Komatsu WB156-5 WB156PS-5 Backhoe Loader Operation & Maintenance Manual - PDF DOWNLOAD

CEAM016704

Operation & Maintenance Manual

WB156-5 WB156PS-5 BACKHOE LOADER SERIAL NUMBERS

ENGINE

WB156-5 A63001 and up WB156PS-5 A73001 and up

S4D102LE-2

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

Copyright 2010 Komatsu Printed in U.S.A. Komatsu America Corp.

July 2010

INTRODUCTION

WB156/156PS-5

0

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INTRODUCTION

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.

The numbers in illustrations correspond to the numbers in (_) in the text, i.e., (1) ➞ ➀.

Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.

•

Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine.

•

This manual should be kept near or with the machine for reference and periodically reviewed by all personnel who operate it.

•

Some actions involved in operation and maintenance can cause a serious accident if they are not performed in the manner described in this manual.

•

The procedures and precautions given in this manual apply only to the intended uses of this machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions described in this manual.

•

KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine.

•

The safety description is given in “SAFETY INFORMATION” on page 0-3 and in the SAFETY section 1.

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WB156/156PS-5

INTRODUCTION

SAFETY INFORMATION Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations. Failure to do so may result in serious injury or death.

The following signal words are used to inform you that there is a potentially hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, different signal words are used to express the potential level of hazard.

The Safety Alert Symbol identifies important safety messages on machines, in manuals, and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Remark This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine. It is also used to indicate information that is useful to know.

Safety precautions are described in SAFETY section 1.

KOMATSU AMERICA CORP. cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions.

If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your local distributor or KOMATSU AMERICA CORP.

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INTRODUCTION

SAFETY LABELS Safety labels are affixed to the machine to inform the operator or maintenance worker of possible hazards when operating or maintaining the machine.

This machine uses "safety labels using words" and "safety labels using pictograms" to indicate safety procedures.

Example of safety label using words

Example of safety label using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazard is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.

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WB156/156PS-5

INTRODUCTION

APPROVED AND NON-APPROVED USES The Komatsu BACKHOE LOADERS described in this manual have been designed and constructed to be used mainly for the following functions. Any non-approved functions may void the warranty, damage the machine, or possibly injure the operator.

Approved Functions • •

Loading, scraping, or grading operations Excavating

Installation of optional equipment can also be used in the following applications. Use only Komatsu-compatible equipment.

• • • •

Handling materials (4-in-1 bucket - pallet forks) Snow plowing (angle dozer blade - snowplow) Demolition (hand hammer - hammer on backhoe unit) Ditch cleaning and digging (special buckets)

Non-approved Functions This paragraph describes some of the improper or unauthorized uses of the machine. It is impossible to predict all the possible improper uses. If the machine is to be used for any particular application other than those listed in the Approved Function list, it is important to contact your authorized Komatsu distributor before carrying out the work operations.

• • • • • • • •

Use of machine for lifting or transporting personnel in any manner Transportation of flammable liquids Lifting, moving, or transporting other machines with the front end loader or backhoe unit Towing other equipment with the tractor unit or work equipment Using the backhoe unit to move or reposition the machine Using the backhoe or loader as a hammer or for striking or driving objects Towing the machine at high speeds Traveling at high speeds

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INTRODUCTION

PRODUCT INFORMATION Komatsu backhoe loader and main components are identified by serial numbers stamped on identification plates or decals attached to the machine or component.

Main Features • • • • • • • •

Simple and easy operation Power-assisted steering with priority hydraulic system Loader control through a single lever ensures combined movements that can be modulated proportionally and continually PPC backhoe control with two levers ensure combined movements that can be modulated proportionally and continually Complete series of instruments visible from the two operating positions (loader or backhoe) Separate engine throttle controls for the two operating positions Foot brake control Easy maintenance with simplified intervals

Breaking-in the New Machine Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for the first 100 hours in order to ensure proper running-in time for the various components. If the machine is subjected to excessive or severe work loads at the beginning of operation, functions will be greatly reduced or damaged. Every new machine must be used carefully, paying special attention to the following indications: • • • •

After start-up, let the engine idle at a low rpm for five minutes to warm up the machine gradually before beginning actual operation.

Operate the machine with limited loads.

Avoid abrupt starts, accelerations, sudden decelerations, abrupt reversals, or sudden stops.

After the first 250 hours, carry out the following maintenance in addition to normal maintenance performed at 250 hours: A. Change the hydraulic transmission oil and filter.

B. Change the differential unit oil (front and rear axle).

C. Change the oil in the final reduction gears (front and rear axle).

D. Check and adjust the engine valve clearance.

E. Change the hydraulic system oil filter.

Synthetic Biodegradable Oil Types On machines in which synthetic biodegradable oils are used, the following operations are to be performed in addition to the standard maintenance operations: • •

0-6

After the first 50 hours of operation, change the hydraulic system filter.

After the first 500 hours of operation, change the hydraulic system oil and filter.

WB156/156PS-5

INTRODUCTION

PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your distributor will need when you require assistance or order replacement parts. It is a good idea to record this information in this manual. See “SERIAL NUMBERS AND DISTRIBUTOR INFORMATION” on page 0-10. All views indicated below are viewed from the operator’s position.

Machine Serial Number The machine serial number is stamped on the right side of the front part of the main tractor frame.

Machine Identification Plate The identification plate is located inside the operator’s cab on the left vertical wall of the frame, behind the brake pedals.

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INTRODUCTION

Engine Serial Number and Emission Label The engine serial number is stamped on a plate located on the left, front side of the engine gear cover.

The emission label is located on the left side also.

Front Axle Serial Number The front axle serial number is stamped on a plate located on the right, rear side of the axle housing.

Rear Axle Serial Number The rear axle serial number is stamped on a plate located inside the axle housing, on the right side.

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INTRODUCTION

Transmission Serial Number The transmission serial number is stamped on a plate located on the left side of the transmission case.

Cab Serial Number The cab serial number is stamped on a plate located on the right, front pillar.

Canopy Serial Number The canopy serial number is stamped on the plate located on the inside, upper right corner.

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INTRODUCTION

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION MODEL: WB156-5 or WB156PS-5

Machine serial No. Engine serial No. Product identification number (PIN) Front axle serial No. Rear axle serial No. Transmission serial No. Cab or Canopy serial No.

Distributor name Address

Service Personnel Phone/Fax

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INTRODUCTION

TABLE OF CONTENTS INTRODUCTION FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 APPROVED AND NON-APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 Approved Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 Non-approved Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 Main Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 Breaking-in the New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 Synthetic Biodegradable Oil Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6 PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 Machine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 Machine Identification Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7 Engine Serial Number and Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 Front Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 Rear Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 Cab Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 Canopy Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 SAFETY SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Location of Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safety and Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 If Abnormalities are Found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Safety at Job Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Clothing and Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Keep Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Fire and Explosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid . . . . . . . . . . . . . . . . . . . . . . 1-15 Fire Caused by Accumulation of Flammable Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Fire Caused by Electric Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Fire Caused by Hydraulic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Explosion Caused by Lighting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Action if Fire Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Asbestos Hazard Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Keep Operator's Cab Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Room Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 WB156/156PS-5

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INTRODUCTION Hot Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leaving the Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Rearview Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crush or Pinch Point Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher and First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inside Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Windows, Mirrors and Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Windshield Wiper Blades and Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions When Using ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unauthorized Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions for Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Coupler Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Large Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Your Work Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work Site Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working on Loose or Unstable Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES) . . . . . . . . . . . . . . . .

Avoid Dangerous Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Voltage Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rules for Traveling in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling on Snow or Frozen Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling on Loose or Unstable Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Under the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Drop Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keeping the Machine Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Running the Machine During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rules for Refueling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Machine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-12

1-18 1-18 1-19 1-19 1-20 1-21 1-21 1-21 1-22 1-22 1-22 1-22 1-23 1-23 1-23 1-23 1-24 1-25 1-25 1-25 1-25 1-26 1-26 1-26 1-26 1-27 1-29 1-29 1-30 1-30 1-31 1-32 1-32 1-33 1-34 1-35 1-35 1-35 1-36 1-36 1-36 1-37 1-37 1-37 1-38 1-39 1-40 1-40 1-41

WB156/156PS-5

INTRODUCTION Safety Handling of High-pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Precaution for High Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 High-Temperature Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 Rotating Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 Disposal of Waste Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 Inflating Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 OPERATION GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Front View of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Rear View of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 OPERATION CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 In the Cab (Joystick Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Steering Column Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Directional Control Switch (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Speed Selector Switch (PS Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Multifunctional Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Front Instrument Panel and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Side Instrument and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Cab Switches and Electric Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Front Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Rear Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Rear Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Rear Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Overhead Lamp (Dome) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Power Outlet Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Front End Loader Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Loader Declutch Control Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Multipurpose Bucket Open Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Differential Lock Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Multipurpose Bucket Close Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Front Loader Speed Control Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Kick Down Button (Power Shift Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Gear Shift Lever Controls (Power Shuttle Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Declutch Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Changing Speed Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 PS Model Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Directional Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Brakes, Parking Brake, Accelerator, and Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Brake Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Hand Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 CAB ENVIRONMENT AND SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Heating and Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 WB156/156PS-5

0-13

INTRODUCTION Air Conditioning (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Equipment and Storage Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Document Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAB AND GUARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doors and Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driver’s Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switches and Extra Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adapter for Radio (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse and Relay Panel Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse and Relay Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating and Air Conditioning Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warming Up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING THE FRONT END LOADER AND BACKHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perform a Walk Around Check of Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

In the Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING YOUR WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Avoid Dangerous Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Voltage Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Front End Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Lever Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multipurpose Bucket Opening Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multipurpose Bucket Close Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performing Loading Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-14

2-27 2-27 2-29 2-29 2-29 2-30 2-30 2-30 2-30 2-30 2-32 2-32 2-32 2-34 2-34 2-35 2-35 2-35 2-35 2-36 2-36 2-36 2-37 2-37 2-39 2-40 2-40 2-40 2-41 2-41 2-41 2-42 2-44 2-44 2-45 2-45 2-45 2-46 2-46 2-46 2-47 2-47 2-50 2-50 2-51 2-52 2-52 2-52 2-53

WB156/156PS-5

INTRODUCTION Bucket Position Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Organizing Your Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Loading Heaped Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Loading a Truck Bed or Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Working on Slopes with a Loaded Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Changing the Front Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Operating the Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 PPC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Adjusting the Backhoe Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Adjusting Joystick Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Adjusting Wrist Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Adjusting Stow Position (Cab Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 Unlocking the Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Pattern Change Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 ISO Backhoe Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Komatsu Backhoe Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 Positioning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64 Digging Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 Changing the Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Adjusting the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 SAFETY LOCK USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Front End Loader Cylinder Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Backhoe Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 TRAVELING WITH THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Traveling on Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 Traveling or Working in Swampy or Wet Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Parking for Short Periods of Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Parking for Long Periods of Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 Parking on an Incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 Loading and Securing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 LIFTING POSITION MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 LIFTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 How to Move the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 PRECAUTIONS DURING SEASONAL CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Cold Seasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Fuel and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 Warm Seasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 Starting the Engine with Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 WB156/156PS-5

0-15

INTRODUCTION Accessing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disconnecting the Booster Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-84 2-84 2-85 2-85 2-86 2-86 2-87 2-87 2-88

MAINTENANCE MAINTENANCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Maintenance Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Carrying Out KOWA (Komatsu Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 KOWA Analysis Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 FUEL, COOLANT, AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Proper Selection According to the Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 APPROVED SYNTHETIC LUBRICANTS (HEES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Multipurpose Bucket and Pallet Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Telescopic Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Torque List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Torque of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Torque of Hose Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Torque of Split Flange Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Torque for Flared Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Torque for O-Ring Boss Piping Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Torque for O-Ring Boss Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Torque for Hoses (Taper Seal Type and Face Seal Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 PERIODIC REPLACEMENT OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Delivery / Return Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Delivery / Return Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 0-16

WB156/156PS-5

INTRODUCTION Maintenance Schedule Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Initial 50 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Initial 250 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Initial 500 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 When Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Cleaning or Changing Engine Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Checking and Cleaning Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Cleaning Air Recirculation Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Checking the Level in Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Checking Windshield Wiper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Lubricating Cab Door Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Bleeding Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Checking and Adjusting Front Wheel Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Checking and Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Checking and Adjusting Brake Pedal Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Adjusting Automatic Return of Front Bucket to the Digging Position . . . . . . . . . . . . . . . . . . 3-34 Checks Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Various Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Checking Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Draining Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Every 10 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Lubricating Joints (Grease Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Joint Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Every 50 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Checking Radiator Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Checking Brake System Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Lubricating Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Lubricating Front Axle Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Checking Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Checking Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Every 250 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Checking Serpentine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Checking A/C Compressor Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Cleaning Outside of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Checking Battery Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Checking Front Axle Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Checking Rear Axle Oil Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Checking Wheel Lug Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 Every 500 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 Changing Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Changing Hydraulic Tank Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Draining Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 Draining Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 WB156/156PS-5

0-17

INTRODUCTION Every 1000 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Front Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Transmission Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking and Adjusting Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 2000 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Hydraulic System Oil and Cleaning Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Brake System Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Alternator and the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the A/C Cooling Gas Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE WHEN USING DEMOLITION HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

During Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-58 3-58 3-59 3-60 3-61 3-61 3-62 3-62 3-65 3-67 3-67 3-67 3-67 3-68 3-68 3-68 3-69 3-69 3-70 3-70

SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retracted Telescopic Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extended Telescopic Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Refill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Bucket Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-2 4-4 4-5 4-6 4-7 4-7 4-7 4-7 4-7 4-8 4-8 4-8 4-8

OPTIONS, ATTACHMENTS AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions Regarding Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Precautions Regarding the Installation of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Equipment Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front End Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Backhoe Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT EQUIPMENT QUICK COUPLING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Control Quick Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MULTIPURPOSE BUCKET (4-IN-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0-18

5-2 5-2 5-3 5-3 5-3 5-4 5-5 5-5 5-6

WB156/156PS-5

INTRODUCTION Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Bucket Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Pallet Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Using the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Preparing the Pallet Forks for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Overturning the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Removing the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Installing the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 BACKHOE TELESCOPIC ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Using the Telescopic Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Adjusting the Guide Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 DEMOLITION HAMMER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Rules for Hammer Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Avoid the Following Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Installing the Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Removing the Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Using the Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 HYDRAULIC JACK HAMMER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Connecting and Removing the Jack Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Connecting the Jack Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Disconnecting the Jack Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Using the Jack Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 LOAD STABILIZER SYSTEM (LSS) (Ride Control Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Load Stabilizer System (LSS) Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Pressurizing the Load Stabilizer System (LSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

WB156/156PS-5

0-19

INTRODUCTION

MEMORANDUM

0-20

WB156/156PS-5

1SAFETY

Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine. Read and follow all safety precautions. Failure to do so may result in serious injury or death.

