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Komatsu WB156-5 Backhoe Loader Shop Manual CEBM016602 – PDF DOWNLOAD
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Description
Komatsu WB156-5 Backhoe Loader Shop Manual
FILE DETAILS:
Komatsu WB156-5 Backhoe Loader Shop Manual
Brands: Komatsu
Equipment Type: Backhoe Loader
Manuals Type: Shop Manual
Machine Model: WB156-5
Serial Number: A63001 and up
Book Code: CEBM016602
Language: English
Pages: 556
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WB156-5 Backhoe Loader Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
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. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section 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:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
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.
OTHERS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu WB156-5 Backhoe Loader Shop Manual
FOREWORD....................................................................................................................................................................................................................................... 2 CONTENTS................................................................................................................................................................................................................................... 2 SAFETY..................................................................................................................................................................................................................................... 9 SAFETY NOTICE.......................................................................................................................................................................................................................... 9 IMPORTANT SAFETY NOTICE............................................................................................................................................................................................................ 9 GENERAL PRECAUTIONS................................................................................................................................................................................................................ 9 PREPARATIONS FOR WORK.............................................................................................................................................................................................................. 9 PRECAUTIONS DURING WORK............................................................................................................................................................................................................ 9 GENERAL.................................................................................................................................................................................................................................... 11 HOW TO READ THE SHOP MANUAL................................................................................................................................................................................................................ 12 VOLUMES................................................................................................................................................................................................................................ 12 DISTRIBUTION AND UPDATING.............................................................................................................................................................................................................. 12 FILING METHOD.......................................................................................................................................................................................................................... 12 REVISED EDITION MARK................................................................................................................................................................................................................... 12 REVISIONS.............................................................................................................................................................................................................................. 12 SYMBOLS................................................................................................................................................................................................................................ 12 HOISTING INSTRUCTIONS...................................................................................................................................................................................................................... 13 HOISTING............................................................................................................................................................................................................................... 13 WIRE ROPES............................................................................................................................................................................................................................. 13 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.............................................................................................................................................................................................. 14 COATING MATERIALS.......................................................................................................................................................................................................................... 16 STANDARD TIGHTENING TORQUE................................................................................................................................................................................................................. 18 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS........................................................................................................................................................................................... 18 TIGHTENING TORQUE OF HOSE NUTS......................................................................................................................................................................................................... 19 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................................................................................................................................................ 19 TIGHTENING TORQUE FOR FLARED NUTS...................................................................................................................................................................................................... 19 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS.............................................................................................................................................................................. 20 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS...................................................................................................................................................................................... 20 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)................................................................................................................................................................. 20 ELECTRIC WIRE CODE......................................................................................................................................................................................................................... 21 CLASSIFICATION BY THICKNESS............................................................................................................................................................................................................ 21 CLASSIFICATION BY COLOR AND CODE....................................................................................................................................................................................................... 21 CONNECTING PUSH-PULL TYPE COUPLER.......................................................................................................................................................................................................... 22 CONVERSION TABLES.......................................................................................................................................................................................................................... 25 METHOD OF USING THE CONVERSION TABLE................................................................................................................................................................................................... 25 01 GENERAL..................................................................................................................................................................................................................................... 30 SPECIFICATION DRAWING...................................................................................................................................................................................................................... 32 SPECIFICATIONS......................................................................................................................................................................................................................... 32 MACHINE DIMENSIONS AND WEIGHTS..................................................................................................................................................................................................... 32 BACKHOE ARM................................................................................................................................................................................................................................ 33 STANDARD ARM........................................................................................................................................................................................................................... 33 TELESCOPIC ARM (RETRACTED)............................................................................................................................................................................................................. 34 TELESCOPIC ARM (EXTENDED).............................................................................................................................................................................................................. 35 MACHINE SYSTEMS SPECIFICATIONS............................................................................................................................................................................................................. 36 ENGINE................................................................................................................................................................................................................................. 36 ELECTRICAL SYSTEM...................................................................................................................................................................................................................... 36 SERVICE REFILL CAPACITIES.............................................................................................................................................................................................................. 36 TRANSMISSION........................................................................................................................................................................................................................... 37 TOTAL MASS............................................................................................................................................................................................................................. 37 LOADER................................................................................................................................................................................................................................. 37 BACKHOE................................................................................................................................................................................................................................ 37 TIRE PRESSURE.......................................................................................................................................................................................................................... 37 WEIGHT TABLE............................................................................................................................................................................................................................... 38 LIFTING THE MACHINE........................................................................................................................................................................................................................ 39 LIFTING POSITION MARKS................................................................................................................................................................................................................. 39 LIFTING PROCEDURE...................................................................................................................................................................................................................... 40 1. Start the engine. Make sure the machine is horizontal; then set the work equipment to the travel posture (A).................................................................................................................... 40 2. The telescopic arm is equipped with a safety element (6) that locks the sliding arm (2) when it is completely retracted and p................................................................................................... 40 3. Raise and center the backhoe boom and engage the safety coupling................................................................................................................................................................ 40 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........................................................................... 40 5. Install the lock pin............................................................................................................................................................................................................ 41 6. Connect the safety cables to prevent accidental lowering of the outriggers...................................................................................................................................................... 