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KOMATSU WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL(SN:A13001 & UP) KOMATSU WB142 5 – PDF DOWNLOAD
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- KOMATSU WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A13001 & UP
- PUBLICATION NUMBER:CEAM018501
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Description
KOMATSU WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL(SN:A13001 & UP) KOMATSU WB142 5
KOMATSU WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL(SN:A13001 & UP) KOMATSU WB142 5 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL(SN:A13001 & UP) KOMATSU WB142 5
- 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 can not 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 WB142-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL(SN:A13001 & UP) KOMATSU WB142 5
COVER.............................................................. 1 INTRODUCTION....................................................... 3 FOREWORD....................................................... 4 SAFETY INFORMATION............................................. 5 APPROVED AND NON-APPROVED USES................................. 6 NON-APPROVED............................................... 6 PRODUCT INFORMATION............................................ 7 MAIN FEATURES.............................................. 7 BREAK-IN PERIOD............................................ 7 SYNTHETIC BIODEGRADABLE OIL TYPES...................... 7 PRODUCT IDENTIFICATION......................................... 8 MACHINE SERIAL NUMBER...................................... 8 MACHINE IDENTIFICATION PLATE............................... 8 ENGINE SERIAL NUMBER AND EMISSION LABEL.................... 9 FRONT AXLE SERIAL NUMBER................................... 9 REAR AXLE SERIAL NUMBER.................................... 9 TRANSMISSION SERIAL NUMBER................................. 10 CANOPY SERIAL NUMBER....................................... 10 SERIAL NUMBERS AND DEALER INFORMATION.......................... 11 MODEL: WB142-5............................................. 11 CONTENTS....................................................... 12 SAFETY............................................................. 21 SAFETY AND WARNING DECALS...................................... 22 LOCATION OF THE SAFETY DECALS.............................. 24 WORK ZONE.............................................. 24 ROTATING PARTS......................................... 24 HYDRAULIC OIL.......................................... 24 BLOCK WHEELS........................................... 24 BEFORE MOVING MACHINE.................................. 25 BEFORE STANDING UP FROM OPERATOR’S SEAT................ 25 WHILE ENGINE IS RUNNING................................ 26 ALWAYS USE SEAT BELT................................... 26 MACHINE OPERATION...................................... 26 IMPROPER OPERATION AND MAINTENANCE..................... 26 DO NOT WELD ONTO ROPS.................................. 27 BOOM LOCK.............................................. 27 ELECTROCUTION HAZARD................................... 27 CRUSH HAZARD: KEEP CLEAR............................... 28 PINCH POINT............................................ 28 INCORRECT STARTING PROCEDURES.......................... 28 BRAKE PEDAL CONNECTOR.................................. 28 4 WHEEL DRIVE.......................................... 29 HYDRAULIC OIL.......................................... 29 HYDRAULIC OIL LEVEL.................................... 29 HYDRAULIC OIL FILTER................................... 29 FUEL................................................... 29 FUEL FILTER............................................ 30 ENGINE LUBRICATION OIL FILTER.......................... 30 ENGINE AIR FILTER...................................... 30 ENGINE COOLANT......................................... 30 COOLANT PRESSURE CAP................................... 30 TRANSMISSION OIL LEVEL................................. 31 TRANSMISSION OIL FILTER................................ 31 POWER OUTLET........................................... 31 BOOM LOCK.............................................. 31 SWING LOCK............................................. 31 ANCHORAGE POINT........................................ 32 EMERGENCY EXIT......................................... 32 BRAKE OIL.............................................. 32 DO NOT LIFT WARNING.................................... 32 GENERAL SAFETY RULES AND PRECAUTIONS........................... 33 GENERAL SAFETY RULES....................................... 33 UNAUTHORIZED MODIFICATIONS............................. 34 GENERAL SAFETY AT JOB SITE............................. 34 WORKING ON LOOSE GROUND................................ 