Komatsu Backhoe-Loader WB97S Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe-Loader WB97S, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe-Loader WB97S 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.
WEAM000702 - Backhoe-Loader WB97S-2 Operation & Maintenance Manual.pdf
WEAM000704 - Backhoe-Loader WB97S-2 Operation & Maintenance Manual.pdf
WEAM007604 - Backhoe-Loader WB97S-5S Operation & Maintenance Manual.pdf
WEBM002400 - Backhoe-Loader WB97S-2 Shop Manual.pdf
WEBM002401 - Backhoe-Loader WB97S-2 Shop Manual.pdf
WEBM002404 - Backhoe-Loader WB97S-2 Shop Manual.pdf
WEBM007500 - Backhoe-Loader WB97S-5 Shop Manual.pdf
WEPB009400 - Backhoe-Loader WB97S-5 Parts Manual.pdf
WHBM002403 - Terna WB97S-2 Manuale d'Officina.pdf
PRODUCT DETAILS:
Total Pages: 3,754 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM000702 - Backhoe-Loader WB97S-2 Operation & Maintenance Manual...1
1.1 FOREWORD...3
1.2 INFORMATION ON SAFETY...4
1.3 INTRODUCTION...6
1.3.1 INTENDED USES...6
1.3.2 IMPROPER OR UNAUTHORIZED USES...6
1.3.3 MAIN CHARACTERISTICS...7
1.3.4 RUNNING-IN...7
1.4 PRODUCT IDENTIFICATION...8
1.4.1 MACHINE SERIAL NUMBER...8
1.4.2 MACHINE IDENTIFICATION PLATE...8
1.4.3 ENGINE SERIAL NUMBER...9
1.4.4 FRONT AXLE SERIAL NUMBER...9
1.4.5 REAR AXLE SERIAL NUMBER...10
1.4.6 TRANSMISSION SERIAL NUMBER...10
1.4.7 CAB SERIAL NUMBER...10
1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS...11
TABLE OF CONTENTS...13
SICUREZ_.pdf...0
2.1 SAFETY, NOISE AND VIBRATION PLATES...22
2.1.1 POSITION OF THE SAFETY PLATES...22
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...24
DANGER IN THE WORK AREA...24
DO NOT OPEN THE HOOD...24
CONSULT THE MANUAL...24
HYDRAULIC OIL TOPPING UP...24
FILLING THE HYDRAULIC SYSTEM WITH OIL...25
REFUELLING...25
ENGINE LUBRICATING OIL FILTER...25
FUEL FILTER...25
ENGINE AIR SUCTION FILTER...25
ENGINE COOLANT...25
ENGINE COOLANT PRESSURE...26
HYDRAULIC OIL LEVEL...26
HYDRAULIC OIL FILTER...26
ELECTRIC OUTLET...26
TRANSMISSION OIL LEVEL...26
HYDRAULIC TRANSMISSION OIL FILTER...26
ANCHORAGE POINT...27
EMERGENCY EXIT...27
BOOM LOCK...27
SWING LOCK...27
BRAKE OIL...27
DO NOT LIFT MORE THAN 1000 kg...27
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...28
NOISE OUTSIDE THE CAB...28
NOISE INSIDE THE CAB...28
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...29
2.2 GENERAL PRECAUTIONS...30
2.2.1 GENERAL SAFETY RULES...30
2.2.2 SAFETY DEVICES AND GUARDS...30
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...30
2.2.4 UNAUTHORIZED MODIFICATIONS...31
2.2.5 LEAVING THE OPERATOR’S SEAT...31
2.2.6 GETTING ON AND OFF THE MACHINE...32
2.2.7 CHECKING THE REAR-VIEW MIRRORS...32
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...32
2.2.9 PREVENTING BURNS...33
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...33
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...34
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...34
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...34
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...34
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...35
2.3.1 SAFETY ON THE WORK SITE...35
2.3.2 FIRE PREVENTION...35
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...35
2.3.4 ROOM VENTILATION...36
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...36
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...37
2.4.1 STARTING THE ENGINE...37
2.4.2 RULES FOR ROAD TRAVEL...37
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...38
2.4.4 MOVING THE MACHINE...38
2.4.5 WORKING ON SLOPES...39
2.4.6 PREVENTING ELECTROCUTION...40
2.4.7 VISIBILITY...41
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES...41
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...41
2.4.10 WORKING ON LOOSE GROUND...41
2.4.11 PARKING THE MACHINE...42
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...43
2.5.1 LOADING AND UNLOADING THE MACHINE...43
2.5.2 THE ROUTE...43
2.6 BATTERY...44
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES...44
2.6.2 STARTING WITH BOOSTER CABLES...44
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...45
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...46
2.8.1 WARNING PLATES...46
2.8.2 TOOLS...46
2.8.3 PERSONNEL...46
2.8.4 EQUIPMENT...47
2.8.5 WORKING UNDER THE MACHINE...47
2.8.6 KEEPING THE MACHINE CLEAN...47
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...48
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...48
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...49
2.8.10 RULES FOR REFUELLING AND ADDING OIL...50
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...50
2.8.12 USING LAMPS...50
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...51
2.8.14 PRECAUTIONS CONCERNING THE STARTER...51
2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT...52
2.8.16 HANDLING HIGH-PRESSURE PIPES...52
2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...52
2.8.18 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...53
2.8.19 COOLING FAN AND FAN BELT...53
2.8.20 WASTE MATERIALS...53
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES...54
2.8.22 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...54
2.8.23 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...55
DESCRI_1.pdf...0
3.1 SAFETY LOCKS...58
3.1.1 FRONT LOADER LOCKS...58
3.1.2 BACKHOE LOCKS...60
3.2 GENERAL VIEWS...61
3.2.1 FRONT GENERAL VIEW...61
3.2.2 BACKHOE GENERAL VIEW...62
3.2.3 CAB INSIDE GENERAL VIEW...63
3.3 INSTRUMENTS AND CONTROLS...64
3.3.1 FRONT INSTRUMENTS...64
3.3.2 SIDE INSTRUMENTS...74
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...80
3.3.4 ELECTRICAL ACCESSORIES...81
3.3.5 MACHINE CONTROLS...82
DESCRI_2.pdf...0
KOMATSU SYSTEM CONTROLS...105
ISO STANDARD CONTROLS...106
“X” SYSTEM CONTROLS...107
3.4 FUSES AND RELAYS...109
3.4.1 EQUIPMENT FUSES AND RELAYS...109
...