41 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.".... 41 8. Clear the area of unwarranted personnel. Make sure enough ground guides are available to keep the area clear.................................................................................................................... 41 9. Lift the machine about 100 - 200 mm (4 - 8 in) above the ground................................................................................................................................................................. 41 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............................................................................. 41 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................................................ 41 FUEL, COOLANT, AND LUBRICANTS.............................................................................................................................................................................................................. 42 PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE.................................................................................................................................................................................. 42 GREASE................................................................................................................................................................................................................................. 43 FUEL REMARKS........................................................................................................................................................................................................................... 43 HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS.................................................................................................................................................................................................... 44 LUBRICATION DIAGRAMS....................................................................................................................................................................................................................... 45 GENERAL VIEW........................................................................................................................................................................................................................... 45 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................................................................................................................................ 46 POWER TRAIN................................................................................................................................................................................................................................ 49 DESCRIPTION............................................................................................................................................................................................................................ 49 POWER FLOW............................................................................................................................................................................................................................. 49 TRANSMISSION DIAGRAM....................................................................................................................................................................................................................... 51 TRANSMISSION............................................................................................................................................................................................................................... 53 COMPLETE ASSEMBLY...................................................................................................................................................................................................................... 53 FORWARD REVERSE CLUTCH................................................................................................................................................................................................................. 57 1ST THROUGH 4TH SPEED SHAFT............................................................................................................................................................................................................ 57 4WD SHAFT.............................................................................................................................................................................................................................. 58 FRONT AXLE................................................................................................................................................................................................................................. 59 COMPLETE ASSEMBLY...................................................................................................................................................................................................................... 59 DIFFERENTIAL....................................................................................................................................................................................................................... 60 PLANETARY.......................................................................................................................................................................................................................... 61 REAR AXLE.................................................................................................................................................................................................................................. 62 COMPLETE ASSEMBLY...................................................................................................................................................................................................................... 62 DIFFERENTIAL........................................................................................................................................................................................................................... 63 PLANETARY.............................................................................................................................................................................................................................. 64 WORK BRAKES............................................................................................................................................................................................................................ 65 DIFFERENTIAL LOCK...................................................................................................................................................................................................................... 66 HYDRAULIC PUMP............................................................................................................................................................................................................................. 67 MAIN PUMP.............................................................................................................................................................................................................................. 68 FUNCTION........................................................................................................................................................................................................................... 70 STRUCTURE.......................................................................................................................................................................................................................... 70 OPERATION.......................................................................................................................................................................................................................... 70 DELIVERY CONTROL VALVE................................................................................................................................................................................................................. 72 LS VALVE FUNCTION.................................................................................................................................................................................................................. 74 PC VALVE FUNCTION.................................................................................................................................................................................................................. 74 PC VALVE OPERATION................................................................................................................................................................................................................. 75 MAIN CONTROL VALVE......................................................................................................................................................................................................................... 78 CLSS....................................................................................................................................................................................................................................... 86 DESCRIPTION............................................................................................................................................................................................................................ 86 CHARACTERISTICS.................................................................................................................................................................................................................... 86 STRUCTURE.......................................................................................................................................................................................................................... 86 OPERATING PRINCIPLES................................................................................................................................................................................................................... 87 PUMPING PLATE CONTROL ANGLE........................................................................................................................................................................................................ 87 PRESSURE COMPENSATION CONTROL...................................................................................................................................................................................................... 88 MAIN CONTROL VALVE................................................................................................................................................................................................................. 89 UNLOADING VALVE.................................................................................................................................................................................................................... 90 LS PRESSURE........................................................................................................................................................................................................................ 93 LS BYPASS PLUG..................................................................................................................................................................................................................... 95 PRESSURE COMPENSATION VALVES....................................................................................................................................................................................................... 96 PRESSURE COMPENSATION VALVE........................................................................................................................................................................................................ 97 PRIORITY VALVE..................................................................................................................................................................................................................... 98 PPC REDUCING VALVE................................................................................................................................................................................................................. 