Komatsu WB93R-5 Backhoe Loader Service Repair Manual PDF Download

Description

KOMATSU WB93R-5 BACKHOE LOADER SHOP MANUAL – PDF DOWNLOAD

FILE DETAILS:

KOMATSU WB93R-5 BACKHOE LOADER SHOP MANUAL – PDF DOWNLOAD

Language : English
Pages : 618
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KOMATSU WB93R-5 BACKHOE LOADER SHOP MANUAL – PDF DOWNLOAD

WEBM005800......................................................................................................  1
	CONTENTS....................................................................................................  3
	REVISED PAGES...............................................................................................  5
	k SAFETY....................................................................................................  7
	FOREWORD....................................................................................................  9
	HOW TO READ THE SHOP MANUAL................................................................................. 10
	HOISTING INSTRUCTIONS....................................................................................... 11
	STANDARD TIGHTENING TORQUE.................................................................................. 12
	COATING MATERIALS........................................................................................... 14
	ELECTRIC.................................................................................................... 15
	WEIGHT TABLE................................................................................................ 16
	TABLE OF OIL AND COOLANT QUANTITIES......................................................................... 17
	CONVERSION TABLE............................................................................................ 19
	10 STRUCTURE AND FUNCTION................................................................................... 27
		POWER TRAIN............................................................................................. 28
		TRANSMISSION (4WD)...................................................................................... 30
		TRANSMISSION............................................................................................ 32
		DRIVE SHAFTS............................................................................................ 35
		CONTROL VALVE BLOCK..................................................................................... 37
		FRONT AXLE.............................................................................................. 38
		REAR AXLE............................................................................................... 41
		HYDRAULIC CIRCUIT (WITH MECHANICAL CONTROL)............................................................. 45
		HYDRAULIC CIRCUIT (WITH SERVOCONTROL)................................................................... 46
		HYDRAULIC PUMP.......................................................................................... 47
		8-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)......................................................... 62
		10-SPOOL CONTROL VALVE (WITH MECHANICAL CONTROL)........................................................ 68
		8-SPOOL CONTROL VALVE (WITH SERVOCONTROL)............................................................... 74
		10-SPOOL CONTROL VALVE (WITH SERVOCONTROL).............................................................. 80
		CLSS.................................................................................................... 87
		STEERING UNIT...........................................................................................108
		PPC VALVES..............................................................................................109
		PPC VALVE (SERVOCONTROL VERSION)........................................................................124
		SOLENOID VALVE GROUP (EV1)..............................................................................126
		SAFETY VALVES...........................................................................................130
		SHOVEL CYLINDERS........................................................................................134
		BACKHOE CYLINDERS.......................................................................................136
		AIR-CONDITIONING UNIT...................................................................................140
		HOW THE AIR-CONDITIONING UNIT FUNCTIONS.................................................................141
		FUSE AND RELAY CENTRE...................................................................................143
		DRIVER SEAT WIRING......................................................................................144
		SWITCH PANEL WIRING.....................................................................................145
		FRONT DASH WIRING.......................................................................................146
		ROOF WIRING.............................................................................................147
		ENGINE WIRING...........................................................................................148
		SPEED SELECTOR WIRING...................................................................................149
		BACKHOE WIRING..........................................................................................150
		JIG ARM WIRING..........................................................................................151
		WIRING DIAGRAM (STANDARD VERSION) (see also Group 90)...................................................152
	20 TESTING AND ADJUSTMENTS..................................................................................153
		NORMAL OR STANDARD TECHNICAL DATA.......................................................................155
		SPECIAL TOOLS...........................................................................................179
		ADJUSTING VALVE CLEARANCE...............................................................................181
		ENGINE SPEED TESTS......................................................................................182
		TENSIONING THE AIR-CONDITIONING COMPRESSOR BELT.........................................................184
		BLEEDING AIR FROM CIRCUITS - ELIMINATING RESIDUAL PRESSURE..............................................185
		ADJUSTING ACCELERATOR PEDAL TRAVEL AND ACCELERATOR LEVER................................................187
		ADJUSTING BRAKE PEDAL SLACK/ALIGNMENT...................................................................189
		BRAKING SYSTEM CHECKS...................................................................................190
		PARKING BRAKE ADJUSTMENT................................................................................193
		CHECKING AND SETTING PRESSURE IN THE ATTACHMENTS HYDRAULIC CIRCUIT......................................194
		CHECKING THE SETTING OF MAIN RELIEF AND SECONDARY VALVES................................................196
		SETTING THE MAIN RELIEF VALVES AND THE REDUCING VALVES..................................................200
		CHECKING AND ADJUSTING THE LS DIFFERENTIAL PRESSURE. ADJUSTING THE LS VALVE.............................202
		CHECKING AND ADJUSTING SERVOCONTROLS SUPPLY PRESSURE....................................................204
		ADJUSTING THE PC VALVE..................................................................................205
		TESTING AND SETTING STEERING CONTROL SYSTEM PRESSURE....................................................206
		CHECKING FOR LEAKS IN THE STEERING CYLINDERS............................................................207
		TESTING PRESSURES IN THE POWER TRAIN GROUP..............................................................208
		TESTING THE CORRECT FUNCTIONING OF THE POWER TRAINCLUTCHES..............................................210
		ANALYSIS OF CAUSES HYDRAULIC DRIFT......................................................................211
		TESTING THE AIR-CONDITIONING UNIT.......................................................................216
		EMPTYING THE AIR-CONDITIONING UNIT......................................................................218
		TROUBLESHOOTING.........................................................................................219
	30 REMOVAL AND INSTALLATION.................................................................................233
		HOW TO READ THE MANUAL..................................................................................235
		PRECAUTIONS TO BE TAKEN WHILE WORKING...................................................................236
		SPECIAL TOOLS...........................................................................................237
		ENGINE HOOD.............................................................................................241
			Removal.............................................................................................241
			Installation........................................................................................242
		FRONT GUARD.............................................................................................243
			Removal.............................................................................................243
