Komatsu Backhoe Loader WB156PS Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB156PS, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB156PS 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.
CEAM016705 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual.pdf
CEBM002201 - Backhoe Loader WB156PS-5 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 821 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM016705 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual....1
INTRODUCTION....5
FOREWORD....6
SAFETY INFORMATION....7
Safety labels....8
APPROVED AND NON-APPROVED USES....9
Approved Functions....9
Non-approved Functions....9
PRODUCT INFORMATION....10
Main Features....10
Breaking-in the New Machine....10
Synthetic Biodegradable Oil Types....10
PRODUCT IDENTIFICATION....11
Machine Serial Number....11
Machine Identification Plate....11
Engine Serial Number and Emission Label....12
Front Axle Serial Number....12
Rear Axle Serial Number....12
Transmission Serial Number....13
Cab Serial Number....13
Canopy Serial Number....13
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION....14
TABLE OF CONTENTS....15
SAFETY....25
SAFETY AND WARNING DECALS....26
Location of Safety Decals....26
Safety and Warning Decals....29
GENERAL SAFETY RULES AND PRECAUTIONS....37
General Safety Rules....37
If Abnormalities are Found....37
Safety at Job Site....38
Safety Features....38
Clothing and Personal Protective Equipment....38
Keep Machine Clean....39
Fire and Explosion Prevention....39
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid....39
Fire Caused by Accumulation of Flammable Material....40
Fire Caused by Electric Wiring....40
Fire Caused by Hydraulic Line....40
Explosion Caused by Lighting Equipment....40
Action if Fire Occurs....40
Asbestos Hazard Alert....41
Keep Operator's Cab Clean....41
Room Ventilation....41
Burn Prevention....42
Hot Coolant....42
Hot Oil....42
PRECAUTIONS FOR OPERATION....43
Seat Belt Inspection....43
Leaving the Operator’s Seat....44
Mounting and Dismounting....45
Checking the Rearview Mirrors....45
Crush or Pinch Point Dangers....45
Fire Extinguisher and First Aid Kit....46
Inside Operator’s Compartment....46
Cleaning Windows, Mirrors and Lights....46
Checking the Windshield Wiper Blades and Bulbs....46
Precautions When Using ROPS....47
Unauthorized Modifications....47
Precautions for Attachments....47
Quick Coupler Attachment....47
Large Attachments....48
PRECAUTIONS BEFORE STARTING OPERATIONS....49
Hand Signals....49
Pre-operational Checks....49
Starting Your Work Operations....49
Work Site Hazards....50
Working on Loose or Unstable Ground....50
Visibility....50
Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES)....50
Avoid Dangerous Situations....51
Working Clearances....53
High Voltage Lines....53
RULES FOR ROAD TRAVEL....54
Travel Precautions....54
Rules for Traveling in Reverse....55
Traveling on Snow or Frozen Surfaces....56
Traveling on Slopes....56
Traveling on Loose or Unstable Ground....57
Parking the Machine....58
PRECAUTIONS DURING MAINTENANCE OPERATIONS....59
Warning Tags....59
Equipment Storage....59
Working Under the Machine....60
Using Drop Lamps....60
Keeping the Machine Clean....60
Running the Machine During Maintenance....61