34 SAFETY FEATURES............................................ 35 PERSONAL PROTECTIVE EQUIPMENT.............................. 35 FIRE AND EXPLOSION PREVENTION.............................. 36 FIRE CAUSED BY FUEL OR OIL............................. 36 FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...... 36 FIRE FROM ELECTRICAL SYSTEM............................ 37 FIRE FROM HYDRAULIC LINE............................... 37 ACTION IF FIRE OCCURS...................................... 37 ASBESTOS DUST HAZARD PREVENTION............................ 37 KEEP OPERATOR'S CAB CLEAN.................................. 37 UNAUTHORIZED MODIFICATIONS................................. 38 LEAVING OPERATOR’S COMPARTMENT............................. 39 MOUNTING AND DISMOUNTING................................... 40 CRUSH OR PINCH POINT DANGERS............................... 40 FIRE EXTINGUISHER AND FIRST AID KIT........................ 41 INSIDE OPERATOR’S COMPARTMENT.............................. 41 PRECAUTIONS WHEN USING ROPS................................ 42 PRECAUTIONS FOR ATTACHMENTS................................ 42 QUICK COUPLER ATTACHMENT............................... 42 LARGE ATTACHMENTS...................................... 42 PRECAUTIONS BEFORE STARTING OPERATIONS......................... 43 PRE-OPERATIONAL CHECKS..................................... 43 STARTING YOUR WORK OPERATIONS.............................. 43 WORK SITE HAZARDS.......................................... 43 AVOIDING DANGEROUS SITUATIONS.............................. 44 WORKING CLEARANCES..................................... 46 HIGH VOLTAGE LINES..................................... 46 RULES FOR ROAD TRAVEL.......................................... 47 PRECAUTIONS WHEN TRAVELING................................. 47 RULES FOR TRAVELING IN REVERSE............................. 49 TRAVELING ON ICY OR SNOW-COVERED SURFACES.................. 49 WORKING ON LOOSE OR UNSTABLE GROUND........................ 49 TRAVEL ON SLOPES........................................... 49 PARKING THE MACHINE........................................ 51 PRECAUTIONS DURING MAINTENANCE OPERATIONS...................... 52 WARNING TAGS............................................... 52 EQUIPMENT STORAGE.......................................... 52 WORKING UNDER THE MACHINE.................................. 53 USING DROP LAMPS........................................... 53 KEEPING THE MACHINE CLEAN.................................. 53 RUNNING THE MACHINE DURING MAINTENANCE..................... 54 RULES FOR REFUELING THE MACHINE............................ 54 COOLING SYSTEM PRECAUTIONS................................. 54 BATTERY PRECAUTIONS........................................ 55 STARTING THE MACHINE....................................... 55 HIGH-PRESSURE HOSES........................................ 56 HANDLING HIGH-PRESSURE HOSES........................... 56 PRECAUTION FOR HIGH FUEL PRESSURE.......................... 56 HIGH TEMPERATURES AREAS.................................... 56 ROTATING PARTS............................................. 57 DISPOSAL OF WASTE MATERIALS................................ 57 INFLATING TIRES............................................ 57 ACCUMULATOR................................................ 58 CRITICAL PARTS............................................. 58 TRANSPORTING THE MACHINE....................................... 59 LOADING AND SECURING THE MACHINE........................... 59 OPERATION.......................................................... 61 GENERAL VIEW OF MACHINE........................................ 62 FRONT VIEW OF MACHINE...................................... 62 REAR VIEW OF MACHINE....................................... 63 DESCRIPTION OF MACHINE OPERATION CONTROLS...................... 64 CONTROL LOCATIONS.......................................... 64 FRONT INSTRUMENT BEZEL AND CONTROLS........................ 65 LOW FUEL ALERT LAMP.................................... 65 FOUR-WHEEL DRIVE (IN/OUT) INDICATOR.................... 66 DIFFERENTIAL (LOCK/UNLOCK) INDICATOR................... 66 PARKING BRAKE ALERT LAMP............................... 66 TRANSMISSION OIL TEMPERATURE ALERT..................... 66 LEFT DIRECTION INDICATOR LAMP.......................... 67 RIGHT DIRECTION INDICATOR LAMP......................... 67 LOW PRESSURE OR BRAKE FLUID ALERT...................... 67 MAIN ALARM LAMP........................................ 67 HIGH BEAM INDICATOR LAMP............................... 68 LOW BEAM INDICATOR LAMP................................ 68 WORK LIGHTS ALERT LAMP................................. 68 STEERING COLUMN SWITCHES................................... 69 DIRECTIONAL CONTROL SWITCH (STANDARD).................. 69 MULTIFUNCTIONAL SWITCH................................. 69 SIDE INSTRUMENT BEZEL AND CONTROLS......................... 