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Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual A63001, A73001 and up – PDF DOWNLOAD
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Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual
Book Code: CEAM016704
SERIAL NUMBERS:
WB156-5 A63001 and up
WB156PS-5 A73001 and up
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Description
Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Backhoe Loader
Manuals Type: Operation & Maintenance Manual
Machine Model: WB156-5 WB156PS-5
Serial Number : A63001, A73001 and up
Book Code: CEAM016704
Language: English
Pages: 260
File Format: Portable Document Format (PDF)
KOMATSU WB156-5 WB156PS-5 BACKHOE LOADER OPERATION & MAINTENANCE MANUAL A63001, A73001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual
FOREWORD:
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical, and safe machine operation and maintenance. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. The safety messages in this manual and on the machine may not include all possible safety precautions.
- If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or actions described in this manual.
- Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. Store this manual in the pocket at the rear of the operator’s seat and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor.
- If you sell the machine, give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes which may not be reflected in this manual. The explanation, values and illustrations in this manual have been prepared based on the latest information available at the date of its publication.
- Consult your local KOMATSU distributor for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU distributor for those items that you may require.
TABLE OF CONTENTS:
Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual
COVER............................................................................. 1 INTRODUCTION...................................................................... 3 FOREWORD...................................................................... 4 SAFETY INFORMATION............................................................ 5 Safety labels............................................................. 6 APPROVED AND NON-APPROVED USES................................................ 7 Approved Functions........................................................ 7 Non-approved Functions.................................................... 7 PRODUCT INFORMATION........................................................... 8 Main Features............................................................. 8 Breaking-in the New Machine............................................... 8 Synthetic Biodegradable Oil Types......................................... 8 PRODUCT IDENTIFICATION........................................................ 9 Machine Serial Number..................................................... 9 Machine Identification Plate.............................................. 9 Engine Serial Number and Emission Label................................... 10 Front Axle Serial Number.................................................. 10 Rear Axle Serial Number................................................... 10 Transmission Serial Number................................................ 11 Cab Serial Number......................................................... 11 Canopy Serial Number...................................................... 11 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION.................................... 12 TABLE OF CONTENTS............................................................. 13 SAFETY............................................................................ 23 SAFETY AND WARNING DECALS..................................................... 24 Location of Safety Decals................................................. 24 Safety and Warning Decals................................................. 27 GENERAL SAFETY RULES AND PRECAUTIONS.......................................... 35 General Safety Rules...................................................... 35 If Abnormalities are Found................................................ 35 Safety at Job Site........................................................ 36 Safety Features........................................................... 36 Clothing and Personal Protective Equipment................................ 36 Keep Machine Clean........................................................ 37 Fire and Explosion Prevention............................................. 37 Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid.......... 37 Fire Caused by Accumulation of Flammable Material..................... 38 Fire Caused by Electric Wiring........................................ 38 Fire Caused by Hydraulic Line......................................... 38 Explosion Caused by Lighting Equipment................................ 38 Action if Fire Occurs................................................. 38 Asbestos Hazard Alert..................................................... 39 Keep Operator's Cab Clean................................................. 39 Room Ventilation.......................................................... 39 Burn Prevention........................................................... 40 Hot Coolant........................................................... 40 Hot Oil............................................................... 40 PRECAUTIONS FOR OPERATION..................................................... 41 Seat Belt Inspection...................................................... 41 Leaving the Operator’s Seat............................................... 42 Mounting and Dismounting.................................................. 43 Checking the Rearview Mirrors............................................. 43 Crush or Pinch Point Dangers.............................................. 43 Fire Extinguisher and First Aid Kit....................................... 44 Inside Operator’s Compartment............................................. 44 Cleaning Windows, Mirrors and Lights...................................... 44 Checking the Windshield Wiper Blades and Bulbs............................ 44 Precautions When Using ROPS............................................... 45 Unauthorized Modifications................................................ 45 Precautions for Attachments............................................... 45 Quick Coupler Attachment.............................................. 45 Large Attachments..................................................... 46 PRECAUTIONS BEFORE STARTING OPERATIONS........................................ 