Komatsu WB156-5 Backhoe Loader Shop Manual CEBM016602

Description

• Model List:
  • WB156-5 Backhoe Loader

• 1. FOREWORD
• 1.1. CONTENTS
• 1.2. SAFETY
• 1.2.1. SAFETY NOTICE
• 1.3. GENERAL
• 1.4. HOW TO READ THE SHOP MANUAL
• 1.4.1. VOLUMES
• 1.4.2. DISTRIBUTION AND UPDATING
• 1.4.3. FILING METHOD
• 1.4.4. REVISED EDITION MARK
• 1.4.5. REVISIONS
• 1.4.6. SYMBOLS
• 1.5. HOISTING INSTRUCTIONS
• 1.5.1. HOISTING
• 1.5.2. WIRE ROPES
• 1.6. EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
• 1.7. COATING MATERIALS
• 1.8. STANDARD TIGHTENING TORQUE
• 1.8.1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
• 1.8.2. TIGHTENING TORQUE OF HOSE NUTS
• 1.8.3. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
• 1.8.4. TIGHTENING TORQUE FOR FLARED NUTS
• 1.8.5. TABLE OF TIGHTENING TORQUES FOR ORING BOSS PIPING JOINTS
• 1.8.6. TABLE OF TIGHTENING TORQUES FOR ORING BOSS PLUGS
• 1.8.7. TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
• 1.9. ELECTRIC WIRE CODE
• 1.9.1. CLASSIFICATION BY THICKNESS
• 1.9.2. CLASSIFICATION BY COLOR AND CODE
• 1.10. CONNECTING PUSHPULL TYPE COUPLER
• 1.11. CONVERSION TABLES
• 1.11.1. METHOD OF USING THE CONVERSION TABLE
• 2. GENERAL
• 2.1. SPECIFICATION DRAWING
• 2.1.1. SPECIFICATIONS
• 2.2. BACKHOE ARM
• 2.2.1. STANDARD ARM
• 2.2.2. TELESCOPIC ARM (RETRACTED)
• 2.2.3. TELESCOPIC ARM (EXTENDED)
• 2.3. MACHINE SYSTEMS SPECIFICATIONS
• 2.3.1. ENGINE
• 2.3.2. ELECTRICAL SYSTEM
• 2.3.3. SERVICE REFILL CAPACITIES
• 2.4. LIFTING THE MACHINE
• 2.4.1. LIFTING POSITION MARKS
• 2.4.2. LIFTING PROCEDURE
• 2.5. FUEL, COOLANT, AND LUBRICANTS
• 2.5.1. PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE
• 2.5.2. GREASE
• 2.5.3. FUEL REMARKS
• 2.6. HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS
• 2.7. LUBRICATION DIAGRAMS
• 2.7.1. GENERAL VIEW
• 3. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 3.1. POWER TRAIN
• 3.1.1. DESCRIPTION
• 3.1.2. POWER FLOW
• 3.2. TRANSMISSION DIAGRAM
• 3.3. TRANSMISSION
• 3.3.1. COMPLETE ASSEMBLY
• 3.3.2. FORWARD REVERSE CLUTCH
• 3.3.3. T THROUGH 4TH SPEED SHAFT
• 3.3.4. D SHAFT
• 3.4. FRONT AXLE
• 3.4.1. COMPLETE ASSEMBLY
• 3.5. REAR AXLE
• 3.5.1. COMPLETE ASSEMBLY
• 3.5.2. DIFFERENTIAL
• 3.5.3. PLANETARY
• 3.5.4. WORK BRAKES
• 3.5.5. DIFFERENTIAL LOCK
• 3.5.6. DELIVERY CONTROL VALVE
• 3.6. MAIN CONTROL VALVE
• 3.7. CLSS
• 3.7.1. DESCRIPTION
• 3.7.2. OPERATING PRINCIPLES
• 3.7.3. HYDRAULIC CONTROLS WITHOUT MULTIPURPOSE (MP) BUCKET
• 3.7.4. HYDRAULIC CONTROLS WITH MULTIPURPOSE (MP) BUCKET
• 3.8. LOADER CYLINDERS
