Komatsu Backhoe Loader WB156 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Backhoe Loader WB156, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Backhoe Loader WB156-5 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.
CEAM016704 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual.pdf
CEBM016602 - Backhoe Loader WB156-5 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 812 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM016704 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual.......1
COVER.......1
INTRODUCTION.......3
FOREWORD.......4
SAFETY INFORMATION.......5
Safety labels.......6
APPROVED AND NON-APPROVED USES.......7
Approved Functions.......7
Non-approved Functions.......7
PRODUCT INFORMATION.......8
Main Features.......8
Breaking-in the New Machine.......8
Synthetic Biodegradable Oil Types.......8
PRODUCT IDENTIFICATION.......9
Machine Serial Number.......9
Machine Identification Plate.......9
Engine Serial Number and Emission Label.......10
Front Axle Serial Number.......10
Rear Axle Serial Number.......10
Transmission Serial Number.......11
Cab Serial Number.......11
Canopy Serial Number.......11
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION.......12
TABLE OF CONTENTS.......13
SAFETY.......23
SAFETY AND WARNING DECALS.......24
Location of Safety Decals.......24
Safety and Warning Decals.......27
GENERAL SAFETY RULES AND PRECAUTIONS.......35
General Safety Rules.......35
If Abnormalities are Found.......35
Safety at Job Site.......36
Safety Features.......36
Clothing and Personal Protective Equipment.......36
Keep Machine Clean.......37
Fire and Explosion Prevention.......37
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid.......37
Fire Caused by Accumulation of Flammable Material.......38
Fire Caused by Electric Wiring.......38
Fire Caused by Hydraulic Line.......38
Explosion Caused by Lighting Equipment.......38
Action if Fire Occurs.......38
Asbestos Hazard Alert.......39
Keep Operator's Cab Clean.......39
Room Ventilation.......39
Burn Prevention.......40
Hot Coolant.......40
Hot Oil.......40
PRECAUTIONS FOR OPERATION.......41
Seat Belt Inspection.......41
Leaving the Operator’s Seat.......42
Mounting and Dismounting.......43
Checking the Rearview Mirrors.......43
Crush or Pinch Point Dangers.......43
Fire Extinguisher and First Aid Kit.......44
Inside Operator’s Compartment.......44
Cleaning Windows, Mirrors and Lights.......44
Checking the Windshield Wiper Blades and Bulbs.......44
Precautions When Using ROPS.......45
Unauthorized Modifications.......45
Precautions for Attachments.......45
Quick Coupler Attachment.......45
Large Attachments.......46
PRECAUTIONS BEFORE STARTING OPERATIONS.......47
Hand Signals.......47
Pre-operational Checks.......47
Starting Your Work Operations.......47
Work Site Hazards.......48
Working on Loose or Unstable Ground.......48
Visibility.......48
Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES).......48
Avoid Dangerous Situations.......49
Working Clearances.......51
High Voltage Lines.......51
RULES FOR ROAD TRAVEL.......52
Travel Precautions.......52
Rules for Traveling in Reverse.......53
Traveling on Snow or Frozen Surfaces.......54
Traveling on Slopes.......54
Traveling on Loose or Unstable Ground.......55
Parking the Machine.......56
PRECAUTIONS DURING MAINTENANCE OPERATIONS.......57
Warning Tags.......57
Equipment Storage.......57
Working Under the Machine.......58
Using Drop Lamps.......58
Keeping the Machine Clean.......58
Running the Machine During Maintenance.......59
Rules for Refueling the Machine.......59
Cooling System Precautions.......59
Battery Precautions.......60
Hazards.......61
Using Booster Cables.......62
Starting the Machine with Booster Cables.......62