70 FUEL LEVEL GAUGE....................................... 71 ENGINE COOLANT TEMPERATURE GAUGE....................... 71 TACHOMETER AND HOUR METER.............................. 72 HYDRAULIC OIL FILTER CLOG INDICATOR.................... 72 ALTERNATOR ALERT....................................... 72 GLOW PLUGS PREHEAT INDICATION.......................... 73 ENGINE COOLANT TEMPERATURE ALERT....................... 73 ENGINE OIL PRESSURE ALERT.............................. 73 AIR CLEANER RESTRICTION ALERT.......................... 73 AUDIBLE WARNING SYSTEM................................. 74 BACKHOE SPEED CONTROL BUTTON........................... 74 BACKHOE BOOM LOCK SWITCH............................... 74 REAR HORN.............................................. 74 HAZARD FLASHERS........................................ 75 PARKING LIGHTS AND LOW BEAM SWITCH..................... 75 FOUR-WHEEL DRIVE SWITCH................................ 75 ROTATING BEACON LAMP................................... 75 FRONT WORK LIGHT SWITCH................................ 76 REAR WORK LIGHT SWITCH................................. 76 OPTIONAL EQUIPMENT SWITCHES............................ 76 IGNITION SWITCH........................................ 76 FRONT END LOADER CONTROLS.................................. 77 LOADER DECLUTCH CONTROL BUTTON......................... 77 DIFFERENTIAL LOCK BUTTON............................... 77 FRONT END LOADER SPEED CONTROL BUTTON.................. 78 BACKHOE CONTROLS........................................... 79 GEAR SHIFT LEVER CONTROLS.................................. 80 DECLUTCH BUTTON........................................ 80 CHANGING SPEED RANGES.................................. 80 DIRECTIONAL CONTROL LEVER.............................. 80 BRAKES, PARKING BRAKE, ACCELERATOR AND THROTTLE CONTROL.... 81 BRAKE PEDALS........................................... 81 PARKING BRAKE.......................................... 81 ACCELERATOR PEDAL...................................... 82 HAND THROTTLE.......................................... 82 SEAT....................................................... 83 SEAT BELT.............................................. 84 DOCUMENT STORAGE....................................... 84 GUARDS..................................................... 85 DRIVER’S OVERHEAD GUARD................................ 85 ENGINE HOOD............................................ 85 ELECTRICAL..................................................... 86 SWITCHES AND EXTRA ACCESSORIES............................. 86 BATTERY DISCONNECT..................................... 86 FUSES AND RELAYS........................................... 87 FUSE AND RELAY PANEL LOCATION.......................... 87 FUSE AND RELAY PANEL LAYOUT............................ 88 OPERATING THE MACHINE.......................................... 91 CHECKING THE FUEL SUPPLY................................... 91 STARTING THE ENGINE........................................ 91 STARTING THE ENGINE IN COLD WEATHER.................... 92 WARMING THE MACHINE UP..................................... 93 SHUTTING THE ENGINE DOWN................................... 93 OPERATING THE FRONT END LOADER AND BACKHOE..................... 94 PRE-OPERATIONAL CHECKS..................................... 94 PERFORM A WALK-AROUND CHECK OF YOUR MACHINE............ 94 UNDER THE HOOD......................................... 95 IN THE OPERATOR’S CANOPY............................... 95 START-UP CHECKS........................................ 95 STARTING YOUR WORK OPERATIONS.................................. 96 AVOIDING DANGEROUS SITUATIONS.............................. 96 WORKING CLEARANCES......................................... 99 OPERATING THE FRONT END LOADER.............................100 CONTROL LEVER POSITIONS................................101 PERFORMING LOADING OPERATIONS..............................102 ORGANIZING YOUR WORK AREA..............................102 LOADING HEAPED MATERIAL................................102 LOADING A TRUCK BED OR TRAILER.........................104 WORKING ON SLOPES WITH A LOADED BUCKET.................104 CHANGING THE FRONT BUCKET..................................105 OPERATING THE BACKHOE......................................106 POSITIONING THE MACHINE................................106 UNLOCKING THE BACKHOE..................................106 ISO BACKHOE CONTROLS...................................109 KOMATSU BACKHOE CONTROLS...............................110 DIGGING METHODS........................................111 CHANGING THE BACKHOE BUCKET................................112 ADJUSTING THE BUCKET...................................112 SAFETY LOCK USAGE..............................................113 FRONT END LOADER CYLINDER LOCK.............................113 