Rules for Refueling the Machine....61
Cooling System Precautions....61
Battery Precautions....62
Hazards....63
Using Booster Cables....64
Starting the Machine with Booster Cables....64
High-Pressure Hoses....65
Safety Handling of High-pressure Hoses....65
Precaution for High Fuel Pressure....65
High-Temperature Areas....65
Rotating Parts....66
Disposal of Waste Materials....66
Inflating Tires....66
Accumulator....67
Critical Parts....67
OPERATION....69
GENERAL VIEW OF MACHINE....70
Front View of Machine....70
Rear View of Machine....71
OPERATION CONTROLS....72
In the Cab (Joystick Controls)....72
Steering Column Switches....73
Directional Control Switch (Standard)....73
Speed Selector Switch (PS Model Only)....73
Multifunctional Switch....73
Front Instrument Panel and Controls....74
Side Instrument and Controls....78
Cab Switches and Electric Accessories....86
Front Work Light Switch....86
Rear Work Light Switch....86
Rear Windshield Wiper Switch....86
Rear Windshield Washer Switch....86
Overhead Lamp (Dome)....87
Power Outlet....87
Power Outlet Socket....87
Front End Loader Controls....88
Loader Declutch Control Button....88
Multipurpose Bucket Open Button....88
Differential Lock Button....89
Multipurpose Bucket Close Button....89
Front Loader Speed Control Button....89
Kick Down Button (Power Shift Only)....90
Gear Shift Lever Controls (Power Shuttle Only)....90
Declutch Button....90
Changing Speed Ranges....90
PS Model Control Lever....91
Directional Control Lever....91
Brakes, Parking Brake, Accelerator, and Throttle Control....92
Brake Pedals....92
Parking Brake....93
Accelerator Pedal....93
Hand Throttle....94
CAB ENVIRONMENT AND SAFETY EQUIPMENT....95
Heating and Ventilation System....95
Air Conditioning (if equipped)....95
Heating System....95
Seat and Seat Belt....97
Seat....97
Seat Belt....97
Safety Equipment and Storage Areas....98
Fire Extinguisher....98
First Aid Kit....98
Document Storage....98
Storage Compartment....98
CAB AND GUARDS....100
Cab....100
Doors and Windows....100
Guards....102
Driver’s Overhead Guard....102
Engine Hood....103
ELECTRICAL....103
Switches and Extra Accessories....103
Battery Disconnect Switch....103
Adapter for Radio (if provided)....104
Fuses and Relays....104
Fuse and Relay Panel Location....104
Fuse and Relay Panel Layout....105
Fuses....105
Relays....107
Heating and Air Conditioning Fuses and Relays....108
Fuses....108
Relays....108
OPERATING THE MACHINE....109
Checking the Fuel Supply....109
Starting the Engine....109
Starting the Engine in Cold Weather....110
Warming Up the Machine....112
Shutting Down the Engine....112
OPERATING THE FRONT END LOADER AND BACKHOE....113
Pre-operational Checks....113
Perform a Walk Around Check of Your Machine....113
Under the Hood....114
In the Operator’s Cab....114
Start-up Checks....114
STARTING YOUR WORK....115
Avoid Dangerous Situations....115
Working Clearances....118
High Voltage Lines....118
Operating the Front End Loader....119
Control Lever Positions....120
Multipurpose Bucket Opening Push Button....120
Multipurpose Bucket Close Push Button....120
Performing Loading Operations....121
Bucket Position Indicator....121
Organizing Your Work Area....121
Loading Heaped Material....121
Loading a Truck Bed or Trailer....123
