The provided document is an operation and maintenance manual for a Komatsu WB93R-5 backhoe loader.
Function Description
The Komatsu WB93R-5 is a backhoe loader designed primarily for loader and excavator functions. Through the installation of optional equipment, it can also be used for:
- Material Handling: utilizing a 4-in-1 bucket or pallet forks.
- Snowplough: with an angledozer blade.
- Demolition: using a hand hammer or a hammer on the backhoe.
- Ditch Cleaning and Digging: with special buckets.
The machine is equipped with multifunction safety locks for both maintenance and road travel. It features servo-assisted steering with a priority hydraulic system and a 4-gear mechanical gearshift and transmission with a hydraulic converter, controlled by a lever under the steering wheel. Loader control is managed by a single servo lever, allowing for modulated and continuous combined movements. Backhoe controls are typically mechanical levers, also enabling modulated and continuous combined movements, with an option for two servo levers. The cab offers complete instrumentation visible from both operating positions (loader or backhoe) and separate accelerator controls for each position, along with foot brake control.
Important Technical Specifications
- Total Weight: Minimum 7300 kg, Maximum 8350 kg.
- Standard Bucket Capacity (SAE): Front bucket 1.03 m³, Backhoe bucket 0.19 m³.
- Engine: Komatsu diesel model S4D104E-3.
- Maximum Power (2200 rpm EEC 80/1269): 74 kW.
- Maximum Torque (1400±100 rpm EEC 80/1269): 398 Nm.
- Electrical System:
- Alternator: 12V, 95 A output.
- Grounding: Negative.
- Battery: 160 - 12V.
- Starter: 3.0 kW.
- Travel Speed (calculated with 16.9-30 tyres and engine at 2200 rpm):
- Forward: 1st gear 6 km/h, 2nd gear 10 km/h, 3rd gear 23 km/h, 4th gear 40 km/h.
- Reverse: R1 6 km/h, R2 10 km/h, R3 23 km/h, R4* 40 km/h (*R4 not homologated for Italian and German markets).
- Tyre Pressure:
- Front (Recommended 12.5/80-R18 PR10 Good Year): 3.10 bar.
- Rear (Recommended 16.9-28 PR10 Good Year, Mitas, Ecomega): 2.20 bar.
- Lifting Capacities: The machine cannot lift weights exceeding 1000 kg unless equipped with appropriate equipment. Lifting operations must be performed on firm and flat ground.
- Standard Arm Length: L=1900 mm.
- Operating Hydraulic Pressure: 24.5 MPa (245 Bar).
- Standard Backhoe Bucket Width/Weight: W=600 mm / 160 kg.
- Hydraulic System Oil Filter Clogging Warning Light: Activates when the filter is clogged and needs replacement.
- Engine Coolant Temperature Warning Light: Activates with an acoustic alarm if the coolant temperature is too high.
- Transmission Oil Temperature Warning Light: Activates with an acoustic alarm if the transmission oil exceeds maximum temperature.
- Air Filter Clogging Warning Light: Activates when the engine air filter needs cleaning.
Usage Features
The WB93R-5 is designed for simple and easy operation. It includes features like:
- Running-in Period: A new machine requires careful use for the first 100 hours to ensure proper running-in of components. This includes idling the engine for 5 minutes after start, avoiding limit loads or high speeds, and preventing abrupt starts, accelerations, decelerations, or reversals. Specific oil and filter changes are recommended after 250 hours (hydraulic transmission oil and filter, differential unit oil, final reduction gear oil, hydraulic circuit oil filter) and for machines using synthetic biodegradable oil (hydraulic circuit drain filter after 50 hours, hydraulic circuit oil after 500 hours).
- Safety Locks: Front loader locks (for maintenance and road travel) and backhoe locks (to prevent lowering and swing). Servo control locking buttons inhibit movements when engaged.
- Controls:
- Reversing Gear Lever: Selects forward (F) or reverse (R) travel. Engine starts only in neutral (N). An acoustic alarm activates if the lever is shifted with the seat rotated incorrectly.
- Brake Pedals: Split pedals allow sharp turns. They must be connected with a pin for high gears and road travel. Automatic 4-wheel drive engagement occurs when brake pedals are pressed in 4th gear.
- Hand Accelerator: Used for warming up the engine and backhoe operations. Max speed corresponds to 1900-2000 rpm.
- Front Loader Control Lever: Controls arm lifting/lowering and bucket folding/dumping. Features "Return-to-dig" device for automatic bucket positioning.
- Gearshift Lever: Engages one of four gears. Declutch push button allows gear shifting during travel.
- Parking Brake: Applied by pulling a lever upwards. Inhibits reversing gear lever functions when applied.
- Backhoe Boom Locking Button: Engages safety lock for the boom during travel or when not in use.
- Backhoe Sliding Lock Switch: Releases the backhoe unit from sliding guides for repositioning.
- Declutch Push Button: Transfers engine power to hydraulic system for lifting material.
- Differential Locking Push Button: Locks differential for improved traction in muddy or loose ground, usable in 1st, 2nd, or 3rd gear.
- 4-in-1 Bucket Opening/Folding Push Buttons: Controls the opening and folding of the 4-in-1 bucket.