99 STEERING UNIT..............................................................................................................................................................................................................................102 TECHNICAL DATA.........................................................................................................................................................................................................................102 OPERATION..............................................................................................................................................................................................................................102 PPC VALVE..................................................................................................................................................................................................................................103 LOADER.................................................................................................................................................................................................................................103 OPERATION..........................................................................................................................................................................................................................105 OUTRIGGER..............................................................................................................................................................................................................................109 OPERATION..........................................................................................................................................................................................................................110 BACKHOE................................................................................................................................................................................................................................113 LEFT VALVE.........................................................................................................................................................................................................................113 RIGHT VALVE........................................................................................................................................................................................................................114 SOLENOID VALVE.............................................................................................................................................................................................................................115 HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE (MP) BUCKET...................................................................................................................................................................................115 HYDRAULIC CONTROLS WITH MULTI-PURPOSE (MP) BUCKET......................................................................................................................................................................................116 LOADER CYLINDERS...........................................................................................................................................................................................................................117 BOOM...................................................................................................................................................................................................................................117 CHARACTERISTICS....................................................................................................................................................................................................................117 BUCKET.................................................................................................................................................................................................................................118 CHARACTERISTICS....................................................................................................................................................................................................................118 MP BUCKET..............................................................................................................................................................................................................................119 CHARACTERISTICS....................................................................................................................................................................................................................119 BACKHOE CYLINDERS..........................................................................................................................................................................................................................120 BOOM...................................................................................................................................................................................................................................120 CHARACTERISTICS....................................................................................................................................................................................................................120 ARM....................................................................................................................................................................................................................................121 CHARACTERISTICS....................................................................................................................................................................................................................121 BUCKET.................................................................................................................................................................................................................................122 CHARACTERISTICS....................................................................................................................................................................................................................122 TELESCOPIC ARM CYLINDER................................................................................................................................................................................................................123 CHARACTERISTICS....................................................................................................................................................................................................................123 SWING..................................................................................................................................................................................................................................124 CHARACTERISTICS....................................................................................................................................................................................................................124 OUTRIGGER..............................................................................................................................................................................................................................125 CHARACTERISTICS....................................................................................................................................................................................................................125 WORK EQUIPMENT.............................................................................................................................................................................................................................126 LOADER.................................................................................................................................................................................................................................126 BACKHOE................................................................................................................................................................................................................................128 AIR CONDITIONING...........................................................................................................................................................................................................................132 20 TESTING, ADJUSTING AND TROUBLESHOOTING......................................................................................................................................................................................................134 STANDARD VALUE TABLE.......................................................................................................................................................................................................................137 ENGINE.................................................................................................................................................................................................................................137 CHASSIS................................................................................................................................................................................................................................138 SPECIAL TOOLS..............................................................................................................................................................................................................................145 ENGINE SPEED...............................................................................................................................................................................................................................146 ENGINE WITH LOAD.......................................................................................................................................................................................................................146 MACHINE IN POWER MODE AT MIN.......................................................................................................................................................................................................146 WITH CONVERTER STALLED.............................................................................................................................................................................................................146 CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD....................................................................................................................................................................................146 ANALYSIS...........................................................................................................................................................................................................................147 VALVE CLEARANCE............................................................................................................................................................................................................................147 AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................................................................................................................................148 BLEED AIR FROM CIRCUITS....................................................................................................................................................................................................................149 BLEED AIR FROM CYLINDERS...............................................................................................................................................................................................................149 BLEED AIR FROM BRAKING CIRCUIT.........................................................................................................................................................................................................149 RELEASING RESIDUAL PRESSURE............................................................................................................................................................................................................149 ACCELERATOR PEDAL AND LEVER................................................................................................................................................................................................................150 ACCELERATOR PEDAL TRAVEL...............................................................................................................................................................................................................150 ACCELERATOR LEVER TRAVEL...............................................................................................................................................................................................................151 BRAKE SYSTEM...............................................................................................................................................................................................................................152 CONTROL................................................................................................................................................................................................................................152 ADJUSTMENT.............................................................................................................................................................................................................................152 CHECKS.................................................................................................................................................................................................................................153 LEAKAGE CHECKS.....................................................................................................................................................................................................................153 INDIVIDUAL PUMP CHECK..............................................................................................................................................................................................................154 BRAKE GROUP LEAKAGE................................................................................................................................................................................................................155 PARKING BRAKE ADJUSTMENT...................................................................................................................................................................................................................156 HYDRAULIC CIRCUIT..........................................................................................................................................................................................................................157 INTRODUCTION...........................................................................................................................................................................................................................157 MAIN CONTROL VALVE.................................................................................................................................................................................................................158 RELIEF VALVES..............................................................................................................................................................................................................................159 TESTING................................................................................................................................................................................................................................159 UNLOADING VALVE....................................................................................................................................................................................................................159 MAIN RELIEF VALVE..................................................................................................................................................................................................................159 SECONDARY VALVES...................................................................................................................................................................................................................159 SETTING RELIEF