• 3.8.1. BOOM
• 3.8.2. BUCKET
• 3.8.3. MP BUCKET
• 3.9. BACKHOE CYLINDERS
• 3.9.1. BOOM
• 3.9.3. BUCKET
• 3.9.4. TELESCOPIC ARM CYLINDER
• 3.9.5. SWING
• 3.9.6. OUTRIGGER
• 3.10. WORK EQUIPMENT
• 3.10.1. LOADER
• 3.10.2. BACKHOE
• 3.11. AIR CONDITIONING
• 4. TESTING, ADJUSTING AND TROUBLESHOOTING
• 4.1. STANDARD VALUE TABLE
• 4.1.1. ENGINE
• 4.1.2. CHASSIS
• 4.2. SPECIAL TOOLS
• 4.3. ENGINE SPEED
• 4.3.1. ENGINE WITH LOAD
• 4.4. VALVE CLEARANCE
• 4.5. AIR CONDITIONER COMPRESSOR BELT TENSION
• 4.6. BLEED AIR FROM CIRCUITS
• 4.6.1. BLEED AIR FROM CYLINDERS
• 4.6.2. BLEED AIR FROM BRAKING CIRCUIT
• 4.6.3. RELEASING RESIDUAL PRESSURE
• 4.7. ACCELERATOR PEDAL AND LEVER
• 4.7.1. ACCELERATOR PEDAL TRAVEL
• 4.7.2. ACCELERATOR LEVER TRAVEL
• 4.8. PARKING BRAKE ADJUSTMENT
• 4.9. HYDRAULIC CIRCUIT
• 4.9.1. INTRODUCTION
• 4.10. RELIEF VALVES
• 4.10.1. TESTING
• 4.11. SETTING RELIEF VALVES
• 4.11.1. MAIN RELIEF VALVE
• 4.11.2. CIRCUIT RELIEF VALVES
• 4.12. LS DIFFERENTIAL PRESSURE
• 4.12.1. CONTROL
• 4.12.2. ADJUSTMENT
• 4.13. PPC SUPPLY PRESSURE
• 4.13.1. CHECK
• 4.13.2. ADJUSTMENT
• 4.14. PC VALVE
• 4.14.1. ADJUSTMENT
• 4.15. STEERING CONTROL SYSTEM
• 4.15.1. CONTROL
• 4.15.2. SETTING
• 4.16. STEERING CYLINDER
• 4.17. POWER TRAIN GROUP
• 4.17.1. CONVERTER OIL PRESSURE
• 4.17.2. CLUTCH ENGAGEMENT PRESSURE
• 4.17.3. SUPPLY PRESSURE
• 4.18. TRANSMISSION CLUTCH FUNCTION
• 4.18.1. MACHINE PREPARATION
• 4.18.2. CONTROL
• 4.19. HYDRAULIC DRIFT
• 4.20. AIR CONDITIONING
• 4.20.1. WORK TEMPERATURE
• 4.20.2. UNIT CHECK
• 4.20.3. EMPTYING THE AIR CONDITIONING UNIT
• 4.21. TROUBLESHOOTING GUIDE
• 4.21.1. FRONT AXLE
• 4.21.2. REAR AXLE
• 4.21.3. TRANSMISSION
• 4.22. FUSES AND RELAYS
• 4.22.1. FUSE AND RELAY PANEL LOCATION
• 4.22.2. FUSE AND RELAY PANEL LAYOUT
• 4.22.3. HEATING AND AIR CONDITIONING FUSES AND RELAYS
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. HOW TO USE THIS MANUAL
• 5.1.1. REMOVAL AND INSTALLATION OF COMPONENTS
• 5.1.2. OVERHAUL OF COMPONENTS
• 5.2. PRECAUTIONS FOR WORK
• 5.3. SPECIAL TOOL LIST
• 5.4. CONNECTOR REPAIR PROCEDURES
• 5.4.1. CONTACT TERMINAL REMOVAL (HD30 TYPE)
• 5.4.2. CRIMPING CONTACT TERMINAL (HD30 TYPE)
• 5.4.3. INSERTION OF CONTACT TERMINAL (HD30 TYPE)
• 5.4.4. CONTACT TERMINAL REMOVAL (DT TYPE)
• 5.4.5. CRIMPING CONTACT TERMINAL (DT TYPE)
• 5.4.6. INSERTION OF CONTACT TERMINAL (DT TYPE)
• 5.4.7. STRIPPING INSULATION
• 5.5. AIR CONDITIONER CONDENSER
• 5.6. AIR CONDITIONER COMPRESSOR
• 5.6.1. REMOVAL
• 5.6.2. INSTALLATION
• 5.7. AIR CONDITIONER COMPRESSOR BELT
