Komatsu Backhoe-Loader WB91R, WB93R Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe-Loader WB91R, WB93R, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe-Loader WB91R, WB93R 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.
WEBM000400 - Backhoe-Loader WB91R-2, WB93R-2 Shop Manual.pdf
WEBM000401 - Backhoe-Loader WB91R-2, WB93R-2 avance Shop Manual.pdf
WEBM000404 - Backhoe-Loader WB91R-2, WB93R-2 avance Shop Manual.pdf
WEBM000405 - Backhoe-Loader WB91R-2, WB93R-2 Shop Manual.pdf
WEBM007600 - Backhoe-Loader WB91R-5 Shop Manual.pdf
WEAM002303 - Backhoe-Loader WB91R-2, WB93R-2 avance Operation & Maintenance Manual.pdf
WEAM002304 - Backhoe-Loader WB91R-2, WB93R-2 avance Operation & Maintenance Manual.pdf
WEAM006000 - Backhoe-Loader WB93R-5 Operation & Maintenance Manual.pdf
WEAM008301 - Backhoe-Loader WB91R-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,534 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
WEAM002303 - Backhoe-Loader WB91R-2, WB93R-2 avance Operation & Maintenance Manual...1
WEAM002304 - Backhoe-Loader WB91R-2, WB93R-2 avance Operation & Maintenance Manual...247
1.1 FOREWORD...249
1.2 INFORMATION ON SAFETY...250
1.3 INTRODUCTION...252
1.3.1 INTENDED USES...252
1.3.2 IMPROPER OR UNAUTHORIZED USES...252
1.3.3 MAIN CHARACTERISTICS...253
1.3.4 RUNNING-IN...253
1.4 PRODUCT IDENTIFICATION...254
1.4.1 MACHINE SERIAL NUMBER...254
1.4.2 MACHINE IDENTIFICATION PLATE...254
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...255
1.4.4 FRONT AXLE SERIAL NUMBER...255
1.4.5 REAR AXLE SERIAL NUMBER...255
1.4.6 TRANSMISSION SERIAL NUMBER...256
1.4.7 CAB SERIAL NUMBER...256
1.4.8 CANOPY SERIAL NUMBER (if provided)...256
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS...257
TABLE OF CONTENTS...259
2.1 SAFETY, NOISE AND VIBRATION PLATES...268
2.1.1 POSITION OF THE SAFETY PLATES...268
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...270
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB (model WB91R-2)...274
2.1.4 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB (model WB93R-2)...275
2.1.5 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...276
2.2 GENERAL PRECAUTIONS...277
2.2.1 GENERAL SAFETY RULES...277
2.2.2 SAFETY DEVICES AND GUARDS...277
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...277
2.2.4 UNAUTHORIZED MODIFICATIONS...278
2.2.5 LEAVING THE OPERATOR’S SEAT...278
2.2.6 GETTING ON AND OFF THE MACHINE...279
2.2.7 CHECKING THE REAR-VIEW MIRRORS...279
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...279
2.2.9 PREVENTING BURNS...280
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...280
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...281
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...281
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...281
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...281
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...282
2.3.1 SAFETY ON THE WORK SITE...282
2.3.2 FIRE PREVENTION...282
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...282
2.3.4 ROOM VENTILATION...283
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...283
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING...284
2.4.1 STARTING THE ENGINE...284
2.4.2 RULES FOR ROAD TRAVEL...284
2.4.3 CHECKS FOR TRAVELLING IN REVERSE...285
2.4.4 MOVING THE MACHINE...285
2.4.5 WORKING ON SLOPES...286
2.4.6 PREVENTING ELECTROCUTION...287
2.4.7 VISIBILITY...288
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES...288
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...288
2.4.10 WORKING ON LOOSE GROUND...288
2.4.11 PARKING THE MACHINE...289
2.5 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...290
2.5.1 LOADING AND UNLOADING...290
2.5.2 TRANSPORT...290
2.6 BATTERY...291
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...291
2.6.2 STARTING WITH BOOSTER CABLES...291
2.7 PRECAUTIONS FOR THE REMOVAL...292
2.8 PRECAUTIONS FOR MAINTENANCE...293
2.8.1 WARNING PLATES...293
2.8.2 TOOLS...293
2.8.3 PERSONNEL...293
2.8.4 EQUIPMENT...294
2.8.5 WORKING UNDER THE MACHINE...294
2.8.6 CLEANING THE MACHINE...294
2.8.7 USE OF THE ENGINE DURING MAINTENANCE OPERATIONS...295
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY...295
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...296
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...297
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...297
2.8.12 USING LAMPS...297
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...298
2.8.14 PRECAUTIONS CONCERNING THE STARTER...298
2.8.15 HANDLING HIGH-PRESSURE PIPES...299
2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING HIGH-PRESSURE OIL...299
2.8.17 PRECAUTIONS FOR MAINTENANCE OPERATIONS AT HIGH TEMPERATURES AND HIGH PRESSURE...299
2.8.18 COOLING FAN AND BELT...300
2.8.19 WASTE MATERIALS...300
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES...300
2.8.21 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...301
2.8.22 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES...301
THIS PAGE WAS INTENTIONALLY LEFT EMPTY...302
3.1 SAFETY LOCKS...304
3.1.1 FRONT LOADER LOCKS...304
3.1.2 BACKHOE LOCKS...306
3.2 GENERAL VIEWS...307
3.2.1 FRONT GENERAL VIEW...307
3.2.2 BACKHOE GENERAL VIEW...308
3.2.3 CAB INSIDE GENERAL VIEW...309
3.2.3.1 CAB INSIDE GENERAL VIEW (Standard version)...309
3.2.3.2 CAB INSIDE GENERAL VIEW (Version with servcontrols available on request)...310
3.3 INSTRUMENTS AND CONTROLS...311
3.3.1 FRONT INSTRUMENTS...311
3.3.2 SIDE INSTRUMENTS...315
3.3.2.1 SIDE INSTRUMENTS (Standard version)...315
3.3.2.2 SIDE INSTRUMENTS (Version with servo controls available on request)...316
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...323
3.3.4 PUSH BUTTON ON THE GEARSHIFT LEVER...323
3.3.5 ELECTRICAL ACCESSORIES...324
3.3.6 MACHINE CONTROLS...325
3.3.6.1 MACHINE CONTROLS (Standard version)...325
3.3.6.2 MACHINE CONTROLS (Version with servo controls available upon request)...326
3.4 FUSES AND RELAYS...354
3.4.1 EQUIPMENT FUSES AND RELAYS...354
3.4.1.1 FUSES...355
3.4.1.2 RELAYS...356
3.4.2 ENGINE FUSES AND RELAYS...356
3.4.2.1 FUSES...357
3.4.2.2 RELAYS...357
3.4.3 SIDE DASHBOARD RELAYS...358
3.4.4 SIDE DASHBOARD RELAYS AND FUSES (Only with servo controls)...358
3.4.4.1 RELAYS...358
3.4.4.2 FUSES...358
3.5 GUARDS, CAB AND DRIVER’S SEAT...359
3.5.1 ENGINE HOOD...359
3.5.2 CANOPY (if provided)...359
3.5.3 CAB...360
3.5.4 VENTILATION AND HEATING...363
3.5.5 AIR CONDITIONER (if installed)...364
3.5.6 SEAT...366
3.5.6.1 SEAT (STANDARD)...366
3.5.6.2 SEAT (OPTIONAL)...367
3.5.7 SAFETY BELT...368
3.5.8 FIRE EXTINGUISHER...368
3.5.9 FIRST AID KIT...368
3.5.10 TECHNICAL DOCUMENTATION...368
3.5.11 ADDITIONAL TOOL BOX (if provided)...369
THIS PAGE WAS INTENTIONALLY LEFT EMPTY...370
3.6 USE OF THE MACHINE...371
3.6.1 CHECKS BEFORE STARTING THE ENGINE...371
3.6.1.1 VISUAL CHECKS...371
3.6.1.2 DAILY CHECKS...371
3.6.1.3 OPERATIONAL CHECKS...372
3.6.2 STARTING THE ENGINE...373
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...373
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...374
3.6.3 WARMING THE ENGINE...375
3.6.4 HEATING THE HYDRAULIC OIL...375
3.6.5 HOW TO MOVE THE MACHINE...376
3.6.5.1 DIFFERENTIAL LOCKING...377
3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE...377
3.6.5.3 WORKING ON SLOPES...378
3.6.5.4 MAXIMUM IMMERSION DEPTH...379
3.7 PARKING THE MACHINE...380
3.7.1 PARKING ON LEVEL GROUND...380
3.7.2 PARKING ON SLOPES...381
3.8 STOPPING THE ENGINE...382
3.9 TRANSPORTING THE MACHINE ON MOTOR VEHICLES...383
3.9.1 LOADING AND UNLOADING THE MACHINE...383
3.9.2 TRANSPORT...384
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...385
3.10.1 FUEL AND LUBRICANTS...385
3.10.2 COOLANT...385
3.10.3 BATTERY...385
3.10.4 OTHER PRECAUTIONS...386
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...386
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON...387
3.12 USING THE MACHINE AS A LOADER...388
3.12.1 BUCKET POSITION INDICATOR...388
3.12.2 ORGANIZING THE WORK AREA...388
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...389
3.12.2.2 LOADING OPERATIONS ON SLOPES...390
3.12.3 CHANGING THE STANDARD FRONT BUCKET...390
3.13 USING THE MACHINE AS AN EXCAVATOR...391
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...391
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...392
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...393
3.13.4 DIGGING METHOD...394
3.13.5 CHANGING THE BACKHOE BUCKET...395
3.14 LONG PERIODS OF INACTIVITY...396
3.14.1 BEFORE THE PERIOD OF INACTIVITY...396
3.14.2 DURING THE PERIOD OF INACTIVITY...398
3.14.3 AFTER THE PERIOD OF INACTIVITY...398