BACKHOE LOCKS..............................................114 MOVING OR TRAVELING WITH THE MACHINE...........................116 TRAVELING..................................................116 TRAVELING ON SLOPES....................................117 TRAVELING OR WORKING IN SWAMPY OR WET AREAS............118 PARKING THE MACHINE............................................119 FOR SHORT OR LONG PERIODS..................................119 PARKING ON AN INCLINE..................................120 TRANSPORTING THE MACHINE.......................................121 LOADING AND SECURING THE MACHINE...........................121 EMERGENCY RECOVERY.............................................122 HOW TO MOVE THE MACHINE....................................122 PRECAUTIONS DURING SEASONAL CHANGES............................123 COLD SEASONS...............................................123 FUEL AND LUBRICANTS....................................123 COOLANT................................................123 BATTERY................................................124 WARM SEASONS...............................................124 BASIC TROUBLESHOOTING..........................................125 THE BATTERY................................................125 SERVICING THE BATTERY..................................125 REMOVAL AND INSTALLATION...............................125 STARTING THE ENGINE WITH BOOSTER CABLE.................126 ELECTRICAL CIRCUITS........................................128 HYDRAULIC SYSTEM...........................................128 BRAKING SYSTEM.............................................129 TRANSMISSION...............................................129 ENGINE.....................................................130 MAINTENANCE........................................................131 GUIDE TO MAINTENANCE...........................................132 MAINTENANCE NOTES..............................................133 ENGINE.....................................................134 ENGINE OIL.............................................134 COOLANT................................................134 FUEL...................................................134 HYDRAULIC SYSTEM...........................................135 ELECTRICAL SYSTEM..........................................135 LUBRICATION................................................135 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING......136 FUEL, COOLANT, AND LUBRICANTS..................................137 PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE......137 GREASE.....................................................138 FUEL REMARKS...............................................138 HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS........................139 LUBRICATION DIAGRAMS...........................................140 GENERAL VIEW...............................................140 PERIODIC REPLACEMENT OF COMPONENTS.............................141 CRITICAL PARTS FOR SAFETY..................................142 FUEL SUPPLY SYSTEM.....................................142 DELIVERY / RETURN HYDRAULIC SYSTEM.....................142 LOADER AND BACKHOE HYDRAULIC SYSTEM....................142 OPERATOR’S SAFETY......................................143 STANDARD TIGHTENING TORQUE.....................................144 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS..............144 SPECIFIC TIGHTENING TORQUES................................144 MAINTENANCE SCHEDULE...........................................144 MAINTENANCE SCHEDULE CHART.................................145 CHECKS BEFORE STARTING.........................................148 VARIOUS CHECKS.............................................148 FUEL LEVEL.................................................148 COOLANT LEVEL..............................................149 ENGINE OIL LEVEL...........................................149 HYDRAULIC OIL LEVEL........................................150 DRAINING WATER SEPARATOR...................................151 MAINTENANCE EVERY 10 HOURS OF OPERATION........................152 LUBRICATING JOINTS (GREASE FITTINGS).......................152 WORK EQUIPMENT LUBRICATION POINTS..........................153 FRONT LOADER LUBRICATION LOCATIONS.....................153 BACKHOE LUBRICATION LOCATIONS..........................154 MAINTENANCE AFTER FIRST 50 HOURS OF OPERATION..................155 MAINTENANCE EVERY 50 HOURS OF OPERATION........................156 CHECKING RADIATOR FLUID LEVEL..............................156 CHECKING BRAKE SYSTEM OIL LEVEL............................156 LUBRICATING DRIVE SHAFTS...................................157 LUBRICATING FRONT AXLE JOINTS..............................158 CHECKING TIRE PRESSURE.....................................158 CHECKING ELECTRICAL SYSTEM.................................159 