High-Pressure Hoses.......63
Safety Handling of High-pressure Hoses.......63
Precaution for High Fuel Pressure.......63
High-Temperature Areas.......63
Rotating Parts.......64
Disposal of Waste Materials.......64
Inflating Tires.......64
Accumulator.......65
Critical Parts.......65
OPERATION.......67
GENERAL VIEW OF MACHINE.......68
Front View of Machine.......68
Rear View of Machine.......69
OPERATION CONTROLS.......70
In the Cab (Joystick Controls).......70
Steering Column Switches.......71
Directional Control Switch (Standard).......71
Speed Selector Switch (PS Model Only).......71
Multifunctional Switch.......71
Front Instrument Panel and Controls.......72
Side Instrument and Controls.......76
Cab Switches and Electric Accessories.......84
Front Work Light Switch.......84
Rear Work Light Switch.......84
Rear Windshield Wiper Switch.......84
Rear Windshield Washer Switch.......84
Overhead Lamp (Dome).......85
Power Outlet.......85
Power Outlet Socket.......85
Front End Loader Controls.......86
Loader Declutch Control Button.......86
Multipurpose Bucket Open Button.......86
Differential Lock Button.......87
Multipurpose Bucket Close Button.......87
Front Loader Speed Control Button.......87
Kick Down Button (Power Shift Only).......88
Gear Shift Lever Controls (Power Shuttle Only).......88
Declutch Button.......88
Changing Speed Ranges.......88
PS Model Control Lever.......89
Directional Control Lever.......89
Brakes, Parking Brake, Accelerator, and Throttle Control.......90
Brake Pedals.......90
Parking Brake.......91
Accelerator Pedal.......91
Hand Throttle.......92
CAB ENVIRONMENT AND SAFETY EQUIPMENT.......93
Heating and Ventilation System.......93
Air Conditioning (if equipped).......93
Heating System.......93
Seat and Seat Belt.......95
Seat.......95
Seat Belt.......95
Safety Equipment and Storage Areas.......96
Fire Extinguisher.......96
First Aid Kit.......96
Document Storage.......96
Storage Compartment.......96
CAB AND GUARDS.......98
Cab.......98
Doors and Windows.......98
Guards.......100
Driver’s Overhead Guard.......100
Engine Hood.......101
ELECTRICAL.......101
Switches and Extra Accessories.......101
Battery Disconnect Switch.......101
Adapter for Radio (if provided).......102
Fuses and Relays.......102
Fuse and Relay Panel Location.......102
Fuse and Relay Panel Layout.......103
Fuses.......103
Relays.......105
Heating and Air Conditioning Fuses and Relays.......106
Fuses.......106
Relays.......106
OPERATING THE MACHINE.......107
Checking the Fuel Supply.......107
Starting the Engine.......107
Starting the Engine in Cold Weather.......108
Warming Up the Machine.......110
Shutting Down the Engine.......110
OPERATING THE FRONT END LOADER AND BACKHOE.......111
Pre-operational Checks.......111
Perform a Walk Around Check of Your Machine.......111
Under the Hood.......112
In the Operator’s Cab.......112
Start-up Checks.......112
STARTING YOUR WORK.......113
Avoid Dangerous Situations.......113
Working Clearances.......116
High Voltage Lines.......116
Operating the Front End Loader.......117
Control Lever Positions.......118
Multipurpose Bucket Opening Push Button.......118
Multipurpose Bucket Close Push Button.......118
Performing Loading Operations.......119
Bucket Position Indicator.......119
Organizing Your Work Area.......119
Loading Heaped Material.......119
Loading a Truck Bed or Trailer.......121
Working on Slopes with a Loaded Bucket.......121
Changing the Front Bucket.......122
Operating the Backhoe.......123
PPC Controls.......123
Adjusting the Backhoe Controls.......123
Adjusting Joystick Positions.......124
Adjusting Wrist Supports.......125
Adjusting Stow Position (Cab Only).......125
Unlocking the Backhoe.......126
Pattern Change Control Lever.......127
