Komatsu WB156PS-5 Backhoe Loader Shop Manual PDF

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Komatsu WB156PS-5 Backhoe Loader Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu WB156PS-5 Backhoe Loader Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 568
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WB156PS-5 Backhoe Loader Shop Manual – PDF DOWNLOAD 

SERIAL NUMBERS WB156PS-5 A73001 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu WB156PS-5 Backhoe Loader Shop Manual – PDF DOWNLOAD 

SERIAL NUMBERS WB156PS-5 A73001 and UP

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
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
FUEL, COOLANT, AND LUBRICANTS 42
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE 42
GREASE 43
FUEL AND ENGINE OIL REMARKS 43
HOMOLOGATED (HEES) SYNTHETIC LUBRICANTS 44
LUBRICATION DIAGRAMS 45
GENERAL VIEW 45
POWER TRAIN 50
DESCRIPTION 50
POWER FLOW 50
TRANSMISSION DIAGRAM 52
TRANSMISSION 53
COMPLETE ASSEMBLY 53
VALVE BODY 55
CLUTCH PACKS 56
FORWARD AND REVERSE PACK 56
DRIVE SHAFT PACK 56
DRIVEN GEAR SHAFT PACK 57
4WD DRIVEN SHAFT PACK 57
FRONT AXLE 58
COMPLETE ASSEMBLY 58
DIFFERENTIAL 59
PLANETARY 60
REAR AXLE 61
COMPLETE ASSEMBLY 61
DIFFERENTIAL 62
FINAL REDUCTION GEARS 63
WHEEL BRAKES 64
DIFFERENTIAL LOCK 65
HYDRAULIC PUMP 66
MAIN PUMP 67
FUNCTION 69
STRUCTURE 69
OPERATION 69
DELIVERY CONTROL VALVE 71
LS VALVE FUNCTION 73
PC VALVE FUNCTION 73
PC VALVE OPERATION 74
MAIN CONTROL VALVE 77
10-SPOOL CONTROL VALVE 77
CLSS 83
DESCRIPTION 83
CHARACTERISTICS 83
STRUCTURE 83
OPERATING PRINCIPLES 84
PUMPING PLATE CONTROL ANGLE 84
PRESSURE COMPENSATION CONTROL 85
MAIN CONTROL VALVE 86
UNLOADING VALVE 87
LS PRESSURE 90
LS BYPASS PLUG 92
PRESSURE COMPENSATION 93
PRESSURE COMPENSATION VALVE 94
PRIORITY VALVE 95
PPC REDUCING VALVE 96
STEERING UNIT 99
TECHNICAL DATA 99
OPERATION 99
PPC VALVES 100
STANDARD VALVE 100
OPERATION 102
PPC VALVE (FLOAT + RETURN TO DIG) 106
OPERATION 108
OUTRIGGER 112
OPERATION 113
BACKHOE 116
LEFT VALVE 116
RIGHT VALVE 117
SOLENOID VALVE 118
HYDRAULIC CONTROLS WITHOUT MULTI-PURPOSE BUCKET 118
HYDRAULIC CONTROLS WITH MULTI-PURPOSE BUCKET 119
SAFETY VALVES 120
BUCKET RAISE 120
BUCKET DUMP 121
BOOM 122
ARM 123
LOADER CYLINDERS 124
BOOM 124
CHARACTERISTICS 124
BUCKET 125
CHARACTERISTICS 125
MULTI-PURPOSE (MP) BUCKET 126
CHARACTERISTICS 126
BACKHOE CYLINDERS 127
BOOM 127
CHARACTERISTICS 127
ARM 128
CHARACTERISTICS 128
BUCKET 129
CHARACTERISTICS 129
TELESCOPIC ARM CYLINDER 130