WB156/156PS-5

1-1

SAFETY

SAFETY AND WARNING DECALS It is important that all safety and warning decals are in good condition and in their proper locations. If a decal is damaged, covered, or removed, replace it immediately. It is also important for the operator to be aware of the decal content and location.

To ensure that the content of these safety decals can be read properly, be sure that they are placed correctly and always keep them clean.

When cleaning any decal, use soap and water. Never use organic solvents or gasoline; these solutions may cause the decals to peel off.

Your Komatsu distributor can provide new replacement decals if the ones on the machine are damaged or missing.

For part numbers of the safety decals, see this manual or check the actual decal then order the new decals from your Komatsu distributor.

When replacing damaged or missing decals, be sure that they are placed in the proper location.

Additional safety or warning decals may be added to your machine, if desired.

Location of Safety Decals

Items 1, 2, 5, and 6 are located on the inside of cab on RH center post.

1-2

WB156/156PS-5

SAFETY

WB156/156PS-5

1-3

SAFETY

Decals (21 and 8) applied on rear frame are on both sides of the swing bracket (two sets of decals).

1-4

WB156/156PS-5

SAFETY

Safety and Warning Decals 1.

Brake pedal connector (42N-93-12330)

WARNING - WHEN TRAVELING ON THE ROAD, THE BRAKE PEDALS MUST BE CONNECTED BY MEANS OF THE PEDAL LATCH.

2.

Read labels and operator’s manual (42N-93-12248)

WARNING - Improper operation and maintenance can cause serious injury or death.

Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and in labels on machine.

Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual.

3.

Accumulators (395-93-11330)

4.

Work zone (42N-93-11380) Sign indicates a crush hazard from a falling working device and keep away when the working device is raised.

WB156/156PS-5

1-5

SAFETY 5.

4-wheel drive (42N-93-12340)

WARNING -DO NOT ENGAGE 4-WHEEL DRIVE DURING ROAD TRAVEL -NE PAS ENGAGER LES 4X4 POUR LE DEPLACEMENT ROUTIER

6.

Block wheels (42N-93-12320)

WARNING Block wheels to prevent machine movement.

Do not risk serious injury or death.

7.

Crush point (42N-93-11220)

8.

Anchorage point (42N-93-11360)

1-6

WB156/156PS-5

SAFETY 9.

Rotating parts (42N-93-11370)

10. Emergency exit (42N-93-11260)

11. Engine is running (37A-98-12170)

WARNING WHILE ENGINE IS RUNNING: 1. DO NOT OPEN COVER. 2. KEEP AWAY FROM FAN AND FAN BELT. DO NOT RISK SERIOUS INJURY.

12. Swing lock (42N-93-11310)

13. Boom lock (42N-93-11320)

WB156/156PS-5

1-7

SAFETY 14. Loader raised red bar lock (42N-93-12130) DANGER Before conducting ANY maintenance activities with the loader raised: -Dump bucket and raise loader.

-Secure lift cylinder with red lock bar.

-Slowly lower lifting cylinder until lock stops lifting cylinder movement.

-Move loader control lock to the LOCK position (in cab).

Do not risk serious injury or death.

15. Do not weld ROPS (42N-93-12310) CAUTION DO NOT WELD ONTO ROPS STRUCTURE. If any damage is sustained to ROPS structure, contact your local Komatsu distributor immediately.

16. Operation warning (42N-93-12270) WARNING Before standing up from operator’s seat, perform the following functions to prevent inadvertent actuation of the levers: 1. LOADER - Lower loader bucket to the ground.

- Move loader control lock (located beneath loader control) to the lock position.

2. BACKHOE - Curl backhoe bucket; move boom and arm in, toward machine frame, until they stop.

- Move backhoe control lock (located beneath backhoe controls) to the LOCK position.

3. MACHINE - Engage parking brake and shut engine down.

Sudden and unwanted machine movement can cause serious injury or death.

1-8

WB156/156PS-5

SAFETY 17. Electrocution hazard (42N-93-12280) DANGER - Electrocution hazard.

Serious injury or death can occur if machine or attachments are not kept a safe distance away from electrical lines.

Line Voltage

Safe Distance

6.6 kV

At least 10 ft (3 m)

66.0 kV

At least 16 ft (5 m)

275.0 kV

At least 33 ft (10 m)

18. Block wheels (42N-93-12320) WARNING - Block wheels to prevent machine movement.

Do not risk serious injury or death.

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SAFETY 19. Always use seat belt (42N-93-12250) WARNING ALWAYS USE SEAT BELT. Avoid being crushed DO NOT JUMP if machine tips.

Do not risk serious injury or death.

20. Before moving machine (42N-93-12290) WARNING - Before moving machine or its attachments: * Honk horn to alert people near by. * Be sure no one is on or near machine or in area of operation. * Use spotter if view is obstructed.

Follow above instructions even if machine is equipped with travel alarm and mirrors.

Do not risk serious injury or death.

21. Crush hazard; keep clear (42N-93-12110) DANGER - CRUSH HAZARD; KEEP CLEAR Operate machine from operator’s seat ONLY. During operations, never place yourself in swing area of machine.

Do not risk serious injury or death.

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SAFETY 22. Raising window warning (42N-93-12180) WARNING - When raising window, sit back in operator’s seat and lock it in place with lock pins on both sides to avoid contact from unexpected window movement.

Failure to follow instructions can cause injury.

23. Swing damage (42N-93-12490) CAUTION - To avoid swing damage, do not swing boom into stabilizers.

24. Coupler - Warning Operation (ME030-0-0230) ★ Not illustrated in location drawings.

WARNING For operating, the following instructions should be followed.

1. Before driving, the machine should be checked. If there is anything unusual, stop running the excavator.

2. Confirm that no one is found around the working area.

3.Confirm that the attachment is locked firmly after installing.

(Some foreign material may be found between the claw and the pin.)

4. Confirm that the locking plate is firmly fixed.

5. Handle with care when removing and installing attachments.

25. Coupler - Warning Interference (ME030-0-0221) ★ Not illustrated in location drawings.

WARNING - Be careful that mounting COUPLER extends the arm of the attachment which will sometimes interfere with the boom or the cabin or the cylinder. This adds weight which might cause an imbalance.

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SAFETY 26. Coupler - Locking Adjustment (ME030-0-0030) Not illustrated in location drawings.

FREE - LOCK

27. Coupler - Maintenance and Service (ME030-0-0270) ★ Not illustrated in location drawings.

MAINTENANCE AND SERVICE 1. Confirm that there are no cracks, no creaking joints and no loosened bolts.

2. A and B should be lubricated every 100 hours.

3. C and D should be lubricated every 500 hours.

4. E should be removed to lubricate its surface every 3 months.

5. F and G should be removed to lubricate their surface so as to prevent them from rusting.

NOTE: Do not operate in the water. If there is flooding, lubricate all the pins and clean the machine.

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GENERAL SAFETY RULES AND PRECAUTIONS General Safety Rules Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy and quick reference.

Only trained and authorized personnel are allowed to operate and service this machine.

Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine.

Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating condition.

Always perform a pre-operational check on your machine before operating it.

If your equipment is designed for operation by one person, it is for one person only. Never allow other personnel to ride on your machine.

The machine is equipped with a seat belt and rollover protective structure. The operator should remain within the confines of the rollover protective structure, with the seat belt fastened snugly around their waist, while operating the machine.

Never use your machine for tasks for which it was not designed; damage to the machine or injury to the operator may result.

It is the owner and/or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from the machine.

Think before you act; study the job carefully. Careful operator and service personnel are the best insurance against accidents.

The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs, or medications that might affect their eyesight, hearing, or reactions.

When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used.

Be sure that all personnel are outside the working radius of the machine before moving or operating the machine. Never allow anyone to stand near the machine while it is in operation. Remember, the larger the machine, the more restricted is your visibility.

If pedestrians are in the area, proceed slowly and sound your horn. Keep in mind that pedestrians have the right-of-way, and a loaded or smaller machine has the right-of-way over an unloaded machine.

Never drive up to anyone standing in your path of travel. Always be sure all personnel are standing to the side when you approach them and acknowledge your approach.

When leaving a job site for long periods of time, always lower all work equipment to the ground, neutralize work equipment controls, and lock and secure your machine properly to avoid tampering by other personnel.

Never leave your machine running and unattended. Always park the machine in a level area, lower any work equipment to the ground, set the parking brake, lock the controls, and turn the engine off before exiting the operator’s compartment.

Follow all rules relating to safety as outlined in this manual and by your company.

If Abnormalities are Found If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report it to the person in charge to have the necessary action taken. Do not operate the machine until the abnormality has been corrected.

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SAFETY

Safety at Job Site • • • • • • • • • • • • •

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

Know where to report an accident or fire. In case of an emergency, have a local emergency phone number available.

Be careful when operating around or near open burning operations.

Maintain the fire extinguisher on the machine and a second one at the job site.

Keep the machine clean, especially from flammable materials such as trash, grease, oil, or fuel.

Keep all safety equipment in good working condition.

Check the terrain and condition of the ground at the work site, and determine the safest method of operation.

Do not operate where there is a hazard of landslides or falling rocks.

If water lines, gas lines, or high-voltage electrical lines may be buried under the work site, contact each utility company and have them identify the location of the lines.

Take action to prevent unauthorized people from approaching the job site.

When working on public roads, position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians.

When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock, and the depth and speed of flow of the water before starting operations.

Conduct periodic safety training and familiarize all personnel with emergency procedures.

Safety Features • • • • • • • •

Be sure that all guards, covers and mirrors are in their proper place, especially after servicing the machine.

Have guards or covers repaired immediately if they are damaged. See “Pre-operational Checks” on page 2-45.

Use safety equipment such as safety locks and seat belt properly.

Never remove any safety features. Always keep them in good operating condition.

Always secure the machine in a safe position; see “PARKING THE MACHINE” on page 2-73.

For seat belt information see “Seat Belt Inspection” on page 1-19.

Improper use of safety features could result in serious bodily injury or death.

Be sure the machine has the correct equipment required by local rules and regulations.

Clothing and Personal Protective Equipment Use all safety equipment provided with your machine when operating your machine.

• Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other protruding parts.

• Always wear a hard hat and safety shoes. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine.

• Always wear safety goggles, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air.

• Check to be sure all personal protective equipment is in good condition before using.

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Keep Machine Clean • •

•

Keep the machine clean, especially from flammable materials such as trash, grease, oil, or fuel.

If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a danger that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.

If water gets into the electrical system, there is a danger that it will cause malfunctions or misoperation. If there is any accidental operation, there is danger that the machine may move unexpectedly and cause serious personal injury or death. When washing the machine with water or steam, do not allow the water or steam to come into direct contact with electrical components.

Fire and Explosion Prevention Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following precautions: • Keep any open flames, airborne sparks, or burning embers away from flammable fluids.

• Stop the engine and do not smoke when refueling.

• Tighten all fuel and oil caps securely.

• Refueling or adding oil should be done in well-ventilated areas.

• Clean up any fluid spills.

Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid Fuel and oils are particularly flammable and can be hazardous. Do not bring any flame or fire close to flammable substances such as fuel, oil, antifreeze, or window washer fluid. There is danger that they may catch fire.

To prevent fire, always observe the following precautions: • • • • • • • • • • • • •

Do not smoke or use any flame near fuel or other flammable substances.

Stop the engine before adding fuel.

Do not leave the machine when adding fuel or oil.

Do not spill fuel on overheated surfaces or on parts of the electrical system.

Wipe up any spills after adding fuel or oil.

Tighten all fuel and oil caps securely.

Inspect the entire fuel system (including fuel lines, filter and injection system) for leaks, seepage, and deteriorated fuel hoses. Clean, repair or replace, if required.

Use well-ventilated areas for adding or storing oil and fuel.

Keep oil and fuel in the determined place and do not allow entry to unauthorized persons.

When carrying out grinding or welding work on the chassis, move any flammable materials to a safe place before starting.

When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire; do not use them.

Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.

Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

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SAFETY Fire Caused by Accumulation of Flammable Material • • • •

Remove any dry leaves, wood chips, paper, wood dust, or any other flammable materials accumulated or affixed around the engine, exhaust manifold, muffler, air cleaner, battery, or inside the undercovers.

Be aware that operations such as logging, mulching, clearing, and landfill work may cause trash and debris to accumulate on the machine. Always remove accumulated trash and debris on a daily, or more frequent, basis.

Clean the machine after servicing the hydraulic system, engine, or fuel system.

Operations near burn piles or other open burning, may cause airborne sparks or glowing embers to cause a fire on the machine.

Fire Caused by Electric Wiring Short circuits in the electrical system can cause a fire.

Always keep electric wiring connections clean and securely tightened.

Check the wiring every day for looseness or damage to the wire insulation.

• Tighten any loose connectors or wiring clamps.

• Repair or replace any damaged, pinched or chaffed wiring.

• Aftermarket radios or other electrical-operated equipment in the cab must be fused close to the power supply.

• Never use a machine with a higher voltage to jump start your machine.

Fire Caused by Hydraulic Line •

•

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

Check for oil leaks daily and repair them immediately.

Explosion Caused by Lighting Equipment • •

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.

When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.

Action if Fire Occurs If a fire occurs, escape from the machine as follows.

• Do not attempt to move the machine or continue operations.

• Turn the start switch OFF to stop the engine.

• Use the handrails and steps to get off the machine. Do not jump off the machine. There is a danger of falling and suffering serious injury.

• If necessary, use the emergency exit to escape.

• Immediately call for help.

• When using a fire extinguisher, always aim the extinguisher at the base of the fire.

• If an optional fire extinguishing system is in place, be familiar with its operating procedures.

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SAFETY

Asbestos Hazard Alert Asbestos dust in the air can cause lung cancer if inhaled. There is a danger of inhaling asbestos materials when working on job sites handling demolition work or industrial waste. Always observe the following precautions:

• • •

• •

Never use compressed air for cleaning.

Spray water to keep down the dust when cleaning.

If there is danger that there may be asbestos in the air, always operate the machine from an upwind position. All workers should use an approved respirator.

Do not allow any other person into the area during operation.

Observe the rules and regulations for the work site and environmental standards.

Keep Operator's Cab Clean •

• • • •

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes. If you operate the pedal with mud or oil on your shoes, your foot may slip and this could cause an accident.

Do not leave parts or tools lying around the operator's compartment.

Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

Do not use cellular telephones inside the operator's compartment when driving or operating the machine.

Never bring any dangerous objects such as flammable or explosive items into the operator's cab.

Room Ventilation The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or machine must be operated inside a building or underground where the ventilation is poor, take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in.

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SAFETY

Burn Prevention Hot Coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant, wait for the water to cool to a temperature where it is possible to touch the radiator cap by hand before starting the operation. Even when the coolant has cooled down, loosen the cap slowly to relieve the pressure inside the radiator before removing the cap.

Hot Oil To prevent burns from hot oil spurting out when checking or draining the oil, wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand. Even when the oil has cooled down, loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.

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PRECAUTIONS FOR OPERATION Seat Belt Inspection

Seat belts must be replaced immediately if there are any signs of wear or damage, no matter how recently they were last replaced.

A thorough inspection of the entire seat belt system should occur before starting the engine.

•

Inspect the full length and both sides of the seat belt webbing for wear, abrasion, dirt, oil, mildew, paint or other damage. Replace immediately if worn or damaged.

• If the webbing is cut, fraying, snagging, kinking, or roping, the seat belt must be replaced. Any of these conditions may limit belt retraction.

•

•

• •

There may be internal and/or external tethers mounted on the suspension mechanism. Inspect these for fatigue as well as the integrity of the mounting hardware.

Inspect the seat belt attachment and adjustment hardware for wear or damage.

• Retractable and non-retractable buckle housings with damage from abrasions, rubbing, forceful impacts and age, must be replaced. These conditions may weaken the strength of the buckle.

• Examine the seat belt buckle and retractor housing(s) for proper function.

• Dirt, debris, lint, leaves, etc. may become encased inside of the retractor housing. With time, this condition may cause a seat belt malfunction.

Check the mounting structure integrity. Verify that the mounting bolts are secure. Tighten to specified torque, if necessary.

Check your records or the seat belt “Date of Installation” label (if equipped). Even if there are no signs of damage, the seat belt must be replaced either five years after the date of manufacture, or every three years after the start of usage, whichever comes first.

• The manufactured date and “Install By” (if equipped) date may be found on the back of the buckle housing and/or on the seat belt webbing.

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SAFETY •

The location of the “Date of Installation” label (if equipped) may vary slightly, but most frequently it will be found on the plastic molding of the seat belt.

If your machine is equipped with a shoulder harness also, inspect the webbing, the shoulder loop web guide and the height adjuster for wear, damage and proper function capabilities

Leaving the Operator’s Seat Below are listed procedures that must be followed when exiting the operator’s cab.

1. Park the machine in a level area and lower all work equipment to the ground.

2.

Place the directional lever in the “N” neutral position.

3.

Engage the parking brake.

4.

To use the PPC Joystick controls to lock all controls, press the switch in the control panel. When the light on the switch is “ON” the controls are locked.

Remark When the machine is shut down, all the controls are automatically locked until the machine is restarted and the PPC lock switch is pressed to release the controls for operation.

5.

Turn the ignition key to the “OFF” position. Remove ignition key and keep it with you.

6.

Use the key to lock and secure all the equipment locks. This will prevent unauthorized personnel from tampering with your machine. You are responsible for securing your machine.

Remark Never leave your machine running and unattended, even for a moment.

See “SAFETY LOCK USAGE” on page 2-67 for information regarding the lock.

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SAFETY

Mounting and Dismounting • • •

• • • •

• •

Use all hand holds and step plates on your machine.

Never jump off or on the machine.

Wipe off any oil, grease, or mud on your shoes, rails, steps or platforms before getting on the machine. Keep these areas clean and in good condition.

Never get on or off a moving machine. These actions may lead to serious injury. Always bring the machine to a full stop.

Be sure that the machine is at a full stop, equipment lowered, and parking brake set before getting on or off the machine.

Never hold any control levers or the steering wheel when getting on or off the machine.

When getting on or off the machine, always face the machine and maintain a Three Point Contact (both feet and one hand or one foot and both hands) with the handrails, steps, and platforms to ensure that you support yourself properly.

Do not get on or off the machine while holding tools in your hand.

Never climb on the engine hood or covers where there are no nonslip pads.

Checking the Rearview Mirrors •

• •

Make sure that the rearview mirrors are clean and correctly positioned. They must allow the operator to see the rear of the machine with no need to move from the normal work position.

If the rearview mirrors move or break during work, stop the machine immediately and fasten or change them.

Working without checking the area behind the machine is dangerous, since the machine may hit persons who are standing in the work area, fixed obstacles, or maneuvering vehicles.

Crush or Pinch Point Dangers •

•

•

Never stand under or place any part of your body between the movable components such as the work equipment and cylinders, or between the machine and work equipment.

The clearance in the area around the work equipment changes with different operations. Do not get close to any rotating or extending/ retracting portion and do not allow anyone to enter this area. Serious personal injury or death may result.

Never drive up to anyone standing in front of a solid object or your path of travel. The brakes could fail or the machine could slide on a slippery surface causing injury or even death.

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SAFETY

Fire Extinguisher and First Aid Kit As a precaution for a fire or an injury, always keep a fire extinguisher and first aid kit on your machine and take the following precautions: • The fire extinguisher must be in good condition.

• Read the instructions on the label to ensure you know how to use it.

• Keep a first aid kit in the storage area. Check the kit periodically and make any additions if necessary.

• Keep a list of emergency phone numbers in case of an accident.

Inside Operator’s Compartment •

•

•

• • • • •

When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. If you operate the brake pedal with mud or oil on your shoes, your foot may slip and cause an accident.

After using the ashtray, make sure matches or cigarettes are properly extinguished and be sure to close the lid. If the ashtray is left open, there is danger of fire.

Do not leave lighters or aerosol cans lying around the operator’s compartment. If the temperature inside the operator’s compartment raises too high, there is danger that the lighter or aerosol can may explode.

Do not stick suction pads to the window glass. Suction pads may act as a lens and could cause a fire.

Aftermarket radios or other electrically-operated equipment in the cab must be fused close to the power supply.

Keep the operator’s compartment clean. Never allow trash or tools to accumulate as these may hinder the operation of the controls or pedals.

When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS. Always use the seat belt equipped with your machine, even when using the loader or backhoe unit. Be sure the seat belt is fastened snugly around your waist before operating the machine.

Cleaning Windows, Mirrors and Lights • • •

Remove any trace of dirt from the cab windows, lights, and rearview mirrors. This will ensure good visibility in the work area.

Adjust the rearview mirrors if they have moved, so that the operator seated in the driving position can clearly see the area behind the machine.

If any window, light or mirror is damaged, change it.

Checking the Windshield Wiper Blades and Bulbs • •

Check the conditions of the windshield wiper blades. The scraping wire must be smooth, with no indentations and attached to the rubber back of the blade. If there is any doubt about the efficiency of the scraping wire, change the blades.

Make sure that the road lights, stop lights, direction indicators and work lights are working properly. If necessary, change the faulty bulbs with new ones, making sure that their power is correct.

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Precautions When Using ROPS The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the operator if the machine should roll over. It is designed to support the load if the machine should roll over and to absorb the energy at point of impact. Never drill, cut, weld, repair, or modify the ROPS in any way. Doing so may weaken the structure which could lead to possible failure in a rollover situation.

The ROPS fulfills all the regulations and standards for all countries. But, if the protective structure is modified without authorization, damaged, deformed by falling objects or by rolling over, its strength will be reduced and will not be able to fulfill its function properly. If the ROPS is damaged in any way, replace it immediately. Do not make repairs to the ROPS. Always fasten your seat belt properly when operating the machine.

Unauthorized Modifications • • •

Komatsu will not be responsible for any injuries, accidents, product failures, or other property damages resulting from modifications made without authorization from Komatsu.

Modifications may have an adverse effect on items such as machine strength and visibility.

Any modifications made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.

Precautions for Attachments When installing and using an optional attachment, read the instruction manual for the attachment and information related to the attachments.

Quick Coupler Attachment •

•

• •

Inspect all quick couplers. Determine whether a manually-installed locking pin and installation procedures have been provided by the manufacturer.

Follow the manufacturer’s recommendations for maintenance and inspection of the quick coupler to prevent a malfunction of the quick coupler that could cause an unintended release of the attachment.

Follow the manufacturer’s installation procedures and recommendations on testing quick coupler attachments.

Train and require all personnel to use and follow manufacturer’s installation, use, and maintenance procedures when using a quick coupler attachment.

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SAFETY Large Attachments •

•

•

When using attachments that are larger than the standard digging bucket, always be aware that these attachments may come in contact with the operator’s cab when the work equipment is retracted for travel purposes.

If you are using a hoe-ram or breaker attachment, never dry fire these attachments, especially in the direction of the cab. The possibility of the tool bit ejecting from the breaker may damage the machine or injure the operator.

Always be aware when operating on slopes or traveling that any attachment changes the center of gravity on the machine and increases the possibility of a rollover situation.

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PRECAUTIONS BEFORE STARTING OPERATIONS As an operator of the machine, you are responsible for the safe operation of the machine at all times regardless of the situation.

Although KOMATSU cannot cover all operating conditions that pose a major hazard, here are a few basic situations to avoid when using the backhoe loader during work or travel operations. It is advisable to study these and always be aware of them before starting your work operations. Failure to do so may result in damage to the machine or injury to the operator and other personnel.

Hand Signals

•

When it is necessary to position loads, make excavations, or move the machine with a reduced field of vision, the operator must be helped by another person (signalman) who should stand on the ground and give signals to indicate the maneuvers to be carried out according to the specific instructions provided by the relevant regulations.

•

No movement or operation may be carried out if the signals have not been clearly understood by the operator and the signalman.

•

When additional instructions different from those defined by the hand signalling system are necessary, these must be agreed upon by the two operators before starting the job.

•

Only one person must be entrusted with giving signals.

•

The operator must make sure that the signalman is always within his field of vision and follow all his signals.

The use of hand signals serves to direct the lifting, handling and positioning of the loads lifted by the work equipment. Hand signals can also be used during digging operations or when the operator’s field of vision is reduced at travel. The direction of movement of the hands and arms in relation to the machine must define the signal, independently of the position of the signalman.

Pre-operational Checks Before starting your work operations it is important to perform a pre-operational check to be sure your equipment is in safe operating condition. If any problems are found during your pre-operational check, have them repaired immediately. Never operate a machine that is unsafe, damaged, or in need of repair. Failure to perform a pre-operational check before starting work operations may result in damage to the machine or injury to the operator and other personnel.

Remark It is important that a pre-operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator. Always perform a pre-operational check before you start work.

Starting Your Work Operations • • • • • •

Before operating the machine, walk around it and check for people or objects that might be in the way.

Do not start the engine if warning tags have been attached to the steering wheel or control levers.

Sound your horn to warn others in the area before starting the engine.

Operate the machine in a seated position only, with the seat belt fastened snugly around your waist.