47 Hand Signals.............................................................. 47 Pre-operational Checks.................................................... 47 Starting Your Work Operations............................................. 47 Work Site Hazards......................................................... 48 Working on Loose or Unstable Ground....................................... 48 Visibility................................................................ 48 Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES)..... 48 Avoid Dangerous Situations................................................ 49 Working Clearances........................................................ 51 High Voltage Lines........................................................ 51 RULES FOR ROAD TRAVEL......................................................... 52 Travel Precautions........................................................ 52 Rules for Traveling in Reverse............................................ 53 Traveling on Snow or Frozen Surfaces...................................... 54 Traveling on Slopes....................................................... 54 Traveling on Loose or Unstable Ground..................................... 55 Parking the Machine....................................................... 56 PRECAUTIONS DURING MAINTENANCE OPERATIONS..................................... 57 Warning Tags.............................................................. 57 Equipment Storage......................................................... 57 Working Under the Machine................................................. 58 Using Drop Lamps.......................................................... 58 Keeping the Machine Clean................................................. 58 Running the Machine During Maintenance.................................... 59 Rules for Refueling the Machine........................................... 59 Cooling System Precautions................................................ 59 Battery Precautions....................................................... 60 Hazards............................................................... 61 Using Booster Cables.................................................. 62 Starting the Machine with Booster Cables.............................. 62 High-Pressure Hoses....................................................... 63 Safety Handling of High-pressure Hoses................................ 63 Precaution for High Fuel Pressure......................................... 63 High-Temperature Areas.................................................... 63 Rotating Parts............................................................ 64 Disposal of Waste Materials............................................... 64 Inflating Tires........................................................... 64 Accumulator............................................................... 65 Critical Parts............................................................ 65 OPERATION......................................................................... 67 GENERAL VIEW OF MACHINE....................................................... 68 Front View of Machine..................................................... 68 Rear View of Machine...................................................... 69 OPERATION CONTROLS............................................................ 70 In the Cab (Joystick Controls)............................................ 70 Steering Column Switches.................................................. 71 Directional Control Switch (Standard)................................. 71 Speed Selector Switch (PS Model Only)................................. 71 Multifunctional Switch................................................ 71 Front Instrument Panel and Controls....................................... 72 Side Instrument and Controls.............................................. 76 Cab Switches and Electric Accessories..................................... 84 Front Work Light Switch............................................... 84 Rear Work Light Switch................................................ 84 Rear Windshield Wiper Switch.......................................... 84 Rear Windshield Washer Switch......................................... 84 Overhead Lamp (Dome).................................................. 85 Power Outlet.......................................................... 85 Power Outlet Socket................................................... 85 Front End Loader Controls................................................. 86 Loader Declutch Control Button........................................ 86 Multipurpose Bucket Open Button....................................... 86 Differential Lock Button.............................................. 87 Multipurpose Bucket Close Button...................................... 87 Front Loader Speed Control Button..................................... 87 Kick Down Button (Power Shift Only)................................... 88 Gear Shift Lever Controls (Power Shuttle Only)............................ 88 Declutch Button....................................................... 88 Changing Speed Ranges................................................. 88 PS Model Control Lever................................................ 89 Directional Control Lever............................................. 89 Brakes, Parking Brake, Accelerator, and Throttle Control.................. 90 Brake Pedals.......................................................... 90 Parking Brake......................................................... 91 Accelerator Pedal..................................................... 91 Hand Throttle......................................................... 92 CAB ENVIRONMENT AND SAFETY EQUIPMENT.......................................... 93 Heating and Ventilation System............................................ 93 Air Conditioning (if equipped)........................................ 93 Heating System........................................................ 93 Seat and Seat Belt........................................................ 95 Seat.................................................................. 95 Seat Belt............................................................. 95 Safety Equipment and Storage Areas........................................ 96 Fire Extinguisher..................................................... 96 First Aid Kit......................................................... 96 Document Storage...................................................... 96 Storage Compartment................................................... 96 CAB AND GUARDS................................................................ 