CHARACTERISTICS 130
SWING 131
CHARACTERISTICS 131
OUTRIGGER 132
CHARACTERISTICS 132
WORK EQUIPMENT 134
LOADER 134
BACKHOE 136
AIR CONDITIONING 139
STANDARD VALUE TABLE 143
ENGINE 143
CHASSIS 144
SPECIAL TOOLS 151
ENGINE SPEED 152
ENGINE WITH LOAD 152
MACHINE IN POWER MODE AT MIN 152
WITH CONVERTER STALLED 152
CONVERTER STALLED AND HYDRAULIC PUMP UNDER LOAD 152
ANALYSIS 153
VALVE CLEARANCE 153
AIR CONDITIONER COMPRESSOR BELT TENSION 154
BLEED AIR FROM CIRCUITS 155
BLEED AIR FROM CYLINDERS 155
BLEED AIR FROM BRAKING CIRCUIT 155
RELEASING RESIDUAL PRESSURE 155
ACCELERATOR PEDAL AND LEVER 156
ACCELERATOR PEDAL TRAVEL 156
ACCELERATOR LEVER TRAVEL 157
BRAKE SYSTEM 158
CONTROL 158
ADJUSTMENT 158
CHECKS 159
LEAKAGE CHECKS 159
INDIVIDUAL PUMP CHECK 160
BRAKE GROUP LEAKAGE 161
PARKING BRAKE ADJUSTMENT 162
HYDRAULIC CIRCUIT 163
INTRODUCTION 163
MAIN CONTROL VALVE 164
RELIEF VALVES 165
TESTING 165
UNLOADING VALVE 165
MAIN RELIEF VALVE 165
SECONDARY VALVES 165
SETTING RELIEF VALVES 168
MAIN RELIEF VALVE 168
CIRCUIT RELIEF VALVES 168
ARM IN, LOADER CURL, BACKHOE BUCKET CURL, BOOM RAISE, AND MP BUCKET 168
SWING, LOADER DUMP, HAMMER, AND BOOM RAISE 169
LS DIFFERENTIAL PRESSURE 170
CONTROL 170
ADJUSTMENT 170
PPC SUPPLY PRESSURE 171
CHECK 171
ADJUSTMENT 171
PC VALVE 172
ADJUSTMENT 172
STEERING CONTROL SYSTEM 173
CONTROL 173
SETTING 173
STEERING CYLINDER 174
POWER TRAIN GROUP 175
CONVERTER OIL PRESSURE 175
CLUTCH ENGAGEMENT PRESSURE 175
SUPPLY PRESSURE 176
TRANSMISSION CLUTCH FUNCTION 177
MACHINE PREPARATION 177
CONTROL 177
HYDRAULIC DRIFT 178
LOADER 178
BOOM CIRCUIT 178
BUCKET CIRCUIT 179
BACKHOE 179
BOOM CIRCUIT 180
ARM CIRCUIT 180
BUCKET CIRCUIT 181
OUTRIGGERS CIRCUIT – WITHOUT LOCK VALVES 182
AIR CONDITIONING 183
WORK TEMPERATURE 183
UNIT CHECK 183
EMPTYING THE AIR CONDITIONING UNIT 184
TROUBLESHOOTING GUIDE 185
FRONT AXLE 185
REAR AXLE 190
TRANSMISSION 195
FUSES AND RELAYS 198
FUSE AND RELAY PANEL LOCATION 198
FUSE AND RELAY PANEL LAYOUT 199
FUSES 199
RELAYS 201
HEATING AND AIR CONDITIONING FUSES AND RELAYS 202
FUSES 202
RELAYS 202
HOW TO USE THIS MANUAL 209
REMOVAL AND INSTALLATION OF COMPONENTS 209
REMOVAL 209
INSTALLATION 209
OVERHAUL OF COMPONENTS 210
DISASSEMBLY PROCEDURES 210
ASSEMBLY PROCEDURES 210
PRECAUTIONS FOR WORK 211
SPECIAL TOOL LIST 213
CONNECTOR REPAIR PROCEDURES 216
CONTACT TERMINAL REMOVAL (HD30 TYPE) 216
CRIMPING CONTACT TERMINAL (HD30 TYPE) 217
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 218
CONTACT TERMINAL REMOVAL (DT TYPE) 219