Do not allow anyone in the cab or on the machine during operations.

Be sure all personnel are clear from your work site before starting any work operations.

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SAFETY

Work Site Hazards Before proceeding with any excavating operations it is important to be aware of the hazards involved with this operation. Below is a list outlining what to do to avoid some of these hazards.

• Before starting any excavating operations, contact all utility departments in your area and have them identify and mark any underground system locations (gas lines, water lines, electrical lines, sewer lines, etc.).

• Check your work area for any unusual ground conditions.

• Make sure your work area is as level as possible and you will be able to maneuver your work equipment or machine easily.

• If you will be working near a high traffic area (pedestrians or cars), have a dedicated worker available to direct traffic or install safety fencing around your work site.

• Always be aware of all your work site dangers or distractions.

• Always be aware of the work site where open burning is allowed.

Airborne sparks or glowing embers may cause fire on the machine.

• Operations such as logging, mulching, land clearing or landfill operations may cause trash and debris to accumulate on the machine. Remove debris or trash on a daily basis (or more frequently, if necessary) to prevent fire.

• Always clean trash from the exhaust system compartments. The hot exhaust compartments may cause fire from contact with flammable material.

• Remove leaves, wood chips, paper, wood dust or anything flammable, that has accumulated around the engine.

Working on Loose or Unstable Ground •

• • •

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over causing serious damage to the machine or injury to the operator.

Surface conditions are loose or unstable after heavy rain, thaw, blasting, or earthquakes.

When working on embankments or near excavated ditches, there is a danger that the weight and vibration of the machine will cause the soil to collapse.

Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

Visibility • •

Switch on the headlights or the work lights as soon as visibility decreases.

If visibility decreases due to mist, smoke, or heavy rain, stop the machine in a safe position and wait for the weather to improve until visibility becomes acceptable.

Precautions to be Taken When Using Synthetic Biodegradable Oil (HEES) •

• •

It is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils. When the temperature increases, insoluble compounds are generated which are deposited on the filters and clog them (the maximum concentration of ordinary oil must not exceed 1% of the total quantity of oil).

Biodegradable oil can be used only in the hydraulic system; it cannot be used for the engine, transmission, the braking system, etc.

Before introducing synthetic biodegradable oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work equipment. Wait until the oil reaches a temperature of at least 40°C (104°F) then start moving the equipment so that all the parts of the system are filled with oil. Stop the engine and check the oil level.

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Avoid Dangerous Situations • •

• •

• •

•

Avoid traveling with the bucket raised. Raising the bucket raises the center of gravity on the machine.

Traveling with a raised bucket, especially a loaded bucket, may result in loss of control or a rollover situation. Never raise the bucket unless the machine is stopped.

If you must travel with the bucket raised and loaded, always travel a short distance at a slow, controllable speed and on level ground.

Never attempt to make sharp turns or stop the machine suddenly.

This may cause the machine to tip forward.

Always handle unstable loads carefully; avoid tipping the bucket back or raising the load too high.

Be sure to operate the work equipment carefully and keep the load as close to the ground as possible. If you must travel with an unstable load, be sure you are on firm, level ground and travel at a slow, safe speed.

Do not use the bucket or lift arms as a crane. The object you are lifting may swing or shift causing the machine to tip, sway, or possibly roll over.

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1-27

SAFETY •

Never work under overhangs or excavated bank areas. These could collapse and damage the machine or injure the operator.

•

Never pick the machine up or reposition it using the work equipment. Loss of control or a rollover situation may result. Keep in mind that the work equipment is for digging, scooping and loading operations.

•

Never allow other personnel in your work area while the machine is in operation. The possibility of the work equipment blocking your view during operations may result in injury to that person.

•

When digging a trench with the backhoe work equipment, always be aware of the ground condition and never attempt to dig too close or under the machine. The possibility of the machine falling into the excavated site becomes greater the closer the excavation is to the machine.

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SAFETY •

If someone should approach you while you are operating the machine, stop all operations immediately and signal them not to approach until the work equipment is lowered to the ground, the work equipment lock lever is set in the “LOCK” position, and it is safe for them to approach. Do not touch any of the machine controls again until they are away from your work area and at a safe distance.

Working Clearances It is always a good idea to know your clearances around, in front, behind, and especially, above your work area or travel route. Know your machine’s traveling height, keeping in mind the backhoe boom and arm on this machine extend at least 914.4 mm (3 ft) above the canopy and cannot be seen during loader, travel, or transport situations.

Failure to keep this in mind may damage the machine or injure the operator or other personnel.

High Voltage Lines • • •

•

•

•

When working or traveling in an area where clearances are a problem, travel at a slow, cautious speed.

If you are not sure of your clearances, request the aid of another person who can guide or warn you if you get too close to objects.

Be aware of the dangers when working around overhead electrical lines; high humidity may pose an electrical hazard even if your machine clears the overhead power lines.

To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body.

If your machine should come in contact with overhead electrical lines, stop the machine and remain on the machine until the power company clears the lines and it is safe to get off or move the machine.

If low power lines pose a danger, ask the power company to remove the lines until your work is finished.

VOLTAGE

LOW VOLTAGE

SPECIAL HIGH VOLTAGE

WB156/156PS-5

SAFE DISTANCE 100V-200V

2m

6,600V

2m

22,000V

3m

66,000V

4m

154,000V

5m

187,000V

6m

275,000V

7m

500,000V

11 m

1-29

SAFETY

RULES FOR ROAD TRAVEL Traveling with your machine may pose some hazards. When traveling, always travel in a safe manner and remain alert at all times. A safety-conscious operator is the most important insurance when traveling with the machine. Below are several situations and information the operator should be aware of.

Travel Precautions The machine is equipped with multifunction safety locks that must be used for maintenance operations and road travel. When necessary to travel on roads, proceed as follows: 1. Raise the backhoe boom and engage the safety coupling.

2.

Center the boom and install the lock pin.

When installing the backhoe lock pin, be extra careful not to get caught between the backhoe frame and boom. Never reach over the backhoe controls to install the lock pin. There is a chance you may bump one of the control levers causing the backhoe work equipment to move. There is also a possibility you may lose your balance and fall into the work equipment. Always install the lock pin while standing on the ground.

3.

Connect the safety cables to prevent accidental lowering of the outriggers.

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WB156/156PS-5

SAFETY 4.

To use the PPC Joystick controls, press the switch until the light on the switch is illuminated indicating the controls, both the front and rear, are locked.

5.

To unlock front and rear work equipment controls, press the switch until the light on the switch goes out.

Always lock all work equipment when traveling with the machine.

Failure to do so may cause damage or loss of control of the machine.

6.

Be sure the brake pedals are locked together and the 4-wheel drive feature is disengaged.

7.

Obey all traffic rules when traveling on local and state roads.

Always travel at a safe, controllable speed.

Rules for Traveling in Reverse Traveling in reverse may pose several hazards. Observe the following precautions when traveling in reverse.

• Be sure the area behind you is clear of people or objects that might be in the way.

• Before moving your machine, sound the horn to warn others in your area that you are moving.

• When operating in an area that may pose a hazard or poor visibility, designate a person to direct your movements.

• Do not rely totally on the machine’s mirrors; keep in mind there are blind spots when using the mirrors.

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1-31

SAFETY

Traveling on Snow or Frozen Surfaces It is extremely important to be careful when traveling or operating the machine on icy surfaces. Snow-covered or frozen surfaces are slippery. Your ability to maneuver is seriously affected. The machine may not respond as you expect when turning the steering wheel.

When frozen ground begins to thaw, the ground becomes soft and could cause a machine to get stuck or tip over.

When traveling on frozen surfaces, proceed in the following manner.

• • • • • • • • • • •

Engage the 4-wheel drive system. Remember, the 4-wheel drive system will not affect your braking.

Travel at a slow, safe speed.

Gently operate the levers.

Avoid rapid acceleration or braking.

Stopping distance is increased during slippery conditions. Give yourself sufficient distance to stop the machine.

Use tire chains when traveling on snow-covered roads.

Avoid deep snow. Be careful not to get trapped in a snow drift.

When clearing snow, it may be difficult to determine where the road shoulder ends. Be careful not to slide off the shoulder and get stuck or tip over. Proceed cautiously.

When clearing snow, you may not see objects buried in the snow. Proceed cautiously.

Even a slight slope may cause the machine to slip out of control. Be particularly careful when working on slopes.

When traveling on snow-covered slopes, apply the brakes gently. Reduce the speed and use the engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times). If necessary, lower the work equipment to the ground to stop the machine.

Traveling on Slopes Traveling on slopes may pose a hazard. In order to prevent tipping the machine or losing control, it is important to follow these directions.

• Never turn the ignition key off when traveling up or down slopes.

• Do not shift into neutral gear on a slope.

• If the engine stops, apply the brakes and stop the machine. Lower all work equipment to the ground immediately.

• When traveling over rough ground, travel at a slow, controllable speed.

•

•

•

When traveling on slopes with an empty bucket, it is important to travel at a safe, controllable speed with the bucket set in a position 20 to 30 cm (8 to 12 in) above the ground.

Travel uphill with the bucket curled upward. If the machine loses control or slides on the slope, lower the bucket to the ground immediately to help stabilize the machine.

Travel downhill with the bucket curled downward. If the machine loses control or slides, lower the bucket to the ground immediately to help stabilize the machine.

1-32

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SAFETY •

When traveling up or down a slope with a load, always keep the bucket 20 to 30 cm (8 to 12 in) above the ground and the load facing the top of the hill.

•

Never travel up or down a slope with the load facing the bottom of the hill. Loss of control may result when the brakes are applied.

•

Always travel straight up or straight down a slope. Traveling at an angle on a slope may cause the machine to tip or possibly roll over.

Traveling on Loose or Unstable Ground •

• • •

Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over causing serious damage to the machine or injury to the operator.

Surface conditions are loose or unstable after heavy rain, in snow, thaw, blasting, or earthquakes.

When working on embankments or near excavated ditches, there is a danger that the weight and vibration of the machine will cause the soil to collapse.

Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.

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1-33

SAFETY

Parking the Machine When parking the machine, it is important to follow several basic safety rules. Keep in mind you are responsible for the security of the machine when it is parked. Below is a list if some basic rules to follow when parking your machine.

1.

Always park the machine on a flat, level location away from moving equipment, pedestrians or traffic.

2.

Lower all work equipment to the ground or lock it in place and neutralize all controls.

3.

Lock all areas on the machine equipped with a locking security feature.

4.

Remove the ignition key, set the parking brake in the “PARK” mode and lock the controls.

See “Leaving the Operator’s Seat” on page 1-20. Be sure all access panels, cab, fuel and oil tanks are locked and secure to prevent tampering with the machine while it is unattended.

5.

Avoid parking the machine on a slope of any kind. If you must park on a slope, park with the bucket facing down the slope and the wheels blocked to prevent any movement of the machine.

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SAFETY

PRECAUTIONS DURING MAINTENANCE OPERATIONS All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance, it is important to follow the outlined maintenance procedures and safety information outlined in this manual and in the Shop Manual for this machine.

Warning Tags • • •

•

Before performing any maintenance operations on this machine, position the machine on level and firm surface.

Lock the equipment controls, remove the ignition key and tag the steering wheel.

Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine around specific points to warn others that this machine is down for maintenance.

If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.

Equipment Storage • •

Always store optional or extra work equipment in a safe and secure location.

Store equipment in such a way that it cannot fall or cause injury to others.

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1-35

SAFETY

Working Under the Machine • • •

Always use approved jack stands to support the machine when performing maintenance under the chassis.

Never rely on hydraulic jacks or the machine’s work equipment to support the machine when working under or on the machine.

Always lower the work equipment to the ground after raising the machine for repairs.

Using Drop Lamps •

Use only approved anti-explosion lamps when checking fuel, oil, or batteries. Non-approved lamps can cause an explosion or fire.

Keeping the Machine Clean •

•

•

• • •

Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts or the machine itself.

Avoid using high-pressure steam cleaners or caustic soaps to wash the machine, if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components.

When washing the interior of the cab, never use high-pressure water or flood the cabin. Doing so may damage sensitive electrical components.

When pressure washing the exterior of the machine, use high-pressure, hot water and mild grease-cutting soaps.

Always grease the machine after cleaning to force out any water from the pivot point connections.

Remove trash daily or more often as necessary. Never allow trash to accumulate on the machine.

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SAFETY

Running the Machine During Maintenance • •

If during maintenance the engine must be run, be sure all work equipment is locked.

Have someone remain in the operator’s seat while the engine is running in case the engine must be shut down quickly.

Rules for Refueling the Machine • • • • • •

Always clean up any spills. Grease, fuel, oil or coolant spills can pose a slip hazard if not mopped up immediately.

Be sure you are adding the correct fluids to the proper locations.

Mixing fluids can cause damage to internal components.

When refueling or adding any fluids, be sure you are in a well-ventilated area.

Never smoke or allow open flames near you while you are refueling the machine.

Never mix gasoline with diesel fuel. Gasoline is extremely flammable and could cause an explosion.

Do not fill the fuel tank completely; leave room for the fuel to expand.

Cooling System Precautions •

Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap.

•

Never dump used coolant on the ground, in a lake, stream or in a sewer system. These fluids are to be captured and recycled properly.