3.15 TROUBLESHOOTING...399
3.15.1 HOW TO REMOVE THE MACHINE...399
3.15.2 AFTER THE FUEL HAS RUN OUT...399
3.15.3 IF THE BATTERY IS DOWN...400
3.15.3.1 STARTING WITH BOOSTER CABLES...401
3.15.4 OTHER TROUBLES...402
3.15.4.1 ELECTRICAL CIRCUIT...402
3.15.4.2 HYDRAULIC SYSTEM...402
3.15.4.3 BRAKING SYSTEM...403
3.15.4.4 CONVERTER...403
3.15.4.5 ENGINE...404
4.1 GUIDE TO MAINTENANCE...406
4.2 MAINTENANCE NOTES...408
4.2.1 NOTES REGARDING THE ENGINE...408
4.2.1.1 ENGINE OIL...408
4.2.1.2 COOLANT...408
4.2.1.3 FUEL...409
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...409
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM...410
4.2.4 NOTES REGARDING LUBRICATION...410
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...411
4.3 FUEL, COOLANT AND LUBRICANTS...412
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS...414
4.4 DRIVING TORQUES FOR SCREWS AND NUTS...415
4.4.1 STANDARD DRIVING TORQUES...415
4.4.2 SPECIFIC TIGHTENING TORQUES...415
4.5 LUBRICATION...416
4.5.1 LUBRICATION DIAGRAM...416
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...417
4.5.3 LUBRICATION DIAGRAM (Front bucket rapid couplings)...418
4.5.4 LUBRICATION DIAGRAM (Telescopic arm)...419
4.5.5 LUBRICATION DIAGRAM (Offset device)...420
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY...421
4.6.1 CRITICAL PARTS FOR SAFETY...422
4.7 MAINTENANCE PLAN...426
4.7.1 WHEN REQUIRED...430
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE...430
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER...431
4.7.1.c CHECKING AND CLEANING THE RECIRCULATING AIR FILTER (only for machines with air conditioner)...432
4.7.1.d BLEEDING THE BRAKING CIRCUIT...433
4.7.1.e CLEANING THE WATER SEPARATOR...434
4.7.1.f CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN...434
4.7.1.g CHECKING AND ADJUSTING THE PARKING BRAKE...435
4.7.1.h CHECKING THE BRAKING EFFICIENCY...436
4.7.1.j CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...437
4.7.1.k ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...437
4.7.1.l CHECKING AND ADJUSTING THE STABILIZER SLACK...438
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...439
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER...439
4.7.2.b CHANGING THE HYDRAULIC OIL...439
4.7.3 CHECKS BEFORE STARTING...440
4.7.3.a VARIOUS CHECKS...440
4.7.3.b CHECKING THE COOLANT LEVEL...440
4.7.3.c CHECKING THE FUEL LEVEL...441
4.7.3.d CHECKING THE ENGINE OIL LEVEL...441
4.7.3.e CHECKING THE HYDRAULIC CIRCUIT OIL LEVEL...442
4.7.3.f DRAINING THE WATER SEPARATOR...443
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...444
4.7.4.a LUBRICATING THE JOINTS...444
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic...446
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...446
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL...446
4.7.6.b CHECKING THE BRAKING SYSTEM OIL LEVEL...446
4.7.6.c LUBRICATING THE PROPELLER SHAFTS...447
4.7.6.d LUBRICATING THE FRONT AXLE JOINTS CENTRAL COUPLING...448
4.7.6.e CHECKING THE TYRE PRESSURE...448
4.7.6.f CHECKING THE ELECTRICAL SYSTEM...449
4.7.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...450
4.7.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...450
4.7.8.a ADJUSTING THE FAN BELT TENSION...450
4.7.8.b ADJUSTING THE A/C COMPRESSOR BELT TENSION (Only for machines with air conditioner)...451
4.7.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL...452
4.7.8.d CHECKING THE FRONT AXLE OIL LEVELS...453
4.7.8.e CHECKING THE REAR AXLE OIL LEVELS...453
4.7.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...454
4.7.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...454
4.7.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the syntheti...455
4.7.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...455
4.7.10.a CHANGING THE ENGINE OIL...455
4.7.10.b CHANGING THE ENGINE OIL FILTER...456
4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...457
4.7.10.d CHANGING THE FUEL FILTER...458
4.7.10.e DRAINING THE FUEL TANK...459
4.7.10.f DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable ...460
4.7.10.g CLEANING THE OUTSIDE OF THE RADIATORS...461
4.7.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (Only for machines with air conditioner)...462
4.7.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...463
4.7.11.a CHANGING THE FRONT AXLE OIL...463
4.7.11.b CHANGING THE REAR AXLE OIL...464
4.7.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...465
4.7.11.d CHANGING THE HYDRAULIC TRANSMISSION FILTER...466
4.7.11.e CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE...466
4.7.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...467
4.7.12.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER...467
4.7.12.b CHANGING THE COOLANT...470
4.7.12.c CHANGING THE BRAKING SYSTEM OIL...472
4.7.12.d CHECKING THE ALTERNATOR AND THE STARTER...473
4.7.12.e CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM (Only for machines with air conditioner)...473
4.7.13 MAINTENANCE EVERY 4000 HOURS OF OPERATION...474
4.7.13.a CHANGING THE A/C DEHYDRATING FILTER (Only for machines with air conditioner)...474
4.7.13.a CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air cond...474
5.1 TECHNICAL DATA...476
5.1.1 STANDARD OVERALL DIMENSIONS...476
5.1.1.1 STANDARD OVERALL DIMENSIONS WITH CENTERED BACKHOE...476
5.1.1.2 STANDARD OVERALL DIMENSIONS WITH FOLDED BACKHOE...476
5.1.2 TECHNICAL CHARACTERISTICS...477
5.1.2.1 TECHNICAL CHARACTERISTICS WB91R-2...477
5.1.2.2 TECHNICAL CHARACTERISTICS WB93R-2...478
5.1.3 LIFTING CAPACITIES...479
5.1.3.1 SYMBOL TABLE...479
5.1.3.2 LIFTING CAPACITY WB91R-2 (STANDARD BOOM)...480
5.1.3.3 LIFTING CAPACITY WB91R-2 (OFFSET BOOM)...481
5.1.3.4 LIFTING CAPACITY WB93R-2 (STANDARD BOOM)...482
5.1.3.5 LIFTING CAPACITY WB93R-2 (OFFSET BOOM)...483
6.1 AUTHORIZED OPTIONAL EQUIPMENT...486
6.1.1 PRECAUTIONS REGARDING SAFETY...486
6.1.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...487
6.1.2.1 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB91R-2...487
6.1.2.2 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT FOR MODEL WB93R-2...488
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES...489
6.2.1 MANUAL CONTROL QUICK COUPLING...489
6.2.2 HYDRAULIC CONTROL QUICK COUPLING FOR STANDARD BUCKET...490
6.2.3 HYDRAULIC CONTROL QUICK COUPLING FOR 4IN1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL...490
6.3 4in1 BUCKET...491
6.3.1 DESCRIPTION AND CONTROLS...491
6.3.2 SAFETY DEVICES...491
6.3.3 INSTALLING THE 4in1 BUCKET...492
6.3.4 USING THE 4in1 BUCKET...493
6.3.5 MAINTENANCE...493
6.4 PALLET FORKS...494
6.4.1 DESCRIPTION...494
6.4.2 SAFETY DEVICES...494
6.4.3 USING THE FORKS...495
6.4.3.1 PREPARING THE PALLET FORKS FOR USE...495
6.4.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS...496
6.4.4 REMOVING THE FORKS...497
6.4.5 INSTALLING THE FORKS...497
6.4.6 MAINTENANCE...497
6.5 BACKHOE TELESCOPIC ARM...498
6.5.1 DESCRIPTION AND CONTROL...498
6.5.1.1 VERSION WITH STANDARD CONTROLS...498
6.5.1.2 VERSION WITH SERVO CONTROLS (if installed)...498
6.5.2 SAFETY DEVICES...499
6.5.3 USING THE TELESCOPIC ARM...499
6.5.4 MAINTENANCE...500
6.5.4.1 ADJUSTING THE GUIDE SLACK...500
6.6 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER...502
6.6.1 DESCRIPTION AND CONTROL...502
6.6.1.1 VERSION WITH STANDARD CONTROLS...502
6.6.1.2 VERSION WITH SERVO CONTROLS (if installed)...502
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...503
FOR A CORRECT USE OF THE HAMMER, IT IS NECESSARY TO:...503
ALWAYS AVOID THE FOLLOWING INCORRECT USES:...505
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...507
6.6.3.1 INSTALLING THE HAMMER...507
6.6.3.2 REMOVING THE HAMMER...509
6.6.4 USING THE HAMMER...509
OPERATIONS WITH THE HYDRAULIC HAMMER AND COMPACTING TOOLS...509
6.6.5 MAINTENANCE...509
6.7 APPLICATION OF THE OFFSET DEVICE...510
6.7.1 DESCRIPTION AND CONTROL...510
6.7.1.1 VERSION WITH STANDARD CONTROLS...510
6.7.1.2 VERSION WITH SERVO CONTROLS (if installed)...511
6.7.2 MAINTENANCE...511
6.8 ARRANGEMENT FOR THE OPERATION OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...512
6.8.1 DESCRIPTION AND CONTROL...512
6.8.1.1 VERSION WITH STANDARD CONTROLS...512
6.8.1.2 VERSION WITH SERVO CONTROLS (if installed)...512
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT...513
6.8.3 MAINTENANCE...513
6.9 ARRANGEMENT FOR THE INSTALLATION OF THE CLAMSHELL BUCKET...514
6.9.1 DESCRIPTION AND CONTROL...514
6.9.1.1 VERSION WITH STANDARD CONTROLS...514
6.9.1.2 VERSION WITH SERVO CONTROLS (if installed)...515
6.9.2 INSTALLING THE CLAMSHELL BUCKET...516
6.9.3 USING THE CLAMSHELL BUCKET...517