CRIMPING CONTACT TERMINAL (DT TYPE) 220
INSERTION OF CONTACT TERMINAL (DT TYPE) 221
STRIPPING INSULATION 222
ENGINE HOOD 223
REMOVAL 223
INSTALLATION 224
FRONT GUARD 225
REMOVAL 225
INSTALLATION 225
RADIATOR 226
REMOVAL 226
INSTALLATION 229
AIR CONDITIONER CONDENSER 230
REMOVAL 230
INSTALLATION 230
MUFFLER 231
REMOVAL 231
INSTALLATION 232
AIR FILTER 233
REMOVAL 233
INSTALLATION 233
TURBOCHARGER 234
REMOVAL 234
INSTALLATION 236
AIR CONDITIONER COMPRESSOR 237
REMOVAL 237
INSTALLATION 239
AIR CONDITIONER COMPRESSOR BELT 240
REMOVAL 240
INSTALLATION 240
EXHAUST STACK 241
REMOVAL 241
INSTALLATION 242
OPERATOR’S SEAT 242
REMOVAL 242
INSTALLATION 242
CAB HEATING AND COOLING SYSTEM 243
REMOVAL 243
FAN 247
HEATER CORE 248
INSTALLATION 249
BATTERY 250
REMOVAL 250
INSTALLATION 251
FUEL TANK 252
REMOVAL 252
INSTALLATION 253
STEERING AND FRONT DASH ASSEMBLY 254
STEERING WHEEL 254
REMOVAL 254
INSTALLATION 255
FRONT DASH ASSEMBLY 256
REMOVAL 256
INSTALLATION 257
STEERING UNIT 258
REMOVAL 258
INSTALLATION 259
BRAKE SYSTEM 260
REMOVAL 260
INSTALLATION 262
BLEED AIR FROM BRAKING CIRCUIT 263
CAB 264
REMOVAL 264
INSTALLATION 270
HYDRAULIC OIL TANK 271
REMOVAL 271
INSTALLATION 277
HYDRAULIC PUMP 278
REMOVAL 278
INSTALLATION 280
TRANSMISSION 281
REMOVAL 281
INSTALLATION 284
BLEED AIR FROM CYLINDERS 285
TRANSMISSION OVERHAUL PROCEDURES 286
TORQUE CONVERTER 286
REMOVAL 286
INSTALLATION 286
PLUGS AND FILTERS 287
DISASSEMBLY 287
ASSEMBLY 291
PUMP 294
DISASSEMBLY 294
ASSEMBLY 296
VALVE BODY 298
DISASSEMBLY 298
ASSEMBLY 301
HYDRAULIC SUPPLY LINES 304
DISASSEMBLY 304
ASSEMBLY 305
TRANSMISSION HOUSING 307
DISASSEMBLY 307
ASSEMBLY 313
CLUTCH PACK (A) AND GEAR SHAFT (D) 318
DISASSEMBLY 318
CLUTCHES AND DISC INSPECTIONS 327
ASSEMBLY 328
CHECKING CLUTCH FUNCTION 337
SHAFT (B) 338
DISASSEMBLY 338
CLUTCHES AND DISC INSPECTIONS 345
ASSEMBLY 346
SHAFT (C) 353
DISASSEMBLY 353
CLUTCHES AND DISC INSPECTIONS 367
1st GEAR CLUTCHES 368
3rd GEAR CLUTCHES 368
4th GEAR CLUTCHES 368
ASSEMBLY 369
SHAFT (E) 385
DISASSEMBLY 385
CLUTCHES AND DISC INSPECTIONS 390
ASSEMBLY 391
ENGINE 398
REMOVAL 398
INSTALLATION 404
CONTROL VALVE 405
REMOVAL 405
INSTALLATION 407
STEERING SOLENOID VALVE 408
REMOVAL 408
INSTALLATION 408
FRONT AXLE ASSEMBLY 409
REMOVAL 409
INSTALLATION 410
FRONT AXLE OVERHAUL PROCEDURES 411
STEERING CYLINDER ASSEMBLY 411
DISASSEMBLY 411
ASSEMBLY 412
FRONT AXLE END PLANETARY ASSEMBLY 417
DISASSEMBLY 417
ASSEMBLY 419
AXLE END HUB ASSEMBLY 420
DISASSEMBLY 420