Working on Slopes with a Loaded Bucket....123
Changing the Front Bucket....124
Operating the Backhoe....125
PPC Controls....125
Adjusting the Backhoe Controls....125
Adjusting Joystick Positions....126
Adjusting Wrist Supports....127
Adjusting Stow Position (Cab Only)....127
Unlocking the Backhoe....128
Pattern Change Control Lever....129
ISO Backhoe Controls....130
Komatsu Backhoe Controls....131
Positioning the Machine....132
Digging Methods....133
Changing the Backhoe Bucket....134
Adjusting the Bucket....134
SAFETY LOCK USAGE....135
Front End Loader Cylinder Lock....135
Backhoe Locks....137
TRAVELING WITH THE MACHINE....138
Traveling....138
Traveling on Slopes....139
Traveling or Working in Swampy or Wet Areas....140
PARKING THE MACHINE....141
Parking for Short Periods of Time....141
Parking for Long Periods of Time....141
Parking on an Incline....142
TRANSPORTING THE MACHINE....143
Loading and Securing the Machine....143
LIFTING THE MACHINE....144
LIFTING POSITION MARKS....144
LIFTING PROCEDURE....145
EMERGENCY RECOVERY....147
How to Move the Machine....147
PRECAUTIONS DURING SEASONAL CHANGES....148
Cold Seasons....148
Fuel and Lubricants....148
Coolant....148
Battery....149
Warm Seasons....149
TROUBLESHOOTING....150
Battery....150
Servicing....150
Removal and Installation....151
Starting the Engine with Booster Cables....152
Accessing the Battery....152
Connecting the Booster Cables....152
Starting the Engine....153
Disconnecting the Booster Cables....153
Electrical Circuits....154
Hydraulic System....154
Braking System....155
Transmission....155
Engine....156
MAINTENANCE....157
MAINTENANCE INFORMATION....158
Maintenance Notes....159
Engine Maintenance....160
Engine Oil....160
Coolant....160
Fuel....160
Hydraulic System Maintenance....160
Carrying Out KOWA (Komatsu Oil Wear Analysis)....161
KOWA Analysis Items....161
Electrical System Maintenance....162
Lubrication....162
WEAR PARTS LIST....163
FUEL, COOLANT, AND LUBRICANTS....164
Proper Selection According to the Ambient Temperature....164
Grease....165
Fuel....165
APPROVED SYNTHETIC LUBRICANTS (HEES)....166
LUBRICATION DIAGRAMS....167
General View....167
Multipurpose Bucket and Pallet Forks....168
Telescopic Arm....169
TORQUE SPECIFICATIONS....170
Torque List....170
Torque of Bolts....170
Torque of Hose Nuts....171
Torque of Split Flange Bolts....171
Torque for Flared Nuts....172
Torque for O-Ring Boss Piping Joints....172
Torque for O-Ring Boss Plugs....173
Torque for Hoses (Taper Seal Type and Face Seal Type)....173
PERIODIC REPLACEMENT OF COMPONENTS....175
SAFETY CRITICAL PARTS....176
Fuel Supply System....176
Delivery / Return Hydraulic System....176
Delivery / Return Hydraulic System....177
Seat Belt System....177
MAINTENANCE SCHEDULE....178
Maintenance Schedule Chart....178
Initial 50 Hours Maintenance....181
Initial 250 Hours Maintenance....181
Initial 500 Hours Maintenance....181
When Required....182
Cleaning or Changing Engine Air Filters....182
Checking and Cleaning Cab Air Filter....184
Cleaning Air Recirculation Filter....185
Checking the Level in Windshield Washer Reservoir....185
Checking Windshield Wiper Blades....185
Lubricating Cab Door Hinges....186
Bleeding Brake System....186
Checking and Adjusting Front Wheel Toe-in....187
