Komatsu Backhoe-Loader WB97S-5E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe-Loader WB97S-5E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe-Loader WB97S-5E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
WEAM009001 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM011704 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM011707 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEAM015502 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual.pdf
WEBM008400 - Backhoe-Loader WB97S-5E0 Shop Manual.pdf
WEBM008402 - Backhoe-Loader WB97S-5E0 Shop Manual.pdf
WETT001308 - Backhoe-Loader WB91R-5EO, WB93R-5EO, WB97R-5EO, WB93S-5EO, WB97S-5EO Basic Technical Training.pdf
PRODUCT DETAILS:
Total Pages: 2,834 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM009001 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...1
WEAM011704 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...295
1.1 FOREWORD...297
1.2 INFORMATION ON SAFETY...298
1.2.1 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...301
1.2.2 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...302
1.2.3 GUIDE WHEN WORKING IN AREAS WHERE AIR POLLUTION...303
1.3 INTRODUCTION...304
1.3.1 INTENDED USES...304
1.3.2 DEMOLITION WORK...304
1.3.3 IMPROPER OR UNAUTHORIZED USE...305
1.3.4 MAIN CHARACTERISTICS...306
1.3.5 RUNNING-IN...306
1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE...307
1.3.6.1 WHEN OPERATING THE LOADER OR TRAVELLING...307
1.3.6.2 WHEN OPERATING THE BACKHOE...308
1.4 PRODUCT IDENTIFICATION...309
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...309
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...309
1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)...310
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...311
1.4.4 FRONT AXLE SERIAL NUMBER...311
1.4.5 REAR AXLE SERIAL NUMBER...312
1.4.6 TRANSMISSION SERIAL NUMBER...312
1.4.7 CAB SERIAL NUMBER...312
1.4.8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...313
1.4.9 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)...313
1.5 KOMTRAX SYSTEM...314
1.5.1 GENERAL PRECAUTIONS...314
TABLE OF CONTENTS...315
2.1 SAFETY, NOISE AND VIBRATION PLATES...326
2.1.1 POSITION OF THE SAFETY PLATES...326
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...328
2.2 GENERAL PRECAUTIONS...342
2.2.1 GENERAL SAFETY RULES...342
2.2.2 SAFETY DEVICES AND GUARDS...342
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...342
2.2.4 UNAUTHORIZED MODIFICATIONS...343
2.2.5 LEAVING THE OPERATOR’S SEAT...343
2.2.6 GETTING ON AND OFF THE MACHINE...344
2.2.7 CHECKING THE REAR-VIEW MIRRORS...344
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...345
2.2.9 LIFTING OF PERSONNEL PROHIBITED...345
2.2.10 PREVENTING BURNS...345
2.2.11 ASBESTOS DUST HAZARD PREVENTION...346
2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...346
2.2.13 DETERGENT FOR THE WINDOWS...346
2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT...347
2.2.15 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...347
2.2.16 CAUTIONS RELATED TO ROPS...348
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT...348
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...349
2.3.1 SAFETY ON THE WORK SITE...349
2.3.2 FIRE PREVENTION...349
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...349
2.3.4 ROOM VENTILATION...350
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...350
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...351
2.4.1 WHEN STARTING THE ENGINE...351
2.4.2 RULES FOR TRAVELLING ON ROADS...351
2.4.3 REGULATIONS FOR ROAD TRANSFER (TUV approval)...352
2.4.4 HAND SIGNALS...354
2.4.5 CHECKS FOR TRAVELLING IN REVERSE...359
2.4.6 MOVING THE MACHINE...359
2.4.7 WORKING ON SLOPES...360
2.4.8 PROHIBITED OPERATIONS...360
2.4.9 PREVENTING ELECTROCUTION...361
2.4.10 VISIBILITY...362
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...362
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...362
2.4.13 WORKING ON LOOSE GROUND...362
2.4.14 PARKING THE MACHINE...363
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...364
2.5.1 LOADING AND UNLOADING THE MACHINE...364
2.5.2 TRANSPORT...364
2.6 BATTERY...365
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...365
2.6.2 STARTING WITH BOOSTER CABLES...366
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...367
2.8 LIFTING OBJECTS WITH LIFTING DEVICE (OPTIONAL EQUIPMENT)...368
2.8.1 SAFETY RULES FOR LIFTING OBJECTS...368
2.9 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...371
2.9.1 WARNING PLATES...371
2.9.2 TOOLS...371
2.9.3 PERSONNEL...372
2.9.4 EQUIPMENT...372
2.9.5 WORKING UNDER THE MACHINE...372
2.9.6 STABILITY...372
2.9.7 REPAIR WELDS...372
2.9.8 KEEPING THE MACHINE CLEAN...373
2.9.9 USE OF THE ENGINE DURING MAINTENANCE...373
2.9.10 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...373
2.9.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...374
2.9.12 BATTERY MAIN SWITCH PRECAUTIONS...375
2.9.13 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...375
2.9.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR...375
2.9.15 USING LAMPS...376
2.9.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...376
2.9.17 PRECAUTIONS CONCERNING THE STARTER...376
2.9.18 HANDLING HIGH-PRESSURE PIPES...377
2.9.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...377
2.9.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...377
2.9.21 HYDRAULIC ACCUMULATOR...378
2.9.22 COOLING FAN AND FAN BELT...378
2.9.23 CHEMICAL HAZARD...378
2.9.24 WASTE MATERIALS...379
2.9.25 SERVICING THE AIR CONDITIONER...379
2.9.26 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...379
2.9.27 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...380
2.9.28 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...380
2.9.29 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...381
2.9.30 FINAL DISPOSAL OF THE MACHINE...381
3.1 SAFETY LOCKS...384
3.1.1 FRONT LOADER LOCKS...384
3.1.2 BACKHOE LOCKS...386
3.2 GENERAL VIEWS...388
3.2.1 FRONT GENERAL VIEW...388
3.2.2 BACKHOE GENERAL VIEW...389
3.2.3 CAB INSIDE GENERAL VIEW...390
3.3 INSTRUMENTS AND CONTROLS...392
3.3.1 FRONT INSTRUMENTS...392
3.3.2 SIDE INSTRUMENTS...397
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...408
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES...410
3.3.5 MACHINE CONTROLS...414
3.3.6 ADJUSTING THE CONTROLS...437
3.4 FUSES AND RELAYS...440
3.4.1 CENTRAL UNIT FUSES - RELAYS AND ENGINE LINE...440
3.4.1.1 FUSES...441
3.4.1.2 RELAYS...443
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS...445
3.4.2.1 FUSES...445
3.4.2.2 RELAYS...445
3.5 GUARDS, CAB AND DRIVER’S SEAT...446
3.5.1 ENGINE HOOD...446
3.5.2 CAB...447
3.5.3 VENTILATION AND HEATING...450
3.5.4 AIR CONDITIONER (if installed)...451
3.5.5 SEAT...453
3.5.5.1 SEAT (Standard mod. CAB SEATING)...453
3.5.5.2 SEAT (Optional mod. CAB SEATING)...455
3.5.5.3 PNEUMATIC SUSPENSION SEAT (optional mod. CAB SEATING)...456
3.5.5.4 SEAT (Standard mod. SEARS SEATING)...457
3.5.5.5 PNEUMATIC SUSPENSION SEAT (optional mod. SEARS SEATING)...458
3.5.6 SAFETY BELT...459
3.5.6.1 STANDARD SAFETY BELTS...459
3.5.6.2 SAFETY BELTS WITH WINDER...459
3.5.7 FIRE EXTINGUISHER...459
3.5.8 FIRST AID KIT...459
3.5.9 TECHNICAL DOCUMENTATION...460
3.5.10 STORAGE COMPARTMENT...460
3.5.11 REFUELLING PUMP (If installed)...461
3.6 USE OF THE MACHINE...463
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...463
3.6.1.1 VISUAL CHECKS...463
3.6.1.2 OPERATIONAL CHECKS...464
3.6.2 STARTING THE ENGINE...465
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...465
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...466
3.6.3 WARMING THE ENGINE...467
3.6.4 HEATING THE HYDRAULIC OIL...467
3.6.5 HOW TO MOVE THE MACHINE...468
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE...469
3.6.5.2 WORKING ON SLOPES...470
3.6.5.3 MAXIMUM IMMERSION DEPTH...471
3.7 PARKING THE MACHINE...472
3.7.1 PARKING ON LEVEL GROUND...472
3.7.2 PARKING ON SLOPES...473
3.8 STOPPING THE ENGINE...474
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...475
3.9.1 LOADING AND UNLOADING THE MACHINE...475
3.9.2 TRANSPORT...476
3.9.3 LIFTING THE MACHINE...477
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...478
3.10.1 FUEL AND LUBRICANTS...478
3.10.2 COOLANT...478
3.10.3 BATTERY...479
3.10.4 OTHER PRECAUTIONS...479
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...479
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...480
3.12 USING THE MACHINE AS A LOADER...481
3.12.1 BUCKET POSITION INDICATOR...481
3.12.2 ORGANIZING THE WORK AREA...481
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...482
3.12.2.2 LOADING OPERATIONS ON SLOPES...483
3.12.3 CHANGING THE STANDARD FRONT BUCKET...483
3.13 USING THE MACHINE AS AN EXCAVATOR...484
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...484