6.9.4 MAINTENANCE...517
6.10 ARRANGEMENT FOR THE INSTALLATION OF THE MANUAL HYDRAULIC HAMMER...518
6.10.1 DESCRIPTION AND CONTROL...518
6.10.2 CONNECTING AND REMOVING THE HAMMER...519
6.10.2.1 CONNECTING THE HAMMER...519
6.10.2.2 REMOVING THE CONNECTIONS...519
6.10.3 USING THE HAMMER...520
6.10.4 MAINTENANCE...520
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)...521
6.11.1 ACCUMULATOR OF THE LOAD STABILIZER SYSTEM (LSS)...521
6.12 REAR EQUIPMENT RAPID COUPLING DEVICE...522
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...523
6.12.2 MAINTENANCE...525
THIS PAGE WAS INTENTIONALLY LEFT EMPTY...526
WEAM006000 - Backhoe-Loader WB93R-5 Operation & Maintenance Manual...527
1.1 FOREWORD...529
1.2 INFORMATION ON SAFETY...530
1.3 INTRODUCTION...532
1.3.1 INTENDED USES...532
1.3.2 IMPROPER OR UNAUTHORIZED USE...532
1.3.3 MAIN CHARACTERISTICS...533
1.3.4 RUNNING-IN...533
1.4 PRODUCT IDENTIFICATION...534
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...534
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) (alternatively for some markets)...534
1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...535
1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...536
1.4.5 FRONT AXLE SERIAL NUMBER...536
1.4.6 REAR AXLE SERIAL NUMBER...537
1.4.7 TRANSMISSION SERIAL NUMBER...537
1.4.8 CAB SERIAL NUMBER...537
1.4.9 SERIAL NUMBERS AND DEALER’S ADDRESS...538
TABLE OF CONTENTS...539
2.1 SAFETY, NOISE AND VIBRATION PLATES...548
2.1.1 POSITION OF THE SAFETY PLATES...548
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...550
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...556
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...557
2.2 GENERAL PRECAUTIONS...558
2.2.1 GENERAL SAFETY RULES...558
2.2.2 SAFETY DEVICES AND GUARDS...558
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...558
2.2.4 UNAUTHORIZED MODIFICATIONS...558
2.2.5 LEAVING THE OPERATOR’S SEAT...559
2.2.6 GETTING ON AND OFF THE MACHINE...560
2.2.7 CHECKING THE REAR-VIEW MIRRORS...560
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...561
2.2.9 PREVENTING BURNS...561
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...562
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...562
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...563
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...563
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...563
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...564
2.3.1 SAFETY ON THE WORK SITE...564
2.3.2 FIRE PREVENTION...564
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...564
2.3.4 ROOM VENTILATION...565
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...565
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...566
2.4.1 WHEN STARTING THE ENGINE...566
2.4.2 RULES FOR TRAVELLING ON ROADS...566
2.4.3 HAND SIGNALS...567
2.4.4 CHECKS FOR TRAVELLING IN REVERSE...572
2.4.5 MOVING THE MACHINE...572
2.4.6 WORKING ON SLOPES...573
2.4.7 PREVENTING ELECTROCUTION...574
2.4.8 VISIBILITY...575
2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES...575
2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...575
2.4.11 WORKING ON LOOSE GROUND...575
2.4.12 PARKING THE MACHINE...576
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...577
2.5.1 LOADING AND UNLOADING THE MACHINE...577
2.5.2 TRANSPORT...577
2.6 BATTERY...578
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...578
2.6.2 STARTING WITH BOOSTER CABLES...578
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...579
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...580
2.8.1 WARNING PLATES...580
2.8.2 TOOLS...580
2.8.3 PERSONNEL...581
2.8.4 EQUIPMENT...581
2.8.5 WORKING UNDER THE MACHINE...581
2.8.6 KEEPING THE MACHINE CLEAN...582
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...582
2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...582
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...583
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...584
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...584
2.8.12 USING LAMPS...584
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR...585
2.8.14 PRECAUTIONS CONCERNING THE STARTER...585
2.8.15 HANDLING HIGH-PRESSURE PIPES...586
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...586
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...586
2.8.18 HYDRAULIC ACCUMULATOR...587
2.8.19 COOLING FAN AND FAN BELT...587
2.8.20 WASTE MATERIALS...587
2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...588
2.8.22 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...588
2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...589
2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...589
3.1 SAFETY LOCKS...592
3.1.1 FRONT LOADER LOCKS...592
3.1.2 BACKHOE LOCKS...594
3.2 GENERAL VIEWS...596
3.2.1 FRONT GENERAL VIEW...596
3.2.2 BACKHOE GENERAL VIEW...597
3.2.3 CAB INSIDE GENERAL VIEW...598
3.2.3.1 CAB INSIDE GENERAL VIEW (mechanical backhoe controls)...598
3.2.3.2 CAB INSIDE GENERAL VIEW (backhoe servo controls)...599
3.3 INSTRUMENTS AND CONTROLS...600
3.3.1 FRONT INSTRUMENTS...600
3.3.2 SIDE INSTRUMENTS...604
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...612
3.3.4 PUSH BUTTON ON THE GEARSHIFT LEVER...613
3.3.5 CAB SWITCHES AND ELECTRIC ACCESSORIES...614
3.3.6 MACHINE CONTROLS...617
3.3.6.1 MACHINE CONTROLS (version with mechanically-controlled backhoe)...617
3.3.6.2 MACHINE CONTROLS (version with servo-assisted backhoe)...619
3.3.6.3 ADJUSTING THE CONTROLS...639
3.4 FUSES AND RELAYS...642
3.4.1 CENTRAL UNIT FUSES - RELAYS AND ENGINE LINE...642
3.4.1.1 FUSES...642
3.4.1.2 RELAYS...644
3.4.2 VENTILATION, HEATING AND AIR CONDITIONING FUSES AND RELAYS...645
3.4.2.1 FUSES...645
3.4.2.2 RELAYS...645
3.5 GUARDS, CAB AND DRIVER’S SEAT...646
3.5.1 ENGINE HOOD...646
3.5.2 CAB...647
3.5.3 VENTILATION AND HEATING...650
3.5.4 AIR CONDITIONER (if installed)...651
3.5.5 SEAT...653
3.5.5.1 SEAT (STANDARD)...653
3.5.5.2 SEAT (OPTIONAL)...654
3.5.6 SAFETY BELT...655
3.5.7 FIRE EXTINGUISHER...655
3.5.8 FIRST AID KIT...655
3.5.9 TECHNICAL DOCUMENTATION...655
3.5.10 STORAGE COMPARTMENT...656
3.6 USE OF THE MACHINE...657
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...657
3.6.1.1 VISUAL CHECKS...657
3.6.1.2 OPERATIONAL CHECKS...658
3.6.2 STARTING THE ENGINE...659
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...659
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...660
3.6.3 WARMING THE ENGINE...661
3.6.4 HEATING THE HYDRAULIC OIL...661
3.6.5 HOW TO MOVE THE MACHINE...662
3.6.5.1 DIFFERENTIAL LOCKING...663
3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE...663
3.6.5.3 WORKING ON SLOPES...664
3.6.5.4 MAXIMUM IMMERSION DEPTH...665
3.7 PARKING THE MACHINE...666
3.7.1 PARKING ON LEVEL GROUND...666
3.7.2 PARKING ON SLOPES...667
3.8 STOPPING THE ENGINE...668
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...669
3.9.1 LOADING AND UNLOADING THE MACHINE...669
3.9.2 TRANSPORT...670
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...671
3.10.1 FUEL AND LUBRICANTS...671
3.10.2 COOLANT...671
3.10.3 BATTERY...672
3.10.4 OTHER PRECAUTIONS...672
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...672
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...673
3.12 USING THE MACHINE AS A LOADER...674
3.12.1 BUCKET POSITION INDICATOR...674
3.12.2 ORGANIZING THE WORK AREA...674
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...675
3.12.2.2 LOADING OPERATIONS ON SLOPES...676
3.12.3 CHANGING THE STANDARD FRONT BUCKET...676
3.13 USING THE MACHINE AS AN EXCAVATOR...677
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...677
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...678
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...679
3.13.4 DIGGING METHOD...680
3.13.4.1 CHANGING THE BACKHOE BUCKET...681
3.14 LONG PERIODS OF INACTIVITY...682
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...682
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...684
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...684
3.14.4 RESTARTING THE ENGINE...685
3.14.5 AFTER THE PERIOD OF INACTIVITY...685
3.15 TROUBLESHOOTING...686
3.15.1 HOW TO REMOVE THE MACHINE...686
3.15.2 AFTER THE FUEL HAS RUN OUT...686
3.15.3 IF THE BATTERY HAS RUN DOWN...687
3.15.3.1 STARTING WITH BOOSTER CABLES...688
3.15.4 OTHER TROUBLES...689
3.15.4.1 ELECTRICAL CIRCUIT...689
3.15.4.2 HYDRAULIC SYSTEM...689
3.15.4.3 BRAKING SYSTEM...690
3.15.4.4 CONVERTER...690
3.15.4.5 ENGINE...690
4.1 GUIDE TO MAINTENANCE...694
4.2 MAINTENANCE NOTES...696
4.2.1 NOTES REGARDING THE ENGINE...696
4.2.1.1 ENGINE OIL...696
4.2.1.2 COOLANT...696