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1-37

SAFETY

Battery Precautions

Do not try to connect/disconnect battery cables or jump start machine with battery top cover in place. Always remove the battery top cover before performing these tasks. Failure to do so may result in injury or death.

• • •

When working on the electrical system, disconnect the negative (-) battery cable first then the positive (+) battery cable last.

On completion of work, reconnect the positive (+) cable first then the negative (-) cable last.

When using booster cables to start the machine as shown below, hook the positive (+) cable first, then the negative (-) cable last to a remote location on the chassis.

Never use a welder or a machine with a higher voltage system to jump-start the machine. Using a higher voltage to jump-start a machine may damage the machine’s electrical system or cause an unexpected explosion or fire. Always jump-start a machine with equal voltages.

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WB156/156PS-5

SAFETY Hazards Danger of Battery Exploding When charging the battery, flammable hydrogen gas is generated from the poles. If the gas ignites, it may explode and cause serious injury or fire. Any mistake in handling may cause serious personal injury, explosion, or fire, so always observe the following: • • • • • •

DO NOT use or charge a battery if the electrolyte is below the LOWER LEVEL mark.

Check the electrolyte level periodically and add distilled water only to the UPPER LEVEL mark, when required.

DO NOT smoke or use any flame close to the battery.

Remove the battery from the machine and take it to a wellventilated area; remove the battery caps; then carry out charging.

After charging the battery, replace and tighten the battery caps securely.

Unplug the charger and remove the cables.

Danger of Dilute Sulfuric Acid Battery electrolyte includes dilute sulfuric acid. If dilute sulfuric acid gets on your skin or in your eyes, you may suffer serious injury.

Always do the following when handling batteries.

• •

•

ALWAYS wear protective goggles and rubber gloves.

If battery electrolyte gets into your eyes: • Immediately wash your eyes with a large amount of fresh water for at least 15 minutes.

• Be sure to wash behind your eyelids.

• Get immediate medical attention.

If battery electrolyte gets on your skin or clothes: • Immediately wash it off with a large amount of water.

• Do not use any alkaline fluid as a neutralizer.

• If you suffer any chemical burn, get immediate medical attention.

Danger of Sparks If sparks are generated, they may fly and cause serious personal injury.

• • • • •

DO NOT short-circuit the battery terminals through contact with metal objects, such as tools across the terminals.

DO NOT leave tools lying around near the battery.

When removing the battery cables, remove the ground cable (negative (-)) cable first.

When installing battery cables, connect the positive (+) cable first.

Secure the battery firmly in the specified position.

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1-39

SAFETY Using Booster Cables ★ If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode.

Always heed the following precautions: • • • • • • •

Wear safety goggles and rubber gloves when starting the engine with booster cables.

When connecting a normal machine to a problem machine with booster cables, always use a normal machine with the same battery voltage as the problem machine.

When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator’s seat and the other working with the battery).

When starting from another machine, do not allow the two machines to touch.

When connecting the booster cables, turn the starting switch to the OFF position for both the normal machine and problem machine. There is a danger that the machine will move when the power is connected.

When removing the booster cables, be careful not to let the booster cable clips touch each other or to let the clips touch the machine.

When using booster cables to start the machine, attach the positive (+) jumper first then the negative (-) jumper last to a remote location on the chassis, as shown in the following figure. For additional information, see“Starting the Engine with Booster Cables” on page 2-81.

Starting the Machine with Booster Cables •

•

Never try to start the machine by tampering or shorting the starter terminals. Accidental movements of the machine could cause injury or even death.

Always use the ignition switch to start the machine while you are seated in the operator’s cab.

•

Never use a welder or a machine with a higher voltage system to jump start the machine. Using a higher voltage to jump-start a machine may damage the machine’s electrical system or cause an unexpected explosion or fire.

•

Always jump start a machine with one of equal voltage.

•

Never allow the machines to touch each other when jumpstarting a machine.

1-40

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SAFETY

High-Pressure Hoses The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury, so always do as follows.

• Do not carry out any inspection or replacement work when the hydraulic system is under pressure.

• If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses.

• When carrying out inspection, wear safety glasses and leather gloves.

• There is a danger that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

Safety Handling of High-pressure Hoses If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor.

Replace the hose if any of the following problems are found.

• Damaged or leaking hydraulic fitting • Frayed or cut covering or exposed reinforcement wire layer • Covering swollen in places • Twisted or crushed movable portion • Foreign material embedded in covering

Precaution for High Fuel Pressure High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance.

High-Temperature Areas When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system is still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns.

Carry out maintenance procedures described in this manual only when the machine has had time to cool down.

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1-41

SAFETY

Rotating Parts • •

Take particular care near rotating parts. Keep your body at a safe distance.

If hands, clothing, or tools become entangled in the fan blades or fan belt, severe injury may result. Keep well away from all rotating parts.

Disposal of Waste Materials • • •

•

Never dump waste fluids in a sewer system, on the ground, in rivers, etc.

Always drain fluids from your machine into the appropriate containers.

Never drain fluids directly onto the ground.

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil. Always recycle whenever possible.

Inflating Tires Tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions.

• Before inflating tires, always check the wheel rims, tire walls and tread for cuts, broken cords, or other damage.

• Have a tire expert perform checks and tire maintenance.

• • •

When inflating tires, use a protective cage, and a compressed air gun with extension hose and pressure gauge.

Make sure there is nobody in the vicinity before starting to inflate a tire. Stand at the tread side of the tire to inflate it.

Never exceed the inflation pressures specified for each type of tire.

Always check the tire pressures on both sides of the machine.

Standard Front Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 x 17.5 Pressure. . . . . . . . . . . . . . . . . . . . 3.31 ± 5 kg/cm2 (47.1±1 psi) Standard Rear Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.5L x 24 Pressure. . . . . . . . . . . . . . . . . . . . 1.88 ± 5 kg/cm2 (26.7±1 psi)

1-42

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SAFETY

Accumulator This machine may be equipped with an accumulator charged with highpressure nitrogen gas. Before servicing the accumulator, observe the following precautions: • Do not dissemble the accumulator.

• Do not expose the accumulator to high heat or an open flame.

• Do not weld on the accumulator.

• Do not drill or cut the accumulator.

• Do not strike or crush the accumulator.

• When replacing or disposing the accumulator, always release the nitrogen pressure from the chamber.

Critical Parts Periodically some parts must be replaced due to safety purposes. Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or pedestrians. Listed are some of the systems containing these components that may fail under extended use: • Fuel supply and delivery hoses • Hydraulic system: main delivery hoses and tubing • Hydraulic hoses: all the hoses that feed and return the hydraulic fluid to and from the work equipment ★ For additional information see “SAFETY CRITICAL PARTS” on page 3-19.

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SAFETY

MEMORANDUM

1-44

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2OPERATION

WB156/156PS-5

2-1

OPERATION

GENERAL VIEW OF MACHINE The views are taken from the operator’s seat facing forward and backward. The front view is when the operator is facing the front of the machine using the front end loader or traveling with the machine. The rear view is when the operator is facing the rear of the machine using the backhoe unit. References to right and left are always in relationship to the machine, not the operator’s position.

Front View of Machine

2-2

1.

Front bucket

6.

Rear axle

2.

Bucket cylinder

7.

Fuel tank

3.

Bucket arms

8.

Lift cylinder

4.

Cab

9.

Front axle

5.

Hydraulic oil tank (in engine compartment)

WB156/156PS-5

OPERATION

Rear View of Machine

1.

Bucket

6.

Boom support

2.

Arm

7.

Battery, hydraulic filter and tool box

3.

Boom

8.

Outriggers

4.

Arm cylinder

9.

Backhoe swing cylinders

5.

Boom cylinder

10. Backhoe lock cylinder 11. Bucket cylinder

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2-3

OPERATION

OPERATION CONTROLS Before operating the machine, it is important to understand all the control functions provided with your machine. Operating the machine without knowledge of all the controls may damage the machine, property or possibly cause injury to the operator.

In the Cab (Joystick Controls) 1.

Direction control lever

2.

Steering wheel

3.

Front dash bezel

4.

Multifunctional switch

5.

Gear shift lever (Power shuttle only)

6.

Steering wheel adjustment lock

7.

Accelerator pedal

8.

Brake pedals

9.

Side dash

10. Front loader control lever 11. Parking brake 12. Hand throttle lever 13. Left backhoe joystick 14. Right backhoe joystick 15. Right outrigger control 16. Left outrigger control

2-4

WB156/156PS-5

OPERATION

Steering Column Switches The switches on the steering column control several functions.

Directional Control Switch (Standard) The direction of the machine can be selected by moving switch (1) toward the forward or reverse position.

Speed Selector Switch (PS Model Only) This switch (1) controls four speed ranges. Select the speed ranges by rotating the knob clockwise or counterclockwise. It is also used to select forward or reverse direction of the machine.

I: II: III: A:

Speed “Low range” Speed “Mid range” Speed “High range” Automatic speed range

Remark When the speed range is set in “A” the transmission shifts through the ranges automatically.

Multifunctional Switch This switch (4) controls several functions: A. B. C. D.

Turn left Turn right Horn High/Low beam control

WB156/156PS-5

E. F. G.

Flasher Windshield wiper Windshield washer

2-5

OPERATION

Front Instrument Panel and Controls

1.

Low fuel alert lamp

8.

Low pressure or brake fluid alert

2.

4-wheel drive (IN/OUT) indicator

9.

Main alert lamp

3.

Differential (LOCK/UNLOCK) indicator

10. High beam indicator lamp

4.

Parking brake alert lamp

11. Low beam indicator lamp

5.

Transmission oil temperature warning lamp

12. Work lights alert lamp

6.

Left directional indicator lamp

13. Gear speed position indicator (PS model only)

7.

Right directional indicator lamp

1.

2-6

Low Fuel Alert Lamp This warning light (1) comes on when there is about 17 liters (4.5 gal) of fuel left in the fuel tank. Refuel the machine as soon as possible. Make sure the machine does not run out of fuel; damage to the injection system may result.

WB156/156PS-5

OPERATION 2.

4-wheel Drive (In/Out) Indicator When the 4-wheel drive feature (2) is selected, this indicator comes on to indicate the 4-wheel drive system is (IN) operation.

When the indicator is off, the 4-wheel drive system is (OUT) of operation.

Remark Do not use the 4-wheel drive feature on dry roads.

3.

Differential (Lock/Unlock) Indicator When the differential lock feature is in (LOCK), the indicator lamp (3) comes on to indicate it is in operation. When the indicator lamp is off, the differential is (UNLOCKED). This feature is controlled by a button in the loader control handle.

4.

Parking Brake Alert Lamp When lamp (4) comes on, the parking brake is applied.

5.

Transmission Oil Temperature Alert This warning light (5) comes on with an audible alarm to alert the operator of a transmission oil overheat condition. If this warning and alarm comes on, immediately stop the machine and select neutral gear. Let the transmission oil cool down with the engine running at about 1200 rpm until the warning and alarm stop. If this occurs repeatedly, have the machine checked by an authorized Komatsu distributor. Do not continue to operate the machine.

WB156/156PS-5

2-7

OPERATION 6.

Left Direction Indicator Lamp This lamp flashes on and off when the multifunctional directional (13) switch is operated to turn left. It also flashes as a warning light when the hazard flashers are activated.

7.

Right Direction Indicator Lamp This lamp flashes on and off when the multifunctional directional (13) switch is operated to turn right. It also flashes as a warning light when the hazard flashers are activated.

8.

Low Pressure or Brake Fluid Alert This warning lamp (8) indicates that the brake oil pressure is low or that there is no oil in the reservoir.

9.

Main Alarm Lamp Alert (9) warning light comes on: A. When the machine is started, the general warning light check is activated for about three seconds.

B. When the maximum temperature allowed for the engine coolant is exceeded.

C. When the engine oil pressure is low.

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WB156/156PS-5

OPERATION 10. High Beam Indicator Lamp This indicator (10) comes on when the high beam is actuated by the multifunctional directional switch (13). When the multifunctional directional switch is actuated again, the high beam is turned off.

High-Low beam option must be installed.

11. Low Beam Indicator Lamp This indicator (11) comes on when the low beam is operated with two clicks of the switch (24) positioned on the side dashboard.

12. Work Lights Alert Lamp This indicator (12) comes on when the parking lights are operated with one click of the switch (24) positioned on the side dashboard.

13. Speed Range Indicator (PS Model Only) This indicator (13) comes on when the speed ranges are selected.

WB156/156PS-5

2-9

OPERATION

Side Instrument and Controls 1.

Fuel level gauge

2.

Engine coolant temperature gauge

3.

Tachometer and hour meter

4.

Hydraulic oil filter clog indicator

5.

Alternator alert

6.

Glow plugs preheat indication

7.

Engine coolant temperature alert

8.

Engine oil pressure warning lamp

9.

Air cleaner restriction alert

10. Audible warning system 11. Joystick work equipment lock switch 12. Backhoe power control switch 13. Backhoe boom lock switch 14. Horn switch 15. 4-wheel drive switch 16. Rotating beacon switch 17. Heater fan (Blower) switch 18. Temperature control switch 19. Starter switch 20. Rear work lights switch 21. Optional switch locations 22. Front work lights switch 23. Hazard switch 24. Low beam switch and parking lights switch

2-10

WB156/156PS-5

OPERATION 1.