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...485
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...486
3.13.4 DIGGING METHOD...487
3.13.4.1 CHANGING THE BACKHOE BUCKET...488
3.13.5 LIFTING LOADS WITH EQUIPMENT...489
3.13.5.1 LIFTING CAPACITIES...490
3.13.5.2 LIFTING CAPACITIES...491
3.14 LONG PERIODS OF INACTIVITY...492
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...492
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...494
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...494
3.14.4 RESTARTING THE ENGINE...495
3.14.5 AFTER THE PERIOD OF INACTIVITY...495
3.14.6 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE...495
3.15 TROUBLESHOOTING...496
3.15.1 HOW TO REMOVE THE MACHINE...496
3.15.2 AFTER THE FUEL HAS RUN OUT...496
3.15.3 IF THE BATTERY IS DOWN...497
3.15.3.1 STARTING WITH BOOSTER CABLES...498
3.15.4 OTHER TROUBLES...500
3.15.4.1 ELECTRICAL CIRCUIT...500
3.15.4.2 HYDRAULIC SYSTEM...500
3.15.4.3 BRAKING SYSTEM...501
3.15.4.4 CONVERTER...501
3.15.4.5 ENGINE...501
4.1 GUIDE TO MAINTENANCE...504
4.2 MAINTENANCE NOTES...506
4.2.1 NOTES REGARDING THE ENGINE...506
4.2.1.1 ENGINE OIL...506
4.2.1.2 COOLANT...506
4.2.1.3 FUEL...507
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...507
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...508
4.2.4 NOTES REGARDING LUBRICATION...508
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...509
4.3 FUEL AND LUBRICANTS...510
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...512
4.4 DRIVING TORQUES...513
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...513
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...514
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...514
4.5 LUBRICATION...515
4.5.1 LUBRICATION DIAGRAM...515
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...516
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...517
4.5.4 LUBRICATION DIAGRAM (offset device)...518
4.5.5 LUBRICATION CHART (For hydraulically-controlled sliding plate)...519
4.5.6 LUBRICATION DIAGRAM (for telescopic boom)...520
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...521
4.6.1 SAFETY RELATED PARTS...522
4.6.1.1 FUEL SYSTEM...522
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...523
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...524
4.6.1.4 BACKHOE HYDRALIC SYSTEM...525
4.6.1.5 OPERATOR’S SAFETY...526
4.7 MAINTENANCE PLAN...527
4.8 MAINTENANCE PROCEDURES...529
4.8.1 WHEN REQUIRED...529
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...529
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...530
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)...531
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR AND TOPPING UP...531
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES...532
4.8.1.f LUBRICATING THE CAB DOOR HINGES...532
4.8.1.g FUSES AND RELAYS - CHECK AND CHANGE...532
4.8.1.h BLEEDING THE BRAKING CIRCUIT...533
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN...534
4.8.1.j CHECKING THE BRAKING EFFICIENCY...534
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE...535
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...536
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...536
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK...537
4.8.1.o 1st STAGE DECANTER DRAINAGE...538
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...539
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...539
4.8.2.b CHANGING THE HYDRAULIC OIL...539
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...540
4.8.3.a VARIOUS CHECKS...540
4.8.3.b CHECKING THE COOLANT LEVEL...540
4.8.3.c CHECKING THE FUEL LEVEL...541
4.8.3.d CHECKING THE ENGINE OIL LEVEL...541
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...542
4.8.4.a LUBRICATING THE JOINTS...542
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...544
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...544
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...544
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...545
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...545
4.8.6.d LUBRICATING THE PROPELLER SHAFTS...546
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS...547
4.8.6.f CHECKING THE TYRE PRESSURE...547
4.8.6.g 2nd STAGE DECANTER DRAINAGE...548
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...549
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...549
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT...549
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (only for machines with air conditioner)...550
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVELAND TOPPING UP...551
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS...552
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL...552
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...553
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...553
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...554
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...554
4.8.10.a CHANGING THE ENGINE OIL...554
4.8.10.b CHANGING THE ENGINE OIL FILTER...555
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...555
4.8.10.d CHANGING THE FUEL FILTERS...558
4.8.10.e DRAINING THE FUEL TANK...560
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)...561
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR...562
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines with air conditioner)...563
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...564
4.8.11.a CHANGING THE FRONT AXLE OIL...564
4.8.11.b CHANGING THE REAR AXLE OIL...565
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...566
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER...567
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...568
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...568
4.8.12.b CLEANING OF THE COOLING SYSTEM AND CHANGING THE COOLANT...570
4.8.12.c CHANGING THE BRAKING SYSTEM OIL...572
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER...573
4.8.12.e CHANGING THE ALTERNATOR BELT...573
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY (only for machines with air conditioner)...573
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION...574
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS...574
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE...574
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION...575
4.8.14.a CHANGING THE A/C DEWATERING FILTER (Only for machines with air conditioner)...575
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air conditioner)...575
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE...575
4.9 END OF SERVICE LIFE...576
5.1 TECHNICAL DATA...578
5.1.1 STANDARD OVERALL DIMENSIONS...578
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM...578
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM...579
5.1.2 TECHNICAL CHARACTERISTICS...580
5.1.3 WORKING RANGES...581
5.1.3.1 WORKING RANGE LOADER AND BACKHOE...581
5.1.4 LIFTING CAPACITIES...583
5.1.4.1 LIFTING CAPACITIES (STANDARD BOOM)...584
5.1.4.2 LIFTING CAPACITIES (BOOM WITH OFFSET DEVICE)...584
6.1 AUTHORIZED OPTIONAL EQUIPMENT...586
6.1.1 PRECAUTIONS REGARDING SAFETY...586
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...587
6.2 SPECIFICATIONS...588
6.2.1 ARM-PIN INFORMATION...588
6.3 ATTACHMENT GUIDE...589
6.3.1 COMBINATIONS OF WORK EQUIPMENT...589
6.3.2 ATTACHMENT CONFIGURATION...589
6.4 FRONT EQUIPMENT QUICK COUPLING DEVICES...592
6.4.1 MANUAL QUICK COUPLING...592
6.4.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET...593
6.4.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...593
6.5 PALLET FORKS...594
6.5.1 LIFTING CAPACITIES (PALLET FORKS)...594
6.5.2 DESCRIPTION...595
6.5.3 USING THE FORKS...595
6.5.4 MAINTENANCE...595
6.6 4in1 BUCKET...596
6.6.1 DESCRIPTION AND CONTROLS...596
6.6.2 SAFETY DEVICES...596
6.6.3 INSTALLING THE 4in1 BUCKET...597
6.6.4 USING THE 4in1 BUCKET...598
6.6.5 MAINTENANCE...598
6.7 FORKS FOR PALLET ON BUCKET 4 IN 1...599
6.7.1 DESCRIPTION...599
6.7.2 LIFTING CAPACITY (FORKS FOR ON BUCKET 4 IN 1)...600
6.7.3 USING THE FORKS...600
6.7.3.1 PREPARING THE PALLET FORKS FOR USE...601
6.7.3.2 OVERTURNING THE FORKS...601
6.7.4 REMOVING THE FORKS...603
6.7.5 INSTALLING THE FORKS...603
6.7.6 MAINTENANCE...603
6.8 BACKHOE TELESCOPIC ARM...604
6.8.1 DESCRIPTION AND CONTROL...604
6.8.2 SAFETY DEVICES...605
6.8.3 USING THE TELESCOPIC ARM...605
6.8.4 MAINTENANCE...606
6.8.4.1 ADJUSTING THE GUIDE SLACK...606
6.9 CONFIGURATION FOR THE INSTALLATION OF THE HYDRAULIC BREAKER...608
6.9.1 DESCRIPTION AND CONTROL...608
6.9.2 USE OF THE HYDRAULIC BREAKER AND RULES TO BE OBSERVED...609
6.9.2.1 HYDRAULIC BREAKER...609
6.9.3 INSTALLING AND REMOVING THE HYDRAULIC BREAKER...614
6.9.3.1 INSTALLING THE BREAKER...614
6.9.3.2 REMOVING THE BREAKER...616