ISO Backhoe Controls.......128
Komatsu Backhoe Controls.......129
Positioning the Machine.......130
Digging Methods.......131
Changing the Backhoe Bucket.......132
Adjusting the Bucket.......132
SAFETY LOCK USAGE.......133
Front End Loader Cylinder Lock.......133
Backhoe Locks.......135
TRAVELING WITH THE MACHINE.......136
Traveling.......136
Traveling on Slopes.......137
Traveling or Working in Swampy or Wet Areas.......138
PARKING THE MACHINE.......139
Parking for Short Periods of Time.......139
Parking for Long Periods of Time.......139
Parking on an Incline.......140
TRANSPORTING THE MACHINE.......141
Loading and Securing the Machine.......141
LIFTING THE MACHINE.......142
LIFTING POSITION MARKS.......142
LIFTING PROCEDURE.......143
EMERGENCY RECOVERY.......145
How to Move the Machine.......145
PRECAUTIONS DURING SEASONAL CHANGES.......146
Cold Seasons.......146
Fuel and Lubricants.......146
Coolant.......146
Battery.......147
Warm Seasons.......147
TROUBLESHOOTING.......148
Battery.......148
Servicing.......148
Removal and Installation.......149
Starting the Engine with Booster Cables.......150
Accessing the Battery.......150
Connecting the Booster Cables.......150
Starting the Engine.......151
Disconnecting the Booster Cables.......151
Electrical Circuits.......152
Hydraulic System.......152
Braking System.......153
Transmission.......153
Engine.......154
MAINTENANCE.......155
MAINTENANCE INFORMATION.......156
Maintenance Notes.......157
Engine Maintenance.......158
Engine Oil.......158
Coolant.......158
Fuel.......158
Hydraulic System Maintenance.......158
Carrying Out KOWA (Komatsu Oil Wear Analysis).......159
KOWA Analysis Items.......159
Electrical System Maintenance.......160
Lubrication.......160
WEAR PARTS LIST.......161
FUEL, COOLANT, AND LUBRICANTS.......162
Proper Selection According to the Ambient Temperature.......162
Grease.......163
Fuel.......163
APPROVED SYNTHETIC LUBRICANTS (HEES).......164
LUBRICATION DIAGRAMS.......165
General View.......165
Multipurpose Bucket and Pallet Forks.......166
Telescopic Arm.......167
TORQUE SPECIFICATIONS.......168
Torque List.......168
Torque of Bolts.......168
Torque of Hose Nuts.......169
Torque of Split Flange Bolts.......169
Torque for Flared Nuts.......170
Torque for O-Ring Boss Piping Joints.......170
Torque for O-Ring Boss Plugs.......171
Torque for Hoses (Taper Seal Type and Face Seal Type).......171
PERIODIC REPLACEMENT OF COMPONENTS.......173
SAFETY CRITICAL PARTS.......174
Fuel Supply System.......174
Delivery / Return Hydraulic System.......174
Delivery / Return Hydraulic System.......175
Seat Belt System.......175
MAINTENANCE SCHEDULE.......176
Maintenance Schedule Chart.......176
Initial 50 Hours Maintenance.......179
Initial 250 Hours Maintenance.......179
Initial 500 Hours Maintenance.......179
When Required.......180
Cleaning or Changing Engine Air Filters.......180
Checking and Cleaning Cab Air Filter.......182
Cleaning Air Recirculation Filter.......183
Checking the Level in Windshield Washer Reservoir.......183
Checking Windshield Wiper Blades.......183
Lubricating Cab Door Hinges.......184
Bleeding Brake System.......184
Checking and Adjusting Front Wheel Toe-in.......185
Checking and Adjusting Parking Brake.......186
Checking and Adjusting Brake Pedal Stroke.......188
Adjusting Automatic Return of Front Bucket to the Digging Position.......188
Checks Before Starting.......189
Various Checks.......189
Checking Fuel Level.......189
Checking Coolant Level.......190
Checking Engine Oil Level.......190
Checking Hydraulic Oil Level.......191
Draining Water Separator.......192
Every 10 Hours Maintenance.......193
Lubricating Joints (Grease Fittings).......193
Joint Lubrication Points.......194
