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Komatsu Backhoe-Loader WB91-93/M/WEAM002304/WB91R/WB93R-2: Every 2000 Hours of Operation Maintenance

Use this maintenance checklist and follow the schedule interval for the proactive and preventive maintenance of your backhoe loader. This has been proven to lower costs by catching small service issues before they blossom into giant repair headaches.

MaintainX

11/04/2022

Komatsu Backhoe-Loader WB91-93/M/WEAM002304/WB91R/WB93R-2: Every 2000 Hours of Operation Maintenance

Carry out these operations together with those to be performed every 50, 250, 500 and 1000 HOURS.

CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER

CAUTION!

On machines containing synthetic biodegradable hydrau- lic oil type HEES, carry out the change after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.

DANGER!

After stopping the engine, with the machine positioned so that maintenance can be performed, release the residual pressures from the work equipment circuits (by operating the controls more than once) and from the tank (by slowly loosening the filling cap).

Let the oil cool down until it reaches 4045°C before carry- ing out any maintenance operation.

Immediately clean any area dirty with oil.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

The filter can be reached after removing the platform (1) with the relevant fastening screws (2). Use a 17 mm spanner.

Remove the filling cap (3). (Use a 24 mm spanner).

Remove the drain plug (4) and let the oil flow out, gathering it into a container with suitable capacity. Use a 41 mm spanner.

Remove the upper flange (5), the filter cartridge (6) and the filter casing (7). Use a 13 mm spanner.

Remove the grid filter (8), complete with gasket (9) and clean it with light solvents (petrol, kerosene, diesel oil, etc.).

Put back the filter (8) complete with the gasket (9).

Change the filter cartridge (6) and reassemble the whole unit. (See “4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER”).

Put back the drain plug (4) and fill the oil tank with the prescribed oil until reaching the level (10).

Raise the front mat and remove the cover (11). Use a 13 mm spanner.

Loosen the bleeder plug (12) positioned on the hydraulic pump, until no air bubbles can be observed in the oil that flows out (use a 3 mm setscrew spanner). Tighten the bleeder plug (12) and put back the cover (11).

Put back the filling cap (3), start the engine and operate the machine making each piston move several times in order to bleed the system. Stop the machine in maintenance position, check the oil level again and if necessary top up. Always use oil of the prescribed type, (see “4.3 FUEL, COOLANT AND LUBRICANTS”).

Put back the upper platform (1) with the relevant fastening screws (2).

IMPORTANT

The hydraulic oil of the machines equipped with demoli- tion hammer deteriorates more rapidly than the oil of the machines used for simple digging operations. Perform the oil changes according to the indications given in the table beside.

CHANGING THE COOLANT

Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approxi- mately 40÷45°C before changing the coolant.

Slowly loosen the radiator cap, in order to release the re- sidual pressure.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

IMPORTANT

The change of the permanent coolant does not require any washing cycle for the descaling of the circuit.

Remove the front guard (1) after removing the relevant fas- tening screws (2). Use a 17 mm hexagon spanner.

Open the engine hood (See “14.1 ENGINE HOOD”).

Loosen and remove the upper cap (3) of the radiator.

Open the radiator drain cock (4) (see Fig. A), loosen the drain valve (5) positioned on the filter carrier head and let the fluid flow out, collecting it in a container with suitable capacity (re- member that the capacity of the cooling system is approxi- mately 14 liters). Use 12 mm spanners.

Close the radiator drain cock (4) (see Fig. B), tighten the valve (5) on the filter carrier head and fill the radiator with new fluid. (See “4.3 FUEL, COOLANT AND LUBRICANTS”).

Start the engine and let it idle for a few minutes; check the level again and top up before putting back the upper cap (2).

Fill the tank (6) until reaching the maximum level.

Close the engine hood.

Put back the front guard (1) with the relevant fastening screws (2). Use a 17 mm hexagon spanner.

CHANGING THE BRAKING SYSTEM OIL

Oil spilled on the floor may cause it to become slippery; immediately clean any dirty area.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

Before changing the braking system oil, it is advisable to brake a few times in order to warm up and fluidize the oil and therefore facilitate draining.

The oil change and the bleeding of the braking system must be carried out with the machine positioned on level ground and locked by means of the parking brake.

Drain the oil and wash the system, proceeding as follows:

Apply a small pipe for the collection of the oil to the drain screws (1) and loosen them. Use a 13 mm spanner.
Open the engine hood (See “3.5.1 ENGINE HOOD”) and remove the cap (2) of the tank (3).
Operate the brake pedals (connected with each other) until the oil contained in the tank (3) runs out.
Fill the tank (3) with new oil and keep pumping; fill the tank (3) more than once, until the used oil (about 0.8 l.) has been changed completely; bleed the residual air. (See “4.7.1.d BLEEDING THE BRAKING CIRCUIT”). For details on the oil to be used, see “4.3 FUEL, COOLANT AND LUBRICANTS”.

CHECKING THE ALTERNATOR AND THE STARTER

For any inspection and/or repair, contact your Komatsu Utility Dealer. If the engine is started frequently, have an inspection carried out every 1000 hours of operation.

CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, it may cause blindness or frostbite. Furthermore, to avoid any explosion, do not generate sparks and do not use naked flames near the air conditioner.

Oils, filters, coolants and batteries are considered special waste and must be recovered and disposed of according to the antipollution regulations in force.