3.5 GUARDS, CAB AND DRIVER’S SEAT...115
3.5.1 ENGINE HOOD...115
3.5.2 CANOPY (if provided)...115
3.5.3 CAB...116
3.5.4 VENTILATION AND HEATING...118
3.5.5 SEAT...119
3.5.6 SAFETY BELT...120
3.5.7 FIRE EXTINGUISHER...120
3.5.8 FIRST AID KIT...120
3.5.9 TECHNICAL DOCUMENTATION...120
USO.pdf...0
3.6 USE OF THE MACHINE...121
3.6.1 CHECKS BEFORE STARTING THE ENGINE...121
3.6.2 STARTING THE ENGINE...123
3.6.3 WARMING THE ENGINE...125
3.6.4 HEATING THE HYDRAULIC OIL...125
3.6.5 HOW TO MOVE THE MACHINE...126
3.7 PARKING THE MACHINE...130
3.7.1 PARKING ON LEVEL GROUND...130
3.7.2 PARKING ON SLOPES...131
3.8 STOPPING THE ENGINE...132
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...133
3.9.1 LOADING AND UNLOADING THE MACHINE...133
3.9.2 TRANSPORT...134
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...135
3.10.1 FUEL AND LUBRICANTS...135
3.10.2 COOLANT...135
3.10.3 BATTERY...135
CHARGE PERCENTAGE...136
FLUID TEMPERATURE...136
...
3.10.4 OTHER PRECAUTIONS...136
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...136
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...137
3.12 USING THE MACHINE AS A LOADER...138
3.12.1 BUCKET POSITION INDICATOR...138
3.12.2 ORGANIZING THE WORK AREA...138
3.12.3 CHANGING THE STANDARD FRONT BUCKET...140
3.13 USING THE MACHINE AS AN EXCAVATOR...141
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT...141
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...142
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...143
3.13.4 DIGGING METHOD...144
3.13.5 CHANGING THE BACKHOE BUCKET...145
3.14 LONG PERIODS OF INACTIVITY...146
3.14.1 BEFORE THE PERIOD OF INACTIVITY...146
3.14.2 DURING THE PERIOD OF INACTIVITY...148
3.14.3 AFTER THE PERIOD OF INACTIVITY...148
3.15 TROUBLESHOOTING...149
3.15.1 HOW TO REMOVE THE MACHINE...149
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED...149
3.15.3 IF THE BATTERY IS DEPLETED...150
3.15.4 OTHER TROUBLES...152
MANUT_1.pdf...0
4.1 GUIDE TO MAINTENANCE...156
4.2 MAINTENANCE NOTES...158
4.2.1 NOTES REGARDING THE ENGINE...158
...
4.7.1 WHEN REQUIRED...180
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...189
4.7.3 CHECKS BEFORE STARTING...190
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...194
JOINT LUBRICATION POINTS...194
FRONT LOADER...194
MANUT_2.pdf...0
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used)...196
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...196
4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...200
4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...201
4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthetic biodegradable oil type HEES is used)...206
4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...207
4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...214
4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...218
DATI.pdf...0
5.1 TECHNICAL DATA...224
5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE...224
5.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE...224
5.1.3 TECHNICAL CHARACTERISTICS...225
TOTAL MASS...225
STANDARD BUCKET CAPACITY...225
SUPERCHARGED ENGINE...225
ELECTRICAL SYSTEM...225
TRAVEL SPEEDS...225
FRONT TYRES...225
REAR TYRES...225
5.1.4 LIFTING CAPACITIES...226
ATTREZZ_.pdf...0
6.1 AUTHORIZED OPTIONAL EQUIPMENT...230
6.1.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...230
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES...231
6.2.1 MANUAL CONTROL QUICK COUPLING...231
6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET...232
6.2.3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...232
6.3 4in1 BUCKET...233
6.3.1 DESCRIPTION AND CONTROLS...233
6.3.2 SAFETY DEVICES...233
6.3.3 INSTALLING THE 4in1 BUCKET...234
6.3.4 USING THE 4in1 BUCKET...235
6.3.5 MAINTENANCE...235
6.4 PALLET FORKS...236
6.4.1 DESCRIPTION...236
6.4.2 SAFETY DEVICES...236
6.4.3 USING THE FORKS...236
6.4.4 REMOVING THE FORKS...238
6.4.5 INSTALLING THE FORKS...238
6.4.6 MAINTENANCE...238
6.5 BACKHOE TELESCOPIC ARM...239
6.5.1 DESCRIPTION AND CONTROL...239
6.5.2 SAFETY DEVICES...239
6.5.3 USING THE TELESCOPIC ARM...240
6.5.4 MAINTENANCE...240
6.6 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER...242
6.6.1 DESCRIPTION AND CONTROL...242
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...243
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...247
6.6.4 USING THE HAMMER...249
6.6.5 MAINTENANCE...249
6.7 APPLICATION OF THE OFFSET DEVICE...250
6.7.1 DESCRIPTION AND CONTROL...250
6.7.2 MAINTENANCE...251
6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...252
6.8.1 DESCRIPTION AND CONTROL...252
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT...252
6.8.3 MAINTENANCE...253
6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET...254
6.9.1 DESCRIPTION AND CONTROL...254
6.9.2 INSTALLING THE CLAMSHELL BUCKET...255
6.9.3 USING THE CLAMSHELL BUCKET...256
6.9.4 MAINTENANCE...256
6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER...257
6.10.1 DESCRIPTION AND CONTROL...257
6.10.2 CONNECTING AND REMOVING THE HAMMER...258
6.10.3 USING THE HAMMER...259
6.10.4 MAINTENANCE...259
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)...260
6.11.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)...260
6.12 AIR CONDITIONER (optional)...261
WEAM000704 - Backhoe-Loader WB97S-2 Operation & Maintenance Manual...265
1.1 FOREWORD...267
1.2 INFORMATION ON SAFETY...268
1.3 INTRODUCTION...270
1.3.1 INTENDED USES...270
1.3.2 IMPROPER OR UNAUTHORIZED USES...270
1.3.3 MAIN CHARACTERISTICS...271
1.3.4 RUNNING-IN...271
1.4 PRODUCT IDENTIFICATION...272