- Front Loader Speed Control Push Button: Increases speed of front loader movements.
- Stabilizer Control Levers: Controls raising and lowering of stabilizers.
- Backhoe Control Levers: Available in ISO, Komatsu, or X-pattern controls, with mechanical or servo-assisted options.
- Pattern Change Control Lever: (Servo-assisted backhoe only) Allows selection between ISO and OPTION control patterns.
- Visibility: Rear-view mirrors must be clean and correctly positioned. Work lights should be used in low visibility.
- Working on Slopes: Keep bucket low (20-30 cm from ground), avoid oblique travel, use low gear, and engage 4-wheel drive.
- Maximum Immersion Depth: Max 50 cm, ensuring engine cooling fan does not touch water.
- Transporting: Loading/unloading on flat surfaces with appropriate ramps (max 15° inclination). Secure machine with tie-downs and wedges.
- Cold Season Precautions: Use winter fuel, suitable viscosity oil, and red permanent antifreeze (50% diluted for -36°C protection). Keep battery charged and insulated.
Maintenance Features
The manual provides simplified maintenance intervals and procedures.
- Maintenance Notes: Emphasizes using genuine Komatsu parts, avoiding mixing oils, and keeping the machine clean. Draining hot oil/coolant is hazardous; wait for temperatures to cool. Check for metal particles during oil/filter changes.
- Periodical Change of Safety Related Components: Fuel pipes, hydraulic pipes, and safety belts must be changed periodically (e.g., every 2 years or 4000 hours for pipes, every 4 years for safety belt).
- When Required Maintenance:
- Engine Air Filters: Clean or change when clogging warning light activates. Primary element can be cleaned with compressed air; safety cartridge must be changed.
- Cab Air Filter: Clean when air circulation decreases.
- Air Recirculation Filter: (A/C machines only) Clean when air circulation decreases.
- Windshield Washer Reservoir: Check and top up detergent.
- Windshield Wiper Blades: Check and change if worn.
- Cab Door Hinges: Lubricate if squealing or showing oxidation.
- Fuses and Relays: Check and change if oxidized, corroded, or damaged.
- Braking Circuit: Bleed to ensure efficiency.
- Front Wheel Toe-in: Check and adjust to 0 mm.
- Braking Efficiency: Periodically check, especially after first 100 hours of running-in.
- Parking Brake: Check and adjust efficiency.
- Brake Pedal Stroke: Check and adjust.
- Automatic Return-to-Dig Device: (If installed) Adjust sensor position.
- Stabilizer Slack: Check and adjust.
- Maintenance Intervals for Demolition Hammer Use: Hydraulic oil filter and hydraulic oil must be changed more frequently (filter after first 100-150 hours, then every 500 hours; oil after first 500 hours, then every 2000 hours for HEES oil).
- Before Starting the Engine Checks: Visual checks (loose screws, leaks, wear, electrical connections, tyre condition, safety plates, clean ladders/handles) and daily checks (coolant, engine oil, hydraulic circuit oil levels, lubrication).
- Every 10 Hours Maintenance: Lubricate joints on front loader and backhoe.
- Every 50 Hours Maintenance: (For HEES oil machines) Change hydraulic system oil filter. (All machines) Check hydraulic oil level, radiator fluid level, braking system oil level, lubricate propeller shafts, front axle joints, central coupling, check tyre pressure, drain water separator.
- Every 250 Hours Maintenance: (All machines) Check alternator-fan belt, A/C compressor belt tension, battery electrolyte level, front axle oil levels, rear axle oil level, hydraulic transmission oil level, wheel nut driving torque.
- Every 500 Hours Maintenance: (For HEES oil machines) Change hydraulic oil and clean intake filter. (All machines) Change engine oil, engine oil filter, hydraulic system oil filter, fuel filter, drain fuel tank, drain hydraulic oil tank, clean outside of radiator, clean outside of A/C condenser.
- Every 1000 Hours Maintenance: Change front axle oil, rear axle oil, hydraulic transmission oil, hydraulic transmission oil filter.
- Every 2000 Hours Maintenance: Change hydraulic oil and clean intake filter, change coolant, change braking system oil, check alternator and starter, change alternator belt, check A/C cooling gas quantity.
- Every 3000 Hours Maintenance: Check engine retaining screws and damping elements, check and adjust engine valve clearance and injection timing advance.
- Every 4000 Hours Maintenance: Change A/C dewatering filter, check operating conditions of A/C compressor, change engine thermostatic valve.
- Waste Materials: Oils, filters, coolant, gaskets, electric wires, and batteries are considered special waste and must be collected and disposed of according to regulations. Avoid contact of burnt materials with skin/eyes and do not inhale fumes.
- Technopolymers and Elastomers: Burnt materials release highly toxic gases. Handle with heavy waterproof gloves and dispose of according to regulations.
- Tyre Inflation: Inflate only in a protection cage, standing beside the tyre. Do not exceed prescribed pressures.
This comprehensive manual ensures operators and maintenance personnel have the necessary information to safely and efficiently operate and maintain the Komatsu WB93R-5 backhoe loader.
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