VALVES......................................................................................................................................................................................................................162 MAIN RELIEF VALVE......................................................................................................................................................................................................................162 CIRCUIT RELIEF VALVES..................................................................................................................................................................................................................162 ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET................................................................................................................................................................162 SWING, LOADER DUMP, HAMMER, AND BOOM RAISE.........................................................................................................................................................................................163 LS DIFFERENTIAL PRESSURE...................................................................................................................................................................................................................164 CONTROL................................................................................................................................................................................................................................164 ADJUSTMENT.............................................................................................................................................................................................................................164 PPC SUPPLY PRESSURE........................................................................................................................................................................................................................165 CHECK..................................................................................................................................................................................................................................165 ADJUSTMENT.............................................................................................................................................................................................................................165 PC VALVE...................................................................................................................................................................................................................................166 ADJUSTMENT.............................................................................................................................................................................................................................166 STEERING CONTROL SYSTEM....................................................................................................................................................................................................................167 CONTROL................................................................................................................................................................................................................................167 SETTING................................................................................................................................................................................................................................167 STEERING CYLINDER..........................................................................................................................................................................................................................168 POWER TRAIN GROUP..........................................................................................................................................................................................................................169 CONVERTER OIL PRESSURE.................................................................................................................................................................................................................169 CLUTCH ENGAGEMENT PRESSURE.............................................................................................................................................................................................................169 SUPPLY PRESSURE........................................................................................................................................................................................................................170 TRANSMISSION CLUTCH FUNCTION...............................................................................................................................................................................................................171 MACHINE PREPARATION....................................................................................................................................................................................................................171 CONTROL................................................................................................................................................................................................................................171 HYDRAULIC DRIFT............................................................................................................................................................................................................................172 LOADER.................................................................................................................................................................................................................................172 BOOM CIRCUIT.......................................................................................................................................................................................................................172 BUCKET CIRCUIT.....................................................................................................................................................................................................................173 BACKHOE................................................................................................................................................................................................................................173 BOOM CIRCUIT.......................................................................................................................................................................................................................174 ARM CIRCUIT........................................................................................................................................................................................................................174 BUCKET CIRCUIT.....................................................................................................................................................................................................................175 OUTRIGGERS CIRCUIT - WITHOUT LOCK VALVES...........................................................................................................................................................................................176 AIR CONDITIONING...........................................................................................................................................................................................................................177 WORK TEMPERATURE.......................................................................................................................................................................................................................177 UNIT CHECK.............................................................................................................................................................................................................................177 EMPTYING THE AIR CONDITIONING UNIT.....................................................................................................................................................................................................178 TROUBLESHOOTING GUIDE......................................................................................................................................................................................................................179 FRONT AXLE.............................................................................................................................................................................................................................179 REAR AXLE..............................................................................................................................................................................................................................184 TRANSMISSION...........................................................................................................................................................................................................................189 FUSES AND RELAYS...........................................................................................................................................................................................................................192 FUSE AND RELAY PANEL LOCATION..........................................................................................................................................................................................................192 FUSE AND RELAY PANEL LAYOUT............................................................................................................................................................................................................193 FUSES..............................................................................................................................................................................................................................193 RELAYS.............................................................................................................................................................................................................................195 HEATING AND AIR CONDITIONING FUSES AND RELAYS..........................................................................................................................................................................................196 FUSES..............................................................................................................................................................................................................................196 RELAYS.............................................................................................................................................................................................................................196 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................................................................196 HOW TO USE THIS MANUAL.....................................................................................................................................................................................................................203 REMOVAL AND INSTALLATION OF COMPONENTS.................................................................................................................................................................................................203 REMOVAL............................................................................................................................................................................................................................203 INSTALLATION.......................................................................................................................................................................................................................203 OVERHAUL OF COMPONENTS.................................................................................................................................................................................................................204 DISASSEMBLY PROCEDURES.............................................................................................................................................................................................................204 ASSEMBLY PROCEDURES................................................................................................................................................................................................................204 PRECAUTIONS FOR WORK.......................................................................................................................................................................................................................205 SPECIAL TOOL LIST..........................................................................................................................................................................................................................207 CONNECTOR REPAIR PROCEDURES................................................................................................................................................................................................................210 CONTACT TERMINAL REMOVAL (HD30 TYPE)...................................................................................................................................................................................................210 CRIMPING CONTACT TERMINAL (HD30 TYPE)..................................................................................................................................................................................................211 INSERTION OF CONTACT TERMINAL (HD30 TYPE)..............................................................................................................................................................................................212 CONTACT TERMINAL REMOVAL (DT TYPE).....................................................................................................................................................................................................213 CRIMPING CONTACT TERMINAL (DT TYPE)....................................................................................................................................................................................................214 INSERTION OF CONTACT TERMINAL (DT TYPE)................................................................................................................................................................................................215 