Checking and Adjusting Parking Brake....188
Checking and Adjusting Brake Pedal Stroke....190
Adjusting Automatic Return of Front Bucket to the Digging Position....190
Checks Before Starting....191
Various Checks....191
Checking Fuel Level....191
Checking Coolant Level....192
Checking Engine Oil Level....192
Checking Hydraulic Oil Level....193
Draining Water Separator....194
Every 10 Hours Maintenance....195
Lubricating Joints (Grease Fittings)....195
Joint Lubrication Points....196
Every 50 Hours Maintenance....198
Checking Radiator Fluid Level....198
Checking Brake System Oil Level....199
Lubricating Drive Shafts....200
Lubricating Front Axle Joints....201
Checking Tire Pressure....201
Checking Electrical System....201
Every 250 Hours Maintenance....202
Checking Serpentine Belt....202
Checking A/C Compressor Belt Tension....202
Cleaning Outside of Radiator....203
Checking Battery Electrolyte....204
Checking Front Axle Oil Levels....205
Checking Rear Axle Oil Levels....205
Transmission Oil Level....206
Checking Wheel Lug Nut Torque....206
Every 500 Hours Maintenance....207
Changing Engine Oil....207
Changing Engine Oil Filter....208
Changing Hydraulic Tank Oil Filter....209
Changing Fuel Filter....212
Draining Fuel Tank....213
Draining Hydraulic Oil Tank....213
Every 1000 Hours Maintenance....214
Changing Front Axle Oil....214
Changing the Rear Axle Oil....215
Changing Transmission Oil....216
Changing Transmission Filter....217
Checking and Adjusting Engine Valve Clearance....217
Every 2000 Hours Maintenance....218
Changing Hydraulic System Oil and Cleaning Suction Filter....218
Changing Coolant....221
Changing Brake System Oil....223
Checking the Alternator and the Starter....223
Changing the Alternator Belt....223
Checking the A/C Cooling Gas Quantity....223
MAINTENANCE WHEN USING DEMOLITION HAMMER....224
Changing Hydraulic Oil Filter....224
Changing Hydraulic Oil....224
LONG TERM STORAGE....225
Before Storage....225
During Storage....226
After Storage....226
SPECIFICATIONS....229
SPECIFICATIONS....230
Machine Dimensions and Weights....230
Standard Arm....232
Retracted Telescopic Arm....233
Extended Telescopic Arm....234
MACHINE SYSTEMS SPECIFICATIONS....235
Engine....235
Electrical System....235
Service Refill Capacities....235
Standard Tires....235
Transmission....236
Total Mass....236
Standard Bucket Capacity....236
Loader....236
OPTIONS, ATTACHMENTS....237
AUTHORIZED OPTIONAL EQUIPMENT....238
Precautions Regarding Safety....238
Precautions Regarding the Installation of Equipment....239
Optional Equipment Measurements....239
Front End Loader....239
Backhoe Unit....240
FRONT EQUIPMENT QUICK COUPLING DEVICES....241
Manual Control Quick Coupling....241
MULTIPURPOSE BUCKET (4-IN-1)....242
Bucket Operation....243
Description....243
Bucket Uses....243
Pallet Forks....244
Description....244
Safety Devices....245
Using the Forks....245
Preparing the Pallet Forks for Use....246
Overturning the Forks....246
Removing the Forks....247
Installing the Forks....247
Maintenance....247
BACKHOE TELESCOPIC ARM....248
Description....248
Control....248
Safety Devices....249
Using the Telescopic Arm....249
Maintenance....250
Adjusting the Guide Slack....250
DEMOLITION HAMMER PIPING....252