6.9.4 USING THE BREAKER...616
6.9.5 MAINTENANCE...616
6.10 APPLICATION OF THE OFFSET DEVICE...617
6.10.1 DESCRIPTION AND CONTROL...617
6.10.2 MAINTENANCE...618
6.11 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...619
6.11.1 DESCRIPTION AND CONTROL...619
6.11.2 INSTALLING AND CONNECTING THE EQUIPMENT...620
6.11.3 MAINTENANCE...620
6.12 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET...621
6.12.1 DESCRIPTION AND CONTROL...621
6.12.2 INSTALLING THE CLAMSHELL BUCKET...622
6.12.3 USING THE CLAMSHELL BUCKET...623
6.12.4 MAINTENANCE...623
6.13 TELESCOPIC BOOM WITH PRE-INSTALLATION FOR HYDRAULIC BREAKER AND OPTIONAL TOOLS...624
6.14 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER...631
6.14.1 DESCRIPTION AND CONTROL...631
6.14.2 INSTALLING AND REMOVING THE HAND HAMMER...632
6.14.2.1 CONNECTING THE HAND HAMMER...632
6.14.2.2 REMOVING THE CONNECTIONS...633
6.14.3 USING THE HAMMER...633
6.14.4 MAINTENANCE...633
6.15 LOAD STABILIZER SYSTEM (LSS) (Optional)...634
6.15.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR...634
6.16 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE...635
6.16.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...636
6.16.1.1 COUPLING PROCEDURE...636
6.16.1.2 RELEASE PROCEDURE...638
6.16.2 MAINTENANCE...639
6.16.3 MAINTENANCE PLAN...639
6.16.3.1 DAILY...639
6.16.3.2 WEEKLY (AT LEAST ONCE PER WEEK)...639
6.16.3.3 TROUBLESHOOTING...639
6.17 HYDRAULIC QUICK COUPLER OF THE REAR EQUIPMENT...640
6.17.1 SAFETY DEVICES...640
6.17.2 QUICK COUPLER TO BACKHOE LOADER CONNECTION...640
6.17.3 CONTROL...641
6.17.4 ADJUSTING THE QUICK COUPLER OPERATING PRESSURE...642
6.17.5 QUICK RELEASE COUPLING HYDRAULIC CONNECTIONS...643
6.17.6 EQUIPMENT COUPLING AND RELEASE PROCEDURE...644
6.17.6.1 COUPLING...644
6.17.6.2 RELEASE...644
6.17.7 MAINTENANCE...644
6.18 HYDRAULICALLY-CONTROLLED SLIDING PLATE FOR BACKHOE...645
WEAM011707 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...649
1.1 FOREWORD...651
1.2 INFORMATION ON SAFETY...652
1.2.1 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...655
1.2.2 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...656
1.2.3 GUIDE WHEN WORKING IN AREAS WHERE AIR POLLUTION...657
1.3 INTRODUCTION...658
1.3.1 INTENDED USES...658
1.3.2 DEMOLITION WORK...658
1.3.3 IMPROPER OR UNAUTHORIZED USE...659
1.3.4 MAIN CHARACTERISTICS...660
1.3.5 RUNNING-IN...660
1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE...661
1.3.6.1 WHEN OPERATING THE LOADER OR TRAVELLING...661
1.3.6.2 WHEN OPERATING THE BACKHOE...662
1.4 PRODUCT IDENTIFICATION...663
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...663
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...663
1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)...664
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...665
1.4.4 FRONT AXLE SERIAL NUMBER...665
1.4.5 REAR AXLE SERIAL NUMBER...666
1.4.6 TRANSMISSION SERIAL NUMBER...666
1.4.7 CAB SERIAL NUMBER...666
1.4.8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...667
1.4.9 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)...667
1.5 KOMTRAX SYSTEM...668
1.5.1 GENERAL PRECAUTIONS...668
TABLE OF CONTENTS...669
2.1 SAFETY, NOISE AND VIBRATION PLATES...680
2.1.1 POSITION OF THE SAFETY PLATES...680
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...682
2.2 GENERAL PRECAUTIONS...697
2.2.1 GENERAL SAFETY RULES...697
2.2.2 SAFETY DEVICES AND GUARDS...697
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...697
2.2.4 UNAUTHORIZED MODIFICATIONS...698
2.2.5 LEAVING THE OPERATOR’S SEAT...698
2.2.6 GETTING ON AND OFF THE MACHINE...699
2.2.7 CHECKING THE REAR-VIEW MIRRORS...699
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...700
2.2.9 LIFTING OF PERSONNEL PROHIBITED...700
2.2.10 PREVENTING BURNS...700
2.2.11 ASBESTOS DUST HAZARD PREVENTION...701
2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...701
2.2.13 DETERGENT FOR THE WINDOWS...701
2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT...702
2.2.15 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...702
2.2.16 CAUTIONS RELATED TO ROPS...703
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT...703
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...704
2.3.1 SAFETY ON THE WORK SITE...704
2.3.2 FIRE PREVENTION...704
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...704
2.3.4 ROOM VENTILATION...705
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...705
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...706
2.4.1 WHEN STARTING THE ENGINE...706
2.4.2 RULES FOR TRAVELLING ON ROADS...706
2.4.3 REGULATIONS FOR ROAD TRANSFER (TUV approval)...707
2.4.4 HAND SIGNALS...709
2.4.5 CHECKS FOR TRAVELLING IN REVERSE...714
2.4.6 MOVING THE MACHINE...714
2.4.7 WORKING ON SLOPES...715
2.4.8 PROHIBITED OPERATIONS...715
2.4.9 PREVENTING ELECTROCUTION...716
2.4.10 VISIBILITY...717
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...717
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...717
2.4.13 WORKING ON LOOSE GROUND...717
2.4.14 PARKING THE MACHINE...718
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...719
2.5.1 LOADING AND UNLOADING THE MACHINE...719
2.5.2 TRANSPORT...719
2.6 BATTERY...720
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...720
2.6.2 STARTING WITH BOOSTER CABLES...721
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...722
2.8 LIFTING OBJECTS WITH LIFTING DEVICE (OPTIONAL EQUIPMENT)...723
2.8.1 SAFETY RULES FOR LIFTING OBJECTS...723
2.9 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...726
2.9.1 WARNING PLATES...726
2.9.2 TOOLS...726
2.9.3 PERSONNEL...727
2.9.4 EQUIPMENT...727
2.9.5 WORKING UNDER THE MACHINE...727
2.9.6 STABILITY...727
2.9.7 REPAIR WELDS...727
2.9.8 KEEPING THE MACHINE CLEAN...728
2.9.9 USE OF THE ENGINE DURING MAINTENANCE...728
2.9.10 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...728
2.9.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...729
2.9.12 BATTERY MAIN SWITCH PRECAUTIONS...730
2.9.13 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...730
2.9.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR...730
2.9.15 USING LAMPS...731
2.9.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...731
2.9.17 PRECAUTIONS CONCERNING THE STARTER...731
2.9.18 HANDLING HIGH-PRESSURE PIPES...732
2.9.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...732
2.9.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...732
2.9.21 HYDRAULIC ACCUMULATOR...733
2.9.22 COOLING FAN AND FAN BELT...733
2.9.23 CHEMICAL HAZARD...733
2.9.24 WASTE MATERIALS...734
2.9.25 SERVICING THE AIR CONDITIONER...734
2.9.26 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...734
2.9.27 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...735
2.9.28 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...735
2.9.29 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...736
2.9.30 FINAL DISPOSAL OF THE MACHINE...736
3.1 SAFETY LOCKS...738
3.1.1 FRONT LOADER LOCKS...738
3.1.2 BACKHOE LOCKS...740
3.2 GENERAL VIEWS...742
3.2.1 FRONT GENERAL VIEW...742
3.2.2 BACKHOE GENERAL VIEW...743
3.2.3 CAB INSIDE GENERAL VIEW...744
3.3 INSTRUMENTS AND CONTROLS...746
3.3.1 FRONT INSTRUMENTS...746
3.3.2 SIDE INSTRUMENTS...751
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...762
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES...764
3.3.5 MACHINE CONTROLS...768
3.3.6 ADJUSTING THE CONTROLS...791
3.4 FUSES AND RELAYS...794
3.4.1 CENTRAL UNIT FUSES – RELAYS AND ENGINE LINE...794
3.4.1.1 FUSES...795
3.4.1.2 RELAYS...797
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS...799
3.4.2.1 FUSES...799
3.4.2.2 RELAYS...799
3.5 GUARDS, CAB AND DRIVER’S SEAT...800
3.5.1 ENGINE HOOD...800
3.5.2 CAB...801
3.5.3 VENTILATION AND HEATING...804
3.5.4 AIR CONDITIONER (if installed)...805
3.5.5 SEAT...807
3.5.5.1 SEAT (Standard mod. CAB SEATING)...807
3.5.5.2 SEAT (Optional mod. CAB SEATING)...809
3.5.5.3 PNEUMATIC SUSPENSION SEAT (optional mod. CAB SEATING)...810
3.5.5.4 SEAT (Standard mod. SEARS SEATING)...811
3.5.5.5 PNEUMATIC SUSPENSION SEAT (optional mod. SEARS SEATING)...812
3.5.6 SAFETY BELT...813
3.5.6.1 STANDARD SAFETY BELTS...813
3.5.6.2 SAFETY BELTS WITH WINDER...813
3.5.7 FIRE EXTINGUISHER...813
3.5.8 FIRST AID KIT...813
3.5.9 TECHNICAL DOCUMENTATION...814
3.5.10 STORAGE COMPARTMENT...814
3.5.11 REFUELLING PUMP (If installed)...815
3.6 USE OF THE MACHINE...817
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...817
3.6.1.1 VISUAL CHECKS...817
3.6.1.2 OPERATIONAL CHECKS...818
3.6.2 STARTING THE ENGINE...819
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...819
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...820
3.6.3 WARMING THE ENGINE...821
3.6.4 HEATING THE HYDRAULIC OIL...821
3.6.5 HOW TO MOVE THE MACHINE...822
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE...823