4.2.1.3 FUEL...697
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...697
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...698
4.2.4 NOTES REGARDING LUBRICATION...698
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...699
4.3 FUEL, COOLANT AND LUBRICANTS...700
4.3.1 LUBRICATION WITH GREASE...701
4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...702
4.4 DRIVING TORQUES...703
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...703
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...704
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...704
4.5 LUBRICATION...705
4.5.1 LUBRICATION DIAGRAM...705
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...706
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...707
4.5.4 LUBRICATION DIAGRAM (offset device)...708
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...709
4.6.1 SAFETY RELATED PARTS...710
4.6.1.1 FUEL SYSTEM...710
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...711
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...712
4.6.1.4 BACKHOE HYDRALIC SYSTEM...713
4.6.1.5 OPERATOR’S SAFETY...714
4.7 MAINTENANCE PLAN...715
4.8 MAINTENANCE PROCEDURES...717
4.8.1 WHEN REQUIRED...717
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...717
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...718
4.8.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines with air conditioner)...719
4.8.1.d CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR...719
4.8.1.e CHECKING THE WINDSHIELD WIPER BLADES...720
4.8.1.f LUBRICATING THE CAB DOOR HINGES...720
4.8.1.g FUSES AND RELAYS - CHECK AND CHANGE...720
4.8.1.h BLEEDING THE BRAKING CIRCUIT...721
4.8.1.i CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN...722
4.8.1.j CHECKING THE BRAKING EFFICIENCY...722
4.8.1.k CHECKING AND ADJUSTING THE PARKING BRAKE...723
4.8.1.l CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...724
4.8.1.m ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...724
4.8.1.n CHECKING AND ADJUSTING THE STABILIZER SLACK...725
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...726
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...726
4.8.2.b CHANGING THE HYDRAULIC OIL...726
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...727
4.8.3.a VARIOUS CHECKS...727
4.8.3.b CHECKING THE COOLANT LEVEL...727
4.8.3.c CHECKING THE FUEL LEVEL...728
4.8.3.d CHECKING THE ENGINE OIL LEVEL...728
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...729
4.8.4.a LUBRICATING THE JOINTS...729
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...731
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...731
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...731
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...732
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...732
4.8.6.d LUBRICATING THE PROPELLER SHAFTS...733
4.8.6.e LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING...734
4.8.6.f CHECKING THE TYRE PRESSURE...734
4.8.6.g DRAINING THE WATER SEPARATOR...735
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...736
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...736
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT...736
4.8.8.b CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (only for machines with air conditioner)...737
4.8.8.c CHECKING THE BATTERY ELECTROLYTE LEVEL...738
4.8.8.d CHECKING THE FRONT AXLE OIL LEVELS...739
4.8.8.e CHECKING THE REAR AXLE OIL LEVEL...739
4.8.8.f CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...740
4.8.8.g CHECKING THE WHEEL NUT DRIVING TORQUE...740
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...741
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...741
4.8.10.a CHANGING THE ENGINE OIL...741
4.8.10.b CHANGING THE ENGINE OIL FILTER...742
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...742
4.8.10.d CHANGING THE FUEL FILTER...745
4.8.10.e DRAINING THE FUEL TANK...746
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)...747
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR...748
4.8.10.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines with air conditioner)...749
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...750
4.8.11.a CHANGING THE FRONT AXLE OIL...750
4.8.11.b CHANGING THE REAR AXLE OIL...751
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...752
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER...753
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...754
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...754
4.8.12.b CHANGING THE COOLANT...756
4.8.12.c CHANGING THE BRAKING SYSTEM OIL...757
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER...758
4.8.12.e CHANGING THE ALTERNATOR BELT...758
4.8.12.f CHECKING THE A/C COOLING GAS QUANTITY (only for machines with air conditioner)...758
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION...759
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS...759
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE...759
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION...760
4.8.14.a CHANGING THE A/C DEWATERING FILTER (Only for machines with air conditioner)...760
4.8.14.b CHECKING THE OPERATING CONDITIONS OF THE A/C COMPRESSOR (Only for machines with air conditioner)...760
4.8.14.c CHANGING THE ENGINE THERMOSTATIC VALVE...760
5.1 TECHNICAL DATA...762
5.1.1 STANDARD OVERALL DIMENSIONS...762
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM...762
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM...762
5.1.2 TECHNICAL CHARACTERISTICS...763
5.1.3 LIFTING CAPACITIES...765
5.1.3.1 SYMBOL TABLE...765
5.1.3.2 LIFTING CAPACITIES (STANDARD ARM)...766
5.1.3.3 LIFTING CAPACITIES (TELESCOPIC ARM)...767
6.1 AUTHORIZED OPTIONAL EQUIPMENT...770
6.1.1 PRECAUTIONS REGARDING SAFETY...770
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...771
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...772
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES...773
6.2.1 MANUAL QUICK COUPLING...773
6.2.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET...774
6.2.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...774
6.3 4in1 BUCKET...775
6.3.1 DESCRIPTION AND CONTROLS...775
6.3.2 SAFETY DEVICES...775
6.3.3 INSTALLING THE 4in1 BUCKET...776
6.3.4 USING THE 4in1 BUCKET...777
6.3.5 MAINTENANCE...777
6.4 PALLET FORKS...778
6.4.1 DESCRIPTION...778
6.4.2 SAFETY DEVICES...779
6.4.3 USING THE FORKS...779
6.4.3.1 PREPARING THE PALLET FORKS FOR USE...780
6.4.3.2 OVERTURNING THE FORKS FOR TRAVEL ON ROADS...780
6.4.4 REMOVING THE FORKS...781
6.4.5 INSTALLING THE FORKS...781
6.4.6 MAINTENANCE...781
6.5 BACKHOE TELESCOPIC ARM...782
6.5.1 DESCRIPTION AND CONTROL...782
6.5.1.1 CONTROL (version with mechanically- controlled backhoe)...782
6.5.1.2 CONTROL (version with servo-assisted backhoe)...782
6.5.2 SAFETY DEVICES...783
6.5.3 USING THE TELESCOPIC ARM...783
6.5.4 MAINTENANCE...784
6.5.4.1 ADJUSTING THE GUIDE SLACK...784
6.6 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER...786
6.6.1 DESCRIPTION AND CONTROL...786
6.6.1.1 CONTROL (version with mechanically- controlled backhoe)...786
6.6.1.2 CONTROL (version with servo-assisted backhoe)...786
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...787
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...791
6.6.3.1 INSTALLING THE HAMMER...791
6.6.3.2 REMOVING THE HAMMER...793
6.6.4 USING THE HAMMER...793
6.6.5 MAINTENANCE...793
6.7 APPLICATION OF THE OFFSET DEVICE...794
6.7.1 DESCRIPTION AND CONTROL...794
6.7.1.1 CONTROL (version with mechanically- controlled backhoe)...794
6.7.1.2 CONTROL (version with servo-assisted backhoe)...795
6.7.2 MAINTENANCE...795
6.8 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...796
6.8.1 DESCRIPTION AND CONTROL...796
6.8.1.1 CONTROL (version with mechanically- controlled backhoe)...796
6.8.1.2 CONTROL (version with servo-assisted backhoe)...796
6.8.2 INSTALLING AND CONNECTING THE EQUIPMENT...797
6.8.3 MAINTENANCE...797
6.9 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET...798
6.9.1 DESCRIPTION AND CONTROL...798
6.9.1.1 CONTROL (version with mechanically-controlled backhoe)...798
6.9.1.2 CONTROL (version with servo-assisted backhoe)...799
6.9.2 INSTALLING THE CLAMSHELL BUCKET...800
6.9.3 USING THE CLAMSHELL BUCKET...801
6.9.4 MAINTENANCE...801
6.10 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER...802
6.10.1 DESCRIPTION AND CONTROL...802
6.10.2 INSTALLING AND REMOVING THE HAND HAMMER...803
6.10.2.1 CONNECTING THE HAND HAMMER...803
6.10.2.2 REMOVING THE CONNECTIONS...804
6.10.3 USING THE HAMMER...804
6.10.4 MAINTENANCE...804