Description....252
Control....252
Rules for Hammer Usage....253
Avoid the Following Uses....254
Installing the Hammer....256
Removing the Hammer....258
Using the Hammer....258
Maintenance....258
HYDRAULIC JACK HAMMER PIPING....259
Description....259
Control....259
Connecting and Removing the Jack Hammer....260
Connecting the Jack Hammer....260
Disconnecting the Jack Hammer....260
Using the Jack Hammer....260
LOAD STABILIZER SYSTEM (LSS) (Ride Control Optional)....261
Load Stabilizer System (LSS) Accumulator....261
Pressurizing the Load Stabilizer System (LSS)....261
CEBM002201 - Backhoe Loader WB156PS-5 Shop Manual....263
CONTENTS....264
SAFETY....271
SAFETY NOTICE....271
IMPORTANT SAFETY NOTICE....271
GENERAL PRECAUTIONS....271
PREPARATIONS FOR WORK....271
PRECAUTIONS DURING WORK....271
GENERAL....273
HOW TO READ THE SHOP MANUAL....274
VOLUMES....274
DISTRIBUTION AND UPDATING....274
FILING METHOD....274
REVISED EDITION MARK....274
REVISIONS....274
SYMBOLS....274
HOISTING INSTRUCTIONS....275
HOISTING....275
WIRE ROPES....275
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD....276
COATING MATERIALS....278
STANDARD TIGHTENING TORQUE....280
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....280
TIGHTENING TORQUE OF HOSE NUTS....281
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....281
TIGHTENING TORQUE FOR FLARED NUTS....281
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS....282
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS....282
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)....282
ELECTRIC WIRE CODE....283
CLASSIFICATION BY THICKNESS....283
CLASSIFICATION BY COLOR AND CODE....283
CONNECTING PUSH-PULL TYPE COUPLER....284
CONVERSION TABLES....287
METHOD OF USING THE CONVERSION TABLE....287
SPECIFICATION DRAWING....294
SPECIFICATIONS....294
MACHINE DIMENSIONS AND WEIGHTS....294
BACKHOE ARM....295
STANDARD ARM....295
TELESCOPIC ARM (RETRACTED)....296
TELESCOPIC ARM (EXTENDED)....297
MACHINE SYSTEMS SPECIFICATIONS....298
ENGINE....298
ELECTRICAL SYSTEM....298
SERVICE REFILL CAPACITIES....298
TRANSMISSION....299
TOTAL MASS....299
LOADER....299
BACKHOE....299
TIRE PRESSURE....299
WEIGHT TABLE....300
LIFTING THE MACHINE....301
LIFTING POSITION MARKS....301
LIFTING PROCEDURE....302
FUEL, COOLANT, AND LUBRICANTS....304
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE....304
GREASE....305
FUEL AND ENGINE OIL REMARKS....305
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS....306
LUBRICATION DIAGRAMS....307
GENERAL VIEW....307
POWER TRAIN....312
DESCRIPTION....312
POWER FLOW....312
TRANSMISSION DIAGRAM....314
TRANSMISSION....315
COMPLETE ASSEMBLY....315
VALVE BODY....317
CLUTCH PACKS....318
FORWARD AND REVERSE PACK....318
DRIVE SHAFT PACK....318
DRIVEN GEAR SHAFT PACK....319
4WD DRIVEN SHAFT PACK....319
FRONT AXLE....320
COMPLETE ASSEMBLY....320
DIFFERENTIAL....321
PLANETARY....322
REAR AXLE....323
COMPLETE ASSEMBLY....323
DIFFERENTIAL....324
FINAL REDUCTION GEARS....325
WHEEL BRAKES....326
DIFFERENTIAL LOCK....327
HYDRAULIC PUMP....328
MAIN PUMP....329
FUNCTION....331
STRUCTURE....331
OPERATION....331
DELIVERY CONTROL VALVE....333
LS VALVE FUNCTION....335
PC VALVE FUNCTION....335
PC VALVE OPERATION....336
MAIN CONTROL VALVE....339
10-SPOOL CONTROL VALVE....339