1.4.1 MACHINE SERIAL NUMBER...272
1.4.2 MACHINE IDENTIFICATION PLATE...272
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...273
1.4.4 FRONT AXLE SERIAL NUMBER...273
1.4.5 REAR AXLE SERIAL NUMBER...273
1.4.6 TRANSMISSION SERIAL NUMBER...274
1.4.7 CAB SERIAL NUMBER...274
1.4.8 CANOPY SERIAL NUMBER (if provided)...274
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS...275
TABLE OF CONTENTS...277
2.1 SAFETY, NOISE AND VIBRATION PLATES...286
2.1.1 POSITION OF THE SAFETY PLATES...286
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...288
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...292
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...293
2.2 GENERAL PRECAUTIONS...294
2.2.1 GENERAL SAFETY RULES...294
2.2.2 SAFETY DEVICES AND GUARDS...294
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...294
2.2.4 UNAUTHORIZED MODIFICATIONS...295
2.2.5 LEAVING THE OPERATOR’S SEAT...295
2.2.6 GETTING ON AND OFF THE MACHINE...296
2.2.7 CHECKING THE REAR-VIEW MIRRORS...296
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...296
2.2.9 PREVENTING BURNS...297
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...297
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...298
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...298
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...298
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...298
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...299
2.3.1 SAFETY ON THE WORK SITE...299
2.3.2 FIRE PREVENTION...299
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...299
2.3.4 ROOM VENTILATION...300
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...300
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...301
2.4.1 STARTING THE ENGINE...301
2.4.2 RULES FOR ROAD TRAVEL...301
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...302
2.4.4 MOVING THE MACHINE...302
2.4.5 WORKING ON SLOPES...303
2.4.6 PREVENTING ELECTROCUTION...304
2.4.7 VISIBILITY...305
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES...305
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...305
2.4.10 WORKING ON LOOSE GROUND...305
2.4.11 PARKING THE MACHINE...306
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...307
2.5.1 LOADING AND UNLOADING THE MACHINE...307
2.5.2 THE ROUTE...307
2.6 BATTERY...308
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES...308
2.6.2 STARTING WITH BOOSTER CABLES...308
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...309
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...310
2.8.1 WARNING PLATES...310
2.8.2 TOOLS...310
2.8.3 PERSONNEL...310
2.8.4 EQUIPMENT...311
2.8.5 WORKING UNDER THE MACHINE...311
2.8.6 KEEPING THE MACHINE CLEAN...311
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...312
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...312
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...313
2.8.10 RULES FOR REFUELLING AND ADDING OIL...314
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...314
2.8.12 USING LAMPS...314
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...315
2.8.14 PRECAUTIONS CONCERNING THE STARTER...315
2.8.15 PRECAUTIONS CONCERNING THE GEARSHIFT...316
2.8.16 HANDLING HIGH-PRESSURE PIPES...316
2.8.17 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...316
2.8.18 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...317
2.8.19 COOLING FAN AND FAN BELT...317
2.8.20 WASTE MATERIALS...317
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES...318
2.8.22 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...318
2.8.23 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...319
THIS PAGE WAS INTENTIONALLY LEFT EMPTY...320
3.1 SAFETY LOCKS...322
3.1.1 FRONT LOADER LOCKS...322
3.1.2 BACKHOE LOCKS...324
3.2 GENERAL VIEWS...325
3.2.1 FRONT GENERAL VIEW...325
3.2.2 BACKHOE GENERAL VIEW...326
3.2.3 CAB INSIDE GENERAL VIEW...327
3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version)...327
3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request)...328
3.3 INSTRUMENTS AND CONTROLS...329
3.3.1 FRONT INSTRUMENTS...329
3.3.2 SIDE INSTRUMENTS...341
3.3.2.1 SIDE INSTRUMENTS (Standard version)...341
3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request)...342
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...350
3.3.4 ELECTRICAL ACCESSORIES...351
3.3.5 MACHINE CONTROLS...352
3.3.5.1 MACHINE CONTROLS (Standard version)...352
3.3.5.2 MACHINE CONTROLS (Version with servo controls available upon request)...353
3.4 FUSES AND RELAYS...393
3.4.1 EQUIPMENT FUSES AND RELAYS...393
3.4.1.1 FUSES...394
3.4.1.2 RELAYS...395
3.4.2 ENGINE LINE FUSES AND RELAYS...395
3.4.2.1 FUSES...396
3.4.2.2 RELAYS...396
3.4.3 SIDE DASHBOARD RELAYS...397
3.4.4 SIDE DASHBOARD RELAYS AND FUSES (Only with servo controls)...397
3.4.4.1 RELAYS...397
3.4.4.2 FUSES...397
3.5 GUARDS, CAB AND DRIVER’S SEAT...398
3.5.1 ENGINE HOOD...398
3.5.2 CANOPY (if provided)...398
3.5.3 CAB...399
3.5.4 VENTILATION AND HEATING...402
3.5.5 AIR CONDITIONER (if installed)...403
3.5.6 SEAT...405
3.5.6.1 SEAT (STANDARD)...405
3.5.6.2 SEAT (OPTIONAL)...406
3.5.7 SAFETY BELT...407
3.5.8 FIRE EXTINGUISHER...407
3.5.9 FIRST AID KIT...407
3.5.10 TECHNICAL DOCUMENTATION...407
3.5.11 ADDITIONAL TOOL BOX (if provided)...408
3.6 USE OF THE MACHINE...409
3.6.1 CHECKS BEFORE STARTING THE ENGINE...409
3.6.1.1 VISUAL CHECKS...409
3.6.1.2 DAILY CHECKS...409
3.6.1.3 OPERATIONAL CHECKS...410
3.6.2 STARTING THE ENGINE...411
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...411
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...412