3.6.5.2 WORKING ON SLOPES...824
3.6.5.3 MAXIMUM IMMERSION DEPTH...825
3.7 PARKING THE MACHINE...826
3.7.1 PARKING ON LEVEL GROUND...826
3.7.2 PARKING ON SLOPES...827
3.8 STOPPING THE ENGINE...828
3.9 TRANSPORTATION...829
3.9.1 PRECAUTIONS FOR TRANSPORTING MACHINE...829
3.9.2 SELECT TRANSPORTATION METHOD...829
3.9.3 PRECAUTIONS FOR LOADING AND UNLOADING WITH TRAILER...829
3.9.4 PROCEDURES FOR LOADING AND SECURING MACHINE ON THE TRAILER...830
3.9.4.1 LOADING MACHINE ON THE TRAILER...830
3.9.4.2 SECURING THE MACHINE...831
3.9.5 LIFTING THE MACHINE...832
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...833
3.10.1 FUEL AND LUBRICANTS...833
3.10.2 COOLANT...833
3.10.3 BATTERY...834
3.10.4 OTHER PRECAUTIONS...834
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...834
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...835
3.12 USING THE MACHINE AS A LOADER...836
3.12.1 BUCKET POSITION INDICATOR...836
3.12.2 ORGANIZING THE WORK AREA...836
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...837
3.12.2.2 LOADING OPERATIONS ON SLOPES...838
3.12.3 CHANGING THE STANDARD FRONT BUCKET...838
3.13 USING THE MACHINE AS AN EXCAVATOR...839
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...839
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...840
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...841
3.13.4 DIGGING METHOD...842
3.13.4.1 CHANGING THE BACKHOE BUCKET...843
3.13.5 LIFTING LOADS WITH EQUIPMENT...844
3.13.5.1 LIFTING CAPACITIES...845
3.13.5.2 LIFTING CAPACITIES...846
3.14 LONG PERIODS OF INACTIVITY...848
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...848
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...850
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...850
3.14.4 RESTARTING THE ENGINE...851
3.14.5 AFTER THE PERIOD OF INACTIVITY...851
3.14.6 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE...851
3.15 TROUBLESHOOTING...852
3.15.1 HOW TO REMOVE THE MACHINE...852
3.15.2 AFTER THE FUEL HAS RUN OUT...852
3.15.3 IF THE BATTERY IS DOWN...853
3.15.3.1 STARTING WITH BOOSTER CABLES...854
3.15.4 OTHER TROUBLES...856
3.15.4.1 ELECTRICAL CIRCUIT...856
3.15.4.2 HYDRAULIC SYSTEM...856
3.15.4.3 BRAKING SYSTEM...857
3.15.4.4 CONVERTER...857
3.15.4.5 ENGINE...857
4.1 GUIDE TO MAINTENANCE...860
4.2 MAINTENANCE NOTES...862
4.2.1 NOTES REGARDING THE ENGINE...862
4.2.1.1 ENGINE OIL...862
4.2.1.2 COOLANT...862
4.2.1.3 FUEL...863
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...863
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...864
4.2.4 NOTES REGARDING LUBRICATION...864
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...865
4.3 FUEL AND LUBRICANTS...866
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...868
4.4 DRIVING TORQUES...869
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...869
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...870
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...870
4.5 LUBRICATION...871
4.5.1 LUBRICATION DIAGRAM...871
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...872
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...873
4.5.4 LUBRICATION DIAGRAM (offset device)...874
4.5.5 LUBRICATION CHART (For hydraulically-controlled sliding plate)...875
4.5.6 LUBRICATION DIAGRAM (for telescopic boom)...876
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...877
4.6.1 SAFETY RELATED PARTS...878
4.6.1.1 FUEL SYSTEM...878
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...879
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...880
4.6.1.4 BACKHOE HYDRALIC SYSTEM...881
4.6.1.5 OPERATOR’S SAFETY...882
4.7 MAINTENANCE PLAN...883
4.8 MAINTENANCE PROCEDURES...885
4.8.1 WHEN REQUIRED...885
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...885
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...886
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)...887
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR AND TOPPING UP...887
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES...888
4.8.1.f LUBRICATING THE CAB DOOR HINGES...888
4.8.1.g FUSES AND RELAYS – CHECK AND CHANGE...888
4.8.1.h BLEEDING THE BRAKING CIRCUIT...889
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN...890
4.8.1.j CHECKING THE BRAKING EFFICIENCY...890
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE...891
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...892
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...892
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK...893
4.8.1.o 1st STAGE DECANTER DRAINAGE...894
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE HYDRAULIC BREAKER...895
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...895
4.8.2.b CHANGING THE HYDRAULIC OIL...895
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...896
4.8.3.a VARIOUS CHECKS...896
4.8.3.b CHECKING THE COOLANT LEVEL...896
4.8.3.c CHECKING THE FUEL LEVEL...897
4.8.3.d CHECKING THE ENGINE OIL LEVEL...897
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...898
4.8.4.a LUBRICATING THE JOINTS...898
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...900
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...900
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...900
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...901
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...901
4.8.6.d LUBRICATING THE PROPELLER SHAFTS...902
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS...903
4.8.6.f CHECKING THE TYRE PRESSURE...903
4.8.6.g 2nd STAGE DECANTER DRAINAGE...904
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...905
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...905
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT...905
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (only for machines with air conditioner)...906
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVELAND TOPPING UP...907
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS...908
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL...908
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...909
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...909
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...910
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...910
4.8.10.a CHANGING THE ENGINE OIL...910
4.8.10.b CHANGING THE ENGINE OIL FILTER...911
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...911
4.8.10.d CHANGING THE FUEL FILTERS...914
4.8.10.e DRAINING THE FUEL TANK...916
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)...917
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR...918
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines with air conditioner)...919
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...920
4.8.11.a CHANGING THE FRONT AXLE OIL...920
4.8.11.b CHANGING THE REAR AXLE OIL...921
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...922
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER...923
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...924
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...924
4.8.12.b CLEANING OF THE COOLING SYSTEM AND CHANGING THE COOLANT...926
4.8.12.c CHANGING THE BRAKING SYSTEM OIL...928
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER...929
4.8.12.e CHANGING THE ALTERNATOR BELT...929
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY (only for machines with air conditioner)...929
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION...930
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS...930
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE...930
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION...931
4.8.14.a CHANGING THE A/C DEWATERING FILTER (Only for machines with air conditioner)...931
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air conditioner)...931
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE...931
4.9 END OF SERVICE LIFE...932
5.1 TECHNICAL DATA...934
5.1.1 STANDARD OVERALL DIMENSIONS...934
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM...934
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM...935
5.1.2 TECHNICAL CHARACTERISTICS...936
5.1.3 WORKING RANGES...937
5.1.3.1 WORKING RANGE LOADER AND BACKHOE...937
5.1.4 LIFTING CAPACITIES...939
5.1.4.1 LIFTING CAPACITIES (STANDARD BOOM)...940
5.1.4.2 LIFTING CAPACITIES (BOOM WITH OFFSET DEVICE)...940
6.1 AUTHORIZED OPTIONAL EQUIPMENT...942
6.1.1 PRECAUTIONS REGARDING SAFETY...942
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...943
6.2 SPECIFICATIONS...944
6.2.1 ARM-PIN INFORMATION...944
6.3 ATTACHMENT GUIDE...945
6.3.1 COMBINATIONS OF WORK EQUIPMENT...945
6.3.2 ATTACHMENT CONFIGURATION...945
6.4 FRONT EQUIPMENT QUICK COUPLING DEVICES...948
6.4.1 MANUAL QUICK COUPLING...948
6.4.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET...950
6.4.2.1 COUPLING...950