98 Cab....................................................................... 98 Doors and Windows..................................................... 98 Guards....................................................................100 Driver’s Overhead Guard...............................................100 Engine Hood...........................................................101 ELECTRICAL....................................................................101 Switches and Extra Accessories............................................101 Battery Disconnect Switch.............................................101 Adapter for Radio (if provided).......................................102 Fuses and Relays..........................................................102 Fuse and Relay Panel Location.........................................102 Fuse and Relay Panel Layout...............................................103 Fuses.................................................................103 Relays................................................................105 Heating and Air Conditioning Fuses and Relays.............................106 Fuses.................................................................106 Relays................................................................106 OPERATING THE MACHINE.........................................................107 Checking the Fuel Supply..................................................107 Starting the Engine.......................................................107 Starting the Engine in Cold Weather.......................................108 Warming Up the Machine....................................................110 Shutting Down the Engine..................................................110 OPERATING THE FRONT END LOADER AND BACKHOE....................................111 Pre-operational Checks....................................................111 Perform a Walk Around Check of Your Machine...............................111 Under the Hood............................................................112 In the Operator’s Cab.....................................................112 Start-up Checks...........................................................112 STARTING YOUR WORK............................................................113 Avoid Dangerous Situations................................................113 Working Clearances........................................................116 High Voltage Lines....................................................116 Operating the Front End Loader............................................117 Control Lever Positions...............................................118 Multipurpose Bucket Opening Push Button...............................118 Multipurpose Bucket Close Push Button.................................118 Performing Loading Operations.............................................119 Bucket Position Indicator.............................................119 Organizing Your Work Area.............................................119 Loading Heaped Material...............................................119 Loading a Truck Bed or Trailer........................................121 Working on Slopes with a Loaded Bucket................................121 Changing the Front Bucket.................................................122 Operating the Backhoe.....................................................123 PPC Controls..........................................................123 Adjusting the Backhoe Controls........................................123 Adjusting Joystick Positions..........................................124 Adjusting Wrist Supports..............................................125 Adjusting Stow Position (Cab Only)....................................125 Unlocking the Backhoe.....................................................126 Pattern Change Control Lever..............................................127 ISO Backhoe Controls..................................................128 Komatsu Backhoe Controls..............................................129 Positioning the Machine...................................................130 Digging Methods...........................................................131 Changing the Backhoe Bucket...............................................132 Adjusting the Bucket..................................................132 SAFETY LOCK USAGE.............................................................133 Front End Loader Cylinder Lock............................................133 Backhoe Locks.............................................................135 TRAVELING WITH THE MACHINE....................................................136 Traveling.................................................................136 Traveling on Slopes.......................................................137 Traveling or Working in Swampy or Wet Areas...............................138 PARKING THE MACHINE...........................................................139 Parking for Short Periods of Time.........................................139 Parking for Long Periods of Time..........................................139 Parking on an Incline.....................................................140 TRANSPORTING THE MACHINE......................................................141 Loading and Securing the Machine..........................................141 LIFTING THE MACHINE...........................................................142 LIFTING POSITION MARKS....................................................142 LIFTING PROCEDURE.........................................................143 EMERGENCY RECOVERY............................................................145 How to Move the Machine...................................................145 PRECAUTIONS DURING SEASONAL CHANGES...........................................146 Cold Seasons..............................................................146 Fuel and Lubricants...................................................146 Coolant...............................................................146 Battery...............................................................147 Warm Seasons..............................................................147 TROUBLESHOOTING...............................................................148 Battery...................................................................148 Servicing.............................................................148 Removal and Installation..............................................149 Starting the Engine with Booster Cables...................................150 Accessing the Battery.................................................150 Connecting the Booster Cables.........................................150 Starting