3.6.3 WARMING THE ENGINE...413
3.6.4 HEATING THE HYDRAULIC OIL...413
3.6.5 HOW TO MOVE THE MACHINE...414
3.6.5.1 ENGAGING THE FOUR-WHEEL DRIVE...415
3.6.5.2 MOVING ON SLOPES...416
3.6.5.3 MAXIMUM IMMERSION DEPTH...417
3.7 PARKING THE MACHINE...418
3.7.1 PARKING ON LEVEL GROUND...418
3.7.2 PARKING ON SLOPES...419
3.8 STOPPING THE ENGINE...420
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...421
3.9.1 LOADING AND UNLOADING THE MACHINE...421
3.9.2 TRANSPORT...422
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...423
3.10.1 FUEL AND LUBRICANTS...423
3.10.2 COOLANT...423
3.10.3 BATTERY...423
3.10.4 OTHER PRECAUTIONS...424
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...424
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...425
3.12 USING THE MACHINE AS A LOADER...426
3.12.1 BUCKET POSITION INDICATOR...426
3.12.2 ORGANIZING THE WORK AREA...426
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...427
3.12.2.2 LOADING OPERATIONS ON SLOPES...428
3.12.3 CHANGING THE STANDARD FRONT BUCKET...428
3.13 USING THE MACHINE AS AN EXCAVATOR...429
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT...429
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...430
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...431
3.13.4 DIGGING METHOD...432
3.13.5 CHANGING THE BACKHOE BUCKET...433
3.14 LONG PERIODS OF INACTIVITY...434
3.14.1 BEFORE THE PERIOD OF INACTIVITY...434
3.14.2 DURING THE PERIOD OF INACTIVITY...436
3.14.3 AFTER THE PERIOD OF INACTIVITY...436
3.15 TROUBLESHOOTING...437
3.15.1 HOW TO REMOVE THE MACHINE...437
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED...437
3.15.3 IF THE BATTERY IS DEPLETED...438
3.15.3.1 STARTING WITH BOOSTER CABLES...439
3.15.4 OTHER TROUBLES...440
3.15.4.1 ELECTRICAL CIRCUIT...440
3.15.4.2 HYDRAULIC SYSTEM...440
3.15.4.3 BRAKING SYSTEM...441
3.15.4.4 CONVERTER...441
3.15.4.5 ENGINE...442
4.1 GUIDE TO MAINTENANCE...444
4.2 MAINTENANCE NOTES...446
4.2.1 NOTES REGARDING THE ENGINE...446
4.2.1.1 ENGINE OIL...446
4.2.1.2 COOLANT...446
4.2.1.3 FUEL...447
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...447
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM...448
4.2.4 NOTES REGARDING LUBRICATION...448
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...449
4.3 FUEL, COOLANT AND LUBRICANTS...450
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...452
4.4 DRIVING TORQUES FOR SCREWS AND NUTS...453
4.4.1 STANDARD DRIVING TORQUES...453
4.4.2 SPECIFIC DRIVING TORQUES...453
4.5 LUBRICATION...454
4.5.1 LUBRICATION DIAGRAM...454
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...455
4.5.3 LUBRICATION DIAGRAM (Front bucket rapid couplings)...456
4.5.4 LUBRICATION DIAGRAM (Telescopic arm)...457
4.5.5 LUBRICATION DIAGRAM (Offset device)...458
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY...459
4.6.1 CRITICAL PARTS FOR SAFETY...460
4.7 MAINTENANCE PLAN...464
4.7.1 WHEN REQUIRED...468
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...468
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER...469
4.7.1.c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER (only for machines with air conditioner)...470
4.7.1.d BLEEDING THE BRAKING CIRCUIT...471
4.7.1.e CLEANING THE WATER SEPARATOR...472
4.7.1.f CHECKING AND ADJUSTING THE WHEEL TOE-IN...472
4.7.1.g CHECKING AND ADJUSTING THE PARKING BRAKE...473
4.7.1.h CHECKING THE BRAKING EFFICIENCY...474
4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...475
4.7.1.k ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...475
4.7.1.l CHECKING AND ADJUSTING THE STABILIZER SLACK...476
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...477
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER...477
4.7.2.b CHANGING THE HYDRAULIC OIL...477
4.7.3 CHECKS BEFORE STARTING...478
4.7.3.a VARIOUS CHECKS...478
4.7.3.b CHECKING THE COOLANT LEVEL...478
4.7.3.c CHECKING THE FUEL LEVEL...479
4.7.3.d CHECKING THE ENGINE OIL LEVEL...479
4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL...480
4.7.3.f DRAINING THE WATER SEPARATOR...481
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...482
4.7.4.a LUBRICATING THE JOINTS...482
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...484
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...484
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL...484
4.7.6.b CHECKING THE BRAKING SYSTEM OIL LEVEL...484
4.7.6.c LUBRICATING THE PROPELLER SHAFTS...485
4.7.6.d LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING AND THE REAR AXLE JOINTS...486
4.7.6.e CHECKING THE TYRE PRESSURE...486
4.7.6.f CHECKING THE ELECTRICAL SYSTEM...487
4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...488
4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...489
4.7.8.a ADJUSTING THE FAN BELT TENSION...489
4.7.8.b ADJUSTING THE A/C COMPRESSOR BELT TENSION (Only for machines with air conditioner)...490
4.7.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL...491
4.7.8.d CHECKING THE FRONT AXLE OIL LEVELS...492
4.7.8.e CHECKING THE REAR AXLE OIL LEVELS...492
4.7.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...493
4.7.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...493
4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti...494
4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...495
4.7.10.a CHANGING THE ENGINE OIL...495
4.7.10.b CHANGING THE ENGINE OIL FILTER...496
4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...496
4.7.10.d CHANGING THE FUEL FILTER...499
4.7.10.e DRAINING THE FUEL TANK...500
4.7.10.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ...501