			Installation........................................................................................243
		RADIATOR GROUP..........................................................................................244
			Removal.............................................................................................244
			Installation........................................................................................247
		CONDENSER...............................................................................................248
		(For machines equipped with an air-conditioning unit)...................................................248
			Removal.............................................................................................248
			Installation........................................................................................248
		MUFFLER.................................................................................................249
			Removal.............................................................................................249
			Installation........................................................................................249
		AIR FILTER..............................................................................................250
			Removal.............................................................................................250
			Installation........................................................................................250
		TURBOCHARGER............................................................................................251
			Removal.............................................................................................251
			Installation........................................................................................252
		AIR-CONDITIONING UNIT COMPRESSOR........................................................................253
			Removal.............................................................................................253
			Installation........................................................................................254
		AIR-CONDITIONING UNIT COMPRESSOR BELT...................................................................255
			Removal.............................................................................................255
			Installation........................................................................................256
		EXHAUST PIPE............................................................................................257
			Removal.............................................................................................257
			Installation........................................................................................257
		FAN AND HEATING GROUP...................................................................................258
			Removal.............................................................................................258
			Installation........................................................................................263
		BATTERY.................................................................................................264
			Removal.............................................................................................264
			Installation........................................................................................265
		FUEL TANK...............................................................................................266
			Removal.............................................................................................266
			Installation........................................................................................267
		STEERING WHEEL AND TRANSMISSION-REVERSE, DIRECTION INDICATOR AND HEADLIGHT DIPPER BEAM CONTROL GROUP....268
			Removal.............................................................................................268
			Installation........................................................................................269
		WORKING BRAKE PUMP GROUP................................................................................270
			Removal.............................................................................................270
			Installation........................................................................................272
		STEERING UNIT...........................................................................................273
			Removal.............................................................................................273
			Installation........................................................................................274
		CAB.....................................................................................................275
			Removal.............................................................................................275
			Installation........................................................................................282
		HYDRAULIC OIL TANK......................................................................................283
			Removal.............................................................................................283
			Installation........................................................................................289
		PISTON PUMP.............................................................................................290
			Removal.............................................................................................290
			Installation........................................................................................291
		TRANSMISSION............................................................................................292
			Removal.............................................................................................292
			Installation........................................................................................296
		TRANSMISSION............................................................................................297
			Disassembly and assembly............................................................................297
		CONVERTOR...............................................................................................401
			Removal.............................................................................................401
			Installation........................................................................................401
		ENGINE..................................................................................................402
			Removal.............................................................................................402
			Installation........................................................................................406
		CONTROL VALVE (Standard version)........................................................................407
			Removal.............................................................................................407
			Installation........................................................................................410
		CONTROL VALVE (version with servocontrol)...............................................................411
			Removal.............................................................................................411
			Installation........................................................................................413
		FRONT AXLE..............................................................................................414
			Removal.............................................................................................414
			Installation........................................................................................416
		FRONT AXLE..............................................................................................417
			Disassembly and assembly............................................................................417
		REAR AXLE...............................................................................................450
			Removal.............................................................................................450
			Installation........................................................................................452
			Disassembly and assembly............................................................................453
		SHOVEL PPC VALVE........................................................................................503
			Removal.............................................................................................503
			Installation........................................................................................504
		SHOVEL LIFT CYLINDERS...................................................................................505
			Removal.............................................................................................505
			Installation........................................................................................506
		SHOVEL DUMP CYLINDERS...................................................................................507
			Removal.............................................................................................507