Every 50 Hours Maintenance.......196
Checking Radiator Fluid Level.......196
Checking Brake System Oil Level.......197
Lubricating Drive Shafts.......198
Lubricating Front Axle Joints.......199
Checking Tire Pressure.......199
Checking Electrical System.......199
Every 250 Hours Maintenance.......200
Checking Serpentine Belt.......200
Checking A/C Compressor Belt Tension.......200
Cleaning Outside of Radiator.......201
Checking Battery Electrolyte.......202
Checking Front Axle Oil Levels.......203
Checking Rear Axle Oil Levels.......203
Transmission Oil Level.......204
Checking Wheel Lug Nut Torque.......204
Every 500 Hours Maintenance.......205
Changing Engine Oil.......205
Changing Engine Oil Filter.......206
Changing Hydraulic Tank Oil Filter.......207
Changing Fuel Filter.......210
Draining Fuel Tank.......211
Draining Hydraulic Oil Tank.......211
Every 1000 Hours Maintenance.......212
Changing Front Axle Oil.......212
Changing the Rear Axle Oil.......213
Changing Transmission Oil.......214
Changing Transmission Filter.......215
Checking and Adjusting Engine Valve Clearance.......215
Every 2000 Hours Maintenance.......216
Changing Hydraulic System Oil and Cleaning Suction Filter.......216
Changing Coolant.......219
Changing Brake System Oil.......221
Checking the Alternator and the Starter.......221
Changing the Alternator Belt.......221
Checking the A/C Cooling Gas Quantity.......221
MAINTENANCE WHEN USING DEMOLITION HAMMER.......222
Changing Hydraulic Oil Filter.......222
Changing Hydraulic Oil.......222
LONG TERM STORAGE.......223
Before Storage.......223
During Storage.......224
After Storage.......224
SPECIFICATIONS.......227
SPECIFICATIONS.......228
Machine Dimensions and Weights.......228
Standard Arm.......230
Retracted Telescopic Arm.......231
Extended Telescopic Arm.......232
MACHINE SYSTEMS SPECIFICATIONS.......233
Engine.......233
Electrical System.......233
Service Refill Capacities.......233
Standard Tires.......233
Transmission.......234
Total Mass.......234
Standard Bucket Capacity.......234
Loader.......234
OPTIONS, ATTACHMENTS.......235
AUTHORIZED OPTIONAL EQUIPMENT.......236
Precautions Regarding Safety.......236
Precautions Regarding the Installation of Equipment.......237
Optional Equipment Measurements.......237
Front End Loader.......237
Backhoe Unit.......238
FRONT EQUIPMENT QUICK COUPLING DEVICES.......239
Manual Control Quick Coupling.......239
MULTIPURPOSE BUCKET (4-IN-1).......240
Bucket Operation.......241
Description.......241
Bucket Uses.......241
Pallet Forks.......242
Description.......242
Safety Devices.......243
Using the Forks.......243
Preparing the Pallet Forks for Use.......244
Overturning the Forks.......244
Removing the Forks.......245
Installing the Forks.......245
Maintenance.......245
BACKHOE TELESCOPIC ARM.......246
Description.......246
Control.......246
Safety Devices.......247
Using the Telescopic Arm.......247
Maintenance.......248
Adjusting the Guide Slack.......248
DEMOLITION HAMMER PIPING.......250
Description.......250
Control.......250
Rules for Hammer Usage.......251
Avoid the Following Uses.......252
Installing the Hammer.......254
Removing the Hammer.......256
Using the Hammer.......256
Maintenance.......256
HYDRAULIC JACK HAMMER PIPING.......257
Description.......257
Control.......257
Connecting and Removing the Jack Hammer.......258
Connecting the Jack Hammer.......258
Disconnecting the Jack Hammer.......258
Using the Jack Hammer.......258
LOAD STABILIZER SYSTEM (LSS) (Ride Control Optional).......259
Load Stabilizer System (LSS) Accumulator.......259
Pressurizing the Load Stabilizer System (LSS).......259
CEBM016602 - Backhoe Loader WB156-5 Shop Manual.......261
FOREWORD.......262
CONTENTS.......262
SAFETY.......269