6.11 LOAD STABILIZER SYSTEM (LSS) (Optional)...805
6.11.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR...805
6.12 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE...806
6.12.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...807
6.12.2 MAINTENANCE...808
WEAM008301 - Backhoe-Loader WB91R-5 Operation & Maintenance Manual...811
1.1 FOREWORD...813
1.2 INFORMATION ON SAFETY...814
1.3 INTRODUCTION...816
1.3.1 INTENDED USES...816
1.3.2 IMPROPER OR UNAUTHORIZED USE...816
1.3.3 MAIN CHARACTERISTICS...817
1.3.4 RUNNING-IN...817
1.4 PRODUCT IDENTIFICATION...818
1.4.1 MACHINE IDENTIFICATION NUMBER (PIN)...818
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) (alternatively for some markets)...818
1.4.3 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)...819
1.4.4 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE...820
1.4.5 FRONT AXLE SERIAL NUMBER (4WD VERSION)...820
1.4.6 FRONT AXLE SERIAL NUMBER (2WD VERSION)...821
1.4.7 REAR AXLE SERIAL NUMBER...821
1.4.8 TRANSMISSION SERIAL NUMBER (4WD VERSION)...821
1.4.9 TRANSMISSION SERIAL NUMBER (2WD VERSION)...821
1.4.10 CAB SERIAL NUMBER...822
1.4.11 SERIAL NUMBERS AND DEALER’S ADDRESS...823
TABLE OF CONTENTS...825
2.1 SAFETY, NOISE AND VIBRATION PLATES...834
2.1.1 POSITION OF THE SAFETY PLATES...834
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS...836
2.1.3 POSITION OF THE NOISE PLATES ON MACHINES WITH CAB...842
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED...843
2.2 GENERAL PRECAUTIONS...844
2.2.1 GENERAL SAFETY RULES...844
2.2.2 SAFETY DEVICES AND GUARDS...844
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS...844
2.2.4 UNAUTHORIZED MODIFICATIONS...845
2.2.5 LEAVING THE OPERATOR’S SEAT...845
2.2.6 GETTING ON AND OFF THE MACHINE...846
2.2.7 CHECKING THE REAR-VIEW MIRRORS...846
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL...847
2.2.9 PREVENTING BURNS...847
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER...848
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...848
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT...849
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE...849
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT...849
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE...850
2.3.1 SAFETY ON THE WORK SITE...850
2.3.2 FIRE PREVENTION...850
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB...850
2.3.4 ROOM VENTILATION...851
2.3.5 CLEANING WINDOWS, MIRRORS AND LIGHTS - CHECKING THE WINDSHIELD WIPER BLADES AND THE BULBS...851
2.4 PRECAUTIONS TO BE TAKEN DURING WORK...852
2.4.1 WHEN STARTING THE ENGINE...852
2.4.2 RULES FOR TRAVELLING ON ROADS...852
2.4.3 HAND SIGNALS...853
2.4.4 CHECKS FOR TRAVELLING IN REVERSE...858
2.4.5 MOVING THE MACHINE...858
2.4.6 WORKING ON SLOPES...859
2.4.7 PREVENTING ELECTROCUTION...860
2.4.8 VISIBILITY...861
2.4.9 WORKING ON ICY OR SNOW-COVERED SURFACES...861
2.4.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT...861
2.4.11 WORKING ON LOOSE GROUND...861
2.4.12 PARKING THE MACHINE...862
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES...863
2.5.1 LOADING AND UNLOADING THE MACHINE...863
2.5.2 TRANSPORT...863
2.6 BATTERY...864
2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY...864
2.6.2 STARTING WITH BOOSTER CABLES...864
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY...865
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE...866
2.8.1 WARNING PLATES...866
2.8.2 TOOLS...866
2.8.3 PERSONNEL...867
2.8.4 EQUIPMENT...867
2.8.5 WORKING UNDER THE MACHINE...867
2.8.6 KEEPING THE MACHINE CLEAN...868
2.8.7 USE OF THE ENGINE DURING MAINTENANCE...868
2.8.8 PERIODICAL CHANGE OF THE SAFETY RELATED PARTS...868
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION...869
2.8.10 RULES TO BE FOLLOWED DURING FUEL OR OIL TOPPING UP...870
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR...870
2.8.12 USING LAMPS...870
2.8.13 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR...871
2.8.14 PRECAUTIONS CONCERNING THE STARTER...871
2.8.15 HANDLING HIGH-PRESSURE PIPES...872
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS...872
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES...872
2.8.18 HYDRAULIC ACCUMULATOR (if provided)...873
2.8.19 COOLING FAN AND FAN BELT...873
2.8.20 WASTE MATERIALS...873
2.8.21 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS...874
2.8.22 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES...874
2.8.23 PRECAUTIONS FOR THE INSTALLATION OF THE EXHAUST SYSTEM TAILPIPE...875
2.8.24 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»...875
3.1 SAFETY LOCKS...878
3.1.1 FRONT LOADER LOCKS...878
3.1.2 BACKHOE LOCKS...880
3.2 GENERAL VIEWS...882
3.2.1 FRONT GENERAL VIEW...882
3.2.2 BACKHOE GENERAL VIEW...883
3.2.3 CAB INSIDE GENERAL VIEW...884
3.3 INSTRUMENTS AND CONTROLS...885
3.3.1 FRONT INSTRUMENTS...885
3.3.2 SIDE INSTRUMENTS...889
3.3.3 PUSH BUTTONS ON THE FRONT LOADER CONTROL LEVER...896
3.3.4 PUSH BUTTON ON THE GEARSHIFT LEVER...897
3.3.5 CAB SWITCHES AND ELECTRIC ACCESSORIES...898
3.3.6 MACHINE CONTROLS...901
3.4 FUSES AND RELAYS...917
3.4.1 CENTRAL UNIT FUSES - RELAYS AND ENGINE LINE...917
3.4.1.1 FUSES...917
3.4.1.2 RELAYS...919
3.4.2 VENTILATION AND HEATING FUSES AND RELAYS...920
3.4.2.1 FUSES...920
3.4.2.2 RELAYS...920
3.5 GUARDS, CAB AND DRIVER’S SEAT...921
3.5.1 ENGINE HOOD...921
3.5.2 CAB...922
3.5.3 VENTILATION AND HEATING...925
3.5.4 SEAT...926
3.5.5 SAFETY BELT...927
3.5.6 FIRE EXTINGUISHER...927
3.5.7 FIRST AID KIT...927
3.5.8 TECHNICAL DOCUMENTATION...927
3.5.9 STORAGE COMPARTMENT...928
3.6 USE OF THE MACHINE...929
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...929
3.6.1.1 VISUAL CHECKS...929
3.6.1.2 OPERATIONAL CHECKS...930
3.6.2 STARTING THE ENGINE...931
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES...931
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES...932
3.6.3 WARMING THE ENGINE...933
3.6.4 HEATING THE HYDRAULIC OIL...933
3.6.5 HOW TO MOVE THE MACHINE...934
3.6.5.1 DIFFERENTIAL LOCKING...935
3.6.5.2 ENGAGING THE FOUR-WHEEL DRIVE (only for the 4WD version)...935
3.6.5.3 WORKING ON SLOPES...936
3.6.5.4 MAXIMUM IMMERSION DEPTH...937
3.7 PARKING THE MACHINE...938
3.7.1 PARKING ON LEVEL GROUND...938
3.7.2 PARKING ON SLOPES...939
3.8 STOPPING THE ENGINE...940
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES...941
3.9.1 LOADING AND UNLOADING THE MACHINE...941
3.9.2 TRANSPORT...942
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON...943
3.10.1 FUEL AND LUBRICANTS...943
3.10.2 COOLANT...943
3.10.3 BATTERY...944
3.10.4 OTHER PRECAUTIONS...944
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK...944
3.11 PRECAUTIONS TO BE TAKEN AT THE END OF THE WINTER...945
3.12 USING THE MACHINE AS A LOADER...946
3.12.1 BUCKET POSITION INDICATOR...946
3.12.2 ORGANIZING THE WORK AREA...946
3.12.2.1 LOADING HEAPED AND LEVEL MATERIAL...947
3.12.2.2 LOADING OPERATIONS ON SLOPES...948
3.12.3 CHANGING THE STANDARD FRONT BUCKET...948
3.13 USING THE MACHINE AS AN EXCAVATOR...949
3.13.1 POSITIONING THE BUCKET ACCORDING TO THE WORK THAT MUST BE CARRIED OUT...949
3.13.2 POSITIONING THE MACHINE FOR DIGGING OPERATIONS...950
3.13.3 SLIDING THE BACKHOE UNIT SIDEWARDS...951
3.13.4 DIGGING METHOD...952
3.13.4.1 CHANGING THE BACKHOE BUCKET...953
3.14 LONG PERIODS OF INACTIVITY...954
3.14.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY...954
3.14.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY...956
3.14.3 MAINTENANCE DURING A PERIOD OF INACTIVITY...956
3.14.4 RESTARTING THE ENGINE...957
3.14.5 AFTER THE PERIOD OF INACTIVITY...957
3.15 TROUBLESHOOTING...958
3.15.1 HOW TO REMOVE THE MACHINE...958
3.15.2 AFTER THE FUEL HAS RUN OUT...958
3.15.3 IF THE BATTERY IS DOWN...959
3.15.3.1 STARTING WITH BOOSTER CABLES...960
3.15.4 OTHER TROUBLES...961
3.15.4.1 ELECTRICAL CIRCUIT...961
3.15.4.2 HYDRAULIC SYSTEM...961
3.15.4.3 BRAKING SYSTEM...962
3.15.4.4 CONVERTER...962
3.15.4.5 ENGINE...962
4.1 GUIDE TO MAINTENANCE...966
4.2 MAINTENANCE NOTES...968
4.2.1 NOTES REGARDING THE ENGINE...968
4.2.1.1 ENGINE OIL...968
4.2.1.2 COOLANT...968
4.2.1.3 FUEL...969
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM...969
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM...970
4.2.4 NOTES REGARDING LUBRICATION...970
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING...971
4.3 FUEL, COOLANT AND LUBRICANTS...972
4.3.1 LUBRICATION WITH GREASE...973
4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”...974
4.4 DRIVING TORQUES...975
4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS...975
4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS...976