6.4.2.2 RELEASE...951
6.4.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT...952
6.5 PALLET FORKS...953
6.5.1 LIFTING CAPACITIES (PALLET FORKS)...953
6.5.2 DESCRIPTION...954
6.5.3 USING THE FORKS...954
6.5.4 MAINTENANCE...954
6.6 4in1 BUCKET...955
6.6.1 DESCRIPTION AND CONTROLS...955
6.6.2 SAFETY DEVICES...955
6.6.3 INSTALLING THE 4in1 BUCKET...956
6.6.4 USING THE 4in1 BUCKET...957
6.6.5 MAINTENANCE...957
6.7 FORKS FOR PALLET ON BUCKET 4 IN 1...958
6.7.1 DESCRIPTION...958
6.7.2 LIFTING CAPACITY (FORKS FOR ON BUCKET 4 IN 1)...959
6.7.3 USING THE FORKS...959
6.7.3.1 PREPARING THE PALLET FORKS FOR USE...960
6.7.3.2 OVERTURNING THE FORKS...960
6.7.4 REMOVING THE FORKS...962
6.7.5 INSTALLING THE FORKS...962
6.7.6 MAINTENANCE...962
6.8 BACKHOE TELESCOPIC ARM...963
6.8.1 DESCRIPTION AND CONTROL...963
6.8.2 SAFETY DEVICES...964
6.8.3 USING THE TELESCOPIC ARM...964
6.8.4 MAINTENANCE...965
6.8.4.1 ADJUSTING THE GUIDE SLACK...965
6.9 CONFIGURATION FOR THE INSTALLATION OF THE HYDRAULIC BREAKER...967
6.9.1 DESCRIPTION AND CONTROL...967
6.9.2 USE OF THE HYDRAULIC BREAKER AND RULES TO BE OBSERVED...968
6.9.2.1 HYDRAULIC BREAKER...968
6.9.3 INSTALLING AND REMOVING THE HYDRAULIC BREAKER...973
6.9.3.1 INSTALLING THE BREAKER...973
6.9.3.2 REMOVING THE BREAKER...975
6.9.4 USING THE BREAKER...975
6.9.5 MAINTENANCE...975
6.10 APPLICATION OF THE OFFSET DEVICE...976
6.10.1 DESCRIPTION AND CONTROL...976
6.10.2 MAINTENANCE...977
6.11 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...978
6.11.1 DESCRIPTION AND CONTROL...978
6.11.2 INSTALLING AND CONNECTING THE EQUIPMENT...979
6.11.3 MAINTENANCE...979
6.12 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET...980
6.12.1 DESCRIPTION AND CONTROL...980
6.12.2 INSTALLING THE CLAMSHELL BUCKET...981
6.12.3 USING THE CLAMSHELL BUCKET...982
6.12.4 MAINTENANCE...982
6.13 TELESCOPIC BOOM WITH PRE-INSTALLATION FOR HYDRAULIC BREAKER AND OPTIONAL TOOLS...983
6.14 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER...990
6.14.1 DESCRIPTION AND CONTROL...990
6.14.2 INSTALLING AND REMOVING THE HAND HAMMER...991
6.14.2.1 CONNECTING THE HAND HAMMER...991
6.14.2.2 REMOVING THE CONNECTIONS...992
6.14.3 USING THE HAMMER...992
6.14.4 MAINTENANCE...992
6.15 LOAD STABILIZER SYSTEM (LSS) (Optional)...993
6.15.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR...993
6.16 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE...994
6.16.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...995
6.16.1.1 COUPLING PROCEDURE...995
6.16.1.2 RELEASE PROCEDURE...997
6.16.2 MAINTENANCE...998
6.16.3 MAINTENANCE PLAN...998
6.16.3.1 DAILY...998
6.16.3.2 WEEKLY (AT LEAST ONCE PER WEEK)...998
6.16.3.3 TROUBLESHOOTING...998
6.17 HYDRAULIC QUICK COUPLER OF THE REAR EQUIPMENT...999
6.17.1 SAFETY DEVICES...999
6.17.2 QUICK COUPLER TO BACKHOE LOADER CONNECTION...999
6.17.3 CONTROL...1000
6.17.4 ADJUSTING THE QUICK COUPLER OPERATING PRESSURE...1001
6.17.5 QUICK RELEASE COUPLING HYDRAULIC CONNECTIONS...1002
6.17.6 EQUIPMENT COUPLING AND RELEASE PROCEDURE...1003
6.17.6.1 COUPLING...1003
6.17.6.2 RELEASE...1003
6.17.7 MAINTENANCE...1003
6.18 HYDRAULICALLY-CONTROLLED SLIDING PLATE FOR BACKHOE...1004
WEAM015502 - Backhoe-Loader WB97S-5E0 Operation & Maintenance Manual...1007
1.1 FOREWORD...1009
1.2 INFORMATION ON SAFETY...1010
1.2.1 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...1013
1.2.2 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...1014
1.2.3 GUIDE WHEN WORKING IN AREAS WHERE AIR POLLUTION...1015
1.3 INTRODUCTION...1016
1.3.1 INTENDED USES...1016
1.3.2 DEMOLITION WORK...1016
1.3.3 IMPROPER OR UNAUTHORIZED USE...1017
1.3.4 MAIN CHARACTERISTICS...1018
1.3.5 RUNNING-IN...1018
1.3.6 POSITIONS AND DIRECTIONS OF THE MACHINE...1019
1.3.6.1 WHEN OPERATING THE LOADER OR TRAVELLING...1019
1.3.6.2 WHEN OPERATING THE BACKHOE...1020
1.4 PRODUCT IDENTIFICATION...1021
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...1021
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...1021
1.4.2.1 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)...1022
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...1023
1.4.4 FRONT AXLE SERIAL NUMBER...1023
1.4.5 REAR AXLE SERIAL NUMBER...1024
1.4.6 TRANSMISSION SERIAL NUMBER...1024
1.4.7 CAB SERIAL NUMBER...1024
1.4.8 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...1025
1.4.9 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)...1025
1.5 KOMTRAX SYSTEM...1026
1.5.1 GENERAL PRECAUTIONS...1026
TABLE OF CONTENTS...1027
SICUREZZA E ANTINFORTUNISTICA...1035
2.1 SAFETY, NOISE AND VIBRATION PLATES...1036
2.1.1 POSITION OF THE SAFETY PLATES...1036
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...1038
2.2 GENERAL PRECAUTIONS...1052
2.2.1 GENERAL SAFETY RULES...1052
2.2.2 SAFETY DEVICES AND GUARDS...1052
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...1052
2.2.4 UNAUTHORIZED MODIFICATIONS...1053
2.2.5 LEAVING THE OPERATOR’S SEAT...1053
2.2.6 GETTING ON AND OFF THE MACHINE...1054
2.2.7 CHECKING THE REAR-VIEW MIRRORS...1054
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...1055
2.2.9 LIFTING OF PERSONNEL PROHIBITED...1055
2.2.10 PREVENTING BURNS...1055
2.2.11 ASBESTOS DUST HAZARD PREVENTION...1056
2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1056
2.2.13 DETERGENT FOR THE WINDOWS...1056
2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT...1057
2.2.15 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...1057
2.2.16 CAUTIONS RELATED TO ROPS...1058
2.2.17 PRECAUTIONS CONCERNING THE EQUIPMENT...1058
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...1059
2.3.1 SAFETY ON THE WORK SITE...1059
2.3.2 FIRE PREVENTION...1059
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...1059
2.3.4 ROOM VENTILATION...1060
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...1060
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...1061
2.4.1 WHEN STARTING THE ENGINE...1061
2.4.2 RULES FOR TRAVELLING ON ROADS...1061
2.4.3 REGULATIONS FOR ROAD TRANSFER (TUV approval)...1062
2.4.4 HAND SIGNALS...1064
2.4.5 CHECKS FOR TRAVELLING IN REVERSE...1069
2.4.6 MOVING THE MACHINE...1069
2.4.7 WORKING ON SLOPES...1070
2.4.8 PROHIBITED OPERATIONS...1070
2.4.9 PREVENTING ELECTROCUTION...1071
2.4.10 VISIBILITY...1072
2.4.11 WORKING ON ICY OR SNOW-COVERED SURFACES...1072
2.4.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...1072
2.4.13 WORKING ON LOOSE GROUND...1072
2.4.14 PARKING THE MACHINE...1073
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...1074
2.5.1 LOADING AND UNLOADING THE MACHINE...1074
2.5.2 TRANSPORT...1074
2.6 BATTERY...1075
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...1075
2.6.2 STARTING WITH BOOSTER CABLES...1076
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...1077
2.8 LIFTING OBJECTS WITH LIFTING DEVICE (OPTIONAL EQUIPMENT)...1078
2.8.1 SAFETY RULES FOR LIFTING OBJECTS...1078
2.9 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...1081
2.9.1 WARNING PLATES...1081
2.9.2 TOOLS...1081
2.9.3 PERSONNEL...1082
2.9.4 EQUIPMENT...1082
2.9.5 WORKING UNDER THE MACHINE...1082
2.9.6 STABILITY...1082
2.9.7 REPAIR WELDS...1082
2.9.8 KEEPING THE MACHINE CLEAN...1083
2.9.9 USE OF THE ENGINE DURING MAINTENANCE...1083
2.9.10 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...1083
2.9.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...1084
2.9.12 BATTERY MAIN SWITCH PRECAUTIONS...1085
2.9.13 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...1085
2.9.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR...1085
2.9.15 USING LAMPS...1086
2.9.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...1086
2.9.17 PRECAUTIONS CONCERNING THE STARTER...1086
2.9.18 HANDLING HIGH-PRESSURE PIPES...1087
2.9.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...1087
2.9.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...1087
2.9.21 HYDRAULIC ACCUMULATOR...1088
2.9.22 COOLING FAN AND FAN BELT...1088
2.9.23 CHEMICAL HAZARD...1088
2.9.24 WASTE MATERIALS...1089
2.9.25 SERVICING THE AIR CONDITIONER...1089
2.9.26 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...1089
2.9.27 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...1090
2.9.28 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...1090
2.9.29 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...1091
2.9.30 FINAL DISPOSAL OF THE MACHINE...1091
DESCRIZIONE MACCHINA ED USO...1093
3.1 SAFETY LOCKS...1094
3.1.1 FRONT LOADER LOCKS...1094
3.1.2 BACKHOE LOCKS...1096
3.2 GENERAL VIEWS...1098
3.2.1 FRONT GENERAL VIEW...1098
3.2.2 BACKHOE GENERAL VIEW...1099
3.2.3 CAB INSIDE GENERAL VIEW...1100
3.3 INSTRUMENTS AND CONTROLS...1102
3.3.1 FRONT INSTRUMENTS...1102
3.3.2 SIDE INSTRUMENTS...1107
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...1118
3.3.4 CAB SWITCHES AND ELECTRIC ACCESSORIES...1120
3.3.5 MACHINE CONTROLS...1124