SAFETY NOTICE.......269
IMPORTANT SAFETY NOTICE.......269
GENERAL PRECAUTIONS.......269
PREPARATIONS FOR WORK.......269
PRECAUTIONS DURING WORK.......269
GENERAL.......271
HOW TO READ THE SHOP MANUAL.......272
VOLUMES.......272
DISTRIBUTION AND UPDATING.......272
FILING METHOD.......272
REVISED EDITION MARK.......272
REVISIONS.......272
SYMBOLS.......272
HOISTING INSTRUCTIONS.......273
HOISTING.......273
WIRE ROPES.......273
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.......274
COATING MATERIALS.......276
STANDARD TIGHTENING TORQUE.......278
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.......278
TIGHTENING TORQUE OF HOSE NUTS.......279
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......279
TIGHTENING TORQUE FOR FLARED NUTS.......279
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS.......280
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS.......280
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).......280
ELECTRIC WIRE CODE.......281
CLASSIFICATION BY THICKNESS.......281
CLASSIFICATION BY COLOR AND CODE.......281
CONNECTING PUSH-PULL TYPE COUPLER.......282
CONVERSION TABLES.......285
METHOD OF USING THE CONVERSION TABLE.......285
01 GENERAL.......290
SPECIFICATION DRAWING.......292
SPECIFICATIONS.......292
MACHINE DIMENSIONS AND WEIGHTS.......292
BACKHOE ARM.......293
STANDARD ARM.......293
TELESCOPIC ARM (RETRACTED).......294
TELESCOPIC ARM (EXTENDED).......295
MACHINE SYSTEMS SPECIFICATIONS.......296
ENGINE.......296
ELECTRICAL SYSTEM.......296
SERVICE REFILL CAPACITIES.......296
TRANSMISSION.......297
TOTAL MASS.......297
LOADER.......297
BACKHOE.......297
TIRE PRESSURE.......297
WEIGHT TABLE.......298
LIFTING THE MACHINE.......299
LIFTING POSITION MARKS.......299
LIFTING PROCEDURE.......300
1. Start the engine. Make sure the machine is horizontal; then set the work equipment to the travel posture (A).......300
2. The telescopic arm is equipped with a safety element (6) that locks the sliding arm (2) when it is completely retracted and p........300
3. Raise and center the backhoe boom and engage the safety coupling.......300
4. Press the work equipment control switch until the light on the switch is illuminated indicating the front and rear work equipment controls are locked.......300
5. Install the lock pin.......301
6. Connect the safety cables to prevent accidental lowering of the outriggers.......301
7. Use wire ropes and slings that match the weight of the machine. The operating weight of the WB146/146PS-5 is 7,300 kg (16,090 lb). Wind the wire rope and fix it to the lifting points as shown in "Lifting Position Marks.".......301
8. Clear the area of unwarranted personnel. Make sure enough ground guides are available to keep the area clear.......301
9. Lift the machine about 100 - 200 mm (4 - 8 in) above the ground.......301
10. Make sure that the wire ropes are not slack and that the machine is level. If ropes require adjustment, lower the machine back to the ground first.......301
11. If the wire ropes are taut and the machine is level, continue to lift the machine slowly. Provide signals to the crane operator and observe areas the crane operator cannot see.......301
FUEL, COOLANT, AND LUBRICANTS.......302
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE.......302
GREASE.......303
FUEL REMARKS.......303
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS.......304
LUBRICATION DIAGRAMS.......305
GENERAL VIEW.......305
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......306
POWER TRAIN.......309
DESCRIPTION.......309
POWER FLOW.......309
TRANSMISSION DIAGRAM.......311
TRANSMISSION.......313
COMPLETE ASSEMBLY.......313
FORWARD REVERSE CLUTCH.......317
1ST THROUGH 4TH SPEED SHAFT.......317
4WD SHAFT.......318