4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS...976
4.5 LUBRICATION...977
4.5.1 LUBRICATION DIAGRAM...977
4.5.2 LUBRICATION DIAGRAM (4in1 bucket and pallet forks)...978
4.5.3 LUBRICATION DIAGRAM (front bucket quick couplings)...979
4.6 PERIODICAL CHANGE OF THE SAFETY RELATED COMPONENTS...980
4.6.1 SAFETY RELATED PARTS...981
4.6.1.1 FUEL SYSTEM...981
4.6.1.2 DELIVERY HYDRAULIC SYSTEM...982
4.6.1.3 FRONT LOADER HYDRAULIC SYSTEM...983
4.6.1.4 BACKHOE HYDRALIC SYSTEM...984
4.6.1.5 OPERATOR’S SAFETY...985
4.7 MAINTENANCE PLAN...986
4.8 MAINTENANCE PROCEDURES...988
4.8.1 WHEN REQUIRED...988
4.8.1.a CHECKING, CLEANING OR CHANGING THE ENGINE AIR FILTERS...988
4.8.1.b CHECKING AND CLEANING THE CAB AIR FILTER...989
4.8.1.c CHECKING THE DETERGENT LEVEL IN THE WINDSHIELD WASHER RESERVOIR...990
4.8.1.d CHECKING THE WINDSHIELD WIPER BLADES...990
4.8.1.e LUBRICATING THE CAB DOOR HINGES...990
4.8.1.f FUSES AND RELAYS - CHECK AND CHANGE...991
4.8.1.g BLEEDING THE BRAKING CIRCUIT...992
4.8.1.h CHECKING AND ADJUSTING THE FRONT WHEEL TOE-IN...993
4.8.1.i CHECKING THE BRAKING EFFICIENCY...993
4.8.1.j CHECKING AND ADJUSTING THE PARKING BRAKE...994
4.8.1.k CHECKING AND ADJUSTING THE BRAKE PEDAL STROKE...995
4.8.1.l ADJUSTING THE AUTOMATIC RETURN- TO-DIG DEVICE OF THE FRONT BUCKET (if installed)...995
4.8.1.m CHECKING AND ADJUSTING THE STABILIZER SLACK...996
4.8.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER...997
4.8.2.a CHANGING THE HYDRAULIC OIL FILTER...997
4.8.2.b CHANGING THE HYDRAULIC OIL...997
4.8.3 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE...998
4.8.3.a VARIOUS CHECKS...998
4.8.3.b CHECKING THE COOLANT LEVEL...998
4.8.3.c CHECKING THE FUEL LEVEL...999
4.8.3.d CHECKING THE ENGINE OIL LEVEL...999
4.8.4 MAINTENANCE EVERY 10 HOURS OF OPERATION...1000
4.8.4.a LUBRICATING THE JOINTS...1000
4.8.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1002
4.8.6 MAINTENANCE EVERY 50 HOURS OF OPERATION...1002
4.8.6.a CHECKING THE HYDRAULIC OIL LEVEL...1002
4.8.6.b CHECKING THE FLUID LEVEL IN THE RADIATOR...1003
4.8.6.c CHECKING THE BRAKING SYSTEM OIL LEVEL...1003
4.8.6.d LUBRICATING THE TRANSMISSION SHAFTS (4WD VERSION)...1004
4.8.6.e LUBRICATING THE TRANSMISSION SHAFT (2WD VERSION)...1005
4.8.6.f LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING (4WD VERSION)...1005
4.8.6.g LUBRICATING THE FRONT AXLE JOINTS AND CENTRAL COUPLING (2WD VERSION)...1006
4.8.6.h CHECKING THE TYRE PRESSURE...1006
4.8.6.i DRAINING THE WATER SEPARATOR...1007
4.8.7 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION...1008
4.8.8 MAINTENANCE EVERY 250 HOURS OF OPERATION...1008
4.8.8.a CHECKING THE ALTERNATOR-FAN BELT...1008
4.8.8.b CHECKING THE BATTERY ELECTROLYTE LEVEL...1009
4.8.8.c CHECKING THE FRONT AXLE OIL LEVELS (ONLY 4WD VERSION)...1010
4.8.8.d CHECKING THE REAR AXLE OIL LEVEL...1010
4.8.8.e CHECKING THE HYDRAULIC TRANSMISSION OIL LEVEL...1011
4.8.8.f CHECKING THE WHEEL NUT DRIVING TORQUE...1011
4.8.9 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil type HEES is used)...1012
4.8.10 MAINTENANCE EVERY 500 HOURS OF OPERATION...1012
4.8.10.a CHANGING THE ENGINE OIL...1012
4.8.10.b CHANGING THE ENGINE OIL FILTER...1013
4.8.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER...1013
4.8.10.d CHANGING THE FUEL FILTER...1016
4.8.10.e DRAINING THE FUEL TANK...1017
4.8.10.f DRAINING THE HYDRAULIC OIL TANK (only for machines in which synthetic biodegradable oil type HEES is used)...1018
4.8.10.g CLEANING THE OUTSIDE OF THE RADIATOR...1019
4.8.11 MAINTENANCE EVERY 1000 HOURS OF OPERATION...1020
4.8.11.a CHANGING THE FRONT AXLE OIL (ONLY 4WD VERSION)...1020
4.8.11.b CHANGING THE REAR AXLE OIL...1021
4.8.11.c CHANGING THE HYDRAULIC TRANSMISSION OIL...1022
4.8.11.d CHANGING THE HYDRAULIC TRANSMISSION OIL FILTER...1023
4.8.12 MAINTENANCE EVERY 2000 HOURS OF OPERATION...1024
4.8.12.a CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER...1024
4.8.12.b CHANGING THE COOLANT...1026
4.8.12.c CHANGING THE BRAKING SYSTEM OIL...1027
4.8.12.d CHECKING THE ALTERNATOR AND THE STARTER...1027
4.8.12.e CHANGING THE ALTERNATOR BELT...1027
4.8.13 MAINTENANCE EVERY 3000 HOURS OF OPERATION...1028
4.8.13.a CHECKING THE ENGINE RETAINING SCREWS AND DAMPING ELEMENTS...1028
4.8.13.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE...1028
4.8.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION...1028
4.8.14.a CHANGING THE ENGINE THERMOSTATIC VALVE...1028
5.1 TECHNICAL DATA...1030
5.1.1 STANDARD OVERALL DIMENSIONS...1030
5.1.1.1 OVERALL DIMENSIONS WITH STANDARD ARM...1030
5.1.1.2 OVERALL DIMENSIONS WITH TELESCOPIC ARM...1030
5.1.2 TECHNICAL CHARACTERISTICS...1031
5.1.3 LIFTING CAPACITIES...1033
5.1.3.1 SYMBOL TABLE...1033
5.1.3.2 LIFTING CAPACITIES (STANDARD ARM)...1034
6.1 AUTHORIZED OPTIONAL EQUIPMENT...1036
6.1.1 PRECAUTIONS REGARDING SAFETY...1036
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT...1037
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT...1038
6.2 FRONT EQUIPMENT QUICK COUPLING DEVICES...1039
6.2.1 MANUAL QUICK COUPLING...1039
6.2.2 HYDRAULIC QUICK COUPLING FOR STANDARD BUCKET...1040
6.2.3 HYDRAULIC QUICK COUPLING FOR 4in1 BUCKET AND OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...1040
6.3 4in1 BUCKET...1041
6.3.1 DESCRIPTION AND CONTROLS...1041
6.3.2 SAFETY DEVICES...1041
6.3.3 INSTALLING THE 4in1 BUCKET...1042
6.3.4 USING THE 4in1 BUCKET...1043
6.3.5 MAINTENANCE...1043
6.4 PALLET FORKS...1044
6.4.1 DESCRIPTION...1044
6.4.2 SAFETY DEVICES...1045
6.4.3 USING THE FORKS...1046
6.4.3.1 PREPARING THE PALLET FORKS FOR USE...1046
6.4.3.2 OVERTURNING THE FORKS...1047
6.4.4 REMOVING THE FORKS...1048
6.4.5 INSTALLING THE FORKS...1048
6.4.6 MAINTENANCE...1048
6.5 BACKHOE TELESCOPIC ARM...1049
6.5.1 DESCRIPTION AND CONTROL...1049
6.5.1.1 CONTROL...1049
6.5.2 SAFETY DEVICES...1049
6.5.3 USING THE TELESCOPIC ARM...1050
6.5.4 MAINTENANCE...1050
6.5.4.1 ADJUSTING THE GUIDE SLACK...1050
6.6 CONFIGURATION FOR THE INSTALLATION OF THE DEMOLITION HAMMER...1052
6.6.1 DESCRIPTION AND CONTROL...1052
6.6.1.1 CONTROL...1052
6.6.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED...1053
6.6.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER...1058
6.6.3.1 INSTALLING THE HAMMER...1058
6.6.3.2 REMOVING THE HAMMER...1060
6.6.4 USING THE HAMMER...1060
6.6.5 MAINTENANCE...1060
6.7 CONFIGURATION FOR THE USE OF OPTIONAL EQUIPMENT WITH UNIDIRECTIONAL OIL FLOW...1061
6.7.1 DESCRIPTION AND CONTROL...1061
6.7.1.1 CONTROL...1061
6.7.2 INSTALLING AND CONNECTING THE EQUIPMENT...1062
6.7.3 MAINTENANCE...1062
6.8 CONFIGURATION FOR THE USE OF THE CLAMSHELL BUCKET...1063
6.8.1 DESCRIPTION AND CONTROL...1063
6.8.1.1 CONTROL...1063
6.8.2 INSTALLING THE CLAMSHELL BUCKET...1064
6.8.3 USING THE CLAMSHELL BUCKET...1065
6.8.4 MAINTENANCE...1065
6.9 CONFIGURATION FOR THE USE OF THE HAND HYDRAULIC HAMMER...1066
6.9.1 DESCRIPTION AND CONTROL...1066
6.9.2 INSTALLING AND REMOVING THE HAND HAMMER...1067
6.9.2.1 CONNECTING THE HAND HAMMER...1067
6.9.2.2 REMOVING THE CONNECTIONS...1068
6.9.3 USING THE HAMMER...1068
6.9.4 MAINTENANCE...1068
6.10 LOAD STABILIZER SYSTEM (LSS) (Optional)...1069
6.10.1 LOAD STABILIZER SYSTEM (LSS) ACCUMULATOR...1069
6.11 REAR EQUIPMENT MECHANICAL QUICK COUPLING DEVICE...1070
6.11.1 EQUIPMENT COUPLING AND RELEASE PROCEDURE...1071
6.11.2 MAINTENANCE...1072
WEBM000400 - Backhoe-Loader WB91R-2, WB93R-2 Shop Manual...1075
COVER...1075
CONTENTS...1077
LIST OF REVISED PAGES...1079
SAFETY...1081
FOREWORD...1083
HOW TO READ THE SHOP MANUAL...1084
HOISTING INSTRUCTIONS ...1085
STANDAR TIGHTENING TORQUE...1086
COATING MATERIALS...1087
ELECTRIC WIRE CODE...1088
WEIGHT TABLE...1089
TABLE OF OIL AND COOLANT QUANTITIES...1090
10 STRUCTURE AND FUNCTION...1093
POWER TRAIN...1094
TRANSMISSION...1096
DRIVE SHAFTS...1101
CONTROL VALVE BLOCK...1103
FRONT AXLE...1104
REAR AXLE...1107
HYDRAULIC PUMP...1112
HYDRAULIC STEERING SYSTEM...1133
HYDRAULIC CIRCUIT...1135
SHOVEL CONTROL VALVE...1136
BACKHOE CONTROL VALVE...1142
CLSS...1149
SOLENOID VALVE...1163
SAFETY VALVE...1164
BRAKE PUMP...1166
SHOVEL CYLINDERS...1167
BACKHOE CYLINDERS...1168
20 TESTING AND ADJUSTMENTS...1173
NORMAL OR STANDAR TECHNICAL DATA...1174
SPECIAL TOOLS...1202
MEASURING ENGINE SPEED...1203
ADJUSTING VALVE CLEARANCE...1204
MEASURING COMPRESSION PRESSURE...1205
TESTING AND ADJUSTING FUEL INJECTION TIMING...1206
CHECKING AND TIGHTENING THE FAN - BELT...1208
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER...1209
ADJUSTING BRAKE PEDAL TRAVEL,BRAKE ALIGNMENT, MICROSWITCHES...1211
AIR BLEEDING - RELEASING RESIDUAL PRESSURE...1212
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...1215