3.3.6 ADJUSTING THE CONTROLS...1147
3.4 FUSES AND RELAYS...1150
3.4.1 CENTRAL UNIT FUSES – RELAYS AND ENGINE LINE...1150
3.4.1.1 FUSES...1151
3.4.1.2 RELAYS...1153
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS...1155
3.4.2.1 FUSES...1155
3.4.2.2 RELAYS...1155
3.5 GUARDS, CAB AND DRIVER’S SEAT...1156
3.5.1 ENGINE HOOD...1156
3.5.2 CAB...1157
3.5.3 VENTILATION AND HEATING...1160
3.5.4 AIR CONDITIONER (if installed)...1161
3.5.5 SEAT...1163
3.5.5.1 SEAT (Standard mod. CAB SEATING)...1163
3.5.5.2 SEAT (Optional mod. CAB SEATING)...1165
3.5.5.3 PNEUMATIC SUSPENSION SEAT (optional mod. CAB SEATING)...1166
3.5.5.4 SEAT (Standard mod. SEARS SEATING)...1167
3.5.5.5 PNEUMATIC SUSPENSION SEAT (optional mod. SEARS SEATING)...1168
3.5.6 SAFETY BELT...1169
3.5.6.1 STANDARD SAFETY BELTS...1169
3.5.6.2 SAFETY BELTS WITH WINDER...1169
3.5.7 FIRE EXTINGUISHER...1169
3.5.8 FIRST AID KIT...1169
3.5.9 TECHNICAL DOCUMENTATION...1170
3.5.10 STORAGE COMPARTMENT...1170
3.5.11 REFUELLING PUMP (If installed)...1171
3.6 USE OF THE MACHINE...1173
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...1173
3.6.1.1 VISUAL CHECKS...1173
3.6.1.2 OPERATIONAL CHECKS...1174
3.6.2 STARTING THE ENGINE...1175
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...1175
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...1176
3.6.3 WARMING THE ENGINE...1177
3.6.4 HEATING THE HYDRAULIC OIL...1177
3.6.5 HOW TO MOVE THE MACHINE...1178
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE...1179
3.6.5.2 WORKING ON SLOPES...1180
3.6.5.3 MAXIMUM IMMERSION DEPTH...1181
3.7 PARKING THE MACHINE...1182
3.7.1 PARKING ON LEVEL GROUND...1182
3.7.2 PARKING ON SLOPES...1183
3.8 STOPPING THE ENGINE...1184
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...1185
3.9.1 LOADING AND UNLOADING THE MACHINE...1185
3.9.2 TRANSPORT...1186
3.9.3 LIFTING THE MACHINE...1187
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...1188
3.10.1 FUEL AND LUBRICANTS...1188
3.10.2 COOLANT...1188
3.10.3 BATTERY...1189
3.10.4 OTHER PRECAUTIONS...1189
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...1189
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...1190
3.12 USING THE MACHINE AS A LOADER...1191
3.12.1 BUCKET POSITION INDICATOR...1191
3.12.2 ORGANIZING THE WORK AREA...1191
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...1192
3.12.2.2 LOADING OPERATIONS ON SLOPES...1193
3.12.3 CHANGING THE STANDARD FRONT BUCKET...1193
3.13 USING THE MACHINE AS AN EXCAVATOR...1194
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...1194
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...1195
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...1196
3.13.4 DIGGING METHOD...1197
3.13.4.1 CHANGING THE BACKHOE BUCKET...1198
3.13.5 LIFTING LOADS WITH EQUIPMENT...1199
3.13.5.1 LIFTING CAPACITIES...1200
3.13.5.2 LIFTING CAPACITIES...1201
3.14 LONG PERIODS OF INACTIVITY...1202
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...1202
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...1204
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...1204
3.14.4 RESTARTING THE ENGINE...1205
3.14.5 AFTER THE PERIOD OF INACTIVITY...1205
3.14.6 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE...1205
3.15 TROUBLESHOOTING...1206
3.15.1 HOW TO REMOVE THE MACHINE...1206
3.15.2 AFTER THE FUEL HAS RUN OUT...1206
3.15.3 IF THE BATTERY IS DOWN...1207
3.15.3.1 STARTING WITH BOOSTER CABLES...1208
3.15.4 OTHER TROUBLES...1210
3.15.4.1 ELECTRICAL CIRCUIT...1210
3.15.4.2 HYDRAULIC SYSTEM...1210
3.15.4.3 BRAKING SYSTEM...1211
3.15.4.4 CONVERTER...1211
3.15.4.5 ENGINE...1211
MAINTENANCE...1213
4.1 GUIDE TO MAINTENANCE...1214
4.2 MAINTENANCE NOTES...1216
4.2.1 NOTES REGARDING THE ENGINE...1216
4.2.1.1 ENGINE OIL...1216
4.2.1.2 COOLANT...1216
4.2.1.3 FUEL...1217
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...1217
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...1218
4.2.4 NOTES REGARDING LUBRICATION...1218
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...1219
4.3 FUEL AND LUBRICANTS...1220
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...1222
4.4 DRIVING TORQUES...1223
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...1223
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...1224
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...1224
4.5 LUBRICATION...1225
4.5.1 LUBRICATION DIAGRAM...1225
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...1226
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...1227
4.5.4 LUBRICATION DIAGRAM (offset device)...1228
4.5.5 LUBRICATION CHART (For hydraulically-controlled sliding plate)...1229
4.5.6 LUBRICATION DIAGRAM (for telescopic boom)...1230
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...1231
4.6.1 SAFETY RELATED PARTS...1232
4.6.1.1 FUEL SYSTEM...1232
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...1233
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...1234
4.6.1.4 BACKHOE HYDRALIC SYSTEM...1235
4.6.1.5 OPERATOR’S SAFETY...1236
4.7 MAINTENANCE PLAN...1237
4.8 MAINTENANCE PROCEDURES...1239
4.8.1 WHEN REQUIRED...1239
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...1239
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...1240
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)...1241
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR AND TOPPING UP...1241
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES...1242
4.8.1.f LUBRICATING THE CAB DOOR HINGES...1242
4.8.1.g FUSES AND RELAYS – CHECK AND CHANGE...1242
4.8.1.h BLEEDING THE BRAKING CIRCUIT...1243
4.8.1.i CHECKING AND ADJUSTING THE WHEEL TOE-IN...1244
4.8.1.j CHECKING THE BRAKING EFFICIENCY...1244
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE...1245
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...1246
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...1246
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK...1247
4.8.1.o 1st STAGE DECANTER DRAINAGE...1248
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...1249
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...1249
4.8.2.b CHANGING THE HYDRAULIC OIL...1249
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...1250
4.8.3.a VARIOUS CHECKS...1250
4.8.3.b CHECKING THE COOLANT LEVEL...1250
4.8.3.c CHECKING THE FUEL LEVEL...1251
4.8.3.d CHECKING THE ENGINE OIL LEVEL...1251
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...1252
4.8.4.a LUBRICATING THE JOINTS...1252
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1254
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...1254
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...1254
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...1255
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...1255
4.8.6.d LUBRICATING THE PROPELLER SHAFTS...1256
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS...1257
4.8.6.f CHECKING THE TYRE PRESSURE...1257
4.8.6.g 2nd STAGE DECANTER DRAINAGE...1258
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...1259
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...1259
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT...1259
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (only for machines with air conditioner)...1260
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVELAND TOPPING UP...1261
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS...1262
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL...1262
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...1263
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...1263
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1264
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...1264
4.8.10.a CHANGING THE ENGINE OIL...1264
4.8.10.b CHANGING THE ENGINE OIL FILTER...1265
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...1265
4.8.10.d CHANGING THE FUEL FILTERS...1268
4.8.10.e DRAINING THE FUEL TANK...1270
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)...1271
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR...1272
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines with air conditioner)...1273
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...1274
4.8.11.a CHANGING THE FRONT AXLE OIL...1274
4.8.11.b CHANGING THE REAR AXLE OIL...1275
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...1276
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER...1277
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...1278
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...1278
4.8.12.b CLEANING OF THE COOLING SYSTEM AND CHANGING THE COOLANT...1280
4.8.12.c CHANGING THE BRAKING SYSTEM OIL...1282
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER...1283
4.8.12.e CHANGING THE ALTERNATOR BELT...1283
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY (only for machines with air conditioner)...1283