			Installation........................................................................................508
		SHOVEL..................................................................................................509
			Removal.............................................................................................509
			Installation........................................................................................509
		FRONT WORKING EQUIPMENT.................................................................................510
			Removal.............................................................................................510
			Installation........................................................................................511
		BACKHOE PPC VALVES (Optional)...........................................................................512
			Removal.............................................................................................512
			Installation........................................................................................513
		PPC VALVE SUPPORT RELEASE CABLES........................................................................514
			Removal.............................................................................................514
			Installation and adjusting..........................................................................516
		PPC VALVE SUPPORT RETURN GAS SPRING.....................................................................517
			Removal.............................................................................................517
			Installation........................................................................................518
		SOLENOID VALVE GROUP (servocontrol and optional attachment).............................................519
			Removal.............................................................................................519
			Installation........................................................................................520
		BACKHOE BOOM CYLINDER...................................................................................521
			Removal.............................................................................................521
			Installation........................................................................................523
		ARM CYLINDER............................................................................................524
			Removal.............................................................................................524
			Installation........................................................................................525
		JIG ARM CYLINDER........................................................................................526
			Removal.............................................................................................526
			Installation........................................................................................526
		OUTRIGGER CYLINDER......................................................................................527
			Removal.............................................................................................527
			Installation........................................................................................528
		BACKHOE SWING CYLINDERS.................................................................................529
			Removal.............................................................................................529
			Installation........................................................................................531
		BACKHOE BUCKET CYLINDER.................................................................................532
			Removal.............................................................................................532
			Installation........................................................................................533
		BACKHOE BOOM SAFETY CYLINDER............................................................................534
			Removal.............................................................................................534
			Installation........................................................................................535
		BACKHOE WORKING EQUIPMENT...............................................................................536
			Removal.............................................................................................536
			Installation........................................................................................537
		BACKHOE BUCKET..........................................................................................538
			Removal.............................................................................................538
			Installation........................................................................................538
		BACKHOE BOOM CYLINDER...................................................................................539
			Removal.............................................................................................539
			Installation........................................................................................539
		ARM.....................................................................................................540
			Removal.............................................................................................540
			Installation........................................................................................540
		JIG ARM.................................................................................................541
			Removal.............................................................................................541
			Installation........................................................................................541
		2nd ARM.................................................................................................542
			Removal.............................................................................................542
			Installation........................................................................................542
		2nd ARM GUIDES..........................................................................................543
			Removal.............................................................................................543
			Installation........................................................................................543
		BACKHOE SWING BRACKET...................................................................................544
			Removal.............................................................................................544
			Installation........................................................................................544
		COMPLETE BACKHOE BACKFRAME..............................................................................545
			Removal.............................................................................................545
			Installation........................................................................................546
		BACKFRAME LOCK PISTONS..................................................................................547
			Removal.............................................................................................547
			Installation........................................................................................548
	40 STANDARD MAINTENANCE.....................................................................................549
		TRANSMISSION............................................................................................550
		FRONT AXLE..............................................................................................555
		REAR AXLE...............................................................................................559
		HYDRAULIC PUMP..........................................................................................563
		CONTROL VALVE...........................................................................................566
		PPC VALVES..............................................................................................598
		SHOVEL CYLINDERS........................................................................................600
		BACKHOE CYLINDERS.......................................................................................602
		FRONT WORKING EQUIPMENT.................................................................................606
		SWING BRACKET...........................................................................................608
		BACKHOE WORKING EQUIPMENT...............................................................................610
	90 OTHER....................................................................................................613
		ELECTRICAL DIAGRAM (STANDARD VERSION)...................................................................615

DESCRIPTION:

KOMATSU WB93R-5 BACKHOE LOADER SHOP MANUAL – PDF DOWNLOAD

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTMENTS
This sections explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating «Problems» to «Causes» are also included in this section.
REMOVAL AND INSTALLATION
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts

S.S 24/12/24