Fuel Level Gauge The fuel level gauge indicates the fuel level in the tank and functions only when the starter key is in position “I.”

Remark • If the indicator reaches the red low fuel area during work, stop the machine and refuel.

•

The warning light (1) on the front instrument panel signals when the fuel level is too low.

2.

Engine Coolant Temperature Gauge This gauge (2) indicates the engine coolant temperature which must be in the operating range between 80-85°C (176-185°F).

Always allow the engine ample time to warm up to within these operating ranges before working the machine. Never allow the engine to exceed these operating temperatures, otherwise damage to the engine could occur.

3.

Tachometer and Hour Meter This gauge (3) indicates the engine rpm (revolutions per minute).

It also indicates the running hours on the engine.

This is a combined instrument that indicates the engine speed with a pointer, while the number of operating hours appears in the lower displays.

The count is continuous; the hour number is increased by one when the engine has worked for one hour, independent of the engine speed.

The hour counter keeps counting even if the machine isn’t working or traveling.

Remark The hour meter is considered valid for calculating the maintenance or service hour intervals for the machine.

4.

Hydraulic Oil Filter Clog Indicator This warning (4) comes on when the hydraulic oil filter is clogged and must be replaced. Replace the filter immediately if this warning is activated, otherwise damage to the hydraulic pump may result.

WB156/156PS-5

2-11

OPERATION 5.

Alternator Alert This warning light (5) comes on, along with an audible alarm, to alert the operator that the battery is not charging. If this light comes on during operation or remains on after initial start-up, have the charging system checked as soon as possible by an authorized Komatsu distributor.

6.

Preheat Indication In cold weather during initial start-up, there is a need to preheat the combustion air to aid in starting the engine. To use this feature, hold the starter switch in the preheat position for approximately 30 seconds. The indicator light (6) will come on and remain on for about 30 seconds; after the light goes out you may crank the engine. This procedure may have to be repeated one more time.

Due to the preheat feature equipped with this machine, do not use ether or other starting aids. Damage to the engine or possible injury to the operator may result.

7.

Engine Coolant Temperature Alert This warning light (7) comes on, along with an audible alarm, to alert the operator of an engine overheat condition. If this warning and alarm should come on, immediately stop the machine and select neutral gear. Let the engine run at about 1200 rpm until the warning and alarm stop. If this condition occurs again, check to make sure the radiator fins are clean and free of debris. Do not continue to operate the machine if the engine is overheating.

8.

Engine Oil Pressure Alert This warning lamp (8) comes on, along with an audible alarm, to alert the operator of an engine oil pressure loss. If this light comes on during operation or remains on after start-up, shut the engine down immediately. If this light does not come on when the starter key is turned on, have the system checked by your Komatsu distributor. Do not operate the machine if this light comes on intermittently or remains on, otherwise damage to the engine may result.

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OPERATION 9.

Air Cleaner Restriction Alert This warning light (9) comes on when the engine air filter is restricted.

If this indicator comes on during operation, shut the machine down and have the air filter system serviced. Do not operate the machine with a restricted air filtering system, otherwise damage to the engine may result.

10. Audible Warning System When the starter switch is on, or the machine is in operation, this audible alarm (10) sounds if: • • • • • •

The engine oil pressure is low.

The engine is overheating.

The transmission is overheating.

The alternator is faulty.

The seat is incorrectly positioned while machine is moving.

The charging system has failed.

11. Joystick Lock Switch When traveling on roads, always engage the joystick locking device.

This switch (11) inhibits the joystick controls; it is used when the machine travels on roads and as a safety lock when leaving the driver’s seat or parking the machine. To lock the joystick controls, press switch (11) ON (switch illuminated). Press the switch OFF to release the controls.

•

•

Whenever the machine is started, the controls are locked automatically ON (switch illuminated); press the switch OFF to use the controls.

For safety reasons, the joystick controls are locked automatically (LED on) (switch illuminated) when the seat is rotated by the operator to change driving position. The joystick controls are automatically released OFF when the rotation has been completed and the seat is in a fixed driving position (front or rear).

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OPERATION 12. Backhoe Power Control Switch This button (12) operates the selection of oil delivery from the hydraulic pump. When the machine is started, the control automatically selects the POWER mode (switch illuminated) which gives you the maximum breakout power at the backhoe. When the button is pressed again, the backhoe goes into the economy mode to reduce breakout power. This feature is used for excavating light material, operating optional attachments, or using the backhoe for grading purposes. If the machine is operated in the forward or reverse gears, the POWER mode is automatically canceled.

13. Backhoe Boom Lock Switch This switch (13) operates the boom lock. This function holds the backhoe in the parked position thus preventing hydraulic drift of the backhoe unit.

This feature should be used only when operating the front end loader or traveling with the machine.

14. Rear Horn This switch (14) activates the rear horn. This horn warns people in the area before you start your work operations.

15. 4-wheel Drive Switch When switch (15) is pressed, 4-wheel drive engages and the warning light on the front instrument panel comes on. When pressed again, it disengages the 4-wheel drive.

Remark When traveling at high speed and on roads, disengage the 4-wheel drive. The 4-wheel drive is automatically engaged when the brake pedals are pressed, and only with the 4th gear engaged.

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OPERATION 16. Rotating Beacon Lamp (if equipped) This switch (16) activates the beacon mounted on the cab roof.

17. Blower Switch The blower switch (17) controls the operation of the blower motor for the air circulation. It has three speeds: • • • •

Off (0) Low (1) Medium (2) High (3)

18. Temperature Control Switch The temperature control switch controls the temperature in the cab.

19. Starter Switch The starter switch (19) is the main switch; it is a four-position rotary switch.

• • • •

Preheat OFF ON Start

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OPERATION 20. Rear Work Light Switch This switch (20) activates the rear work lights installed on the cab.

When traveling on roads, switch off the work lights.

21. Optional Equipment Switches Location (21) is for any optional equipment.

A. Load Stabilizer System (Ride Control) Switch (if installed) When this switch (21) is turned on, the load stabilizer system (LSS) is activated. This feature is used to help stabilize the machine when the loader bucket is loaded and you are traveling on rough ground.

B. Hydraulic Hammer Switch (if installed) When pressed, switch (21) enables the hydraulic circuit of the hand hammer. When pressed again, it disables the circuit.

22. Front Work Light Switch This switch (22) activates the front work lights installed on the cab. When traveling on roads, switch off the work lights.

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OPERATION 23. Hazard Flashers This switch (23) operates both direction indicators at the same time and must be used when traveling on roads, while temporarily parked/stopped along roadways, during emergencies, or in case of unusual circumstances.

24. Parking Lights and Low Beam Switch Switch (24) is a two-position switch; with one click it switches on the parking lights and instruments, with two clicks it switches on the low beam. The parking lights can be switched on even with the machine at rest.

Air Conditioning Switch (if equipped) When this switch (location not shown) is turned on, the air conditioning system is in operation. When the switch is off, the air conditioning system is deactivated.

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OPERATION

Cab Switches and Electric Accessories Front Work Light Switch This switch (22) enables the front work lights installed on the cab.

When traveling on roads, switch off the work lights.

Rear Work Light Switch This switch (20) enables the rear work lights installed on the cab. When traveling on roads, switch off the work lights.

Rear Windshield Wiper Switch This switch (H) operates the rear windshield wiper.

Rear Windshield Washer Switch This switch (I), with automatic return to the OFF position, operates the rear windshield washer.

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OPERATION Overhead Lamp (Dome) The overhead lamp (25) is used to check the instruments and the inside of the cab when visibility is limited.

Power Outlet The 12V power outlet is in compliance with the ISO 4165-1979 standard. It is used for the connection of the revolving light, of the inspection lamp when maintenance operations are to be carried out, limited visibility and the emergency light.

Power Outlet Socket Socket is positioned on the lower part of the side dashboard and is powered by a 12V supply. It is used for the cigarette lighter and is compatible with the cigarette lighters available on the market. It can also be used to recharge mobile phones. Before use, remove the protection cap.

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OPERATION

Front End Loader Controls 1.

2.

3.

4.

5.

6.

Loader declutch control button.

Multipurpose bucket open button Differential lock button Multipurpose bucket close button Front loader speed control button Kickdown button (Lower) (power shift only)

Remark Buttons 1 - 4 are thumb buttons; 5 and 6 are trigger buttons.

Loader Declutch Control Button This button (1) allows the operator the option of transferring all engine power from the drive line to the loader hydraulics when lifting heavy loads. This feature should only be used on level ground.

•

Do not use this button for more than 15 to 20 seconds.

•

Do not use this button during travel on roads and especially when traveling downhill, since this function releases the clutch and sets the machine in neutral.

Multipurpose Bucket Open Button On machines equipped with the multipurpose (4-in-1) bucket, this button (2) opens the top half of the bucket allowing the operator the option of converting the loader bucket into a dozer blade when filling in trenches or using the bucket for picking up items.

Remark This control is also used to activate a hydraulic quick coupling device or other hydraulic attachment.

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OPERATION Differential Lock Button Remark • Locking the differential is possible only with 1st or 2nd forward or reverse gear engaged, since a safety device prevents the engagement of 3rd and 4th gear. •

Before locking the differential, lower the speed as much as possible in order to reduce the impact loads on the axle.

Locking the differential must be used only when it is necessary to engage the rear driving wheels, in case of skidding or if the machine is stuck in sand or mud. Lock the differential by pressing the button (3) and only with the lower gears engaged (1st or 2nd).

The differential is automatically released when the 2-wheel drive is engaged. The warning light on the front instrument panel signals that the differential is locked.

Do not use this feature when traveling on slopes. To engage the differential lock feature, the system must disengage the drive line first. Loss of control may result.

Multipurpose Bucket Close Button On machines equipped with the multipurpose (4-in-1) bucket, this button (4) closes the top half of the bucket, allowing the operator to use the bucket for scoop and loading operations.

Remark This control is also used to activate a hydraulic quick coupling device or other hydraulic attachment.

Front Loader Speed Control Button When upper button (5) is activated, the maximum quantity of oil is delivered by the hydraulic pump for heavy-duty applications.

Press the push button to increase oil delivery; when the push button is released, the oil delivery returns to the standard operating values.

Remark It is advisable to use this feature for no more than five to six seconds during loader operation.

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OPERATION Kick Down Button (Power Shift Only) The button (6) is enabled with both automatic and manual gearshift and allows the gears to be shifted from 2nd to 1st and vice versa.

In manual mode, downshifting from 2nd to 1st gear is indicated by the warning light flashing on the front dashboard. The flashing of the warning light indicates that there is no correspondence between the selection made and the gear engaged. Press the KICK DOWN button again to return to the 2nd gear.

In automatic mode, the KICK DOWN button allows downshifting from 2nd to 1st gear; the KICK DOWN function is deactivated automatically depending on the speed of the vehicle, thus allowing automatic sequential upshifting from 1st to 4th gear.

Gear Shift Lever Controls (Power Shuttle Only) The gear shift lever (5) is used to change travel speed ranges. It is equipped with a declutching button (1) used to disengage the drive line for changing speed ranges.

•

Engage the gears only with the engine running at a low rpm and the machine is traveling slowly or stopped.

•

Avoid up-shifting when using the machine in heavy operations.

•

Always shift the lever into a neutral position (N) when parking the machine and set the parking brake.

Declutch Button To change speed ranges, slow the machine down; press the declutch button; shift to the desired speed range; then release the button as quickly as possible.

Changing Speed Ranges The machine is equipped with four speed ranges. The lower speed ranges are for using the front end loader or slow maneuvering on a job site. The higher ranges are for forward ground or road travel.

3rd and 4th speed ranges are for forward operation only.

Do not travel in reverse using the 3rd or 4th speed range.

Loss of control may result.

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OPERATION PS Model Control Lever This switch (1) controls four speed ranges. By rotating the knob clockwise or counterclockwise, four speed ranges can be selected. It is also used to select forward or reverse direction of the machine.

I: II: III: A:

Speed “Low range” Speed “Mid range” Speed “High range” Automatic speed range

Remark When the speed range is set in “A” the transmission shifts through the ranges automatically.

Directional Control Lever When operating in a desired speed range, you can choose the forward or reverse direction using the directional control lever (1). This function allows you to change direction quickly and easily without using any type of clutching mechanism.

To operate, lift the lever and move it into any direction: F- Forward travel N- Neutral R- Reverse travel Remark The machine can only be started in the (N) neutral position.

When parking the machine, shift into the (N) position and set the parking brake for safety. Avoid changing direction when traveling at fast speeds. Always slow down and apply the brakes before changing direction.

3rd and 4th speed ranges are for forward operation only.

Do not travel in reverse using the 3rd or 4th speed range.

Loss of control may result.

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OPERATION

Brakes, Parking Brake, Accelerator, and Throttle Control Brake Pedals The machine is equipped with a tandem brake pedal. This setup makes it possible to separate the right and left braking pedals for making sharp, tight turns in close working conditions.

•

•

During normal operation or when traveling on roads, the brake pedals (2) should be locked to allow for equal braking at each wheel.

When operating at slow speeds in tight locations, the brake pedals (2) can be separated to allow independent braking at the right or left wheel.

When operating with the brakes separated or unlocked: • Always operate at a slow speed no higher than 1st gear.