4.7.10.g CLEANING THE OUTSIDE OF THE RADIATORS...502
4.7.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (Only for machines with air conditioner)...503
4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...504
4.7.11.a CHANGING THE FRONT AXLE OIL...504
4.7.11.b CHANGING THE REAR AXLE OIL...505
4.7.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...506
4.7.11.d CHANGING THE HYDRAULIC TRANSMISSION FILTER...507
4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...507
4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...508
4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...508
4.7.12.b CHANGING THE COOLANT...510
4.7.12.c CHANGING THE BRAKING SYSTEM OIL...512
4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER...512
4.7.12.e CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM (Only for machines with air conditioner)...513
4.7.13 MAINTENANCE EVERY 4000 HOURS OF OPERATION...514
4.7.13.a CHANGING THE A/C DEHYDRATING FILTER (Only for machines with air conditioner)...514
4.7.13.a CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air cond...514
5.1 TECHNICAL DATA...516
5.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE...516
5.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE...516
5.1.3 TECHNICAL CHARACTERISTICS...517
5.1.4 LIFTING CAPACITIES...518
5.1.4.1 SYMBOL TABLE...518
5.1.4.2 LIFTING CAPACITY (STANDARD BOOM)...519
5.1.4.3 LIFTING CAPACITY (OFFSET BOOM)...520
6.1 AUTHORIZED OPTIONAL EQUIPMENT...522
6.1.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...522
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES...523
6.2.1 MANUAL CONTROL QUICK COUPLING...523
6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET...524
6.2.3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL...524
6.3 4in1 BUCKET...525
6.3.1 DESCRIPTION AND CONTROLS...525
6.3.2 SAFETY DEVICES...525
6.3.3 INSTALLING THE 4in1 BUCKET...526
6.3.4 USING THE 4in1 BUCKET...527
6.3.5 MAINTENANCE...527
6.4 PALLET FORKS...528
6.4.1 DESCRIPTION...528
6.4.2 SAFETY DEVICES...528
6.4.3 USING THE FORKS...529
6.4.3.1 PREPARING THE PALLET FORKS FOR USE...529
6.4.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS...530
6.4.4 REMOVING THE FORKS...531
6.4.5 INSTALLING THE FORKS...531
6.4.6 MAINTENANCE...531
6.5 BACKHOE TELESCOPIC ARM...532
6.5.1 DESCRIPTION AND CONTROL...532
6.5.1.1 VERSION WITH STANDARD CONTROLS...532
6.5.1.2 VERSION WITH SERVO CONTROLS (if installed)...532
6.5.2 SAFETY DEVICES...533
6.5.3 USING THE TELESCOPIC ARM...533
6.5.4 MAINTENANCE...534
6.5.4.1 ADJUSTING THE GUIDE SLACK...534
6.6 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER...536
6.6.1 DESCRIPTION AND CONTROL...536
6.6.1.1 VERSION WITH STANDARD CONTROLS...536
6.6.1.2 VERSION WITH SERVO CONTROLS (if installed)...536
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...537
FOR A CORRECT USE OF THE HAMMER, IT IS NECESSARY TO:...537
ALWAYS AVOID THE FOLLOWING INCORRECT USES:...539
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...541
6.6.3.1 INSTALLING THE HAMMER...541
6.6.3.2 REMOVING THE HAMMER...543
6.6.4 USING THE HAMMER...543
OPERATIONS WITH THE HYDRAULIC HAMMER AND COMPACTING TOOLS...543
6.6.5 MAINTENANCE...543
6.7 APPLICATION OF THE OFFSET DEVICE...544
6.7.1 DESCRIPTION AND CONTROL...544
6.7.1.1 VERSION WITH STANDARD CONTROLS...544
6.7.1.2 VERSION WITH SERVO CONTROLS (if installed)...545
6.7.2 MAINTENANCE...545
6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...546
6.8.1 DESCRIPTION AND CONTROL...546
6.8.1.1 VERSION WITH STANDARD CONTROLS...546
6.8.1.2 VERSION WITH SERVO CONTROLS (if installed)...546
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT...547
6.8.3 MAINTENANCE...547
6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET...548
6.9.1 DESCRIPTION AND CONTROL...548
6.9.1.1 VERSION WITH STANDARD CONTROLS...548
6.9.1.2 VERSION WITH SERVO CONTROLS (if installed)...549
6.9.2 INSTALLING THE CLAMSHELL BUCKET...550
6.9.3 USING THE CLAMSHELL BUCKET...551
6.9.4 MAINTENANCE...551
6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER...552
6.10.1 DESCRIPTION AND CONTROL...552
6.10.2 CONNECTING AND REMOVING THE HAMMER...553
6.10.2.1 CONNECTING THE HAMMER...553
6.10.2.2 REMOVING THE CONNECTIONS...553
6.10.3 USING THE HAMMER...554
6.10.4 MAINTENANCE...554
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)...555
6.11.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)...555
6.12 REAR EQUIPMENT RAPID COUPLING DEVICE...556
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...557
6.12.2 MAINTENANCE...559
THIS PAGE WAS INTENTIONALLY LEFT EMPTY...560
WEAM007604 - Backhoe-Loader WB97S-5S Operation & Maintenance Manual...561
WEBM002400 - Backhoe-Loader WB97S-2 Shop Manual...845
WEBM002401 - Backhoe-Loader WB97S-2 Shop Manual...1161
COVER...1161
CONTENTS...1163
LIST OF REVISED PAGES...1165
SAFETY...1167
FOREWORD...1169
HOWTO READ THE SHOP MANUAL...1170
HOISTING INSTRUCTIONS...1171
STANDARD TIGHTENING TORQUE...1172
COATI NG MATERI ALS...1174
ELECTRIC...1175
WEIGHT TABLE...1176
TABLE OF OIL AND COOLANT QUANTITIES...1177
CONVERSION TABLE...1179
10. STRUCTURE AND FUNCTION...1189
POWER TRAIN...1190
TRANSMISSION...1192
DRIVE SHAFTS...1196
CONTROL VALVE BLOCK...1198
FRONT AXLE...1200
REAR AXLE...1203
STEERING SYSTEM (4WS)...1207
HYDRAULIC PUMP...1212
STEERING UNIT...1233
HYDRAULIC CIRCUIT...1235
SHOVEL CONTROL VALVE...1236
BACKHOE CONTROL VALVE...1242
CLSS...1249
SOLENOID VALVE...1263
SAFETY VALVE...1265
BRAKE PUMP...1267
SHOVEL CYLINDERS...1268
BACKHOE CYLINDERS...1269
AIR-CONDITIONING UNIT...1273