The maintenance of the air conditioning system must be carried out exclusively by specialized person- nel.

Source: MaintainX (Community Member)

Please note that any procedure, checklist, or other document available in the MaintainX Procedure Hub is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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Carry out these operations together with those to be performed every 50, 250, 500 and 1000 HOURS.

CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER

CAUTION!

On machines containing synthetic biodegradable hydrau- lic oil type HEES, carry out the change after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.

DANGER!

After stopping the engine, with the machine positioned so that maintenance can be performed, release the residual pressures from the work equipment circuits (by operating the controls more than once) and from the tank (by slowly loosening the filling cap).

Let the oil cool down until it reaches 4045°C before carry- ing out any maintenance operation.

Immediately clean any area dirty with oil.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

The filter can be reached after removing the platform (1) with the relevant fastening screws (2). Use a 17 mm spanner.

Remove the filling cap (3). (Use a 24 mm spanner).

Remove the drain plug (4) and let the oil flow out, gathering it into a container with suitable capacity. Use a 41 mm spanner.

Remove the upper flange (5), the filter cartridge (6) and the filter casing (7). Use a 13 mm spanner.

Remove the grid filter (8), complete with gasket (9) and clean it with light solvents (petrol, kerosene, diesel oil, etc.).

Put back the filter (8) complete with the gasket (9).

Change the filter cartridge (6) and reassemble the whole unit. (See “4.7.10.c CHANGING THE HYDRAULIC SYSTEM OIL FILTER”).

Put back the drain plug (4) and fill the oil tank with the prescribed oil until reaching the level (10).

Raise the front mat and remove the cover (11). Use a 13 mm spanner.

Loosen the bleeder plug (12) positioned on the hydraulic pump, until no air bubbles can be observed in the oil that flows out (use a 3 mm setscrew spanner). Tighten the bleeder plug (12) and put back the cover (11).

Put back the upper platform (1) with the relevant fastening screws (2).

IMPORTANT

The hydraulic oil of the machines equipped with demoli- tion hammer deteriorates more rapidly than the oil of the machines used for simple digging operations. Perform the oil changes according to the indications given in the table beside.

CHANGING THE COOLANT

Soon after the machine has been stopped the coolant is very hot and under pressure and it may cause serious burns; let the engine cool down until it reaches approxi- mately 40÷45°C before changing the coolant.

Slowly loosen the radiator cap, in order to release the re- sidual pressure.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

IMPORTANT

The change of the permanent coolant does not require any washing cycle for the descaling of the circuit.

Remove the front guard (1) after removing the relevant fas- tening screws (2). Use a 17 mm hexagon spanner.

Open the engine hood (See “14.1 ENGINE HOOD”).

Loosen and remove the upper cap (3) of the radiator.

Open the radiator drain cock (4) (see Fig. A), loosen the drain valve (5) positioned on the filter carrier head and let the fluid flow out, collecting it in a container with suitable capacity (re- member that the capacity of the cooling system is approxi- mately 14 liters). Use 12 mm spanners.

Close the radiator drain cock (4) (see Fig. B), tighten the valve (5) on the filter carrier head and fill the radiator with new fluid. (See “4.3 FUEL, COOLANT AND LUBRICANTS”).

Start the engine and let it idle for a few minutes; check the level again and top up before putting back the upper cap (2).

Fill the tank (6) until reaching the maximum level.

Close the engine hood.

Put back the front guard (1) with the relevant fastening screws (2). Use a 17 mm hexagon spanner.

CHANGING THE BRAKING SYSTEM OIL

Oil spilled on the floor may cause it to become slippery; immediately clean any dirty area.

Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of ac- cording to the anti-pollution regulations in force.

Before changing the braking system oil, it is advisable to brake a few times in order to warm up and fluidize the oil and therefore facilitate draining.

The oil change and the bleeding of the braking system must be carried out with the machine positioned on level ground and locked by means of the parking brake.

Drain the oil and wash the system, proceeding as follows:

Apply a small pipe for the collection of the oil to the drain screws (1) and loosen them. Use a 13 mm spanner.

Open the engine hood (See “3.5.1 ENGINE HOOD”) and remove the cap (2) of the tank (3).

Operate the brake pedals (connected with each other) until the oil contained in the tank (3) runs out.

Fill the tank (3) with new oil and keep pumping; fill the tank (3) more than once, until the used oil (about 0.8 l.) has been changed completely; bleed the residual air. (See “4.7.1.d BLEEDING THE BRAKING CIRCUIT”). For details on the oil to be used, see “4.3 FUEL, COOLANT AND LUBRICANTS”.

CHECKING THE ALTERNATOR AND THE STARTER

For any inspection and/or repair, contact your Komatsu Utility Dealer. If the engine is started frequently, have an inspection carried out every 1000 hours of operation.

CHECKING THE QUANTITY OF COOLANT IN THE A/C SYSTEM

The coolant used in the air conditioning system is very dangerous. If it is sprayed into the eyes or in case of contact with the skin, it may cause blindness or frostbite. Furthermore, to avoid any explosion, do not generate sparks and do not use naked flames near the air conditioner.

Oils, filters, coolants and batteries are considered special waste and must be recovered and disposed of according to the antipollution regulations in force.

The maintenance of the air conditioning system must be carried out exclusively by specialized person- nel.