CAB ENVIRONMENT AND SAFETY EQUIPMENT...............................109 HEATING AND AIR CONDITIONING...................................109 AIR CONDITIONING...........................................109 HEATING SYSTEM.............................................109 SEAT AND SEAT BELT.............................................110 SEAT.......................................................110 SEAT BELT..................................................110 SAFETY EQUIPMENT AND STORAGE AREAS.............................111 FIRE EXTINGUISHER..........................................111 FIRST AID KIT..............................................111 DOCUMENT STORAGE...........................................111 TOOL CASE..................................................111 CAB AND GUARDS.....................................................112 CAB............................................................112 DOORS AND WINDOWS..........................................112 ENGINE HOOD................................................114 ELECTRICAL.........................................................115 SWITCHES AND EXTRA ACCESSORIES.................................115 OVERHEAD LAMP..............................................115 BATTERY DISCONNECT.........................................115 OPTIONAL ELECTRICAL SWITCH LOCATION........................115 FUSES AND RELAYS - ACCESSORIES.................................116 FUSE AND RELAY GRID........................................116 FUSES IDENTIFIED...........................................117 RELAYS IDENTIFIED..........................................118 DASHBOARD RELAYS...........................................118 FUSES AND RELAYS - ENGINE......................................119 FUSE GRID..................................................120 FUSES IDENTIFIED...........................................120 RELAYS IDENTIFIED..........................................120 OPERATING THE MACHINE..............................................121 DAILY CHECKS BEFORE STARTING...................................121 OPERATIONAL CHECKS.............................................121 CHECKING THE FUEL SUPPLY...................................122 STARTING THE ENGINE............................................122 STARTING THE ENGINE IN COLD WEATHER........................123 WARMING UP THE MACHINE.........................................124 MOVING THE MACHINE.............................................125 DIFFERENTIAL LOCK..........................................126 FOUR WHEEL DRIVE...........................................126 BEFORE TURNING THE ENGINE OFF..................................127 OPERATING THE LOADER...............................................128 CONTROL LEVER POSITIONS........................................129 LOADER BUCKET/ARM POSITIONS................................129 DUAL FUNCTIONAL BUCKET/ARM POSITIONS.......................129 PERFORMING LOADING OPERATIONS..................................130 BUCKET POSITION INDICATOR..................................130 ORGANIZING THE WORK AREA...................................131 LOADING HEAPED MATERIAL....................................131 LOADING A TRUCK BED OR TRAILER.............................132 WORKING ON SLOPES WITH A LOADED BUCKET.....................133 CHANGING THE FRONT BUCKET......................................133 OPERATING THE BACKHOE..............................................134 POSITIONING THE MACHINE........................................134 ADJUSTING THE DIGGING BUCKET...................................135 DIGGING METHODS................................................136 CHANGING THE BACKHOE BUCKET....................................138 ISO BACKHOE CONTROLS...........................................139 KOMATSU BACKHOE CONTROLS.......................................140 TRAVELING..........................................................141 TRAVELING OR WORKING IN WATER..................................141 MAINTENANCE............................................................143 MAINTENANCE GUIDE..................................................144 PRECAUTIONS DURING SEASONAL CHANGES................................145 COLD WEATHER...................................................145 FUEL AND LUBRICANTS........................................145 COOLANT....................................................145 BATTERY....................................................145 WARM WEATHER...................................................146 BASIC TROUBLESHOOTING..............................................147 THE BATTERY....................................................147 SERVICING THE BATTERY......................................147 REMOVAL AND INSTALLATION...................................147 ELECTRICAL CIRCUITS............................................148 HYDRAULIC SYSTEM...............................................148 BRAKING SYSTEM.................................................149 TORQUE CONVERTER SYSTEM........................................149 ENGINE.........................................................150 MAINTENANCE NOTES..................................................151 NOTES REGARDING THE ENGINE.....................................151 ENGINE OIL.................................................151 COOLANT....................................................152 FUEL.......................................................152 NOTES REGARDING THE HYDRAULIC SYSTEM...........................152 NOTES REGARDING THE ELECTRICAL SYSTEM..........................153 NOTES REGARDING LUBRICATION....................................153 