STRIPPING INSULATION...................................................................................................................................................................................................................216 ENGINE HOOD................................................................................................................................................................................................................................217 REMOVAL................................................................................................................................................................................................................................217 INSTALLATION...........................................................................................................................................................................................................................218 FRONT GUARD................................................................................................................................................................................................................................219 REMOVAL................................................................................................................................................................................................................................219 INSTALLATION...........................................................................................................................................................................................................................219 RADIATOR...................................................................................................................................................................................................................................220 REMOVAL................................................................................................................................................................................................................................220 INSTALLATION...........................................................................................................................................................................................................................223 AIR CONDITIONER CONDENSER..................................................................................................................................................................................................................224 REMOVAL................................................................................................................................................................................................................................224 INSTALLATION...........................................................................................................................................................................................................................224 MUFFLER....................................................................................................................................................................................................................................225 REMOVAL................................................................................................................................................................................................................................225 INSTALLATION...........................................................................................................................................................................................................................226 AIR FILTER.................................................................................................................................................................................................................................227 REMOVAL................................................................................................................................................................................................................................227 INSTALLATION...........................................................................................................................................................................................................................227 TURBOCHARGER...............................................................................................................................................................................................................................228 REMOVAL................................................................................................................................................................................................................................228 INSTALLATION...........................................................................................................................................................................................................................230 AIR CONDITIONER COMPRESSOR.................................................................................................................................................................................................................231 REMOVAL................................................................................................................................................................................................................................231 INSTALLATION...........................................................................................................................................................................................................................233 AIR CONDITIONER COMPRESSOR BELT............................................................................................................................................................................................................234 REMOVAL................................................................................................................................................................................................................................234 INSTALLATION...........................................................................................................................................................................................................................234 EXHAUST STACK..............................................................................................................................................................................................................................235 REMOVAL................................................................................................................................................................................................................................235 INSTALLATION...........................................................................................................................................................................................................................236 OPERATOR’S SEAT............................................................................................................................................................................................................................236 REMOVAL................................................................................................................................................................................................................................236 INSTALLATION...........................................................................................................................................................................................................................236 CAB HEATING AND COOLING SYSTEM.............................................................................................................................................................................................................237 REMOVAL................................................................................................................................................................................................................................237 FAN................................................................................................................................................................................................................................241 HEATER CORE........................................................................................................................................................................................................................242 INSTALLATION...........................................................................................................................................................................................................................243 BATTERY....................................................................................................................................................................................................................................244 REMOVAL................................................................................................................................................................................................................................244 INSTALLATION...........................................................................................................................................................................................................................245 FUEL TANK..................................................................................................................................................................................................................................246 REMOVAL................................................................................................................................................................................................................................246 INSTALLATION...........................................................................................................................................................................................................................247 STEERING AND FRONT DASH ASSEMBLY...........................................................................................................................................................................................................248 STEERING WHEEL.........................................................................................................................................................................................................................248 REMOVAL............................................................................................................................................................................................................................248 INSTALLATION.......................................................................................................................................................................................................................249 FRONT DASH ASSEMBLY....................................................................................................................................................................................................................250 REMOVAL............................................................................................................................................................................................................................250 INSTALLATION.......................................................................................................................................................................................................................251 STEERING UNIT..........................................................................................................................................................................................................................252 REMOVAL............................................................................................................................................................................................................................252 INSTALLATION.......................................................................................................................................................................................................................253 BRAKE SYSTEM...............................................................................................................................................................................................................................254 REMOVAL................................................................................................................................................................................................................................254 INSTALLATION...........................................................................................................................................................................................................................256 BLEED AIR FROM BRAKING CIRCUIT.........................................................................................................................................................................................................257 CAB........................................................................................................................................................................................................................................258 REMOVAL................................................................................................................................................................................................................................258 INSTALLATION...........................................................................................................................................................................................................................264 HYDRAULIC OIL TANK.........................................................................................................................................................................................................................265 REMOVAL................................................................................................................................................................................................................................265 INSTALLATION...........................................................................................................................................................................................................................271 