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)...1221
CHECKING UNLOADING VALVE FUNCTIONALITY...1222
TESTING PUMP DELIVERY...1223
TESTING PRIORITY VALVE OPERATION...1225
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...1226
TESTING BRAKE SYSTEM...1227
CONTROL OF THE ENGINE SPEED UNDER LOAD...1229
TESTING PRESSURES IN THE POWER TRAIN GROUP...1231
TESTING THE CORRECT FUNCTIONING OH THE POWER TRAIN CLUTCHES...1233
ADJUSTING THE SENSOR OF RETURN TO DIG DEVICE...1234
ANALYSIS OF CAUSES HYDRAULIC DRIFT...1235
30 REMOVAL AND INSTALLATION...1241
HOW TO READ THE MANUAL...1243
PRECAUTIONS TO BE TAKEN WHILE WORKING...1244
SPECIAL TOOLS...1245
STARTING MOTOR...1249
ALTERNATOR...1250
INJECTION PUMP...1251
INJECTION NOZZLES...1255
THERMOSTAT...1256
COOLING LIQUID PUMP...1257
TURBOCOMPRESSOR...1259
CYLINDER HEAD...1261
FRONT COUNTERWEIGHT...1265
RADIATOR-OIL COOLER UNIT...1266
HYDRAULIC OIL COOLER...1269
TRANSMISSION OIL COOLER...1270
MUFFLER - EXHAUST PIPE...1271
ENGINE HOOD...1272
CAB...1273
CAB HEATING GROUP...1277
FUEL TANK...1278
HYDRAULIC OIL TANK...1279
ENGINE-GEARBOX-PUMP GROUP...1280
PISTON PUMP...1286
TRANSMISSION...1288
CONVERTOR...1373
REMOVAL OF THE TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...1374
STEERING UNIT...1375
WORKING BRAKE PUMP GROUP...1376
FORNT WORKING EQUIPMENT CONTROL VALVE...1377
FRONT AXLE...1378
REAR AXLE...1420
FRONT BUCKET BOOM-RAISING CYLINDER...1479
FRONT BUCKET TILT CYLINDERS...1480
FRONT BUCKET...1481
FRONT WORKING EQUIPMENT...1482
BACKHOE CONTROL VALVE...1484
BACKHOE BOOM CYLINDER...1486
BACKHOE ARM CYLINDER...1487
OUTRIGGER CYLINDERS...1489
BACKHOE SWING CYLINDERS...1491
BACKHOE BACKFRAME LOCK CYLINDER...1492
CYLINDERS...1493
BOOM SWING CYLINDER...1499
BACKHOE BACKFRAME LOCK CYLINDER...1502
BOOM SAFETY CYLINDER...1503
BACKHOE WORKING CYLINDER...1504
BACKHOE BUCKET...1505
ARM...1506
BACKHOE BOOM...1507
BACKHOE SWING BRACKET...1508
BACKHOE BACKFRAME...1509
40 STANDAR MAINTENANCE...1511
TRANSMISSION...1513
FRONT AXLE...1518
REAR AXLE...1521
HYDRAULIC PUMP...1526
2-SPOOL CONTROL VALVE...1528
3-SPOOL CONTROL VALVE...1530
3-SPOOL CONTROL VALVE-with return to dig...1532
6-SPOOL CONTROL VALVE...1534
7-SPOOL CONTROL VALVE...1537
8-SPOOL CONTROL VALVE...1539
BRAKE PUMP...1541
SHOVEL CYLINDER...1542
BACKHOE CYLINDER...1544
FRONT WORKING EQUIPMENT...1548
SWING BRACKET...1550
BACKHOE WORKING EQUIPMENT...1552
WEBM000401 - Backhoe-Loader WB91R-2, WB93R-2 avance Shop Manual...1555
COVER...1555
CONTENTS...1557
LIST OF REVISED PAGES...1559
SAFETY...1561
FOREWORD...1563
HOT TO READ THE SHOP MANUAL...1564
HOISTING INSTRUCTIONS...1565
STANDAR TIGHTENING TORQUE...1566
COATING MATERIALS...1568
ELECTRIC WIRE CODE...1569
WEIGHT TABLE...1570
TABLE OF OIL AND COOLANT QUANTITIES...1571
10 STRUCTURE AND FUNCTION...1573
POWER TRAIN...1574
TRANSMISSION...1576
DRIVE SHAFTS...1581
CONTROL VALVE BLOCK...1583
FRONT AXLE...1584
REAR AXLE...1587
HYDRAULIC PUMP...1592
HYDRAULIC STEERING SYSTEM...1613
HYDRAULIC CIRCUIT...1615
SHOVEL CONTROL VALVE...1616
BACKHOE CONTROL VALVE...1622
CLSS...1629
SOLENOID VALVE...1643
SAFETY VALVE...1644
BRAKE PUMP...1646
SHOVEL CYLINDERS...1647
BACKHOE CYLINDERS...1648
AIR-CONDITIONING UNIT...1652
HOT THE AIR-CONDITIONING UNIT FUNCTIONS...1653
ELECTRICAL DIAGRAM (1/5)...1655
ELECTRICAL DIAGRAM (2/5)...1657
ELECTRICAL DIAGRAM (3/5)...1659
ELECTRICAL DIAGRAM (4/5)...1661
ELECTRICAL DIAGRAM (5/5)...1663
20 TESTING AND ADJUSTMENTS...1665
NORMAL OR STANDAR TECHNICAL DATA...1666
SPECIAL TOOLS...1694
MEASURING ENGINE SPEED...1695
ADJUSTING VALVE CLEARANCE...1696
MEASURING COMPRESSION PRESSURE...1697
TESTING AND ADJUSTING FUEL INJECTION TIMING...1698
CHECKING AND TGHTENING THE FAN - BELT...1700
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT...1701
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER...1702
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT,MICROSWITCHES...1704
AIR BLEEDING - RELEASING RESIDUAL PRESSURE...1705
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...1708
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL...1714
CHECKING UNLOADING VALVE FUNCTIONALITY...1715
TESTING PUMP DELIVERY...1716
TESTING PRIORITY VALVE OPERATION...1718
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...1719
TESTING BRAKE SYSTEM...1720
CONTROL OF THE ENGINE SPEED UNDER LOAD...1722
TESTING PRESSURES IN THE POWER TRAIN GROUP...1724
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES...1726
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE...1727
ANALYSIS OF CAUSES HYDRAULIC DRIFT...1728
TESTING THE AIR-CONDITIONING UNIT...1733
30 REMOVAL AND INSTALLATION...1735
HOW TO READ THE MANUAL...1737
PRECAUTION TO BE TAKEN WHILE WORKING...1738
SPECIAL TOOLS...1739
STARTING MOTOR...1743
ALTERNATOR...1744
INJECTION PUMP...1746
INJECTION NOZZLES...1750
THERMOSTAT...1751
COOLING LIQUID PUMP...1752
TURBOCOMPRESSOR...1754
CYLINDER HEAD...1756
FRONT COUNTERWEIGHT...1760
RADIATOR-OIL COOLER UNIT ...1761
RADIATOR-OIL COOLER GROUP...1763
CONDENSER...1764
HYDRAULIC OIL COOLER...1765
TRANSMISSION OIL COOLER...1767
MUFFLER - EXHAUST PIPE...1768
ENGINE HOOD...1769
CAB...1771
HEAT AND AIR-CONDITIONING GROUP...1775
FUEL TANK...1777
HYDRAULIC OIL TANK...1778
ENGINE-GEARBOX-PUMP GROUP...1779
PISTON PUMP...1785
TRANSMISSION...1787
CONVERTOR...1872
TRANSMISSION-REVERSE,DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...1873
STEERING UNIT...1874
WORKING BRAKE PUMP GROUP...1875
FRONT WORKING EQUIPMENT CONTROL VALVE...1876
FRONT AXLE...1877
REAR AXLE...1919
FRONT BUCKET BOOM-RAISING CYLINDER...1978
FRONT BUCKET TILT CYLINDERS...1979
FRONT BUCKET...1980
FRONT WORKING EQUIPMENT...1981
BACKHOE CONTROL VALVE...1983
BACKHOE BOOM CYLINDER...1985
BACKHOE ARM CYLINDER...1986
BACKHOE BUCKET CYLINDER...1987
OUTRIGGER CYLINDERS...1988
BACKHOE SWING CYLINDERS...1990
BACKHOE BACKFRAME CYLINDER...1991
CYLINDERS...1992
BOOM SWING CYLINDER...1998
BACKHOE BACKFRAME LOCK CYLINDER...2001
BOOM SAFETY CYLINDER...2002
BACKHOE WORKING EQUIPMENT...2003
BACKHOE BUCKET...2004
ARM...2005
BACKHOE BOOM...2006
BACKHOE SWING BRACKET...2007
BACKHOE BACKFRAME...2008
40 STANDAR MAINTENANCE...2009
TRANSMISSION...2011
FRONT AXLE...2016
REAR AXLE...2019
HYDRAULIC PUMP...2024
2-SPOOL CONTROL VALVE...2026
3-SPOOL CONTROL VALVE...2028
3-SPOOL CONTROL VALVE-with return to dig...2030
6-SPOOL CONTROL VALVE...2032
7-SPOOL CONTROL VALVE...2035
8-SPOOL CONTROL VALVE...2037
BRAKE PUMP...2039
SHOVEL CYLINDER...2040
BACKHOE CYLINDER...2042
FRONT WORKING EQUIPMENT...2046
SWING BRACKET...2048
BACKHOE WORKING EQUIPMENT...2050
WEBM000404 - Backhoe-Loader WB91R-2, WB93R-2 avance Shop Manual...2053
COVER...2053
CONTENTS...2055
LIST OF REVISED PAGES...2057
SAFETY...2059
FOREWORD...2061
HOW TO READ THE SHOP MANUAL...2062
HOISTING INSTRUCTIONS...2063
STANDARD TIGHTENING TORQUE...2064
COATI NG MATERI ALS...2066
ELECTRIC...2067
WEIGHT TABLE...2068
TABLE OF OIL AND COOLANT QUANTITIES...2069
CONVERSION TABLE...2071
10. STRUCTURE AND FUNCTION...2081
POWER TRAIN...2082
TRANSMISSION (4WD)...2084
TRANSMISSION...2086
DRIVE SHAFTS...2089
CONTROL VALVE BLOCK...2091
FRONT AXLE...2092
REAR AXLE...2095
HYDRAULIC PUMP...2100
STEERING UNIT...2121
HYDRAULIC CIRCUIT...2123
SHOVEL CONTROL VALVE...2124
BACKHOE CONTROL VALVE...2130
CLSS...2137
SOLENOID VALVE...2151
SAFETY VALVE...2152
BRAKE PUMP...2154
SHOVEL CYLINDERS...2155
BACKHOE CYLINDERS...2156
AIR-CONDITIONING UNIT...2160
HOW THE AIR-CONDITIONING UNIT FUNCTIONS...2161
ELECTRICAL DIAGRAM...2163
ELECTRICAL DIAGRAM (AIR CONDITIONING)...2175
20. TESTING AND ADJUSTMENTS...2179
NORMAL OR STANDARD TECHNICAL DATA...2180
SPECIAL TOOLS...2204
MEASURING ENGINE SPEED...2205
ADJUSTING VALVE CLEARANCE...2206
MEASURING COMPRESSION PRESSURE...2207
TESTING AND ADJUSTING FUEL INJECTION TIMING...2208
CHECKING AND TIGHTENING THE FAN - BELT...2210
CHECKING AND TIGHTENING THE COMPRESSOR FAN - BELT...2211
MEASURING ACCELERATOR PEDAL OPERATING TRAVEL AND ACCELERATOR LEVER...2212
ADJUSTING BRAKE PEDAL TRAVEL, BRAKE ALIGNMENT, MICROSWITCHES...2214
AIR BLEEDING - RELEASING RESIDUAL PRESSURE...2215
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...2218
TESTING AND ADJUSTING OF LOAD SENSING SIGNAL (LS VALVE)...2224
TESTING AND ADJUSTING OF UNLOADING VALVE...2225
CHECKING UNLOADING VALVE FUNCTIONALITY...2226
TESTING PRIORITY VALVE OPERATION...2227
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...2228
TESTING BRAKE SYSTEM...2229
CONTROL OF THE ENGINE SPEED UNDER LOAD...2231
TESTING PRESSURES IN THE POWER TRAIN GROUP...2233
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAIN CLUTCHES...2235