ASSEMBLY 424
AXLE HOUSING 427
DISASSEMBLY 427
ASSEMBLY 429
DIFFERENTIAL 430
DISASSEMBLY 430
ASSEMBLY 432
PINION 436
DISASSEMBLY 436
ASSEMBLY 439
CARRIER 443
DISASSEMBLY 443
ASSEMBLY 444
REAR AXLE ASSEMBLY 446
REMOVAL 446
INSTALLATION 448
REAR AXLE OVERHAUL PROCEDURES 449
PARKING BRAKE ASSEMBLY 449
DISASSEMBLY 449
ASSEMBLY 451
MAINTENANCE 453
SERVICE BRAKE ASSEMBLY 456
DISASSEMBLY 456
ASSEMBLY 461
REAR AXLE END PLANETARY ASSEMBLY 467
DISASSEMBLY 467
ASSEMBLY 472
DIFFERENTIAL 476
DISASSEMBLY 476
ASSEMBLY 478
DIFFERENTIAL LOCK 483
DISASSEMBLY 483
ASSEMBLY 486
CARRIER 489
DISASSEMBLY 489
ASSEMBLY 493
PINION 497
DISASSEMBLY 497
ASSEMBLY 499
FRONT LOADER PPC VALVE 503
REMOVAL 503
INSTALLATION 504
FRONT-END LOADER ASSEMBLY 505
LOADER BOOM CYLINDERS 505
INSTALLATION 506
BUCKET CYLINDERS 507
REMOVAL 507
INSTALLATION 508
FRONT LOADER BUCKET 509
REMOVAL 509
INSTALLATION 509
LOADER BOOM ASSEMBLY 510
REMOVAL 510
INSTALLATION 511
BACKHOE PPC VALVE 512
REMOVAL 512
INSTALLATION 513
PPC VALVE SUPPORT RELEASE CABLES 514
REMOVAL 514
INSTALLATION AND ADJUSTING 516
PPC VALVE GAS STRUT 517
REMOVAL 517
INSTALLATION 519
SOLENOID VALVE 520
REMOVAL 520
INSTALLATION 520
BACKHOE ASSEMBLY 521
BUCKET CYLINDER 521
REMOVAL 521
INSTALLATION 522
TELESCOPIC ARM CYLINDER 523
REMOVAL 523
INSTALLATION 523
ARM CYLINDER 524
REMOVAL 524
INSTALLATION 525
BOOM CYLINDER 526
REMOVAL 526
INSTALLATION 527
SWING CYLINDERS 528
REMOVAL 528
INSTALLATION 530
BOOM LOCK CYLINDER 531
REMOVAL 531
INSTALLATION 532
BACKHOE BUCKET 532
REMOVAL 532
INSTALLATION 532
BACKHOE ARM 533
REMOVAL 533
INSTALLATION 535
TELESCOPIC ARM 536
REMOVAL 536
INSTALLATION 536
TELESCOPIC ARM GIBS 537
REMOVAL 537
INSTALLATION 537
BACKHOE BOOM 538
REMOVAL 538
INSTALLATION 539
BACKHOE SWING FRAME 540
REMOVAL 540
INSTALLATION 540
OUTRIGGER CYLINDERS 541
REMOVAL 541
INSTALLATION 542
OUTRIGGER ARMS 543
REMOVAL 543
INSTALLATION 543
WORK EQUIPMENT CYLINDER OVERHAUL 544
LOADER AND BACKHOE CYLINDERS 544
DISASSEMBLY 544
ASSEMBLY 546
SWING CYLINDERS 549
DISASSEMBLY 549
ASSEMBLY 551
Section 90 pdf 0
90 DIAGRAMS AND SCHEMATICS 555
HYDRAULIC CIRCUIT 557
1 OF 4 557
2 OF 4 558
3 OF 4 559
4 OF 4 560
ELECTRICAL SCHEMATICS 561
RIGHT SIDE DASH (WIRING – 1 OF 8) 561
HARNESS AND SWITCHES (WIRING – 2 OF 8) 562
RELAYS AND SWITCHES (WIRING – 3 OF 8) 563
HARNESS (WIRING – 4 OF 8) 564
MOTORS AND CONTROLS (WIRING – 5 OF 8) 565
SOLENOIDS (WIRING – 6 OF 8) 566
OPTIONAL 4WS (WIRING – 7 OF 8) 567
LIST OF CONNECTORS (WIRING – 8 OF 8) 568

S.V 11/12/24