FRONT AXLE.......319
COMPLETE ASSEMBLY.......319
DIFFERENTIAL.......320
PLANETARY.......321
REAR AXLE.......322
COMPLETE ASSEMBLY.......322
DIFFERENTIAL.......323
PLANETARY.......324
WORK BRAKES.......325
DIFFERENTIAL LOCK.......326
HYDRAULIC PUMP.......327
MAIN PUMP.......328
FUNCTION.......330
STRUCTURE.......330
OPERATION.......330
DELIVERY CONTROL VALVE.......332
LS VALVE FUNCTION.......334
PC VALVE FUNCTION.......334
PC VALVE OPERATION.......335
MAIN CONTROL VALVE.......338
CLSS.......346
DESCRIPTION.......346
CHARACTERISTICS.......346
STRUCTURE.......346
OPERATING PRINCIPLES.......347
PUMPING PLATE CONTROL ANGLE.......347
PRESSURE COMPENSATION CONTROL.......348
MAIN CONTROL VALVE.......349
UNLOADING VALVE.......350
LS PRESSURE.......353
LS BYPASS PLUG.......355
PRESSURE COMPENSATION VALVES.......356
PRESSURE COMPENSATION VALVE.......357
PRIORITY VALVE.......358
PPC REDUCING VALVE.......359
STEERING UNIT.......362
TECHNICAL DATA.......362
OPERATION.......362
PPC VALVE.......363
LOADER.......363
OPERATION.......365
OUTRIGGER.......369
OPERATION.......370
BACKHOE.......373
LEFT VALVE.......373
RIGHT VALVE.......374
SOLENOID VALVE.......375
HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE (MP) BUCKET.......375
HYDRAULIC CONTROLS WITH MULTI-PURPOSE (MP) BUCKET.......376
LOADER CYLINDERS.......377
BOOM.......377
CHARACTERISTICS.......377
BUCKET.......378
CHARACTERISTICS.......378
MP BUCKET.......379
CHARACTERISTICS.......379
BACKHOE CYLINDERS.......380
BOOM.......380
CHARACTERISTICS.......380
ARM.......381
CHARACTERISTICS.......381
BUCKET.......382
CHARACTERISTICS.......382
TELESCOPIC ARM CYLINDER.......383
CHARACTERISTICS.......383
SWING.......384
CHARACTERISTICS.......384
OUTRIGGER.......385
CHARACTERISTICS.......385
WORK EQUIPMENT.......386
LOADER.......386
BACKHOE.......388
AIR CONDITIONING.......392
20 TESTING, ADJUSTING AND TROUBLESHOOTING.......394
STANDARD VALUE TABLE.......397
ENGINE.......397
CHASSIS.......398
SPECIAL TOOLS.......405
ENGINE SPEED.......406
ENGINE WITH LOAD.......406
MACHINE IN POWER MODE AT MIN.......406
WITH CONVERTER STALLED.......406
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD.......406
ANALYSIS.......407
VALVE CLEARANCE.......407
AIR CONDITIONER COMPRESSOR BELT TENSION.......408
BLEED AIR FROM CIRCUITS.......409
BLEED AIR FROM CYLINDERS.......409
BLEED AIR FROM BRAKING CIRCUIT.......409
RELEASING RESIDUAL PRESSURE.......409
ACCELERATOR PEDAL AND LEVER.......410
ACCELERATOR PEDAL TRAVEL.......410
ACCELERATOR LEVER TRAVEL.......411
BRAKE SYSTEM.......412
CONTROL.......412
ADJUSTMENT.......412
CHECKS.......413
LEAKAGE CHECKS.......413
INDIVIDUAL PUMP CHECK.......414
BRAKE GROUP LEAKAGE.......415
PARKING BRAKE ADJUSTMENT.......416
HYDRAULIC CIRCUIT.......417
INTRODUCTION.......417
MAIN CONTROL VALVE.......418
RELIEF VALVES.......419
TESTING.......419
UNLOADING VALVE.......419
MAIN RELIEF VALVE.......419
SECONDARY VALVES.......419
SETTING RELIEF VALVES.......422
MAIN RELIEF VALVE.......422
CIRCUIT RELIEF VALVES.......422
ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET.......422
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE.......423
LS DIFFERENTIAL PRESSURE.......424
CONTROL.......424
ADJUSTMENT.......424
PPC SUPPLY PRESSURE.......425
CHECK.......425
ADJUSTMENT.......425
PC VALVE.......426
ADJUSTMENT.......426
STEERING CONTROL SYSTEM.......427
CONTROL.......427
SETTING.......427
STEERING CYLINDER.......428
POWER TRAIN GROUP.......429
CONVERTER OIL PRESSURE.......429
CLUTCH ENGAGEMENT PRESSURE.......429
SUPPLY PRESSURE.......430
TRANSMISSION CLUTCH FUNCTION.......431
MACHINE PREPARATION.......431
CONTROL.......431
HYDRAULIC DRIFT.......432
LOADER.......432
BOOM CIRCUIT.......432
BUCKET CIRCUIT.......433
BACKHOE.......433