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION...1284
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS...1284
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE...1284
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION...1285
4.8.14.a CHANGING THE A/C DEWATERING FILTER (Only for machines with air conditioner)...1285
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air conditioner)...1285
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE...1285
4.9 END OF SERVICE LIFE...1286
TECHNICAL DATA...1287
5.1 TECHNICAL DATA...1288
5.1.1 STANDARD OVERALL DIMENSIONS...1288
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM...1288
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM...1289
5.1.2 TECHNICAL CHARACTERISTICS...1290
5.1.3 WORKING RANGES...1291
5.1.3.1 WORKING RANGE LOADER AND BACKHOE...1291
5.1.4 LIFTING CAPACITIES...1293
5.1.4.1 LIFTING CAPACITIES (STANDARD BOOM)...1294
5.1.4.2 LIFTING CAPACITIES (BOOM WITH OFFSET DEVICE)...1294
AUTHORIZED OPTIONAL EQUIPMENT...1295
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1296
6.1.1 PRECAUTIONS REGARDING SAFETY...1296
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1297
6.2 SPECIFICATIONS...1298
6.2.1 ARM-PIN INFORMATION...1298
6.3 ATTACHMENT GUIDE...1299
6.3.1 COMBINATIONS OF WORK EQUIPMENT...1299
6.3.2 ATTACHMENT CONFIGURATION...1299
6.4 FRONT EQUIPMENT QUICK COUPLING DEVICES...1302
6.4.1 MANUAL QUICK COUPLING...1302
6.4.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET...1303
6.4.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...1303
6.5 PALLET FORKS...1304
6.5.1 LIFTING CAPACITIES (PALLET FORKS)...1304
6.5.2 DESCRIPTION...1305
6.5.3 USING THE FORKS...1305
6.5.4 MAINTENANCE...1305
6.6 4 in 1 BUCKET...1306
6.6.1 DESCRIPTION AND CONTROLS...1306
6.6.2 SAFETY DEVICES...1306
6.6.3 INSTALLING THE 4 in 1 BUCKET...1307
6.6.4 USING THE 4 in 1 BUCKET...1308
6.6.5 MAINTENANCE...1308
6.7 FORKS FOR PALLET ON BUCKET 4 IN 1...1309
6.7.1 DESCRIPTION...1309
6.7.2 LIFTING CAPACITY (FORKS FOR ON BUCKET 4 IN 1)...1310
6.7.3 USING THE FORKS...1310
6.7.3.1 PREPARING THE PALLET FORKS FOR USE...1311
6.7.3.2 OVERTURNING THE FORKS...1311
6.7.4 REMOVING THE FORKS...1313
6.7.5 INSTALLING THE FORKS...1313
6.7.6 MAINTENANCE...1313
6.8 HOOK ON BUCKET 4 IN 1...1314
6.8.1 USING THE HOOK...1314
6.8.2 MAINTENANCE...1315
6.9 BACKHOE TELESCOPIC ARM...1316
6.9.1 DESCRIPTION AND CONTROL...1316
6.9.2 SAFETY DEVICES...1317
6.9.3 USING THE TELESCOPIC ARM...1317
6.9.4 MAINTENANCE...1318
6.9.4.1 ADJUSTING THE GUIDE SLACK...1318
6.10 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER...1320
6.10.1 DESCRIPTION AND CONTROL...1320
6.10.2 USE OF THE HYDRAULIC BREAKER AND RULES TO BE OBSERVED...1321
6.10.2.1 HYDRAULIC BREAKER...1321
6.10.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...1326
6.10.3.1 INSTALLING THE HAMMER...1326
6.10.3.2 REMOVING THE HAMMER...1328
6.10.4 USING THE HAMMER...1328
6.10.5 MAINTENANCE...1328
6.11 APPLICATION OF THE OFFSET DEVICE...1329
6.11.1 DESCRIPTION AND CONTROL...1329
6.11.2 MAINTENANCE...1330
6.12 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...1331
6.12.1 DESCRIPTION AND CONTROL...1331
6.12.2 INSTALLING AND CONNECTING THE EQUIPMENT...1332
6.12.3 MAINTENANCE...1332
6.13 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET...1333
6.13.1 DESCRIPTION AND CONTROL...1333
6.13.2 INSTALLING THE CLAMSHELL BUCKET...1334
6.13.3 USING THE CLAMSHELL BUCKET...1335
6.13.4 MAINTENANCE...1335
6.14 TELESCOPIC BOOM WITH PRE-INSTALLATION FOR DEMOLITION HAMMER AND OPTIONAL TOOLS...1336
6.15 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER...1343
6.15.1 DESCRIPTION AND CONTROL...1343
6.15.2 INSTALLING AND REMOVING THE HAND HAMMER...1344
6.15.2.1 CONNECTING THE HAND HAMMER...1344
6.15.2.2 REMOVING THE CONNECTIONS...1345
6.15.3 USING THE HAMMER...1345
6.15.4 MAINTENANCE...1345
6.16 LOAD STABILIZER SYSTEM (LSS) (Optional)...1346
6.16.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR...1346
6.17 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE...1347
6.17.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...1348
6.17.1.1 COUPLING PROCEDURE...1348
6.17.1.2 RELEASE PROCEDURE...1350
6.17.2 MAINTENANCE...1351
6.17.3 MAINTENANCE PLAN...1351
6.17.3.1 DAILY...1351
6.17.3.2 WEEKLY (AT LEAST ONCE PER WEEK)...1351
6.17.3.3 TROUBLESHOOTING...1351
6.18 HYDRAULIC QUICK COUPLER OF THE REAR EQUIPMENT...1352
6.18.1 SAFETY DEVICES...1352
6.18.2 QUICK COUPLER TO BACKHOE LOADER CONNECTION...1352
6.18.3 CONTROL...1353
6.18.4 ADJUSTING THE QUICK COUPLER OPERATING PRESSURE...1354
6.18.5 QUICK RELEASE COUPLING HYDRAULIC CONNECTIONS...1355
6.18.6 EQUIPMENT COUPLING AND RELEASE PROCEDURE...1356
6.18.6.1 COUPLING...1356
6.18.6.2 RELEASE...1356
6.18.7 MAINTENANCE...1356
6.19 HYDRAULICALLY-CONTROLLED SLIDING PLATE FOR BACKHOE...1357
WEBM008400 - Backhoe-Loader WB97S-5E0 Shop Manual...1361
CONTENTS...1363
REVISED PAGES...1365
k SAFETY...1367
FOREWORD...1369
HOW TO READ THE SHOP MANUAL...1370
HOISTING INSTRUCTIONS...1371
STANDARD TIGHTENING TORQUE...1372
COATING MATERIALS...1374
ELECTRIC...1375
WEIGHT TABLE...1376
TABLE OF OIL AND COOLANT QUANTITIES...1377
CONVERSION TABLE...1379
10 STRUCTURE AND FUNCTION...1387
POWER TRAIN...1388
TRANSMISSION (4WD)...1390
TRANSMISSION...1392
CONTROL VALVE BLOCK...1394
DRIVE SHAFTS...1395
FRONT AXLE...1397
REAR AXLE...1400
STEERING SYSTEM (4WS)...1404
HYDRAULIC CIRCUIT...1409
HYDRAULIC PUMP...1411
1. MAIN PUMP...1412
2. DELIVERY CONTROL VALVE...1417
8-SPOOL CONTROL VALVE...1426
10-SPOOL CONTROL VALVE...1432
CLSS...1439
1. DESCRIPTION...1439
2. OPERATING PRINCIPLES...1440
3. OPERATION FOR EACH CIRCUIT AND VALVE...1442
STEERING UNIT...1458
PPC VALVES...1459
SHOVEL PPC VALVE (STANDARD)...1459
SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)...1463
OUTRIGGERS PPC VALVE...1469
BACKHOE LH PPC VALVE...1474
BACKHOE RH PPC VALVE...1475
SOLENOID VALVE GROUP (EV1)...1476
BACKHOE VERSION WITHOUT 4 IN 1 BUCKET...1476
BACKHOE VERSION WITH 4 IN 1 BUCKET...1477
SOLENOID VALVE GROUP (EV2)...1478
SAFETY VALVES...1479
SHOVEL RAISE...1479
SHOVEL DUMP...1480
BOOM...1481
ARM...1482
SHOVEL CYLINDERS...1483
RAISING CYLINDER...1483
DUMPING CYLINDER...1483
4 IN 1 BUCKET...1484
BACKHOE CYLINDERS...1485
BOOM CYLINDER...1485
ARM...1485
BUCKET CYLINDER...1486
OUTRIGGER CYLINDER...1486
BOOM SWING CYLINDER...1487
JIG ARM CYLINDER...1487
AIR-CONDITIONING UNIT...1489
OPERATION OF THE AIR CONDITIONING UNIT...1490
FUSE AND RELAY CENTRE...1491
DRIVER SEAT WIRING...1492
SWITCH PANEL WIRING...1493
FRONT DASH WIRING...1494
LATERAL DASH WIRING...1495
ROOF WIRING...1496
ENGINE WIRING...1497
SPEED SELECTOR WIRING...1498
BACKHOE WIRING...1499
4WS PUSH-BUTTONS PANEL WIRING...1500
4WD SOLENOID VALVES WIRING...1501
WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)...1502
20 TESTING AND ADJUSTMENTS...1503
NORMAL OR STANDARD TECHNICAL DATA...1505
SPECIAL TOOLS...1520
VALVE CLEARANCE ADJUSTING...1521
ENGINE SPEED TESTS...1522
TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT...1524
BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE...1525
ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER...1527
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...1529
BRAKING SYSTEM CHECKS...1530
PARKING BRAKE ADJUSTMENT...1533
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...1535
CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES...1537
SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES...1541
CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE...1543
CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE...1545
ADJUSTING THE PC VALVE...1546
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...1547
CHECKING FOR LEAKS IN THE STEERING CYLINDERS...1548
TESTING PRESSURES IN THE POWER TRAIN GROUP...1549
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES...1551
ANALYSIS OF CAUSES HYDRAULIC DRIFT...1552
FRONT EQUIPMENT...1552
BACKHOE...1554
TESTING THE AIR-CONDITIONING UNIT...1557
EMPTYING THE AIR-CONDITIONING UNIT...1559
TROUBLESHOOTING...1560
FRONT AXLE TROUBLESHOOTING...1560
FRONT AXLE CHECKING AND TROUBLESHOOTING...1563
REAR AXLE TROUBLESHOOTING...1565
REAR AXLE CHECKING AND TROUBLESHOOTING...1568
TRANSMISSION TROUBLESHOOTING...1570
30 REMOVAL AND INSTALLATION...1573
HOW TO READ THE MANUAL...1575
PRECAUTIONS TO BE TAKEN WHILE WORKING...1576
SPECIAL TOOLS...1577
ENGINE HOOD...1581
Removal...1581
Installation...1582
FRONT GUARD...1583
Removal...1583
Installation...1583
RADIATOR GROUP - INTERCOOLER...1584
Removal...1584
Installation...1588
INTERCOOLER...1589
Removal...1589
Installation...1590
CONDENSER...1591
(For machines equipped with an air-conditioning unit)...1591
Removal...1591
Installation...1591
EXHAUST PIPE...1592
Removal...1592
Installation...1592
MUFFLER...1593
Removal...1593