NORMAL WEAR PARTS..............................................154 FUEL, COOLANT, AND LUBRICANTS..................................155 SELECTION ACCORDING TO AMBIENT TEMPERATURE.................155 GREASE.........................................................156 HEES - SYNTHETIC, BIODEGRADABLE HYDRAULIC OIL......................159 LUBRICATION DIAGRAMS...............................................160 GENERAL........................................................160 MULTIPURPOSE BUCKET AND PALLET FORKS...........................161 FRONT BUCKET QUICK COUPLINGS...................................162 TELESCOPIC ARM.................................................163 SAFETY RELATED PARTS MAINTENANCE...................................164 CRITICAL SAFETY PARTS..........................................165 FUEL SUPPLY SYSTEM.........................................165 DELIVERY/RETURN HYDRAULIC SYSTEM...........................166 LOADER AND BACKHOE HYDRAULIC SYSTEM............................167 OPERATOR'S SAFETY..........................................168 TORQUE VALUES......................................................169 GENERAL TORQUE VALUES - BOLTS AND NUTS.........................169 SPECIFIC TORQUE VALUES.........................................169 MAINTENANCE PLAN...................................................170 CHECKS BEFORE STARTING.........................................170 MAINTENANCE EVERY 10 HOURS OF OPERATION........................170 MAINTENANCE AFTER THE FIRST 50 HOURS OPERATION.................170 MAINTENANCE EVERY 50 HOURS OF OPERATION........................171 MAINTENANCE AFTER FIRST 250 HOURS OF OPERATION.................171 MAINTENANCE EVERY 250 HOURS OF OPERATION.......................171 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION.............172 MAINTENANCE EVERY 500 HOURS OF OPERATION.......................172 MAINTENANCE EVERY 1000 HOURS OF OPERATION......................172 MAINTENANCE EVERY 2000 HOURS OF OPERATION......................172 WHEN REQUIRED..................................................173 MAINTENANCE INTERVALS WHEN DEMOLITION HAMMER IS USED...........173 CHECKS BEFORE STARTING.............................................174 VARIOUS CHECKS.................................................174 CHECK THE FUEL LEVEL...........................................174 CHECK THE COOLANT LEVEL........................................175 CHECK THE ENGINE OIL LEVEL.....................................175 CHECK THE HYDRAULIC OIL LEVEL..................................176 DRAIN THE WATER SEPARATOR......................................177 MAINTENANCE EVERY 10 HOURS OF OPERATION............................177 LUBRICATING JOINTS (GREASE FITTINGS)...........................177 JOINT LUBRICATION POINTS.......................................178 LUBRICATION LOCATIONS - LOADER.............................178 LUBRICATION LOCATIONS - BACKHOE............................179 MAINTENANCE AFTER FIRST 50 HOURS OF OPERATION......................180 MAINTENANCE EVERY 50 HOURS OF OPERATION............................180 CHECK THE RADIATOR COOLANT LEVEL...............................180 CHECK THE BRAKE FLUID LEVEL....................................180 LUBRICATE THE PROPELLER SHAFTS.................................181 LUBRICATE THE KING PIN.........................................182 CHECK TIRE PRESSURE............................................182 CHECK THE ELECTRICAL SYSTEM....................................183 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.................183 MAINTENANCE EVERY 250 HOURS OF OPERATION...........................184 ADJUST THE FAN BELT TENSION....................................184 CLEAN THE OUTSIDE OF RADIATOR..................................185 CHECK BATTERY ELECTROLYTE LEVEL................................185 CHECK THE FRONT AXLE OIL LEVEL.................................186 CHECK THE REAR AXLE OIL LEVELS.................................186 CHECK THE TRANSMISSION OIL LEVEL...............................187 CHECK THE WHEEL LUG NUT TORQUE.................................187 MAINTENANCE AFTER FIRST 500 HOURS OF OPERATION.....................188 MAINTENANCE EVERY 500 HOURS OF OPERATION...........................188 CHANGE THE ENGINE OIL..........................................188 CHANGE THE ENGINE OIL FILTER...................................189 CHANGE THE HYDRAULIC OIL FILTER................................190 CHANGE THE FUEL FILTER.........................................192 DRAIN THE FUEL TANK............................................193 DRAIN THE HYDRAULIC OIL TANK...................................194 MAINTENANCE EVERY 1000 HOURS.......................................195 CHANGE THE FRONT AXLE OIL......................................195 DIFFERENTIAL...............................................195 PLANETARY..................................................195 CHANGE THE REAR AXLE OIL.......................................196 DIFFERENTIAL...............................................196 PLANETARY..................................................196 CHANGE THE TRANSMISSION OIL....................................197 CHANGE THE TRANSMISSION FILTER.................................198 CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE..................199 MAINTENANCE EVERY 2000 HOURS ......................................199 CHANGE THE HYDRAULIC OIL AND CLEAN THE SUCTION FILTER..........199 CHANGE THE COOLANT.............................................201 CHANGE THE BRAKE FLUID.........................................203 CHECK THE ALTERNATOR AND