BOOM CIRCUIT.......434
ARM CIRCUIT.......434
BUCKET CIRCUIT.......435
OUTRIGGERS CIRCUIT - WITHOUT LOCK VALVES.......436
AIR CONDITIONING.......437
WORK TEMPERATURE.......437
UNIT CHECK.......437
EMPTYING THE AIR CONDITIONING UNIT.......438
TROUBLESHOOTING GUIDE.......439
FRONT AXLE.......439
REAR AXLE.......444
TRANSMISSION.......449
FUSES AND RELAYS.......452
FUSE AND RELAY PANEL LOCATION.......452
FUSE AND RELAY PANEL LAYOUT.......453
FUSES.......453
RELAYS.......455
HEATING AND AIR CONDITIONING FUSES AND RELAYS.......456
FUSES.......456
RELAYS.......456
30 DISASSEMBLY AND ASSEMBLY.......456
HOW TO USE THIS MANUAL.......463
REMOVAL AND INSTALLATION OF COMPONENTS.......463
REMOVAL.......463
INSTALLATION.......463
OVERHAUL OF COMPONENTS.......464
DISASSEMBLY PROCEDURES.......464
ASSEMBLY PROCEDURES.......464
PRECAUTIONS FOR WORK.......465
SPECIAL TOOL LIST.......467
CONNECTOR REPAIR PROCEDURES.......470
CONTACT TERMINAL REMOVAL (HD30 TYPE).......470
CRIMPING CONTACT TERMINAL (HD30 TYPE).......471
INSERTION OF CONTACT TERMINAL (HD30 TYPE).......472
CONTACT TERMINAL REMOVAL (DT TYPE).......473
CRIMPING CONTACT TERMINAL (DT TYPE).......474
INSERTION OF CONTACT TERMINAL (DT TYPE).......475
STRIPPING INSULATION.......476
ENGINE HOOD.......477
REMOVAL.......477
INSTALLATION.......478
FRONT GUARD.......479
REMOVAL.......479
INSTALLATION.......479
RADIATOR.......480
REMOVAL.......480
INSTALLATION.......483
AIR CONDITIONER CONDENSER.......484
REMOVAL.......484
INSTALLATION.......484
MUFFLER.......485
REMOVAL.......485
INSTALLATION.......486
AIR FILTER.......487
REMOVAL.......487
INSTALLATION.......487
TURBOCHARGER.......488
REMOVAL.......488
INSTALLATION.......490
AIR CONDITIONER COMPRESSOR.......491
REMOVAL.......491
INSTALLATION.......493
AIR CONDITIONER COMPRESSOR BELT.......494
REMOVAL.......494
INSTALLATION.......494
EXHAUST STACK.......495
REMOVAL.......495
INSTALLATION.......496
OPERATOR’S SEAT.......496
REMOVAL.......496
INSTALLATION.......496
CAB HEATING AND COOLING SYSTEM.......497
REMOVAL.......497
FAN.......501
HEATER CORE.......502
INSTALLATION.......503
BATTERY.......504
REMOVAL.......504
INSTALLATION.......505
FUEL TANK.......506
REMOVAL.......506
INSTALLATION.......507
STEERING AND FRONT DASH ASSEMBLY.......508
STEERING WHEEL.......508
REMOVAL.......508
INSTALLATION.......509
FRONT DASH ASSEMBLY.......510
REMOVAL.......510
INSTALLATION.......511
STEERING UNIT.......512
REMOVAL.......512
INSTALLATION.......513
BRAKE SYSTEM.......514
REMOVAL.......514
INSTALLATION.......516
BLEED AIR FROM BRAKING CIRCUIT.......517
CAB.......518
REMOVAL.......518
INSTALLATION.......524
HYDRAULIC OIL TANK.......525
REMOVAL.......525
INSTALLATION.......531
HYDRAULIC PUMP.......532
REMOVAL.......532
INSTALLATION.......534
TRANSMISSION.......535
REMOVAL.......535
INSTALLATION.......539
BLEED AIR FROM CYLINDERS.......539
TRANSMISSION OVERHAUL PROCEDURES.......540
TORQUE CONVERTER.......540
REMOVAL.......540
INSTALLATION.......540
PLUGS AND FILTERS.......541
DISASSEMBLY.......541
ASSEMBLY.......544
PUMP.......547
DISASSEMBLY.......547
ASSEMBLY.......549
OIL LINE.......551
REMOVAL.......551
ASSEMBLY.......551
VALVE BODY.......552
DISASSEMBLY.......552
ASSEMBLY.......560
4-WHEEL DRIVE SOLENOID VALVE.......568
DISASSEMBLY.......568
ASSEMBLY.......570
TRANSMISSION HOUSING.......572
DISASSEMBLY.......572
ASSEMBLY.......582
CLUTCH PACK (A) AND GEAR SHAFT (D).......592
DISASSEMBLY.......592
CLUTCHES AND DISC INSPECTIONS.......601
ASSEMBLY.......602
CHECKING CLUTCH FUNCTION.......611
GEAR SHAFTS (B) AND (C).......612
DISASSEMBLY.......612
ASSEMBLY.......621
GEAR SHAFT (E).......630
DISASSEMBLY.......630
ASSEMBLY.......634
SHIFTER TOWER AND FORKS.......640
DISASSEMBLY.......640
ASSEMBLY.......643