ADJUSTING THE SENSOR FOR RETURN TO DIG DEVICE...2236
ANALYSIS OF CAUSES HYDRAULIC DRIFT...2237
TESTING THE AIR-CONDITIONING UNIT...2242
EMPTYING THE AIR-CONDITIONING UNIT...2244
TROUBLESHOOTING...2245
FRONT AXLE TROUBLESHOOTING...2246
REAR AXLE TROUBLESHOOTING...2251
TRANSMISSION TROUBLESHOOTING...2256
30. REMOVAL AND INSTALLATION...2261
HOW TO READ THE MANUAL...2263
PRECAUTIONS TO BE TAKEN WHILE WORKING...2264
SPECIAL TOOLS...2265
STARTING MOTOR...2269
ALTERNATOR...2270
AIR-CONDITIONING UNIT COMPRESSOR...2272
INJECTION PUMP...2274
INJECTION NOZZLES...2278
THERMOSTAT...2279
COOLING LIQUID PUMP...2280
TURBOCOMPRESSOR...2282
CYLINDER HEAD...2284
FRONT COUNTERWEIGHT...2288
RADIATOR GROUP...2289
CONDENSER...2292
MUFFLER...2293
EXHAUST PIPE...2294
ENGINE HOOD...2295
CAB...2297
HEAT AND AIR-CONDITIONING GROUP...2301
FUEL TANK...2303
HYDRAULIC OIL TANK...2304
ENGINE-GEARBOX-PUMP GROUP...2305
PISTON PUMP...2311
TRANSMISSION...2313
OVERHAULING THE TRANSMISSION...2317
CONVERTOR...2395
TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...2396
STEERING UNIT...2397
WORKING BRAKE PUMP GROUP...2398
FRONT WORKING EQUIPMENT CONTROL VALVE...2399
FRONT AND BACKHOE CONTROL VALVE...2400
FRONT AXLE...2414
REAR AXLE...2441
FRONT BUCKET BOOM-RAISING CYLINDER...2477
FRONT BUCKET TILT CYLINDERS...2478
FRONT BUCKET...2479
FRONT WORKING EQUIPMENT...2480
BACKHOE CONTROL VALVE...2482
BACKHOE BOOM CYLINDER...2484
BACKHOE ARM CYLINDER...2485
JIG ARM CYLINDER...2486
BACKHOE BUCKET CYLINDER...2487
OUTRIGGER CYLINDERS...2488
BACKHOE SWING CYLINDERS...2490
BACKHOE BACKFRAME LOCK CYLINDER...2491
CYLINDERS...2492
BOOM SWING CYLINDER...2498
BACKHOE BACKFRAME LOCK CYLINDER...2501
BOOM SAFETY CYLINDER...2502
BACKHOE WORKING EQUIPMENT...2503
BACKHOE BUCKET...2504
ARM...2505
JIG ARM...2506
2nd ARM...2507
2nd ARM GUIDES...2508
BACKHOE BOOM...2509
BACKHOE SWING BRACKET...2510
BACKHOE BACKFRAME...2511
40. STANDARD MAINTENANCE...2515
TRANSMISSION...2516
FRONT AXLE...2521
REAR AXLE...2524
HYDRAULIC PUMP...2528
2-SPOOL CONTROL VALVE...2530
3-SPOOL CONTROL VALVE...2532
3-SPOOL CONTROL VALVE (With Returnto Dig)...2534
6-SPOOL CONTROL VALVE...2536
7-SPOOL CONTROL VALVE...2539
8-SPOOL CONTROL VALVE...2541
BRAKE PUMP...2543
SHOVEL CYLINDERS...2545
BACKHOE CYLINDERS...2546
FRONT WORKING EQUIPMENT...2550
SWING BRACKET...2552
BACKHOE WORKING EQUIPMENT...2554
WEBM000405 - Backhoe-Loader WB91R-2, WB93R-2 Shop Manual...2557
WEBM007600 - Backhoe-Loader WB91R-5 Shop Manual...3099
CONTENTS...3101
REVISED PAGES...3103
k SAFETY...3105
INTRODUCTION...3107
HOW TO READ THE SHOP MANUAL...3108
HOISTING INSTRUCTIONS...3109
STANDARD TIGHTENING TORQUE...3110
COATING MATERIALS...3112
ELECTRIC...3113
WEIGHT TABLE...3114
TABLE OF OIL AND COOLANT QUANTITIES...3115
CONVERSION TABLE...3117
10 STRUCTURE AND FUNCTION...3125
POWER TRAIN...3126
TRANSMISSION (4WD)...3129
DRIVE SHAFTS...3134
CONTROL VALVE BLOCK...3136
TRANSMISSION (2WD)...3137
DRIVE SHAFTS...3142
CONTROL VALVE BLOCK...3143
FRONT AXLE (4WD)...3144
FRONT AXLE (2WD)...3147
REAR AXLE...3149
HYDRAULIC PUMP...3155
SHOVEL CONTROL VALVE...3157
BACKHOE CONTROL VALVE...3161
SOLENOID VALVE...3166
BRAKES PUMP...3167
SHOVEL CYLINDERS...3168
RAISING CYLINDER...3168
DUMPING CYLINDER...3168
4 IN 1 BUCKET...3169
BACKHOE CYLINDERS...3170
BOOM CYLINDER...3170
ARM...3170
BUCKET CYLINDER...3171
OUTRIGGER CYLINDER...3171
BOOM SWING CYLINDER...3172
JIG ARM CYLINDER...3172
20 TESTING AND ADJUSTMENTS...3175
NORMAL OR STANDARD TECHNICAL DATA...3177
SPECIAL TOOLS...3191
VALVE CLEARANCE ADJUSTING...3193
ENGINE SPEED TESTS...3194
BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE...3196
ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER...3198
ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...3200
BRAKING SYSTEM CHECKS...3201
PARKING BRAKE ADJUSTMENT...3204
CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT...3205
CHECKING THE LOAD SENSING SIGNAL (LS VALVE)...3212
CHECKING FOR PROPER FUNCTIONING OF THE COMPENSATED FLOW VALVE...3213
CHECKING FOR PROPER OPERATION OF THE PRIORITY VALVE...3214
TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE...3215
CHECKING FOR LEAKS IN THE STEERING CYLINDERS...3216
TESTING PRESSURES IN THE POWER TRAIN GROUP...3217
TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES...3219
ADJUSTING THE RETURN-TO-DIG DEVICE SENSOR (Optional)...3220
ANALYSIS OF CAUSES HYDRAULIC DRIFT...3221
FRONT EQUIPMENT...3221
BACKHOE...3223
TROUBLESHOOTING...3226
FRONT AXLE (2WD)...3226
FRONT AXLE CHECKING AND TROUBLESHOOTING (2WD)...3227
FRONT AXLE (4WD)...3228
FRONT AXLE CHECKING AND TROUBLESHOOTING (4WD)...3231
REAR AXLE TROUBLESHOOTING...3233
REAR AXLE CHECKING AND TROUBLESHOOTING...3236
TRANSMISSION TROUBLESHOOTING (2WD)...3238
TRANSMISSION TROUBLESHOOTING (4WD)...3241
30 REMOVAL AND INSTALLATION...3245
HOW TO READ THE MANUAL...3247
PRECAUTIONS TO BE TAKEN WHILE WORKING...3248
SPECIAL TOOLS...3249
ENGINE HOOD...3253
Removal...3253
Installation...3254
FRONT GUARD...3255
Removal...3255
Installation...3255
RADIATOR GROUP...3256
Removal...3256
Installation...3259
MUFFLER...3260
Removal...3260
Installation...3260
AIR FILTER...3261
Removal...3261
Installation...3261
EXHAUST PIPE...3262
Removal...3262
Installation...3262
FAN AND HEATING GROUP...3263
Removal...3263
Installation...3268
BATTERY...3269
Removal...3269
Installation...3270
FUEL TANK...3271
Removal...3271
Installation...3272
STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP...3273
Removal...3273
Installation...3274
WORKING BRAKE PUMP GROUP...3275
Removal...3275
Installation...3277
STEERING UNIT...3278
Removal...3278
Installation...3279
CAB...3280
Removal...3280
Installation...3285
HYDRAULIC OIL TANK...3287
Removal...3287
Installation...3293
PUMP...3294
Removal...3294
Installation...3295
TRANSMISSION...3296
Removal...3296
Installation...3300
TRANSMISSION 2WD...3301
Disassembly and 2WD shift assembly...3301
TRANSMISSION 4WD...3381
Disassembly and 4WD shift assembly...3381
CONVERTOR...3487
Removal...3487
Installation...3487
ENGINE...3488
Removal...3488
Installation...3491
BACKHOE CONTROL VALVE...3492
Removal...3492
Installation...3495
FRONT AXLE...3496
Removal...3496
Installation...3497
FRONT AXLE (2WD)...3499
Disassembly and assembly front axle (2WD)...3499
FRONT AXLE (4WD)...3513
Disassembly and assembly front axle 4WD...3513
REAR AXLE...3546
Removal...3546
Installation...3548
Disassembly and assembly...3549
FRONT EQUIPMENT CONTROL VALVE...3599
Removal...3599
Installation...3600
SOLENOID VALVE GROUP (Boom safety differential lock)...3601
Removal...3601
Installation...3601
SHOVEL LIFT CYLINDERS...3602
Removal...3602
Installation...3603
SHOVEL DUMP CYLINDERS...3604
Removal...3604
Installation...3605
SHOVEL...3606
Removal...3606
Installation...3606
FRONT WORKING EQUIPMENT...3607
Removal...3607
Installation...3608
BACKHOE BOOM CYLINDER...3609
Removal...3609
Installation...3611
ARM CYLINDER...3612
Removal...3612
Installation...3613
JIG ARM CYLINDER...3614
Removal...3614
Installation...3614
OUTRIGGER CYLINDER...3615
Removal...3615
Installation...3616
BACKHOE SWING CYLINDERS...3617
Removal...3617
Installation...3619
BACKHOE BUCKET CYLINDER...3620
Removal...3620
Installation...3621
BACKHOE BOOM SAFETY CYLINDER...3622
Removal...3622
Installation...3623
CYLINDER...3624
SHOVEL ARM, SHOVEL, BOOM, ARM, BUCKET, OUTRIGGERS...3624
Disassembly...3624
Assembly...3626
BACKHOE SWING CYLINDERS...3629
Disassembly...3629
Assembly...3632
BACKHOE WORKING EQUIPMENT...3635
Removal...3635
Installation...3636
BACKHOE BUCKET...3637
Removal...3637
Installation...3637
BACKHOE BOOM CYLINDER...3638
Removal...3638
Installation...3638
ARM...3639
Removal...3639
Installation...3639
JIG ARM...3640
Removal...3640
Installation...3640
2nd ARM...3641
Removal...3641
Installation...3641
2nd ARM GUIDES...3642
Removal...3642
Installation...3642
BACKHOE SWING BRACKET...3643
Removal...3643
Installation...3643
COMPLETE BACKHOE BACKFRAME...3644
Removal...3644
Installation...3645
BACKFRAME LOCK PISTONS...3646
Removal...3646
Installation...3647
40 STANDARD MAINTENANCE...3649
TRANSMISSION 2WD...3650
TRANSMISSION 4WD...3655
FRONT AXLE (2WD)...3660
FRONT AXLE (4WD)...3661
REAR AXLE 2WD - 4WD...3665
SHOVEL CYLINDERS...3669
DUMP CYLINDER...3669
RAISE CYLINDER...3669
4 IN 1 BUCKET...3670
BACKHOE CYLINDERS...3672
BOOM...3672
ARM...3672
BUCKET...3672
BOOM SWING...3673
OUTRIGGERS...3674
JIG ARM...3674
FRONT WORKING EQUIPMENT...3676
SWING BRACKET...3678
BACKHOE WORKING EQUIPMENT...3680
90 OTHER...3683
ELECTRICAL DIAGRAM (STANDARD VERSION)...3685
Komatsu Backhoe-Loader WB91R, WB93R Repair Service Manual
