Komatsu WB156PS-5 Backhoe Loader Workshop Repair Service Manual PDF - MKMTSWB156PS.zip
This is a full service and repair guide, complete with electrical wiring diagrams, for the Komatsu Backhoe Loader WB156PS. It contains every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way a professional technician would.
Inside the Komatsu Backhoe Loader WB156PS workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM016705 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual.pdf
CEBM002201 - Backhoe Loader WB156PS-5 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 821 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM016705 - Backhoe Loader WB156-5, WB156PS-5 Operation & Maintenance Manual....1
INTRODUCTION....5
FOREWORD....6
SAFETY INFORMATION....7
Safety labels....8
APPROVED AND NON-APPROVED USES....9
Approved Functions....9
Non-approved Functions....9
PRODUCT INFORMATION....10
Main Features....10
Breaking-in the New Machine....10
Synthetic Biodegradable Oil Types....10
PRODUCT IDENTIFICATION....11
Machine Serial Number....11
Machine Identification Plate....11
Engine Serial Number and Emission Label....12
Front Axle Serial Number....12
Rear Axle Serial Number....12
Transmission Serial Number....13
Cab Serial Number....13
Canopy Serial Number....13
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION....14
TABLE OF CONTENTS....15
SAFETY....25
SAFETY AND WARNING DECALS....26
Location of Safety Decals....26
Safety and Warning Decals....29
GENERAL SAFETY RULES AND PRECAUTIONS....37
General Safety Rules....37
If Abnormalities are Found....37
Safety at Job Site....38
Safety Features....38
Clothing and Personal Protective Equipment....38
Keep Machine Clean....39
Fire and Explosion Prevention....39
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid....39
Fire Caused by Accumulation of Flammable Material....40
Fire Caused by Electric Wiring....40
Fire Caused by Hydraulic Line....40
Explosion Caused by Lighting Equipment....40
Action if Fire Occurs....40
Asbestos Hazard Alert....41
Keep Operator's Cab Clean....41
Room Ventilation....41
Burn Prevention....42
Hot Coolant....42
Hot Oil....42
PRECAUTIONS FOR OPERATION....43
Seat Belt Inspection....43
Leaving the Operator’s Seat....44
Mounting and Dismounting....45
Checking the Rearview Mirrors....45
Crush or Pinch Point Dangers....45
Fire Extinguisher and First Aid Kit....46
Inside Operator’s Compartment....46
Cleaning Windows, Mirrors and Lights....46
Checking the Windshield Wiper Blades and Bulbs....46
Precautions When Using ROPS....47
Unauthorized Modifications....47
Precautions for Attachments....47
Quick Coupler Attachment....47
Large Attachments....48
PRECAUTIONS BEFORE STARTING OPERATIONS....49
Hand Signals....49
Pre-operational Checks....49
Starting Your Work Operations....49
Work Site Hazards....50
Working on Loose or Unstable Ground....50
Visibility....50
Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES)....50
Avoid Dangerous Situations....51
Working Clearances....53
High Voltage Lines....53
RULES FOR ROAD TRAVEL....54
Travel Precautions....54
Rules for Traveling in Reverse....55
Traveling on Snow or Frozen Surfaces....56
Traveling on Slopes....56
Traveling on Loose or Unstable Ground....57
Parking the Machine....58
PRECAUTIONS DURING MAINTENANCE OPERATIONS....59
Warning Tags....59
Equipment Storage....59
Working Under the Machine....60
Using Drop Lamps....60
Keeping the Machine Clean....60
Running the Machine During Maintenance....61
Rules for Refueling the Machine....61
Cooling System Precautions....61
Battery Precautions....62
Hazards....63
Using Booster Cables....64
Starting the Machine with Booster Cables....64
High-Pressure Hoses....65
Safety Handling of High-pressure Hoses....65
Precaution for High Fuel Pressure....65
High-Temperature Areas....65
Rotating Parts....66
Disposal of Waste Materials....66
Inflating Tires....66
Accumulator....67
Critical Parts....67
OPERATION....69
GENERAL VIEW OF MACHINE....70
Front View of Machine....70
Rear View of Machine....71
OPERATION CONTROLS....72
In the Cab (Joystick Controls)....72
Steering Column Switches....73
Directional Control Switch (Standard)....73
Speed Selector Switch (PS Model Only)....73
Multifunctional Switch....73
Front Instrument Panel and Controls....74
Side Instrument and Controls....78
Cab Switches and Electric Accessories....86
Front Work Light Switch....86
Rear Work Light Switch....86
Rear Windshield Wiper Switch....86
Rear Windshield Washer Switch....86
Overhead Lamp (Dome)....87
Power Outlet....87
Power Outlet Socket....87
Front End Loader Controls....88
Loader Declutch Control Button....88
Multipurpose Bucket Open Button....88
Differential Lock Button....89