the Engine...................................................151 Disconnecting the Booster Cables......................................151 Electrical Circuits.......................................................152 Hydraulic System..........................................................152 Braking System............................................................153 Transmission..............................................................153 Engine....................................................................154 MAINTENANCE.......................................................................155 MAINTENANCE INFORMATION.......................................................156 Maintenance Notes.........................................................157 Engine Maintenance........................................................158 Engine Oil............................................................158 Coolant...............................................................158 Fuel..................................................................158 Hydraulic System Maintenance..............................................158 Carrying Out KOWA (Komatsu Oil Wear Analysis).............................159 KOWA Analysis Items...................................................159 Electrical System Maintenance.............................................160 Lubrication...............................................................160 WEAR PARTS LIST...............................................................161 FUEL, COOLANT, AND LUBRICANTS.................................................162 Proper Selection According to the Ambient Temperature.....................162 Grease....................................................................163 Fuel......................................................................163 APPROVED SYNTHETIC LUBRICANTS (HEES)..........................................164 LUBRICATION DIAGRAMS..........................................................165 General View..............................................................165 Multipurpose Bucket and Pallet Forks......................................166 Telescopic Arm............................................................167 TORQUE SPECIFICATIONS.........................................................168 Torque List...............................................................168 Torque of Bolts.......................................................168 Torque of Hose Nuts...................................................169 Torque of Split Flange Bolts..........................................169 Torque for Flared Nuts................................................170 Torque for O-Ring Boss Piping Joints..................................170 Torque for O-Ring Boss Plugs..........................................171 Torque for Hoses (Taper Seal Type and Face Seal Type).................171 PERIODIC REPLACEMENT OF COMPONENTS............................................173 SAFETY CRITICAL PARTS.........................................................174 Fuel Supply System........................................................174 Delivery / Return Hydraulic System........................................174 Delivery / Return Hydraulic System........................................175 Seat Belt System..........................................................175 MAINTENANCE SCHEDULE..........................................................176 Maintenance Schedule Chart................................................176 Initial 50 Hours Maintenance..............................................179 Initial 250 Hours Maintenance.............................................179 Initial 500 Hours Maintenance.............................................179 When Required.............................................................180 Cleaning or Changing Engine Air Filters...............................180 Checking and Cleaning Cab Air Filter..................................182 Cleaning Air Recirculation Filter.....................................183 Checking the Level in Windshield Washer Reservoir.....................183 Checking Windshield Wiper Blades......................................183 Lubricating Cab Door Hinges...........................................184 Bleeding Brake System.................................................184 Checking and Adjusting Front Wheel Toe-in.............................185 Checking and Adjusting Parking Brake..................................186 Checking and Adjusting Brake Pedal Stroke.............................188 Adjusting Automatic Return of Front Bucket to the Digging Position....188 Checks Before Starting....................................................189 Various Checks........................................................189 Checking Fuel Level...................................................189 Checking Coolant Level................................................190 Checking Engine Oil Level.............................................190 Checking Hydraulic Oil Level..........................................191 Draining Water Separator..............................................192 Every 10 Hours Maintenance................................................193 Lubricating Joints (Grease Fittings)..................................193 Joint Lubrication Points..............................................194 Every 50 Hours Maintenance................................................196 Checking Radiator Fluid Level.........................................196 Checking Brake System Oil Level.......................................197 Lubricating Drive Shafts..............................................198 Lubricating Front Axle Joints.........................................199 Checking Tire Pressure................................................199 Checking Electrical System............................................199 Every 250 Hours Maintenance...............................................200 Checking Serpentine Belt..............................................200 Checking A/C Compressor Belt Tension..................................200 Cleaning Outside of Radiator..........................................201 Checking Battery Electrolyte..........................................202 Checking Front Axle Oil Levels........................................203 Checking Rear Axle Oil Levels.........................................203 Transmission Oil Level................................................204 Checking Wheel Lug Nut Torque.........................................204 Every 500 Hours Maintenance...............................................205 Changing Engine Oil...................................................205 Changing Engine Oil