• 5.8. OPERATORS SEAT
• 5.8.1. REMOVAL
• 5.9. CAB HEATING AND COOLING SYSTEM
• 5.10. STEERING AND FRONT DASH ASSEMBLY
• 5.10.1. STEERING WHEEL
• 5.10.2. FRONT DASH ASSEMBLY
• 5.10.3. BLEED AIR FROM BRAKING CIRCUIT
• 5.11.1. REMOVAL
• 5.11.2. INSTALLATION
• 5.12. HYDRAULIC OIL TANK
• 5.12.1. BLEED AIR FROM CYLINDERS
• 5.13. TRANSMISSION OVERHAUL PROCEDURES
• 5.13.1. TORQUE CONVERTER
• 5.13.2. PLUGS AND FILTERS
• 5.13.3. WHEEL DRIVE SOLENOID VALVE
• 5.13.4. TRANSMISSION HOUSING
• 5.13.5. CLUTCH PACK (A) AND GEAR SHAFT (D)
• 5.13.6. GEAR SHAFTS (B) AND (C)
• 5.13.7. GEAR SHAFT (E)
• 5.13.8. SHIFTER TOWER AND FORKS
• 5.14. STEERING SOLENOID VALVE
• 5.14.1. REMOVAL
• 5.14.2. INSTALLATION
• 5.15. FRONT AXLE ASSEMBLY
• 5.15.1. REMOVAL
• 5.15.2. INSTALLATION
• 5.16. FRONT AXLE OVERHAUL PROCEDURES
• 5.16.1. STEERING CYLINDER ASSEMBLY
• 5.16.2. FRONT AXLE END PLANETARY ASSEMBLY
• 5.16.3. AXLE END HUB ASSEMBLY
• 5.17. REAR AXLE ASSEMBLY
• 5.17.1. REMOVAL
• 5.17.2. INSTALLATION
• 5.18. REAR AXLE OVERHAUL PROCEDURES
• 5.18.1. PARKING BRAKE ASSEMBLY
• 5.18.2. SERVICE BRAKE ASSEMBLY
• 5.18.3. REAR AXLE END PLANETARY ASSEMBLY
• 5.18.4. DIFFERENTIAL
• 5.18.5. DIFFERENTIAL LOCK
• 5.19. FRONT LOADER PPC VALVE
• 5.19.1. REMOVAL
• 5.19.2. INSTALLATION
• 5.20. FRONTEND LOADER ASSEMBLY
• 5.20.1. LOADER BOOM CYLINDERS
• 5.20.2. INSTALLATION
• 5.20.3. BUCKET CYLINDERS
• 5.20.4. FRONT LOADER BUCKET
• 5.20.5. LOADER BOOM ASSEMBLY
• 5.21. BACKHOE PPC VALVE
• 5.21.1. REMOVAL
• 5.21.2. INSTALLATION
• 5.22. PPC VALVE SUPPORT RELEASE CABLES
• 5.22.1. REMOVAL
• 5.22.2. INSTALLATION AND ADJUSTING
• 5.23. SOLENOID VALVE
• 5.23.1. REMOVAL
• 5.23.2. INSTALLATION
• 5.24. PPC VALVE GAS STRUT
• 5.24.1. REMOVAL
• 5.24.2. INSTALLATION
• 5.25. BACKHOE ASSEMBLY
• 5.25.1. BUCKET CYLINDER
• 5.25.2. TELESCOPIC ARM CYLINDER
• 5.25.3. SWING CYLINDERS
• 5.25.4. BOOM LOCK CYLINDER
• 5.25.5. TELESCOPIC ARM GIBS
• 5.25.6. BACKHOE BOOM
• 5.25.7. BACKHOE SWING FRAME
• 5.25.8. OUTRIGGER CYLINDERS
• 5.25.9. OUTRIGGER ARMS
• 5.26. WORK EQUIPMENT CYLINDER OVERHAUL
• 5.26.1. LOADER AND BACKHOE CYLINDERS
• 5.26.2. SWING CYLINDERS
• 6. OTHERS
• 6.1. HYDRAULIC CIRCUIT
• 6.1.1. HYDRAULIC CIRCUIT (1 OF 4)
• 6.1.2. HYDRAULIC CIRCUIT (2 OF 4)
• 6.1.3. HYDRAULIC CIRCUIT (3 OF 4)
• 6.1.4. HYDRAULIC CIRCUIT (4 OF 4)
• 6.2. ELECTRICAL SCHEMATIC
• 6.2.1. WIRING 1 OF 7
• 6.2.2. WIRING 2 OF 7
• 6.2.3. WIRING 3 OF 7
• 6.2.4. WIRING 4 OF 7
• 6.2.5. WIRING 5 OF 7
• 6.2.6. WIRING 6 OF 7
• 6.2.7. WIRING 7 OF 7
• 6.2.8. LEGEND FOR WIRING SCHEMATIC