CLSS....345
DESCRIPTION....345
CHARACTERISTICS....345
STRUCTURE....345
OPERATING PRINCIPLES....346
PUMPING PLATE CONTROL ANGLE....346
PRESSURE COMPENSATION CONTROL....347
MAIN CONTROL VALVE....348
UNLOADING VALVE....349
LS PRESSURE....352
LS BYPASS PLUG....354
PRESSURE COMPENSATION....355
PRESSURE COMPENSATION VALVE....356
PRIORITY VALVE....357
PPC REDUCING VALVE....358
STEERING UNIT....361
TECHNICAL DATA....361
OPERATION....361
PPC VALVES....362
STANDARD VALVE....362
OPERATION....364
PPC VALVE (FLOAT + RETURN TO DIG)....368
OPERATION....370
OUTRIGGER....374
OPERATION....375
BACKHOE....378
LEFT VALVE....378
RIGHT VALVE....379
SOLENOID VALVE....380
HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE BUCKET....380
HYDRAULIC CONTROLS WITH MULTI-PURPOSE BUCKET....381
SAFETY VALVES....382
BUCKET RAISE....382
BUCKET DUMP....383
BOOM....384
ARM....385
LOADER CYLINDERS....386
BOOM....386
CHARACTERISTICS....386
BUCKET....387
CHARACTERISTICS....387
MULTI-PURPOSE (MP) BUCKET....388
CHARACTERISTICS....388
BACKHOE CYLINDERS....389
BOOM....389
CHARACTERISTICS....389
ARM....390
CHARACTERISTICS....390
BUCKET....391
CHARACTERISTICS....391
TELESCOPIC ARM CYLINDER....392
CHARACTERISTICS....392
SWING....393
CHARACTERISTICS....393
OUTRIGGER....394
CHARACTERISTICS....394
WORK EQUIPMENT....396
LOADER....396
BACKHOE....398
AIR CONDITIONING....401
STANDARD VALUE TABLE....405
ENGINE....405
CHASSIS....406
SPECIAL TOOLS....413
ENGINE SPEED....414
ENGINE WITH LOAD....414
MACHINE IN POWER MODE AT MIN....414
WITH CONVERTER STALLED....414
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD....414
ANALYSIS....415
VALVE CLEARANCE....415
AIR CONDITIONER COMPRESSOR BELT TENSION....416
BLEED AIR FROM CIRCUITS....417
BLEED AIR FROM CYLINDERS....417
BLEED AIR FROM BRAKING CIRCUIT....417
RELEASING RESIDUAL PRESSURE....417
ACCELERATOR PEDAL AND LEVER....418
ACCELERATOR PEDAL TRAVEL....418
ACCELERATOR LEVER TRAVEL....419
BRAKE SYSTEM....420
CONTROL....420
ADJUSTMENT....420
CHECKS....421
LEAKAGE CHECKS....421
INDIVIDUAL PUMP CHECK....422
BRAKE GROUP LEAKAGE....423
PARKING BRAKE ADJUSTMENT....424
HYDRAULIC CIRCUIT....425
INTRODUCTION....425
MAIN CONTROL VALVE....426
RELIEF VALVES....427
TESTING....427
UNLOADING VALVE....427
MAIN RELIEF VALVE....427
SECONDARY VALVES....427
SETTING RELIEF VALVES....430
MAIN RELIEF VALVE....430
CIRCUIT RELIEF VALVES....430
ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET....430
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE....431
LS DIFFERENTIAL PRESSURE....432
CONTROL....432
ADJUSTMENT....432
PPC SUPPLY PRESSURE....433
CHECK....433
ADJUSTMENT....433
PC VALVE....434
ADJUSTMENT....434
STEERING CONTROL SYSTEM....435
CONTROL....435
SETTING....435
STEERING CYLINDER....436
POWER TRAIN GROUP....437
CONVERTER OIL PRESSURE....437
CLUTCH ENGAGEMENT PRESSURE....437
SUPPLY PRESSURE....438
TRANSMISSION CLUTCH FUNCTION....439
MACHINE PREPARATION....439
CONTROL....439
HYDRAULIC DRIFT....440
LOADER....440
BOOM CIRCUIT....440
BUCKET CIRCUIT....441
BACKHOE....441
BOOM CIRCUIT....442
ARM CIRCUIT....442
BUCKET CIRCUIT....443
OUTRIGGERS CIRCUIT - WITHOUT LOCK VALVES....444
AIR CONDITIONING....445
WORK TEMPERATURE....445
UNIT CHECK....445
EMPTYING THE AIR CONDITIONING UNIT....446
TROUBLESHOOTING GUIDE....447