Filter............................................206 Changing Hydraulic Tank Oil Filter....................................207 Changing Fuel Filter..................................................210 Draining Fuel Tank....................................................211 Draining Hydraulic Oil Tank...........................................211 Every 1000 Hours Maintenance..............................................212 Changing Front Axle Oil...............................................212 Changing the Rear Axle Oil............................................213 Changing Transmission Oil.............................................214 Changing Transmission Filter..........................................215 Checking and Adjusting Engine Valve Clearance.........................215 Every 2000 Hours Maintenance..............................................216 Changing Hydraulic System Oil and Cleaning Suction Filter.............216 Changing Coolant......................................................219 Changing Brake System Oil.............................................221 Checking the Alternator and the Starter...............................221 Changing the Alternator Belt..........................................221 Checking the A/C Cooling Gas Quantity.................................221 MAINTENANCE WHEN USING DEMOLITION HAMMER......................................222 Changing Hydraulic Oil Filter.............................................222 Changing Hydraulic Oil....................................................222 LONG TERM STORAGE.............................................................223 Before Storage............................................................223 During Storage............................................................224 After Storage.............................................................224 SPECIFICATIONS....................................................................227 SPECIFICATIONS................................................................228 Machine Dimensions and Weights............................................228 Standard Arm..............................................................230 Retracted Telescopic Arm..................................................231 Extended Telescopic Arm...................................................232 MACHINE SYSTEMS SPECIFICATIONS................................................233 Engine....................................................................233 Electrical System.........................................................233 Service Refill Capacities.................................................233 Standard Tires............................................................233 Transmission..............................................................234 Total Mass................................................................234 Standard Bucket Capacity..................................................234 Loader....................................................................234 OPTIONS, ATTACHMENTS..............................................................235 AUTHORIZED OPTIONAL EQUIPMENT.................................................236 Precautions Regarding Safety..............................................236 Precautions Regarding the Installation of Equipment.......................237 Optional Equipment Measurements...........................................237 Front End Loader......................................................237 Backhoe Unit..........................................................238 FRONT EQUIPMENT QUICK COUPLING DEVICES........................................239 Manual Control Quick Coupling.............................................239 MULTIPURPOSE BUCKET (4-IN-1)..................................................240 Bucket Operation..........................................................241 Description...........................................................241 Bucket Uses...........................................................241 Pallet Forks..................................................................242 Description...............................................................242 Safety Devices............................................................243 Using the Forks...........................................................243 Preparing the Pallet Forks for Use....................................244 Overturning the Forks.................................................244 Removing the Forks....................................................245 Installing the Forks..................................................245 Maintenance...........................................................245 BACKHOE TELESCOPIC ARM........................................................246 Description...............................................................246 Control...................................................................246 Safety Devices............................................................247 Using the Telescopic Arm..................................................247 Maintenance...............................................................248 Adjusting the Guide Slack.................................................248 DEMOLITION HAMMER PIPING......................................................250 Description...............................................................250 Control...................................................................250 Rules for Hammer Usage....................................................251 Avoid the Following Uses..................................................252 Installing the Hammer.....................................................254 Removing the Hammer.......................................................256 Using the Hammer..........................................................256 Maintenance...............................................................256 HYDRAULIC JACK HAMMER PIPING..................................................257 Description...............................................................257 Control...................................................................257 Connecting and Removing the Jack Hammer...................................258 Connecting the Jack Hammer............................................258 Disconnecting the Jack Hammer.........................................258 Using the Jack Hammer.....................................................258 LOAD STABILIZER SYSTEM (LSS) (Ride Control Optional)..........................259 Load Stabilizer System (LSS) Accumulator..................................259 Pressurizing the Load Stabilizer System (LSS).............................259
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