ELECTRICAL DIAGRAM...1275
20. TESTING AND ADJUSTMENTS...1289
NORMAL OR STANDARD TECHNICAL DATA...1290
SPECIAL TOOLS...1302
MEASURING ENGINE SPEED...1303
ADJUSTING VALVE CLEARANCE...1304
MEASURING COMPRESSION PRESSURE...1305
TESTING AND ADJUSTING FUEL INJECTION TIMING...1306
CHECKING AND TIGHTENING THE FAN - BELT...1308
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT...1309
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER...1310
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES...1312
AIR BLEEDING - RELEASING RESIDUAL PRESSURE...1313
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...1316
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)...1322
TESTING AND ADJUSTING OF UNLOADING VALVE...1323
CHECKING UNLOADING VALVE FUNCTIONALITY...1324
TESTING PRIORITY VALVE OPERATION...1325
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...1326
TESTING BRAKE SYSTEM...1327
CONTROL OF THE ENGINE SPEED UNDER LOAD...1329
TESTING PRESSURES IN THE POWER TRAIN GROUP...1331
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES...1333
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE...1334
ANALYSIS OF CAUSES HYDRAULIC DRIFT...1335
TESTING THE AIR-CONDITIONING UNIT...1340
EMPTYING THE AIR-CONDITIONING UNIT...1342
TROUBLESHOOTING...1343
FRONT AXLE TROUBLESHOOTING...1344
REAR AXLE TROUBLESHOOTING...1349
TRANSMISSION TROUBLESHOOTING...1354
CHECKING AND INSPECTION OF THE ELETRONIC CONTROL UNIT...1357
30. REMOVAL AND INSTALLATION...1361
HOW TO READ THE MANUAL...1363
PRECAUTIONS TO BE TAKEN W ILE WORKING...1364
SPECIAL TOOLS...1365
STARTING MOTOR...1369
ALTERNATOR...1370
AIR-CONDITIONING UNIT COMPRESSOR...1372
INJECTION PUMP...1374
INJECTION NOZZLES...1378
THERMOSTAT...1379
COOLING LIQUID PUMP...1380
TURBOCOMPRESSOR...1382
CYLINDER HEAD...1384
FRONT COUNTERWEIGHT...1388
RADIATOR-OIL COOLER UNIT...1389
CONDENSER...1392
HYDRAULIC OIL COOLER...1393
TRANSMISSION OIL COOLER...1395
MUFFLER...1396
EXHAUST PIPE...1397
ENGINE HOOD...1398
CAB...1400
HEAT AND AIR-CONDITIONING GROUP...1404
FUEL TANK...1406
HYDRAULIC OIL TANK...1407
ENGINE-GEARBOX-PUMP GROUP...1408
PISTON PUMP...1414
TRANSMISSION...1416
CONVERTOR...1518
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...1519
STEERING UNIT...1520
WORKING BRAKE PUMP GROUP...1521
FRONT WORKING EQUIPMENT CONTROL VALVE...1522
FRONT AXLE...1523
REAR AXLE...1554
STEERING SOLENOID VALVE GROUP...1598
FRONT BUCKET BOOM-RAISING CYLINDER...1599
FRONT BUCKET TILT CYLINDERS...1600
FRONT BUCKET...1601
FRONT WORKING EQUIPMENT...1602
BACKHOE CONTROL VALVE...1604
BACKHOE BOOM CYLINDER...1606
BACKHOE ARM CYLINDER...1607
JIG ARM CYLINDER...1608
BACKHOE BUCKET CYLINDER...1609
OUTRIGGER CYLINDERS...1610
BACKHOE SWING CYLINDERS...1612
BACKHOE BACKFRAME LOCK CYLINDER...1613
CYLINDERS...1614
BOOM SWING CYLINDER...1620
BACKHOE BACKFRAME LOCK CYLINDER...1623
BOOM SAFETY CYLINDER...1624
BACKHOE WORKING EQUIPMENT...1625
BACKHOE BUCKET...1626
ARM...1627
JIG ARM...1628
2nd ARM...1629
2nd ARM GUIDES...1630
BACKHOE BOOM...1631
BACKHOE SWING BRACKET...1632
BACKHOE BACKFRAME...1633
40. STANDARD MAINTENANCE...1637
TRANSMISSION...1638
FRONT AXLE...1641
REAR AXLE...1644
HYDRAULIC PUMP...1648
2-SPOOL CONTROL VALVE...1650
3-SPOOL CONTROL VALVE...1652
3-SPOOL CONTROL VALVE (With Return to Dig)...1654
6-SPOOL CONTROL VALVE...1656
7-SPOOL CONTROL VALVE...1659
8-SPOOL CONTROL VALVE...1661
BRAKE PUMP...1663
SHOVEL CYLINDERS...1664
BACKHOE CYLINDERS...1666
FRONT WORKING EQUIPMENT...1670
SWING BRACKET...1672
BACKHOE WORKING EQUIPMENT...1674
WEBM002404 - Backhoe-Loader WB97S-2 Shop Manual...1677
WEBM007500 - Backhoe-Loader WB97S-5 Shop Manual...2259
CONTENTS...2261
REVISED PAGES...2263
k SAFETY...2265
FOREWORD...2267
HOW TO READ THE SHOP MANUAL...2268
HOISTING INSTRUCTIONS...2269
STANDARD TIGHTENING TORQUE...2270
COATING MATERIALS...2272
ELECTRIC...2273
WEIGHT TABLE...2274
TABLE OF OIL AND COOLANT QUANTITIES...2275
CONVERSION TABLE...2277
10 STRUCTURE AND FUNCTION...2285
POWER TRAIN...2286
TRANSMISSION (4WD)...2288
TRANSMISSION...2290
CONTROL VALVE BLOCK...2292
DRIVE SHAFTS...2293
FRONT AXLE...2295
REAR AXLE...2298
STEERING SYSTEM (4WS)...2302
HYDRAULIC CIRCUIT...2307
HYDRAULIC PUMP...2309
1. MAIN PUMP...2310
2. DELIVERY CONTROL VALVE...2315
8-SPOOL CONTROL VALVE...2324
10-SPOOL CONTROL VALVE...2330
CLSS...2337
1. DESCRIPTION...2337
2. OPERATING PRINCIPLES...2338
3. OPERATION FOR EACH CIRCUIT AND VALVE...2340
STEERING UNIT...2356
PPC VALVES...2357
SHOVEL PPC VALVE (STANDARD)...2357
SHOVEL PPC VALVE (FLOAT + RETURN TO DIG)...2361
OUTRIGGERS PPC VALVE...2367
BACKHOE LH PPC VALVE...2372
BACKHOE RH PPC VALVE...2373
SOLENOID VALVE GROUP (EV1)...2374
BACKHOE VERSION WITHOUT 4 IN 1 BUCKET...2374
BACKHOE VERSION WITH 4 IN 1 BUCKET...2375
SOLENOID VALVE GROUP (EV2)...2376
SAFETY VALVES...2377
SHOVEL RAISE...2377
SHOVEL DUMP...2378
BOOM...2379
ARM...2380
SHOVEL CYLINDERS...2381
RAISING CYLINDER...2381
DUMPING CYLINDER...2381
4 IN 1 BUCKET...2382
BACKHOE CYLINDERS...2383
BOOM CYLINDER...2383
ARM...2383
BUCKET CYLINDER...2384
OUTRIGGER CYLINDER...2384
BOOM SWING CYLINDER...2385
JIG ARM CYLINDER...2385
AIR-CONDITIONING UNIT...2387
OPERATION OF THE AIR CONDITIONING UNIT...2388
FUSE AND RELAY CENTRE...2389
DRIVER SEAT WIRING...2390
SWITCH PANEL WIRING...2391
FRONT DASH WIRING...2392
LATERAL DASH WIRING...2393
ROOF WIRING...2394
ENGINE WIRING...2395
SPEED SELECTOR WIRING...2396
BACKHOE WIRING...2397
JIG ARM WIRING...2398
4WS PUSH-BUTTONS PANEL WIRING...2399
4WD SOLENOID VALVES WIRING...2400
WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)...2401