FRONT AXLE....447
REAR AXLE....452
TRANSMISSION....457
FUSES AND RELAYS....460
FUSE AND RELAY PANEL LOCATION....460
FUSE AND RELAY PANEL LAYOUT....461
FUSES....461
RELAYS....463
HEATING AND AIR CONDITIONING FUSES AND RELAYS....464
FUSES....464
RELAYS....464
HOW TO USE THIS MANUAL....471
REMOVAL AND INSTALLATION OF COMPONENTS....471
REMOVAL....471
INSTALLATION....471
OVERHAUL OF COMPONENTS....472
DISASSEMBLY PROCEDURES....472
ASSEMBLY PROCEDURES....472
PRECAUTIONS FOR WORK....473
SPECIAL TOOL LIST....475
CONNECTOR REPAIR PROCEDURES....478
CONTACT TERMINAL REMOVAL (HD30 TYPE)....478
CRIMPING CONTACT TERMINAL (HD30 TYPE)....479
INSERTION OF CONTACT TERMINAL (HD30 TYPE)....480
CONTACT TERMINAL REMOVAL (DT TYPE)....481
CRIMPING CONTACT TERMINAL (DT TYPE)....482
INSERTION OF CONTACT TERMINAL (DT TYPE)....483
STRIPPING INSULATION....484
ENGINE HOOD....485
REMOVAL....485
INSTALLATION....486
FRONT GUARD....487
REMOVAL....487
INSTALLATION....487
RADIATOR....488
REMOVAL....488
INSTALLATION....491
AIR CONDITIONER CONDENSER....492
REMOVAL....492
INSTALLATION....492
MUFFLER....493
REMOVAL....493
INSTALLATION....494
AIR FILTER....495
REMOVAL....495
INSTALLATION....495
TURBOCHARGER....496
REMOVAL....496
INSTALLATION....498
AIR CONDITIONER COMPRESSOR....499
REMOVAL....499
INSTALLATION....501
AIR CONDITIONER COMPRESSOR BELT....502
REMOVAL....502
INSTALLATION....502
EXHAUST STACK....503
REMOVAL....503
INSTALLATION....504
OPERATOR’S SEAT....504
REMOVAL....504
INSTALLATION....504
CAB HEATING AND COOLING SYSTEM....505
REMOVAL....505
FAN....509
HEATER CORE....510
INSTALLATION....511
BATTERY....512
REMOVAL....512
INSTALLATION....513
FUEL TANK....514
REMOVAL....514
INSTALLATION....515
STEERING AND FRONT DASH ASSEMBLY....516
STEERING WHEEL....516
REMOVAL....516
INSTALLATION....517
FRONT DASH ASSEMBLY....518
REMOVAL....518
INSTALLATION....519
STEERING UNIT....520
REMOVAL....520
INSTALLATION....521
BRAKE SYSTEM....522
REMOVAL....522
INSTALLATION....524
BLEED AIR FROM BRAKING CIRCUIT....525
CAB....526
REMOVAL....526
INSTALLATION....532
HYDRAULIC OIL TANK....533
REMOVAL....533
INSTALLATION....539
HYDRAULIC PUMP....540
REMOVAL....540
INSTALLATION....542
TRANSMISSION....543
REMOVAL....543
INSTALLATION....546
BLEED AIR FROM CYLINDERS....547
TRANSMISSION OVERHAUL PROCEDURES....548
TORQUE CONVERTER....548
REMOVAL....548
INSTALLATION....548
PLUGS AND FILTERS....549
DISASSEMBLY....549
ASSEMBLY....553
PUMP....556
DISASSEMBLY....556
ASSEMBLY....558
VALVE BODY....560
DISASSEMBLY....560
ASSEMBLY....563
HYDRAULIC SUPPLY LINES....566
DISASSEMBLY....566
ASSEMBLY....567
TRANSMISSION HOUSING....569
DISASSEMBLY....569
ASSEMBLY....575
CLUTCH PACK (A) AND GEAR SHAFT (D)....580
DISASSEMBLY....580
CLUTCHES AND DISC INSPECTIONS....589
ASSEMBLY....590
CHECKING CLUTCH FUNCTION....599
SHAFT (B)....600
DISASSEMBLY....600
CLUTCHES AND DISC INSPECTIONS....607
ASSEMBLY....608
SHAFT (C)....615
DISASSEMBLY....615
CLUTCHES AND DISC INSPECTIONS....629
1st GEAR CLUTCHES....630
3rd GEAR CLUTCHES....630
4th GEAR CLUTCHES....630
ASSEMBLY....631
SHAFT (E)....647
DISASSEMBLY....647
CLUTCHES AND DISC INSPECTIONS....652
ASSEMBLY....653
ENGINE....660
REMOVAL....660
INSTALLATION....666
CONTROL VALVE....667
REMOVAL....667
INSTALLATION....669
STEERING SOLENOID VALVE....670