Installation...1593
AIR FILTER...1594
Removal...1594
Installation...1594
ENGINE BELT...1595
Replacement...1595
TURBOCHARGER...1596
Removal...1596
Installation...1597
AIR-CONDITIONING UNIT COMPRESSOR...1598
Removal...1598
Installation...1599
AIR-CONDITIONING UNIT COMPRESSOR BELT...1600
Removal...1600
Installation...1601
FAN AND HEATING GROUP...1602
Removal...1602
Installation...1607
BATTERY...1608
Removal...1608
Installation...1609
FUEL TANK...1610
Removal...1610
Installation...1611
STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...1612
Removal...1612
Installation...1613
WORKING BRAKE PUMP GROUP...1614
Removal...1614
Installation...1616
STEERING UNIT...1617
Removal...1617
Installation...1618
CAB...1619
Removal...1619
Installation...1625
HYDRAULIC OIL TANK...1627
Removal...1627
Installation...1633
PISTON PUMP...1634
Removal...1634
Installation...1635
TRANSMISSION...1636
Removal...1636
Installation...1640
TRANSMISSION...1641
Disassembly and assembly...1641
CONVERTOR...1749
Removal...1749
Installation...1749
ENGINE...1750
Removal...1750
Installation...1754
CONTROL VALVE...1755
Removal...1755
Installation...1757
STEERING SOLENOID VALVE GROUP...1758
Removal...1758
Installation...1758
FRONT AXLE...1759
Removal...1759
Installation...1761
FRONT AXLE...1763
Disassembly and assembly...1763
REAR AXLE...1807
Removal...1807
Installation...1809
Disassembly and assembly...1810
SHOVEL PPC VALVE...1871
Removal...1871
Installation...1872
SHOVEL LIFT CYLINDERS...1873
Removal...1873
Installation...1874
SHOVEL DUMP CYLINDERS...1875
Removal...1875
Installation...1876
SHOVEL...1877
Removal...1877
Installation...1877
FRONT WORKING EQUIPMENT...1878
Removal...1878
Installation...1879
BACKHOE PPC VALVES...1880
Removal...1880
Installation...1881
PPC VALVE SUPPORT RELEASE CABLES...1882
Removal...1882
Installation...1883
PPC VALVE SUPPORT RETURN GAS SPRING...1884
Removal...1884
Installation...1885
SOLENOID VALVE GROUP (servocontrol and optional attachment)...1886
Removal...1886
Installation...1887
BACKHOE BOOM CYLINDER...1888
Removal...1888
Installation...1890
ARM CYLINDER...1891
Removal...1891
Installation...1892
JIG ARM CYLINDER...1893
Removal...1893
Installation...1893
OUTRIGGER CYLINDER...1894
Removal...1894
Installation...1895
BACKHOE SWING CYLINDERS...1896
Removal...1896
Installation...1898
BACKHOE BUCKET CYLINDER...1899
Removal...1899
Installation...1900
BACKHOE BOOM SAFETY CYLINDER...1901
Removal...1901
Installation...1902
CYLINDER...1903
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS...1903
Disassembly...1903
Assembly...1905
BACKHOE SWING CYLINDERS...1908
Disassembly...1908
Assembly...1911
BACKHOE WORKING EQUIPMENT...1914
Removal...1914
Installation...1915
BACKHOE BUCKET...1916
Removal...1916
Installation...1916
BACKHOE BOOM CYLINDER...1917
Removal...1917
Installation...1917
ARM...1918
Removal...1918
Installation...1918
JIG ARM...1919
Removal...1919
Installation...1919
2nd ARM...1920
Removal...1920
Installation...1920
2nd ARM GUIDES...1921
Removal...1921
Installation...1921
BACKHOE SWING BRACKET...1922
Removal...1922
Installation...1922
COMPLETE BACKHOE BACKFRAME...1923
Removal...1923
Installation...1924
BACKFRAME LOCK PISTONS...1925
Removal...1925
Installation...1926
40 STANDARD MAINTENANCE...1927
TRANSMISSION...1928
FRONT AXLE...1931
REAR AXLE...1934
HYDRAULIC PUMP...1938
CONTROL VALVE...1940
8-SPOOL VERSION...1940
10-SPOOL VERSION...1948
PPC VALVES...1956
SHOVEL CONTROL...1956
SHOVEL CYLINDERS...1958
DUMP CYLINDER...1958
RAISE CYLINDER...1958
4 IN 1 BUCKET...1959
BACKHOE CYLINDERS...1960
BOOM...1960
ARM...1960
BUCKET...1960
BOOM SWING...1961
OUTRIGGERS...1962
JIG ARM...1962
FRONT WORKING EQUIPMENT...1964
SWING BRACKET...1966
BACKHOE WORKING EQUIPMENT...1968
90 OTHER...1971
ELECTRICAL DIAGRAM (STANDARD VERSION)...1973
WEBM008402 - Backhoe-Loader WB97S-5E0 Shop Manual...1977
CONTENTS...1979
SAFETY...1981
FOREWORD...1983
HOW TO READ THE SHOP MANUAL...1984
HOISTING INSTRUCTIONS...1985
STANDARD TIGHTENING TORQUE...1986
COATING MATERIALS...1988
ELECTRIC...1989
WEIGHT TABLE...1990
TABLE OF OIL AND COOLANT QUANTITIES...1991
CONVERSION TABLE...1993
10 STRUCTURE AND FUNCTION...2001
POWER TRAIN...2002
TRANSMISSION (4WD)...2004
TRANSMISSION...2006
CONTROL VALVE BLOCK...2008
DRIVE SHAFTS...2009
FRONT AXLE...2011
REAR AXLE...2014
STEERING SYSTEM (4WS)...2018
HYDRAULIC PUMP...2022
8-SPOOL CONTROL VALVE...2036
10-SPOOL CONTROL VALVE...2044
CLSS...2053
STEERING UNIT...2074
PPC VALVES (SHOVEL CONTROL)...2075
PPC VALVE (BACKHOE CONTROLS)...2090
SOLENOID VALVE GROUP (EV1)...2096
SOLENOID VALVE GROUP (EV2)...2097
HAMMER AND JIG ARM SOLENOID VALVE...2098
HAMMER SOLENOID VALVE...2099
JIG ARM SOLENOID VALVE...2100
JIG ARM AND SIDE DIGGING BOOM SOLENOID VALVE...2101
JIG ARM AND 2-WAY ATTACHMENT SOLENOID VALVE...2102
SIDE DIGGING BOOM SOLENOID VALVE...2103
2-WAY ATTACHMENT SOLENOID VALVE...2104
SAFETY VALVES...2105
SHOVEL CYLINDERS...2110
BACKHOE CYLINDERS...2112
AIR-CONDITIONING UNIT...2117
OPERATION OF THE AIR CONDITIONING UNIT...2119
20 TESTING AND ADJUSTMENTS...2121
NORMAL OR STANDARD TECHNICAL DATA...2122
SPECIAL TOOLS...2137
VALVE CLEARANCE ADJUSTING...2138
ENGINE SPEED TESTS...2139
TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT...2140
BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE...2141
ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER...2142
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...2144
BRAKING SYSTEM CHECKS...2145
PARKING BRAKE ADJUSTMENT...2147
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...2149
CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES...2151
SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES...2154
CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE...2156
CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE...2157
ADJUSTING THE PC VALVE...2158
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...2159
CHECKING FOR LEAKS IN THE STEERING CYLINDERS...2160
TESTING PRESSURES IN THE POWER TRAIN GROUP...2161
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES...2163
ANALYSIS OF CAUSES HYDRAULIC DRIFT...2164
JIG ARM CLEARANCE ADJUSTMENT...2168
TESTING THE AIR-CONDITIONING UNIT...2170
EMPTYING THE AIR-CONDITIONING UNIT...2172
TROUBLESHOOTING...2173
30 REMOVAL AND INSTALLATION...2187
HOW TO READ THE MANUAL...2188
PRECAUTIONS TO BE TAKEN WHILE WORKING...2189
SPECIAL TOOLS...2190
ENGINE HOOD...2194
FRONT GUARD...2195
RADIATOR GROUP - INTERCOOLER...2196
INTERCOOLER...2199
CONDENSER...2201
(For machines equipped with an air-conditioning unit)...2201
EXHAUST PIPE...2202
MUFFLER...2203
AIR FILTER...2204
ENGINE BELT...2205
TURBOCHARGER...2206
AIR-CONDITIONING UNIT COMPRESSOR...2207
AIR-CONDITIONING UNIT COMPRESSOR BELT...2209
FAN AND HEATING GROUP...2210
BATTERY...2215
FUEL TANK...2216
STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...2217
WORKING BRAKE PUMP GROUP...2219
STEERING UNIT...2221
CAB...2223
HYDRAULIC OIL TANK...2228
PISTON PUMP...2233
TRANSMISSION...2235
CONVERTOR...2316
ENGINE...2317
CONTROL VALVE...2320
STEERING SOLENOID VALVE GROUP...2323
FRONT AXLE...2324
REAR AXLE...2369
SHOVEL PPC VALVE...2429
SHOVEL LIFT CYLINDERS...2430
SHOVEL DUMP CYLINDERS...2432
SHOVEL...2433
FRONT WORKING EQUIPMENT...2434
BACKHOE PPC VALVES...2436
PPC VALVE SUPPORT RELEASE CABLES...2437
PPC VALVE SUPPORT RETURN GAS SPRING...2439
SOLENOID VALVE GROUP (servocontrol and optional attachment)...2441
BACKHOE BOOM CYLINDER...2442
ARM CYLINDER...2444
JIG ARM CYLINDER...2446
OUTRIGGER CYLINDER...2447
BACKHOE SWING CYLINDERS...2449
BACKHOE BUCKET CYLINDER...2451
BACKHOE BOOM SAFETY CYLINDER...2453
CYLINDER...2455
BACKHOE WORKING EQUIPMENT...2463
BACKHOE BUCKET...2465
BACKHOE BOOM CYLINDER...2466
ARM...2467
JIG ARM...2468
2nd ARM...2469
2nd ARM GUIDES...2470
BACKHOE SWING BRACKET...2471
COMPLETE BACKHOE BACKFRAME...2472
BACKFRAME LOCK PISTONS...2474
40 STANDARD MAINTENANCE...2477
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...2478
TRANSMISSION...2480
FRONT AXLE...2483
REAR AXLE...2486
HYDRAULIC PUMP...2490
CONTROL VALVE...2492
PPC VALVES...2508
SHOVEL CYLINDERS...2510
BACKHOE CYLINDERS...2512
FRONT WORKING EQUIPMENT...2515
SWING BRACKET...2517
BACKHOE WORKING EQUIPMENT...2519
90 DIAGRAMS AND DRAWINGS...2521
HYDRAULIC CIRCUIT DIAGRAM - FROM S/N F30451 TO S/N F30794 AND FROM S/N F30796 TO S/N F30796...2523
HYDRAULIC CIRCUIT DIAGRAM - FROM S/N F30795 TO S/N F30795 AND FROM S/N F30797 AND UP...2525
HYDRAULIC CIRCUIT DIAGRAM - OPTIONAL...2527
HYDRAULIC CIRCUIT DIAGRAM - STEERING...2529
ELECTRICAL CIRCUIT DIAGRAM (1/3)...2531
ELECTRICAL CIRCUIT DIAGRAM (2/3)...2533
ELECTRICAL CIRCUIT DIAGRAM (3/3)...2535
WETT001308 - Backhoe-Loader WB91R-5EO, WB93R-5EO, WB97R-5EO, WB93S-5EO, WB97S-5EO Basic Technical Training...2539
Komatsu Backhoe-Loader WB97S-5E0 Repair Service Manual