•

The brake pedals must always be connected when the 3rd or 4th gear is engaged and when the machine travels on roads.

•

Never operate the machine at high speeds with the pedals unlocked.

•

Once you have finished your work, always relock the brake pedals immediately for safety purposes.

Failure to comply with this warning may result in serious injury.

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OPERATION Parking Brake Before exiting the cab, it is important to apply the parking brake.

1.

Bring the machine to a full stop.

2.

Grasp the brake handle firmly.

3.

Squeeze the lock lever below the brake handle.

4.

Pull up on the handle until the brake handle locks in place.

5.

Release the lock lever.

6.

The brake set indicator comes on indicating that the brake is set.

Remark Leaving the machine in gear with the engine off and the directional control set in the forward or reverse position does not hold the machine in place. The parking brake must be used. Always park the machine in neutral.

Remark The rear wheel must be firmly on the ground in order for the parking brake to work. Always set the parking brake when exiting the cab.

Release the parking brake in this manner.

1.

Grasp the brake handle firmly.

2.

Pull the handle up slightly.

3.

Squeeze the lock lever below the handle.

4.

Lower the handle down completely until it is fully released.

5.

The brake set indicator will go off indicating the brakes are released.

Accelerator Pedal The accelerator pedal (3) is used mainly for road travel or when using the front end loader. When using the front end loader with the accelerator pedal, be careful not to strain the machine. Always accelerate smoothly when loading the front end loader.

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OPERATION Hand Throttle

The use of the hand accelerator is allowed only under the conditions specified below; use in any other condition may cause serious accidents.

The hand accelerator can be used only when the engine is warming up and afterwards only when it is necessary to work with the backhoe; it can also be used for certain maintenance operations.

The positions for the hand throttle are: Idling Position: . . . . . . . . . . . . . . . . Throttle handle pulled back

Maximum rpm Position: . . . . .Throttle handled pushed forward.

Throttle Operating Tips Avoid using the machine with the throttle lever in the maximum rpm position. Fuel consumption and engine wear increase at high engine speeds. For proper throttle use, refer to the indications listed on the decal near the throttle handle.

•

•

Green area “A”: This area indicates the engine speed is approximately 1900 rpm, which is the value recommended for normal operation.

Red area “B”: This area indicates the engine speed is in the range of 2200 rpm, which is the maximum speed allowed for the use of the backhoe.

Remark Throttle speed can be monitored using the tachometer on the side instrument panel.

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OPERATION

CAB ENVIRONMENT AND SAFETY EQUIPMENT Ventilating, cooling and heating the cab increases operator comfort in cold or hot environments. If your machine is equipped with a cab, this system reduces condensation on cab windows and improves uncomfortable temperature conditions.

Heating and Ventilation System Air Conditioning (if equipped) If your machine is equipped with air conditioning (1), beside the air conditioning switch and blower control switch (2), there are two other controls.

These controls are for temperature control and for recirculation.

• •

To adjust temperature, turn the knob (3) clockwise to increase temperature and counterclockwise to decrease temperature.

To regulate air supply, turn knob (4) clockwise to recirculate inside cab air and counterclockwise to allow outside air in. Feature (4) allows the cab to warm up or cool down rapidly.

Heating System If your machine does not have the optional air conditioning, it still has the temperature control switch (4) and the blower control switch (3).

•

To adjust temperature, simply turn the knob clockwise to increase temperature and counterclockwise to decrease temperature.

•

The ventilation and cooling system ensures air suction both from the outside and the inside of the cab. Air suction from the outside is protected by a filter positioned on the right side of the cab, while air suction from the inside (recirculation) is protected by an internal filter (5) positioned on the right, under the storage compartment. Internal air recirculation ensures quicker cooling and is very useful when working in areas where air pollution is considerable (tunnels, dusty places, small or badly ventilated rooms, etc.).

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OPERATION •

Adjust air distribution using the adjustable vent. Note there are vents in the seat pedestal also (not shown).

• •

Adjust vents above the dashboard to assist defogging and deicing.

At the beginning of summer and before using the air conditioner, clean the suction filters (only for machines with air conditioner).

During the season, clean the filters periodically. Time intervals vary according to the environment in which the machine operates (minimum every five days - maximum every 15 days).

•

•

Before operating the heater, turn on hot water flow by rotating the valve (9) positioned in the engine compartment clockwise.

Remark Start the air conditioner only with low engine rpm and not during acceleration, to avoid damaging the system and breaking the compressor drive belt. In periods where the air conditioner is not used, operate the compressor at low speed for approximately three to five minutes at least once a month. This operation ensures the lubrication of all the moving parts of the compressor.

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OPERATION

Seat and Seat Belt Seat The seat is designed for maximum operator comfort which helps reduce operator fatigue. There are six adjustments with the seat.

1. Longitudinal adjustment (front-back) 2. Back inclination adjustment 3. Adjustment of seat suspension 4. Seat cushion height 5. Armrest adjustment 6. Rotation for backhoe operation The operator can choose the most comfortable operating position using the listed features.

• •

•

•

For longitudinal adjustment, lever (1) can be used to position the seat in forward and backward positions.

The back adjustment (2) is for positioning the upright inclination for the operator’s back angle. The softness or dampening of the ride and vibrations can be controlled by adjusting knob (3) to the desired setting. To increase firmness, turn the knob clockwise; to decrease firmness turn the knob counterclockwise.

The height of the seat can be adjusted with lever (4). To adjust the armrest angle, use the roll knobs (5) to change the inclination of the arm rest angle.

When operating the backhoe, use lever (6) to rotate the seat from a loader position to the backhoe position.

Seat Belt The seat belt (1) is provided for your safety during operation of the machine. Law requires the operator to use this seat belt during operation.

•

•

•

The purpose of the seat belt is to keep the operator in the seat if the machine should be involved in a rollover situation. Before starting the engine or doing anything in the cab, fasten the seat belt snugly around your waist first.

Always use the seat belt when operating the machine, even just for a moment. If the seat belt is damaged or worn, replace it immediately.

Never rely on a damaged or worn seat belt to hold you in place if a rollover should occur. Getting in the habit of using the seat belt could save your life.

Remark The seat belt must be replaced every three years after the start of usage or five years after the date of manufacture or at the first sign of wear or damage. See “Seat Belt Inspection” on page 1-19.

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OPERATION

Safety Equipment and Storage Areas Fire Extinguisher The machine owner must provide a fire extinguisher for the machine.

There is a storage area (1) provided in the cab to hold the fire extinguisher.

If you equip your machine with a fire extinguisher, learn how to use it and where it is stored. Before starting any work operations, always check the fire extinguisher to be sure it is charged and in good condition.

First Aid Kit The machine owner must provide a first aid kit for the machine. There is a storage area (1) provided in the cab to hold the first aid kit.

It is important to periodically check the first aid kit to be sure it is in good condition and the medical supplies are not damaged or missing.

Document Storage This area is provided for the storage of any service documents. It is also for storing the service manual which must be kept with the machine at all times for quick reference by the operator.

Storage Compartment A storage compartment (1) is located on the inner side of the right wheel well and can be reached after opening the door (2).

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OPERATION The door (2) is equipped with a lock (3).

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OPERATION

CAB AND GUARDS The cab offers the operator the option of a controlled environment as well as the safety of the ROPS (rollover protective structure). The guards equipped with the machine are there to protect personnel from injury due to contact with moving or hot parts.

It is important that all these structures be kept in good condition and replaced if damaged.

Cab Doors and Windows On the cab, the rear upper window (1) can be opened completely. When open, the window is positioned and secured under the roof. When raising the upper window, be sure it is securely latched in place.

The rear cab window (1) can be opened only after releasing the latches (2), then pulling and lifting the window itself. Once the window is in the upper position, the latches (2) must lock in place to secure the window.

The rear, side windows can be opened partially or completely.

To open them partially, proceed in this manner.

1.

Release the lever (3) from the lower coupling pin (4), in the direction indicated by the arrow shown in Figure (A).

2.

Lift the lever (3) with a sliding movement, and at the same time, push the lever toward the outside of the cab. After lifting the lever (3), push its end downwards in order to engage it in the upper coupling pin (5), as shown in Figure (B).

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OPERATION If it is necessary to open the rear side windows completely, proceed in this manner.

1.

Release the lever (3) from the upper coupling pin (5) in the direction indicated by the arrow shown in Figure (C).

2.

With the window open, lower the lever (3) until it is engaged in the lower coupling pin (4), as shown in Figure (D).

3.

Rotate the rear side windows towards the front of the machine, until the coupling (6) is engaged in the rubber element (7), as shown in Figure (E).

4.

To close the rear side windows, turn the knob (8) and release the rubber element (7) from the coupling (6). Close the side windows and couple the lever (3) to the lower pin (4), as indicated in Figure (A).

•

When the rear side windows are partially open or completely closed, they must always be locked by engaging the lever (3) with the lower (4) or upper (5) coupling pin.

When the rear side windows are rotated towards the front of the machine in order to open them completely, make sure that they are perfectly fixed in the relevant rubber elements (7).

Periodically lubricate the rubber elements (7) with specific greases, in order to facilitate the coupling operation.

•

•

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OPERATION •

The cab doors can be opened fully or partially. The partial opening is available by fitting the optional retainers (9) onto mounts in the handle supports.

Remark Partially opened doors need an optional kit.

Remark The doors must always be secured with the retainers, (9) and (10), or closed.

Guards •

•

The guards equipped with your machine are in place to protect the operator from the machine or the environment the machine is operating in.

Never remove or modify the machine’s guards in any way. Doing so may result in injury or even death.

Driver’s Overhead Guard •

•

The driver’s overhead guard is designed to protect the operator from falling objects or in a rollover situation. Always inspect the overhead guard for damage. If damaged in any way, the integrity of the overhead guard has been changed and should be replaced before operating the machine.

Never drill, weld, cut, or modify any part of the driver’s overhead guard.

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OPERATION Engine Hood

When working on the engine with the hood raised: • Do not open the hood with the engine running.

•

Do not operate the machine without a hood.

•

When doing maintenance with the front end loader raised, be sure to engage the safety lock in the loader arm.

•

Always lower the loader completely to the ground before opening the hood.

The engine hood (2) is designed to cover the operating components in the engine compartment. Never operate the machine without an engine hood. To open the hood, press the lock (1) located on the right side of the hood, then carefully swing the hood forward over the nose of the machine.

ELECTRICAL This machine is controlled by a series of electrical components, switches, relays, systems, etc. It is important to know where the system shutdown and electrical protection systems are located if extra security is needed or if an electrical system should fail.

Switches and Extra Accessories Battery Disconnect Switch •

•

•

The battery disconnect switch is used to shut the machine’s electrical system down completely. This feature offers extra security on the job site when the machine is unattended for long periods of time.

To use this feature, locate the switch in the right battery and tool box. Rotate the switch counterclockwise to disconnect the electrical system.

To reconnect the electrical system, rotate the switch clockwise.

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OPERATION Adapter for Radio (if provided) If the machine is provided with an aperture for the installation of a car radio, remove the cover (10) and install the radio. Contact your distributor for assistance.

Fuses and Relays Fuse and Relay Panel Location •

•

• •

•

The fuses and relays are grounded on a single board positioned on the right side of the cab. Removing cover (1) exposes the fuses and relays, if it is necessary to service them.

If an electrical system fails during operation, it is important to check the fuses or relays first.

Once cover (1) is removed, the fuses and relays are easily accessible.

With the starter key in the “ON” position, check each fuse with a test light. This will indicate which bank of fuses or relays has failed.

To replace a fuse or relay, the starter switch must be in the “OFF” position.

Remark When replacing fuses or relays, always check the condition of the contacts for corrosion. If the panel is badly corroded, contact your Komatsu distributor for repair. Never replace a fuse with a fuse of higher or lower amp rating. Damage to the electrical system may result.

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OPERATION

Fuse and Relay Panel Layout Fuses

Position

Color

Amps

F1

Light blue

15

Front work lamps

F2

Light blue

15

Rear work lamps

F3

Violet

3

Parking lights front left and rear right, warning lamps and dash lamps

F4

Violet

3

Parking lights front right and rear left, cigarette lighter

F5

Red

10

Front horn

F6

Light blue

15

Lateral rear work lights

F7

Brown

7.5

Rear windshield wiper and rear horn

F8

Brown

7.5

Stop lights and stop light relay

F9

Light blue

15

Lateral front work lights

F10

Red

10

Front windshield wiper, windshield washer pump

F11

Brown

7.5

Boom lock solenoid valve

F12

Orange

5

Buzzer power supply, general alarm and warning lamps supply

F13

Red

10

Optional equipment, differential and 4-wheel drive solenoid power supply

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Circuit

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OPERATION

Fuse Position

2-38

Description

F14

High/low beam, horn and safety solenoid valve

F15

Engine stop solenoid, A/C relay and functions relay

F16

Rotating beacon

F17

Hour meter memory, hazard warning light

F18

Cigarette lighter and cab lamp

F19

Left and right low beam

F20

Left and right high beam

F21

Return-to-dig sensor, LSS solenoid valve, loader arm float solenoid, return-to-dig solenoid valve and direction indicator

F22

Joystick control lock solenoid, EC power solenoid valve, PPC power supply

F23

Steering unit

F24

Direction indicator power supply

F25

Declutching relay, forward gear solenoid valve, reverse gear solenoid valve and reverse alarm

F27

General system fuse, starter key, start relay, and preheat power supply

WB156/156PS-5

OPERATION Relays

Relay Position

Description

K1

Safety unit (against repeated start)

K2

Turn signal and/or flasher

K3

Low beam relay

K4

High beam relay

K5

Front horn relay

K6

Return-to-dig relay

K7

Stop light relay

K8

Start enabling relay

K9

Forward gear relay

K10

Reverse relay

K11

Directional indicator power supply relay (declutch)

K12

Machine function relay

K13

Start relay

K14

Preheating relay

K15

Multifunction unit

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OPERATION

Heating and Air Conditioning Fuses and Relays The fuses and relays are grouped on a single board positioned under the storage compartment and can be reached after opening the door (1) and removing the container (2).