REMOVAL....670
INSTALLATION....670
FRONT AXLE ASSEMBLY....671
REMOVAL....671
INSTALLATION....672
FRONT AXLE OVERHAUL PROCEDURES....673
STEERING CYLINDER ASSEMBLY....673
DISASSEMBLY....673
ASSEMBLY....674
FRONT AXLE END PLANETARY ASSEMBLY....679
DISASSEMBLY....679
ASSEMBLY....681
AXLE END HUB ASSEMBLY....682
DISASSEMBLY....682
ASSEMBLY....686
AXLE HOUSING....689
DISASSEMBLY....689
ASSEMBLY....691
DIFFERENTIAL....692
DISASSEMBLY....692
ASSEMBLY....694
PINION....698
DISASSEMBLY....698
ASSEMBLY....701
CARRIER....705
DISASSEMBLY....705
ASSEMBLY....706
REAR AXLE ASSEMBLY....708
REMOVAL....708
INSTALLATION....710
REAR AXLE OVERHAUL PROCEDURES....711
PARKING BRAKE ASSEMBLY....711
DISASSEMBLY....711
ASSEMBLY....713
MAINTENANCE....715
SERVICE BRAKE ASSEMBLY....718
DISASSEMBLY....718
ASSEMBLY....723
REAR AXLE END PLANETARY ASSEMBLY....729
DISASSEMBLY....729
ASSEMBLY....734
DIFFERENTIAL....738
DISASSEMBLY....738
ASSEMBLY....740
DIFFERENTIAL LOCK....745
DISASSEMBLY....745
ASSEMBLY....748
CARRIER....751
DISASSEMBLY....751
ASSEMBLY....755
PINION....759
DISASSEMBLY....759
ASSEMBLY....761
FRONT LOADER PPC VALVE....765
REMOVAL....765
INSTALLATION....766
FRONT-END LOADER ASSEMBLY....767
LOADER BOOM CYLINDERS....767
INSTALLATION....768
BUCKET CYLINDERS....769
REMOVAL....769
INSTALLATION....770
FRONT LOADER BUCKET....771
REMOVAL....771
INSTALLATION....771
LOADER BOOM ASSEMBLY....772
REMOVAL....772
INSTALLATION....773
BACKHOE PPC VALVE....774
REMOVAL....774
INSTALLATION....775
PPC VALVE SUPPORT RELEASE CABLES....776
REMOVAL....776
INSTALLATION AND ADJUSTING....778
PPC VALVE GAS STRUT....779
REMOVAL....779
INSTALLATION....781
SOLENOID VALVE....782
REMOVAL....782
INSTALLATION....782
BACKHOE ASSEMBLY....783
BUCKET CYLINDER....783
REMOVAL....783
INSTALLATION....784
TELESCOPIC ARM CYLINDER....785
REMOVAL....785
INSTALLATION....785
ARM CYLINDER....786
REMOVAL....786
INSTALLATION....787
BOOM CYLINDER....788
REMOVAL....788
INSTALLATION....789
SWING CYLINDERS....790
REMOVAL....790
INSTALLATION....792
BOOM LOCK CYLINDER....793
REMOVAL....793
INSTALLATION....794
BACKHOE BUCKET....794
REMOVAL....794
INSTALLATION....794
BACKHOE ARM....795
REMOVAL....795
INSTALLATION....797
TELESCOPIC ARM....798
REMOVAL....798
INSTALLATION....798
TELESCOPIC ARM GIBS....799
REMOVAL....799
INSTALLATION....799
BACKHOE BOOM....800
REMOVAL....800
INSTALLATION....801
BACKHOE SWING FRAME....802
REMOVAL....802
INSTALLATION....802
OUTRIGGER CYLINDERS....803
REMOVAL....803
INSTALLATION....804
OUTRIGGER ARMS....805
REMOVAL....805
INSTALLATION....805
WORK EQUIPMENT CYLINDER OVERHAUL....806
LOADER AND BACKHOE CYLINDERS....806
DISASSEMBLY....806
ASSEMBLY....808
SWING CYLINDERS....811
DISASSEMBLY....811
ASSEMBLY....813
Section 90.pdf....0
90 DIAGRAMS AND SCHEMATICS....817
HYDRAULIC CIRCUIT....819
1 OF 4....819
2 OF 4....820
3 OF 4....821
4 OF 4....822
ELECTRICAL SCHEMATICS....823
RIGHT SIDE DASH (WIRING - 1 OF 8)....823
HARNESS AND SWITCHES (WIRING - 2 OF 8)....824
RELAYS AND SWITCHES (WIRING - 3 OF 8)....825
HARNESS (WIRING - 4 OF 8)....826
MOTORS AND CONTROLS (WIRING - 5 OF 8)....827
SOLENOIDS (WIRING - 6 OF 8)....828
OPTIONAL 4WS (WIRING - 7 OF 8)....829
LIST OF CONNECTORS (WIRING - 8 OF 8)....830
Komatsu Backhoe Loader WB156PS Repair Service Manual