HYDRAULIC PUMP.............................................................................................................................................................................................................................272 REMOVAL................................................................................................................................................................................................................................272 INSTALLATION...........................................................................................................................................................................................................................274 TRANSMISSION...............................................................................................................................................................................................................................275 REMOVAL................................................................................................................................................................................................................................275 INSTALLATION...........................................................................................................................................................................................................................279 BLEED AIR FROM CYLINDERS...............................................................................................................................................................................................................279 TRANSMISSION OVERHAUL PROCEDURES...........................................................................................................................................................................................................280 TORQUE CONVERTER.......................................................................................................................................................................................................................280 REMOVAL............................................................................................................................................................................................................................280 INSTALLATION.......................................................................................................................................................................................................................280 PLUGS AND FILTERS......................................................................................................................................................................................................................281 DISASSEMBLY........................................................................................................................................................................................................................281 ASSEMBLY...........................................................................................................................................................................................................................284 PUMP...................................................................................................................................................................................................................................287 DISASSEMBLY........................................................................................................................................................................................................................287 ASSEMBLY...........................................................................................................................................................................................................................289 OIL LINE...............................................................................................................................................................................................................................291 REMOVAL............................................................................................................................................................................................................................291 ASSEMBLY...........................................................................................................................................................................................................................291 VALVE BODY.............................................................................................................................................................................................................................292 DISASSEMBLY........................................................................................................................................................................................................................292 ASSEMBLY...........................................................................................................................................................................................................................300 4-WHEEL DRIVE SOLENOID VALVE...........................................................................................................................................................................................................308 DISASSEMBLY........................................................................................................................................................................................................................308 ASSEMBLY...........................................................................................................................................................................................................................310 TRANSMISSION HOUSING...................................................................................................................................................................................................................312 DISASSEMBLY........................................................................................................................................................................................................................312 ASSEMBLY...........................................................................................................................................................................................................................322 CLUTCH PACK (A) AND GEAR SHAFT (D).....................................................................................................................................................................................................332 DISASSEMBLY........................................................................................................................................................................................................................332 CLUTCHES AND DISC INSPECTIONS......................................................................................................................................................................................................341 ASSEMBLY...........................................................................................................................................................................................................................342 CHECKING CLUTCH FUNCTION...........................................................................................................................................................................................................351 GEAR SHAFTS (B) AND (C)................................................................................................................................................................................................................352 DISASSEMBLY........................................................................................................................................................................................................................352 ASSEMBLY...........................................................................................................................................................................................................................361 GEAR SHAFT (E).........................................................................................................................................................................................................................370 DISASSEMBLY........................................................................................................................................................................................................................370 ASSEMBLY...........................................................................................................................................................................................................................374 SHIFTER TOWER AND FORKS................................................................................................................................................................................................................380 DISASSEMBLY........................................................................................................................................................................................................................380 ASSEMBLY...........................................................................................................................................................................................................................383 ENGINE.....................................................................................................................................................................................................................................386 REMOVAL................................................................................................................................................................................................................................386 INSTALLATION...........................................................................................................................................................................................................................392 CONTROL VALVE..............................................................................................................................................................................................................................393 REMOVAL................................................................................................................................................................................................................................393 INSTALLATION...........................................................................................................................................................................................................................395 STEERING SOLENOID VALVE....................................................................................................................................................................................................................396 REMOVAL................................................................................................................................................................................................................................396 INSTALLATION...........................................................................................................................................................................................................................396 FRONT AXLE ASSEMBLY........................................................................................................................................................................................................................397 REMOVAL................................................................................................................................................................................................................................397 INSTALLATION...........................................................................................................................................................................................................................398 FRONT AXLE OVERHAUL PROCEDURES.............................................................................................................................................................................................................399 STEERING CYLINDER ASSEMBLY.............................................................................................................................................................................................................399 DISASSEMBLY........................................................................................................................................................................................................................399 ASSEMBLY...........................................................................................................................................................................................................................400 FRONT AXLE END PLANETARY ASSEMBLY......................................................................................................................................................................................................405 DISASSEMBLY........................................................................................................................................................................................................................405 ASSEMBLY...........................................................................................................................................................................................................................407 AXLE END HUB ASSEMBLY..................................................................................................................................................................................................................408 DISASSEMBLY........................................................................................................................................................................................................................408 ASSEMBLY...........................................................................................................................................................................................................................412 AXLE