Multipurpose Bucket Close Button....89
Front Loader Speed Control Button....89
Kick Down Button (Power Shift Only)....90
Gear Shift Lever Controls (Power Shuttle Only)....90
Declutch Button....90
Changing Speed Ranges....90
PS Model Control Lever....91
Directional Control Lever....91
Brakes, Parking Brake, Accelerator, and Throttle Control....92
Brake Pedals....92
Parking Brake....93
Accelerator Pedal....93
Hand Throttle....94
CAB ENVIRONMENT AND SAFETY EQUIPMENT....95
Heating and Ventilation System....95
Air Conditioning (if equipped)....95
Heating System....95
Seat and Seat Belt....97
Seat....97
Seat Belt....97
Safety Equipment and Storage Areas....98
Fire Extinguisher....98
First Aid Kit....98
Document Storage....98
Storage Compartment....98
CAB AND GUARDS....100
Cab....100
Doors and Windows....100
Guards....102
Driver’s Overhead Guard....102
Engine Hood....103
ELECTRICAL....103
Switches and Extra Accessories....103
Battery Disconnect Switch....103
Adapter for Radio (if provided)....104
Fuses and Relays....104
Fuse and Relay Panel Location....104
Fuse and Relay Panel Layout....105
Fuses....105
Relays....107
Heating and Air Conditioning Fuses and Relays....108
Fuses....108
Relays....108
OPERATING THE MACHINE....109
Checking the Fuel Supply....109
Starting the Engine....109
Starting the Engine in Cold Weather....110
Warming Up the Machine....112
Shutting Down the Engine....112
OPERATING THE FRONT END LOADER AND BACKHOE....113
Pre-operational Checks....113
Perform a Walk Around Check of Your Machine....113
Under the Hood....114
In the Operator’s Cab....114
Start-up Checks....114
STARTING YOUR WORK....115
Avoid Dangerous Situations....115
Working Clearances....118
High Voltage Lines....118
Operating the Front End Loader....119
Control Lever Positions....120
Multipurpose Bucket Opening Push Button....120
Multipurpose Bucket Close Push Button....120
Performing Loading Operations....121
Bucket Position Indicator....121
Organizing Your Work Area....121
Loading Heaped Material....121
Loading a Truck Bed or Trailer....123
Working on Slopes with a Loaded Bucket....123
Changing the Front Bucket....124
Operating the Backhoe....125
PPC Controls....125
Adjusting the Backhoe Controls....125
Adjusting Joystick Positions....126
Adjusting Wrist Supports....127
Adjusting Stow Position (Cab Only)....127
Unlocking the Backhoe....128
Pattern Change Control Lever....129
ISO Backhoe Controls....130
Komatsu Backhoe Controls....131
Positioning the Machine....132
Digging Methods....133
Changing the Backhoe Bucket....134
Adjusting the Bucket....134
SAFETY LOCK USAGE....135
Front End Loader Cylinder Lock....135
Backhoe Locks....137
TRAVELING WITH THE MACHINE....138
Traveling....138
Traveling on Slopes....139
Traveling or Working in Swampy or Wet Areas....140
PARKING THE MACHINE....141
Parking for Short Periods of Time....141
Parking for Long Periods of Time....141
Parking on an Incline....142
TRANSPORTING THE MACHINE....143
Loading and Securing the Machine....143
LIFTING THE MACHINE....144
LIFTING POSITION MARKS....144
LIFTING PROCEDURE....145
EMERGENCY RECOVERY....147
How to Move the Machine....147
PRECAUTIONS DURING SEASONAL CHANGES....148
Cold Seasons....148
Fuel and Lubricants....148
Coolant....148
Battery....149
Warm Seasons....149
TROUBLESHOOTING....150
Battery....150
Servicing....150
Removal and Installation....151
Starting the Engine with Booster Cables....152
Accessing the Battery....152
Connecting the Booster Cables....152
Starting the Engine....153
Disconnecting the Booster Cables....153
Electrical Circuits....154
Hydraulic System....154
Braking System....155
Transmission....155
Engine....156
MAINTENANCE....157
MAINTENANCE INFORMATION....158
Maintenance Notes....159
Engine Maintenance....160
Engine Oil....160
Coolant....160
Fuel....160
Hydraulic System Maintenance....160
Carrying Out KOWA (Komatsu Oil Wear Analysis)....161
KOWA Analysis Items....161
Electrical System Maintenance....162
Lubrication....162
WEAR PARTS LIST....163
FUEL, COOLANT, AND LUBRICANTS....164
Proper Selection According to the Ambient Temperature....164
Grease....165
Fuel....165
APPROVED SYNTHETIC LUBRICANTS (HEES)....166
LUBRICATION DIAGRAMS....167
General View....167
Multipurpose Bucket and Pallet Forks....168
Telescopic Arm....169
TORQUE SPECIFICATIONS....170
Torque List....170
Torque of Bolts....170
Torque of Hose Nuts....171
Torque of Split Flange Bolts....171
Torque for Flared Nuts....172
Torque for O-Ring Boss Piping Joints....172
Torque for O-Ring Boss Plugs....173
Torque for Hoses (Taper Seal Type and Face Seal Type)....173
PERIODIC REPLACEMENT OF COMPONENTS....175
SAFETY CRITICAL PARTS....176
Fuel Supply System....176
Delivery / Return Hydraulic System....176