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION.............160 MAINTENANCE EVERY 250 HOURS OF OPERATION.......................161 CHECKING SERPENTINE BELT...................................161 CLEANING OUTSIDE OF RADIATOR...............................162 CHECKING BATTERY ELECTROLYTE...............................163 CHECKING FRONT AXLE OIL LEVELS.............................163 CHECKING REAR AXLE OIL LEVELS..............................164 TRANSMISSION OIL LEVEL.....................................164 CHECKING WHEEL LUG NUT TORQUE..............................164 MAINTENANCE AFTER FIRST 500 HOURS OF OPERATION.................165 MAINTENANCE EVERY 500 HOURS OF OPERATION.......................166 CHANGING ENGINE OIL........................................166 CHANGING ENGINE OIL FILTER.................................167 CHANGING FUEL FILTER.......................................171 FUEL FILTER............................................171 BLEEDING THE CIRCUIT...................................171 DRAINING FUEL TANK.........................................172 DRAINING HYDRAULIC OIL TANK................................173 MAINTENANCE EVERY 1000 HOURS...................................174 CHANGING FRONT AXLE OIL....................................174 DIFFERENTIAL...........................................174 PLANETARY..............................................174 CHANGING THE REAR AXLE OIL.................................175 DIFFERENTIAL...........................................175 PLANETARY..............................................175 CHANGING TRANSMISSION OIL AND FILTER.......................176 CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE..............177 MAINTENANCE EVERY 2000 HOURS OF OPERATION......................178 CHANGING HYDRAULIC SYSTEM OIL FILTER.......................178 CHANGING COOLANT...........................................181 CHANGING THE BRAKING SYSTEM OIL............................182 CHECKING THE ALTERNATOR AND THE STARTER....................183 CHANGING THE ALTERNATOR BELT...............................183 WHEN REQUIRED..................................................184 CLEANING OR CHANGING THE ENGINE AIR FILTERS................184 BLEEDING BRAKE SYSTEM......................................186 CHECKING AND ADJUSTING FRONT WHEEL TOE-IN..................187 CHECKING AND ADJUSTING PARKING BRAKE.......................188 CHECK..................................................188 ADJUSTMENT.............................................189 CHECKING THE BRAKING EFFICIENCY............................189 CHECKING AND ADJUSTING BRAKE PEDAL STROKE..................190 MAINTENANCE INTERVALS FOR DEMOLITION HAMMER USE................191 CHANGING HYDRAULIC OIL FILTER..............................191 CHANGING HYDRAULIC OIL.....................................191 LONG TERM STORAGE..............................................192 BEFORE STORAGE.............................................192 DURING STORAGE.............................................193 AFTER STORAGE..............................................193 SPECIFICATIONS.....................................................195 SPECIFICATIONS.................................................196 MACHINE DIMENSIONS AND WEIGHTS.............................196 BACKHOE ARM................................................197 MACHINE SYSTEMS SPECIFICATIONS.................................198 ENGINE.....................................................198 ELECTRICAL SYSTEM..........................................198 SERVICE REFILL CAPACITIES..................................198 TRANSMISSION...............................................199 TOTAL MASS.................................................199 STANDARD BUCKET CAPACITY...................................199 LOADER.....................................................199 OPTIONAL ATTACHMENTS...............................................201 AUTHORIZED OPTIONAL EQUIPMENT..................................202 BASIC PRECAUTIONS..........................................202 OPTIONAL EQUIPMENT MEASUREMENTS FOR WB142-5................203 FRONT END LOADER.......................................203 BACKHOE UNIT...........................................203 DEMOLITION HAMMER..............................................204 DESCRIPTION AND CONTROL....................................204 RULES FOR HAMMER USAGE.................................205 ALWAYS AVOID THE FOLLOWING USES:.......................206 INSTALLATION AND REMOVAL OF THE DEMOLITION HAMMER..........208 INSTALLATION...........................................208 REMOVAL................................................208 CONNECTING AND REMOVING THE JACK HAMMER................209 USING THE JACK HAMMER..................................209
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