ENGINE.......646
REMOVAL.......646
INSTALLATION.......652
CONTROL VALVE.......653
REMOVAL.......653
INSTALLATION.......655
STEERING SOLENOID VALVE.......656
REMOVAL.......656
INSTALLATION.......656
FRONT AXLE ASSEMBLY.......657
REMOVAL.......657
INSTALLATION.......658
FRONT AXLE OVERHAUL PROCEDURES.......659
STEERING CYLINDER ASSEMBLY.......659
DISASSEMBLY.......659
ASSEMBLY.......660
FRONT AXLE END PLANETARY ASSEMBLY.......665
DISASSEMBLY.......665
ASSEMBLY.......667
AXLE END HUB ASSEMBLY.......668
DISASSEMBLY.......668
ASSEMBLY.......672
AXLE HOUSING.......675
DISASSEMBLY.......675
ASSEMBLY.......677
DIFFERENTIAL.......678
DISASSEMBLY.......678
ASSEMBLY.......680
PINION.......684
DISASSEMBLY.......684
ASSEMBLY.......687
CARRIER.......691
DISASSEMBLY.......691
ASSEMBLY.......692
REAR AXLE ASSEMBLY.......694
REMOVAL.......694
INSTALLATION.......696
REAR AXLE OVERHAUL PROCEDURES.......697
PARKING BRAKE ASSEMBLY.......697
DISASSEMBLY.......697
ASSEMBLY.......699
MAINTENANCE.......701
SERVICE BRAKE ASSEMBLY.......704
DISASSEMBLY.......704
ASSEMBLY.......709
REAR AXLE END PLANETARY ASSEMBLY.......715
DISASSEMBLY.......715
ASSEMBLY.......720
DIFFERENTIAL.......724
DISASSEMBLY.......724
ASSEMBLY.......726
DIFFERENTIAL LOCK.......731
DISASSEMBLY.......731
ASSEMBLY.......734
CARRIER.......737
DISASSEMBLY.......737
ASSEMBLY.......741
PINION.......745
DISASSEMBLY.......745
ASSEMBLY.......747
FRONT LOADER PPC VALVE.......751
REMOVAL.......751
INSTALLATION.......752
FRONT-END LOADER ASSEMBLY.......753
LOADER BOOM CYLINDERS.......753
INSTALLATION.......754
BUCKET CYLINDERS.......755
REMOVAL.......755
INSTALLATION.......756
FRONT LOADER BUCKET.......757
REMOVAL.......757
INSTALLATION.......757
LOADER BOOM ASSEMBLY.......758
REMOVAL.......758
INSTALLATION.......759
BACKHOE PPC VALVE.......760
REMOVAL.......760
INSTALLATION.......761
PPC VALVE SUPPORT RELEASE CABLES.......762
REMOVAL.......762
INSTALLATION AND ADJUSTING.......764
SOLENOID VALVE.......768
REMOVAL.......768
INSTALLATION.......768
PPC VALVE GAS STRUT.......765
REMOVAL.......765
INSTALLATION.......767
BACKHOE ASSEMBLY.......769
BUCKET CYLINDER.......769
REMOVAL.......769
INSTALLATION.......770
TELESCOPIC ARM CYLINDER.......771
REMOVAL.......771
INSTALLATION.......771
ARM CYLINDER.......772
REMOVAL.......772
INSTALLATION.......773
BOOM CYLINDER.......774
REMOVAL.......774
INSTALLATION.......775
SWING CYLINDERS.......776
REMOVAL.......776
INSTALLATION.......778
BOOM LOCK CYLINDER.......779
REMOVAL.......779
INSTALLATION.......780
BACKHOE BUCKET.......780
REMOVAL.......780
INSTALLATION.......780
BACKHOE ARM.......781
REMOVAL.......781
INSTALLATION.......783
TELESCOPIC ARM.......784
REMOVAL.......784
INSTALLATION.......784
TELESCOPIC ARM GIBS.......785
REMOVAL.......785
INSTALLATION.......785
BACKHOE BOOM.......786
REMOVAL.......786
INSTALLATION.......787
BACKHOE SWING FRAME.......788
REMOVAL.......788
INSTALLATION.......788
OUTRIGGER CYLINDERS.......789
REMOVAL.......789
INSTALLATION.......790
OUTRIGGER ARMS.......791
REMOVAL.......791
INSTALLATION.......791
WORK EQUIPMENT CYLINDER OVERHAUL.......792
LOADER AND BACKHOE CYLINDERS.......792
DISASSEMBLY.......792
ASSEMBLY.......794
SWING CYLINDERS.......797
DISASSEMBLY.......797
ASSEMBLY.......799
90 OTHERS.......802
HYDRAULIC CIRCUIT.......805
HYDRAULIC CIRCUIT (1 OF 4).......805
HYDRAULIC CIRCUIT (2 OF 4).......806
HYDRAULIC CIRCUIT (3 OF 4).......807
HYDRAULIC CIRCUIT (4 OF 4).......808
ELECTRICAL SCHEMATIC .......809
WIRING - 1 OF 7.......809
WIRING - 2 OF 7.......810
WIRING - 3 OF 7.......811
WIRING - 4 OF 7.......812
WIRING - 5 OF 7.......813
WIRING - 6 OF 7.......814
WIRING - 7 OF 7.......815
LEGEND FOR WIRING SCHEMATIC.......816
Komatsu Backhoe Loader WB156 Repair Service Manual