20 TESTING AND ADJUSTMENTS...2403
NORMAL OR STANDARD TECHNICAL DATA...2405
SPECIAL TOOLS...2420
ADJUSTING VALVE CLEARANCE...2421
ENGINE SPEED TESTS...2422
TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT...2424
BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE...2425
ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER...2427
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...2429
BRAKING SYSTEM CHECKS...2430
PARKING BRAKE ADJUSTMENT...2433
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...2435
CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES...2437
SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES...2441
CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE...2443
CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE...2445
ADJUSTING THE PC VALVE...2446
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...2447
CHECKING FOR LEAKS IN THE STEERING CYLINDERS...2448
TESTING PRESSURES IN THE POWER TRAIN GROUP...2449
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES...2451
ANALYSIS OF CAUSES HYDRAULIC DRIFT...2452
FRONT EQUIPMENT...2452
BACKHOE...2454
TESTING THE AIR-CONDITIONING UNIT...2457
EMPTYING THE AIR-CONDITIONING UNIT...2459
TROUBLESHOOTING...2460
FRONT AXLE TROUBLESHOOTING...2460
FRONT AXLE CHECKING AND TROUBLESHOOTING...2463
REAR AXLE TROUBLESHOOTING...2465
REAR AXLE CHECKING AND TROUBLESHOOTING...2468
TRANSMISSION TROUBLESHOOTING...2470
30 REMOVAL AND INSTALLATION...2473
HOW TO READ THE MANUAL...2475
PRECAUTIONS TO BE TAKEN WHILE WORKING...2476
SPECIAL TOOLS...2477
ENGINE HOOD...2481
Removal...2481
Installation...2482
FRONT GUARD...2483
Removal...2483
Installation...2483
RADIATOR GROUP...2484
Removal...2484
Installation...2487
CONDENSER...2488
(For machines equipped with an air-conditioning unit)...2488
Removal...2488
Installation...2488
MUFFLER...2489
Removal...2489
Installation...2489
AIR FILTER...2490
Removal...2490
Installation...2490
TURBOCHARGER...2491
Removal...2491
Installation...2492
AIR-CONDITIONING UNIT COMPRESSOR...2493
Removal...2493
Installation...2494
AIR-CONDITIONING UNIT COMPRESSOR BELT...2495
Removal...2495
Installation...2496
EXHAUST PIPE...2497
Removal...2497
Installation...2497
FAN AND HEATING GROUP...2498
Removal...2498
Installation...2503
BATTERY...2504
Removal...2504
Installation...2505
FUEL TANK...2506
Removal...2506
Installation...2507
STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...2508
Removal...2508
Installation...2509
WORKING BRAKE PUMP GROUP...2510
Removal...2510
Installation...2512
STEERING UNIT...2513
Removal...2513
Installation...2514
CAB...2515
Removal...2515
Installation...2521
HYDRAULIC OIL TANK...2523
Removal...2523
Installation...2529
PISTON PUMP...2530
Removal...2530
Installation...2531
TRANSMISSION...2532
Removal...2532
Installation...2536
Disassembly and assembly...2537
CONVERTOR...2645
Removal...2645
Installation...2645
ENGINE...2646
Removal...2646
Installation...2650
CONTROL VALVE...2651
Removal...2651
Installation...2653
STEERING SOLENOID VALVE GROUP...2654
Removal...2654
Installation...2654
FRONT AXLE...2655
Disassembly and assembly...2659
Removal...2655
Installation...2657
REAR AXLE...2703
Removal...2703
Installation...2705
Disassembly and assembly...2706
SHOVEL PPC VALVE...2767
Removal...2767
Installation...2768
SHOVEL LIFT CYLINDERS...2769
Removal...2769
Installation...2770
SHOVEL DUMP CYLINDERS...2771
Removal...2771
Installation...2772
SHOVEL...2773
Removal...2773
Installation...2773
FRONT WORKING EQUIPMENT...2774
Removal...2774
Installation...2775
BACKHOE PPC VALVES...2776
Removal...2776
Installation...2777
PPC VALVE SUPPORT RELEASE CABLES...2778
Removal...2778
Installation and adjusting...2780
PPC VALVE SUPPORT RETURN GAS SPRING...2781
Removal...2781
Installation...2782
SOLENOID VALVE GROUP (servocontrol and optional attachment)...2783
Removal...2783
Installation...2784
BACKHOE BOOM CYLINDER...2785
Removal...2785
Installation...2787
ARM CYLINDER...2788
Removal...2788
Installation...2789
JIG ARM CYLINDER...2790
Removal...2790
Installation...2790
OUTRIGGER CYLINDER...2791
Removal...2791
Installation...2792
BACKHOE SWING CYLINDERS...2793
Removal...2793
Installation...2795
BACKHOE BUCKET CYLINDER...2796
Removal...2796
Installation...2797
BACKHOE BOOM SAFETY CYLINDER...2798
Removal...2798
Installation...2799
CYLINDER...2800
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS...2800
Disassembly...2800
Assembly...2802
BACKHOE SWING CYLINDERS...2805
Disassembly...2805
Assembly...2808
BACKHOE WORKING EQUIPMENT...2811
Removal...2811
Installation...2812
BACKHOE BUCKET...2813
Removal...2813
Installation...2813
BACKHOE BOOM CYLINDER...2814
Removal...2814
Installation...2814
ARM...2815
Removal...2815
Installation...2815
JIG ARM...2816
Removal...2816
Installation...2816
2nd ARM...2817
Removal...2817
Installation...2817
2nd ARM GUIDES...2818
Removal...2818
Installation...2818
BACKHOE SWING BRACKET...2819
Removal...2819
Installation...2819
COMPLETE BACKHOE BACKFRAME...2820
Removal...2820
Installation...2821
BACKFRAME LOCK PISTONS...2822
Removal...2822
Installation...2823
40 STANDARD MAINTENANCE...2825
TRANSMISSION...2826
FRONT AXLE...2829
REAR AXLE...2832
HYDRAULIC PUMP...2836
CONTROL VALVE...2838
8-SPOOL VERSION...2838
10-SPOOL VERSION...2846
PPC VALVES...2854
SHOVEL CONTROL...2854
SHOVEL CYLINDERS...2856
DUMP CYLINDER...2856
RAISE CYLINDER...2856
4 IN 1 BUCKET...2857
BACKHOE CYLINDERS...2858
BOOM...2858
ARM...2858
BUCKET...2858
BOOM SWING...2859
OUTRIGGERS...2860
JIG ARM...2860
FRONT WORKING EQUIPMENT...2862
SWING BRACKET...2864