HOUSING...........................................................................................................................................................................................................................415 DISASSEMBLY........................................................................................................................................................................................................................415 ASSEMBLY...........................................................................................................................................................................................................................417 DIFFERENTIAL...........................................................................................................................................................................................................................418 DISASSEMBLY........................................................................................................................................................................................................................418 ASSEMBLY...........................................................................................................................................................................................................................420 PINION.................................................................................................................................................................................................................................424 DISASSEMBLY........................................................................................................................................................................................................................424 ASSEMBLY...........................................................................................................................................................................................................................427 CARRIER................................................................................................................................................................................................................................431 DISASSEMBLY........................................................................................................................................................................................................................431 ASSEMBLY...........................................................................................................................................................................................................................432 REAR AXLE ASSEMBLY.........................................................................................................................................................................................................................434 REMOVAL................................................................................................................................................................................................................................434 INSTALLATION...........................................................................................................................................................................................................................436 REAR AXLE OVERHAUL PROCEDURES..............................................................................................................................................................................................................437 PARKING BRAKE ASSEMBLY.................................................................................................................................................................................................................437 DISASSEMBLY........................................................................................................................................................................................................................437 ASSEMBLY...........................................................................................................................................................................................................................439 MAINTENANCE........................................................................................................................................................................................................................441 SERVICE BRAKE ASSEMBLY.................................................................................................................................................................................................................444 DISASSEMBLY........................................................................................................................................................................................................................444 ASSEMBLY...........................................................................................................................................................................................................................449 REAR AXLE END PLANETARY ASSEMBLY.......................................................................................................................................................................................................455 DISASSEMBLY........................................................................................................................................................................................................................455 ASSEMBLY...........................................................................................................................................................................................................................460 DIFFERENTIAL...........................................................................................................................................................................................................................464 DISASSEMBLY........................................................................................................................................................................................................................464 ASSEMBLY...........................................................................................................................................................................................................................466 DIFFERENTIAL LOCK......................................................................................................................................................................................................................471 DISASSEMBLY........................................................................................................................................................................................................................471 ASSEMBLY...........................................................................................................................................................................................................................474 CARRIER................................................................................................................................................................................................................................477 DISASSEMBLY........................................................................................................................................................................................................................477 ASSEMBLY...........................................................................................................................................................................................................................481 PINION.................................................................................................................................................................................................................................485 DISASSEMBLY........................................................................................................................................................................................................................485 ASSEMBLY...........................................................................................................................................................................................................................487 FRONT LOADER PPC VALVE.....................................................................................................................................................................................................................491 REMOVAL................................................................................................................................................................................................................................491 INSTALLATION...........................................................................................................................................................................................................................492 FRONT-END LOADER ASSEMBLY..................................................................................................................................................................................................................493 LOADER BOOM CYLINDERS..................................................................................................................................................................................................................493 INSTALLATION...........................................................................................................................................................................................................................494 BUCKET CYLINDERS.......................................................................................................................................................................................................................495 REMOVAL............................................................................................................................................................................................................................495 INSTALLATION.......................................................................................................................................................................................................................496 FRONT LOADER BUCKET....................................................................................................................................................................................................................497 REMOVAL............................................................................................................................................................................................................................497 INSTALLATION.......................................................................................................................................................................................................................497 LOADER BOOM ASSEMBLY...................................................................................................................................................................................................................498 REMOVAL............................................................................................................................................................................................................................498 INSTALLATION.......................................................................................................................................................................................................................499 BACKHOE PPC VALVE..........................................................................................................................................................................................................................500 REMOVAL................................................................................................................................................................................................................................500 INSTALLATION...........................................................................................................................................................................................................................501 PPC VALVE SUPPORT RELEASE CABLES...........................................................................................................................................................................................................502 REMOVAL................................................................................................................................................................................................................................502 INSTALLATION AND ADJUSTING.............................................................................................................................................................................................................504 SOLENOID VALVE.............................................................................................................................................................................................................................508 REMOVAL................................................................................................................................................................................................................................508 INSTALLATION...........................................................................................................................................................................................................................508 PPC VALVE GAS STRUT........................................................................................................................................................................................................................505 REMOVAL................................................................................................................................................................................................................................505 INSTALLATION...........................................................................................................................................................................................................................507 BACKHOE