STARTER...............................203 WHEN REQUIRED......................................................204 CHECK, CLEAN, OR CHANGE THE AIR CLEANER CARTRIDGE..............204 CHECK AND CLEAN CAB AIR FILTERS................................205 BLEED THE BRAKE SYSTEM.........................................206 FLUSH THE COOLING SYSTEM.......................................207 CLEAN THE WATER SEPARATOR......................................210 CHECK AND ADJUST THE FRONT WHEEL TOE-IN........................210 CHECK AND ADJUST THE PARKING BRAKE.............................211 CHECK THE SERVICE BRAKE........................................212 CHECK AND ADJUST BRAKE PEDAL STROKE............................212 ADJUST AUTOMATIC RETURN OF FRONT BUCKET TO DIG POSITION........213 MAINTENANCE INTERVALS WHEN DEMOLITION HAMMER USED..................214 CHANGE THE HYDRAULIC OIL FILTER................................214 CHANGE THE HYDRAULIC OIL.......................................214 LONG TERM STORAGE..................................................215 BEFORE STORAGE.................................................215 DURING STORAGE.................................................216 REMOVING FROM STORAGE..........................................216 SPECIFICATIONS.........................................................217 TECHNICAL DATA.....................................................218 STANDARD OVERALL DIMENSIONS....................................218 TECHNICAL CHARACTERISTICS WB140PS-2N...........................219 TOTAL MASS.................................................219 STANDARD BUCKET CAPACITY...................................219 TURBOCHARGED ENGINE........................................219 ELECTRICAL SYSTEM..........................................219 TRAVEL SPEEDS..............................................219 TIRES......................................................219 TECHNICAL CHARACTERISTICS WB150PS-2N...........................220 TOTAL MASS.................................................220 STANDARD BUCKET CAPACITY...................................220 TURBOCHARGED ENGINE........................................220 ELECTRICAL SYSTEM..........................................220 TRAVEL SPEEDS..............................................220 TIRES......................................................220 LIFTING CAPACITIES.............................................221 LIFTING CAPACITY - WB140PS-2N..............................222 LIFTING CAPACITY - WB150PS-2N..............................224 OPTIONAL ATTACHMENTS...................................................227 AUTHORIZED OPTIONAL EQUIPMENT......................................228 BASIC PRECAUTIONS..............................................228 OPTIONAL EQUIPMENT MEASUREMENTS - WB140PS-2N...................229 FRONT END LOADER...........................................229 BACKHOE UNIT...............................................229 OPTIONAL EQUIPMENT MEASUREMENTS - WB150PS-2N...................230 FRONT END LOADER...........................................230 BACKHOE....................................................230 MULTIPURPOSE BUCKET................................................231 MULTIPURPOSE BUCKET COUPLING...................................233 MANUAL COUPLING............................................233 HYDRAULIC COUPLING.........................................234 MULTIPURPOSE BUCKET INSTALLATION...............................235 MULTIPURPOSE BUCKET USES.......................................236 MULTIPURPOSE BUCKET WITH FORK LIFT.............................237 FORK ADJUSTMENT............................................237 BEFORE TRAVELING...........................................238 REMOVING AND INSTALLING THE FORKS..........................238 BACKHOE TELESCOPIC ARM.............................................239 DESCRIPTION AND CONTROL........................................239 SAFETY LOCKS...............................................239 MAINTENANCE................................................240 DEMOLITION HAMMER..................................................242 DESCRIPTION AND CONTROL........................................242 HAMMER USAGE RULES.............................................243 ALWAYS AVOID THE FOLLOWING.................................245 DEMOLITION HAMMER INSTALLATION AND REMOVAL.....................247 INSTALLATION...............................................247 REMOVAL....................................................249 CLAMSHELL BUCKET...................................................250 DESCRIPTION AND CONTROL........................................250 CLAMSHELL BUCKET INSTALLATION..................................251 STANDARD ARM...............................................251 TELESCOPIC ARM.............................................252 CLAMSHELL BUCKET REMOVAL.......................................252 OPERATING THE CLAMSHELL BUCKET.................................252 HYDRAULIC JACK HAMMER..............................................253 DESCRIPTION AND CONTROL........................................253 CONNECTING THE JACK HAMMER.....................................254 DISCONNECTING THE JACK HAMMER..................................254 USING THE JACK HAMMER..........................................254 OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW....................255 INSTALLING AND CONNECTING THE EQUIPMENT........................255 LOAD STABILIZER SYSTEM (LSS).......................................256
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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