BACKHOE WORKING EQUIPMENT...2866
90 OTHER...2869
ELECTRICAL DIAGRAM (STANDARD VERSION)...2871
WEPB009400 - Backhoe-Loader WB97S-5 Parts Manual...2875
WHBM002403 - Terna WB97S-2 Manuale d'Officina...3233
COVER...3233
CONTENUTO...3235
PAGINE REVISIONATE...3237
SICUREZZE...3239
PREMESSA...3241
COME LEGGERE IL MANUALE D ’OFFICINA...3242
ISTRUZIONI DI SOLLEVAMENTO...3243
COPPIA DI SERRAGGIO STANDARD...3244
MATERIALI DI BLOCCAGGIO VITI,TENUTA E LUBRIFICAZIONE...3246
CAVI...3247
TABELLA DEI PESI...3248
TABELLA DELLE QUANTITÀ DEI LUBRIFICANTI E REFRIGERANTI...3249
TABELLE DI CONVERSIONE UNITÀ DI MISURA...3251
10. DATI TECNICI DI FUNZIONAMENTO...3261
TRASMISSIONE DEL MOTO...3262
TRASMISSIONE...3264
ALBERI DI COMANDO...3268
BLOCCO DISTRIBUTORE...3270
ASSALE ANTERIORE...3272
ASSALE POSTERIORE...3275
IMPIANTO DI STERZATURA (4WS)...3279
POMPA IDRAULICA...3284
IDROGUIDA...3305
SCHEMA IDRAULICO...3307
DISTRIBUTORE PALA...3308
DISTRIBUTORE RETROESCAVATORE...3314
CLSS...3321
ELETTROVALVOLE...3335
VALVOLE DI SICUREZZA...3337
POMPE FRENI...3339
CILINDRI PALA...3340
CILINDRI RETROESCAVATORE...3341
IMPIANTO DI CLIMATIZZAZIONE...3345
SCHEMI ELETTRICI...3347
20. CONTROLLI E REGOLAZIONI...3361
DATI TECNICI NORMALI O STANDARD...3362
ATTREZZI SPECIALI...3374
CONTROLLO DELLA VELOCITÀ DEL MOTORE...3375
REGISTRAZIONE GIOCO VALVOLE...3376
MISURAZIONE DELLA PRESSIONE DI COMPRESSIONE...3377
CONTROLLO E REGOLAZIONE DEL PUNTO DI INIEZIONE...3378
CONTROLLO E TENSIONAMENTO CINGHIA DEL VENTILATORE...3380
CONTROLLO E TENSIONAMENTO CINGHIA DEL COMPRESSORE...3381
REGOLAZIONE CORSA PEDALE ACCELERATORE E LEVA ACCELERATORE MANUALE...3382
REGOLAZIONE CORSA A VUOTO ED ALLINEAMENTO PEDALI FRENI E MICROINTERRUTTORI...3384
SPURGO DELL’ARIA - ELIMINAZIONE DELLE PRESSIONI RESIDUE - PRESSURIZZAZIONI...3385
CONTROLLO E TARATURA PRESSIONI DEI CIRCUITI IDRAULICI DELLE ATTREZZATURE DI LAVORO...3388
CONTROLLO E REGOLAZIONE DEL SEGNALE LOAD SENSING (VALVOLA LS)...3394
CONTROLLO E REGOLAZIONE PRESSIONE VALVOLA UNLOADING...3395
CONTROLLO DELLA FUNZIONALITÀ DELLA VALVOLA DI FLUSSO COMPENSATO...3396
CONTROLLO DEL FUNZIONAMENTO DELLA VALVOLA PRIORITARIA...3397
CONTROLLO E TARATURA PRESSIONE IMPIANTO DI STERZATURA...3398
CONTROLLI PER L’IMPIANTO FRENANTE...3399
CONTROLLO DELLA VELOCITÀ DEL MOTORE SOTTO CARICO...3401
CONTROLLO PRESSIONI DEL GRUPPO TRASMISSIONE...3403
CONTROLLO FUNZIONALITÀ FRIZIONI DELLA TRASMISSIONE...3405
REGOLAZIONE SENSORE PER DISPOSITIVO RETURN TO DIG...3406
ANALISI DELLE CAUSE CHE PROVOCANO LE DERIVE IDRAULICHE...3407
CONTROLLO IMPIANTO DI CLIMATIZZAZIONE...3412
SVUOTAMENTO IMPIANTO DI CLIMATIZZAZIONE...3414
RICERCA GUASTI...3415
RICERCA GUASTI ASSALE ANTERIORE...3416
CONTROLLO ED ESAME GUASTI ASSALE ANTERIORE...3419
RICERCA GUASTI ASSALE POSTERIORE...3421
CONTROLLO ED ESAME GUASTI ASSALE POSTERIORE...3424
CONTROLLO ED ESAME GUASTI TRASMISSIONE...3426
CONTROLLO ED ESAME DEI GUASTI SEGNALATI DALL ’UNITÀ DI GESTIONE ELETTRONICA...3429
30. RIMOZIONI ED INSTALLAZIONI...3433
METODO DI CONSULTAZIONE DEL MANUALE...3435
PRECAUZIONI DA USARE DURANTE L ’ESECUZIONE DEI LAVORI...3436
ATTREZZI SPECIALI...3437
MOTORINO D ’AVVIAMENTO...3441
ALTERNATORE...3442
COMPRESSORE IMPIANTO DI CLIMATIZZAZIONE...3444
POMPA D ’INIEZIONE...3446
INIETTORI...3450
TERMOSTATO...3451
POMPA DEL LIQUIDO DI RAFFREDDAMENTO...3452
TURBOCOMPRESSORE...3454
TESTA MOTORE...3456
ZAVORRA ANTERIORE...3460
GRUPPO RADIATORE...3461
CONDENSATORE...3464
MARMITTA...3465
TUBO DI SCARI O...3466
COFANO MOTORE...3467
CABINA COMPLETA...3469
GRUPPO DI RISCALDAMENTO E CLIMATIZZAZIONE...3473
SERBATOIO COMBUSTIBILE...3475
SERBATOIO OLIO IDRAULICO...3476
GRUPPO MOTORE-CAMBIO-POMPA...3477
POMPA A PISTONI...3483
CAMBIO...3485
CONVERTITORE...3587
GRUPPI COMANDO INVERTITORE, DEVIOGUIDA -DEVIOLUCI...3588
IDROGUIDA...3589
GRUPPO POMPE FRENI DI LAVORO...3590
DISTRIBUTORE ATTREZZATURE ANTERIORI...3591
DISTIBUTORI PALA E RETROESCAVATORE...3592
ASSALE ANTERIORE...3606
ASSALE POSTERIORE...3637
GRUPPO ELETTROVALVOLE DI STERZATURA...3681
CILINDRI DI SOLLEVAMENTO BRACCIO BENNA ANTERIORE...3682
CILINDRI ROVESCIAMENTO BENNA ANTERIORE...3683
BENNA ANTERIORE...3684
ATTREZZATURE DI LAVORO ANTERIORI...3685
DISTRIBUTORE DEL RETROESCAVATORE...3687
CILINDRO 1° BRACCIO RETROESCAVATORE...3689
CILINDRO 2° BRACCIO RETROESCAVATORE...3690
CILINDRO 2° BRACCIO TELESCOPICO...3691
CILINDRO BENNA RETROESCAVATORE...3692
CILINDRI STABILIZZATORI...3693
CILINDRI DI ROTAZIONE RETROESCAVATORE...3695
CILINDRI DI BLOCCAGGIO PIASTRA SCORREVOLE RETROESCAVATORE...3696
CILINDRI...3697
CILINDRO ROTAZIONE 1° BRACCIO...3703
CILINDRI BLOCCAGGIO PIASTRA RETROESCAVATORE...3706
CILINDRO SICUREZZA 1° BRACCIO...3707
ATTREZZATURE DI LAVORO RETROESCAVATORE...3708
BENNA DEL RETROESCAVATORE...3709
2° BRACCIO...3710
2° BRACCIO TELESCOPICO COMPLETO...3711
BRACCIO SCORREVOLE...3712
PATTINI GUIDA BRACCIO SCORREVOLE...3713
1° BRACCIO RETROESCAVATORE...3714
SUPPORTO GIREVOLE RETROESCAVATORE...3715
PIASTRA SCORREVOLE RETROESCAVATORE...3716
40. MANUTENZIONE STANDARD...3719
TRASMISSIONE...3720
ASSALE ANTERIORE...3723
ASSALE POSTERIORE...3726
POMPA IDRAULICA...3730
DISTRIBUTORE 2 ELEMENTI...3732
DISTRIBUTORE 3 ELEMENTI...3734
DISTRIBUTORE 3 ELEMENTI (Versione Return to Dig)...3736
DISTRIBUTORE 6 ELEMENTI...3738
DISTRIBUTORE 7 ELEMENTI...3741
DISTRIBUTORE 8 ELEMENTI...3743
POMPA FRENI...3745
CILINDRI PALA...3746
CILINDRI RETROESCAVATORE...3748
ATTREZZATURE DI LAVORO ANTERIORI...3752
SUPPORTO GIREVOLE...3754
ATTREZZATURE DI LAVORO RETROESCAVATORE...3756
Komatsu Backhoe-Loader WB97S Repair Service Manual