ASSEMBLY...........................................................................................................................................................................................................................509 BUCKET CYLINDER........................................................................................................................................................................................................................509 REMOVAL............................................................................................................................................................................................................................509 INSTALLATION.......................................................................................................................................................................................................................510 TELESCOPIC ARM CYLINDER................................................................................................................................................................................................................511 REMOVAL............................................................................................................................................................................................................................511 INSTALLATION.......................................................................................................................................................................................................................511 ARM CYLINDER...........................................................................................................................................................................................................................512 REMOVAL............................................................................................................................................................................................................................512 INSTALLATION.......................................................................................................................................................................................................................513 BOOM CYLINDER..........................................................................................................................................................................................................................514 REMOVAL............................................................................................................................................................................................................................514 INSTALLATION.......................................................................................................................................................................................................................515 SWING CYLINDERS........................................................................................................................................................................................................................516 REMOVAL............................................................................................................................................................................................................................516 INSTALLATION.......................................................................................................................................................................................................................518 BOOM LOCK CYLINDER.....................................................................................................................................................................................................................519 REMOVAL............................................................................................................................................................................................................................519 INSTALLATION.......................................................................................................................................................................................................................520 BACKHOE BUCKET.........................................................................................................................................................................................................................520 REMOVAL............................................................................................................................................................................................................................520 INSTALLATION.......................................................................................................................................................................................................................520 BACKHOE ARM............................................................................................................................................................................................................................521 REMOVAL............................................................................................................................................................................................................................521 INSTALLATION.......................................................................................................................................................................................................................523 TELESCOPIC ARM.........................................................................................................................................................................................................................524 REMOVAL............................................................................................................................................................................................................................524 INSTALLATION.......................................................................................................................................................................................................................524 TELESCOPIC ARM GIBS....................................................................................................................................................................................................................525 REMOVAL............................................................................................................................................................................................................................525 INSTALLATION.......................................................................................................................................................................................................................525 BACKHOE BOOM...........................................................................................................................................................................................................................526 REMOVAL............................................................................................................................................................................................................................526 INSTALLATION.......................................................................................................................................................................................................................527 BACKHOE SWING FRAME....................................................................................................................................................................................................................528 REMOVAL............................................................................................................................................................................................................................528 INSTALLATION.......................................................................................................................................................................................................................528 OUTRIGGER CYLINDERS....................................................................................................................................................................................................................529 REMOVAL............................................................................................................................................................................................................................529 INSTALLATION.......................................................................................................................................................................................................................530 OUTRIGGER ARMS.........................................................................................................................................................................................................................531 REMOVAL............................................................................................................................................................................................................................531 INSTALLATION.......................................................................................................................................................................................................................531 WORK EQUIPMENT CYLINDER OVERHAUL...........................................................................................................................................................................................................532 LOADER AND BACKHOE CYLINDERS...........................................................................................................................................................................................................532 DISASSEMBLY........................................................................................................................................................................................................................532 ASSEMBLY...........................................................................................................................................................................................................................534 SWING CYLINDERS........................................................................................................................................................................................................................537 DISASSEMBLY........................................................................................................................................................................................................................537 ASSEMBLY...........................................................................................................................................................................................................................539 90 OTHERS......................................................................................................................................................................................................................................542 HYDRAULIC CIRCUIT..........................................................................................................................................................................................................................545 HYDRAULIC CIRCUIT (1 OF 4).............................................................................................................................................................................................................545 HYDRAULIC CIRCUIT (2 OF 4).............................................................................................................................................................................................................546 HYDRAULIC CIRCUIT (3 OF 4).............................................................................................................................................................................................................547 HYDRAULIC CIRCUIT (4 OF 4).............................................................................................................................................................................................................548 ELECTRICAL SCHEMATIC ......................................................................................................................................................................................................................549 WIRING - 1 OF 7........................................................................................................................................................................................................................549 WIRING - 2 OF 7........................................................................................................................................................................................................................550 WIRING - 3 OF 7........................................................................................................................................................................................................................551 WIRING - 4 OF 7........................................................................................................................................................................................................................552 WIRING - 5 OF 7........................................................................................................................................................................................................................553 WIRING - 6 OF 7........................................................................................................................................................................................................................554 WIRING - 7 OF 7........................................................................................................................................................................................................................555 LEGEND FOR WIRING SCHEMATIC............................................................................................................................................................................................................556
KOMATSU WB156-5 BACKHOE LOADER SHOP MANUAL CEBM016602 – PDF DOWNLOAD:
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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