The following tables indicate the characteristics and the functions of the single fuses and relays.

Fuses Fuse Position

Color

Amps

1

Yellow

20

1 and 2 fan speed power supply

2

Orange

40

3rd fan speed power supply

3

Brown

7.5

Refrigerant compressor

Circuit

Relays Relay Position

Description

4

3rd fan speed relay

5

General heating relay

6

Refrigerant compressor relay

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OPERATION

OPERATING THE MACHINE Before starting your work operations, it is important to perform several procedures to be sure your equipment is safe to operate. It is also important to be aware of the hazards involved when operating your machine. Study the Safety Section of this manual. See “PRECAUTIONS BEFORE STARTING OPERATIONS” on page 1-25 before proceeding with any work operations.

Checking the Fuel Supply Before starting the machine, it is important to be sure that there is enough fuel in the fuel tank.

• • •

To check, turn the starter key to the “ON” position and read the fuel gauge (1).

Add fuel if the supply is low. Leave enough space in the tank for the fuel to expand. Never overfill the fuel tank.

Do not smoke when refueling and do not use fuel additives or mix gasoline with diesel fuel. These may damage fuel pump and injector parts.

Starting the Engine Before starting the engine, be sure all personnel are clear of your work area or travel path. To start the engine do the following procedure.

1.

Place the directional control lever (1) in the neutral (N) position.

The engine will not start with the directional control lever in the forward or reverse position.

2.

Set the throttle control lever to a low idle speed.

3.

With your foot off the accelerator pedal, turn the starter key to the start position.

4.

When the engine starts, release the key; the starter switch returns to the “I” position automatically.

5.

With the engine now running, check all the gauges and warning indicators. Be sure the system is operating normally. Allow the engine and hydraulic system time to warm up before starting work.

Remark If the engine does not start within 15 seconds, release the starter switch and wait for 30 seconds before trying again. If it does not start, do not continue to crank the engine; damage to the starter may result. Contact your Komatsu distributor for repairs.

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OPERATION

Starting the Engine in Cold Weather

Do not use any starting fluids or ether-based product to aid in the starting of the engine. These products may cause an explosion, damaging the engine or causing injury.

To start the engine in cold weather or in extremely cold climates, use the following procedures.

1.

Place the directional control lever in neutral position. The engine will not start with the directional control lever in forward or reverse.

2.

Set the throttle control to a low idle speed.

3.

Turn the key to the preheat position. The preheat time is determined by the outside temperatures.

4.

Once the preheat indicator goes out you are ready to crank the engine.

5.

With the accelerator depressed halfway, or fully depressed in extremely cold weather, crank the engine until it starts. Do not pump the accelerator pedal.

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OPERATION 6.

When the engine starts, release the key and accelerator pedal; the switch returns to the “I� position automatically.

7.

With the engine now running, check all the gauges and warning indicators. Be sure that the system is operating normally. Allow the engine and hydraulic system time to warm up before starting work.

Remark If the engine does not start within 15 seconds, release the starter switch and wait for 30 seconds before trying again. If it does not start, do not continue to crank the engine; damage to the starter may result. Contact your Komatsu distributor for repairs.

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OPERATION

Warming Up the Machine When warming the engine, especially in cold weather, it is advisable to also warm up the hydraulic system oil. Always allow an ample amount of time to warm up the machine. Starting work operations with a cold machine causes excessive and unnecessary wear on parts. To warm up the engine and hydraulic system do this procedure.

1.

Unlock the front end loader control lever (4).

2.

Set the throttle at a ¼ position above a low idle.

3.

Raise and lower the loader boom while operating the bucket. Do this several times to warm up the engine and hydraulic oil.

Remark Do not accelerate or rev the engine at high speeds when cold. Damage to internal engine parts may result.

Shutting Down the Engine After operating the machine, it is recommended that you allow the engine to idle at a low rpm for a short period of time to cool down the system.

To shut down the engine, proceed as follows: • • • • •

Lower all work equipment to the ground.

Shift the directional control lever into the neutral position.

Set the throttle at a low idle position.

Set the parking brake.

See “PARKING THE MACHINE” on page 2-73.

Turn the starter switch to the “OFF” position and remove the key.

Remark Never shut the engine down at a high rpm. Always allow the engine time to idle and cool before shutting down.

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OPERATION

OPERATING THE FRONT END LOADER AND BACKHOE When preparing to operate the front end loader or backhoe, it is important to be aware of your working conditions and hazards involved. Always study the job carefully before starting any operations. Operate within the operating parameters specified in this manual. Never use this work equipment for something for which it was not intended, otherwise the equipment may be damaged or the operator may be injured.

Pre-operational Checks Before starting your machine and preceding with any work operations, it is important to be sure your machine is safe to operate. Below is a list of some basic items to check before any work begins. If any problems are found during your pre-operational check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.

Perform a Walk Around Check of Your Machine A. Look for any obvious missing or damaged items.

B. Check the condition of the loading and backhoe buckets. Look for loose or missing attachment pins, damaged surfaces or missing parts.

C. Check the condition of all visible hydraulic hoses. Look for worn or leaking fittings and cut, scuffed or cracked hose surfaces. If any hose is worn, cracked or leaking, have it repaired or replaced immediately.

D. Check for leaking or damaged hydraulic cylinders. If any cylinder is damaged or leaking have it repaired immediately.

E. Inspect the mechanical lift, dump and backhoe arms, and pivot points. Look for any loose or missing parts and cracked, bent or damaged areas.

F.

Be sure all safety decals are in place and are not damaged. Be sure they are clean and visible for all personnel to see.

G. Check the condition of the front and rear tires. Look for excess wear, cut surfaces or objects imbedded in the tire.

Check tire inflation.

H. Check under the machine for any buildup of debris or leaks. Remove any debris and repair leaks immediately.

I.

Inspect the fuel tank for damage or leaks. Be sure the fill cap is installed and locked in place.

J.

Be sure the steps are not damaged or covered with mud.

K. Check the condition of the cab. Inspect the windows, mirrors, handrails, work lights, directional lights and canopy for any damage or missing parts. Be sure all locks are functional.

L. Check the exhaust stack. Be sure it is not damaged, kinked or restricted in any way. Be sure the exhaust outlet is facing away from the cab and is not restricted.

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OPERATION

Under the Hood A. Open the hood and check all fluid levels. Be sure they are at the specified level outlined in the Maintenance section.

B. Check the engine and radiator and remove any trash, wood chips, rubbish, leaves or other flammable materials. Look for buildup of oil or dust as well. Keep these areas clean.

C. Inspect all fuel lines for signs of leakage or deterioration. If the fuel lines are deteriorated or leaking, have them replaced or repaired immediately.

D. Inspect the hydraulic tank for damage or leaks. Be sure the fill cap is installed and secure.

E. Be sure the hood closes properly and will lock securely to prevent tampering by others.

In the Operator’s Cab A. Check the condition of the cab floor. Be sure it is clean and free from tools, objects, excess dirt, trash and grease.

B. Check to be sure both doors open and close properly. Be sure the right door is unlocked for safety purpose.

C. Check the windows for cleanliness; remove any stickers or objects applied to the windows.

D. Make sure the fire extinguisher is in place and in operating condition.

E. Be sure the operator’s manual, safety manual and all cab safety decals are in place and in good condition.

F.

Check that the seat and seat belt work properly.

Start-up Checks

When performing start-up checks, be sure your machine is in a well-ventilated area.

A. Start the engine and allow it to idle at a low rpm.

B. Check the operation of all gauges and warning systems. Be sure they all operate normally.

C. Check the operation of all switches. Be sure the lights, wipers, directional, horn and warning flashers and alarms work properly.

D. Check the brakes, throttle operation and steering wheel. Be sure they are clean and free from dirt or grease.

E. Check the operation of all work controls.

Remark It is important that a pre-operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator. Always perform a pre-operational check before you start work.

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OPERATION

STARTING YOUR WORK Before starting any work operations it is important to be aware of several dangerous situations related to a backhoe loader.

Although KOMATSU cannot predict all dangerous situations, the following are situations of which you should be aware. For more information on safe operation of the machine, see Section 1 - SAFETY. • • • • •

Do not start the engine if warning tags have been attached to the steering wheel or control levers.

Sound your horn to warn others in the area before starting the engine or operating the machine.

Operate the machine when you are in a seated position only, with the seat belt fastened snugly around your waist.

Do not allow anyone in the cab or on the machine during operations.

Check the work area to be sure all personnel are clear of the machine and your swing area.

Avoid Dangerous Situations • •

• •

• •

Avoid traveling with the bucket raised. Raising the bucket also raises the center of gravity on the machine.

Traveling with a raised bucket, especially a loaded bucket, may result in loss of control or a rollover situation. Never raise the bucket unless the machine is stopped.

If you must travel with the bucket raised and loaded, always travel a short distance at a slow, controllable speed and on level ground.

Never attempt to make sharp turns or stop the machine suddenly as this may cause the machine to tip forward.

Always handle unstable loads carefully. Avoid tipping the bucket back or raising the load too high.

Be sure to operate the work equipment carefully and keep the load as close to the ground as possible. If you must travel with an unstable load, be sure that you are on level, firm ground and travel at a slow safe speed.

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OPERATION •

Do not use the bucket or lift arms as a crane. The lifted object may swing or shift, causing the machine to tip, sway or possibly roll over.

•

Never work under overhangs or excavated bank areas. These could collapse and damage the machine or injure the operator.

•

Never pick the machine up or reposition it using the work equipment. Loss of control or a rollover situation may result. Keep in mind that the work equipment is for digging, scooping and loading operations.

•

Never allow other personnel in your work area while the machine is in operation. The possibility of the work equipment blocking your view during operations may result in injury to that person.

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OPERATION •

When digging a trench with the backhoe work equipment, always be aware of the ground condition and never attempt to dig too close or under the machine. The possibility of the machine falling into the excavated site increases the closer the excavation is to the machine.

•

If someone approaches you while you are operating the machine, stop all operations immediately and signal the person not to approach until the work equipment is lowered to the ground and it is safe for them to approach. Do not touch any of the machine controls again until the person has moved out of your work area and is at a safe distance.

When possible, lock the controls until it is safe to resume work.

•

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OPERATION

Working Clearances It is necessary to be aware of the clearances around, in front, behind and especially above your work area or travel route. Always be aware of your machine’s traveling height.

•

•

The backhoe boom and arm on this machine stick up at least 914.4 mm (3 ft) above the canopy and cannot be seen during loader, travel or transport situations.

If the backhoe boom or arm strikes an object, the machine may be damaged or somebody injured.

High Voltage Lines • • •

•

•

When working or traveling in an area where clearances are a problem, travel at a slow, cautious speed.

If you are not sure of your clearances, request the aid of another person who can guide or warn you if you get too close to objects.

Be aware of the dangers when working around overhead electrical lines. High humidity may pose an electrical hazard even if your machine clears the overhead power lines.

If your machine comes in contact with overhead electrical lines, stop the machine and remain on the machine until the power company clears the lines and it is safe to get off or move the machine.

If low power lines pose a danger, ask the power company to remove the lines until your work is finished.

Voltage Low voltage

Special high voltage

2-50

Safe Distance 100V-200V

2m

6,600V

2m

22,000V

3m

66,000V

4m

154,000V

5m

187,000V

6m

275,000V

7m

500,000V

11 m

WB156/156PS-5

OPERATION

Operating the Front End Loader Before using the front end loader, be sure front end loader lock (A) is unlocked. When operating the front end loader, you must be seated in the operator’s seat with the seat belt fastened snugly around your waist.

• • ★ • •

Both outriggers must be up and locked.

Be sure the backhoe unit is locked and pinned.

See “Backhoe Locks” on page 2-69.

Check your work area to be sure no personnel are near you.

Sound your horn before beginning work operations.

When operating the front end loader: • Always keep the bucket as close to the ground as possible.

•

Never raise or lower the bucket while traveling. Always come to a complete stop when raising or lowering the loader bucket.

•

Avoid lowering the bucket too quickly; damage to the lift arm cylinders may result.

•

When traveling with a loaded bucket, maintain a height of 50 cm (20 in) above the ground.

•

When loader operations are completed, lower the loader bucket to the ground and set the loader lock.

•

Avoid sharp turns with a loaded bucket.

•

When loading the bucket, never ram a load at high speeds and never overload the bucket.

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OPERATION Control Lever Positions Loader Bucket and Arm Operations •

When the control lever is moved forward or backward and at right and left angles, the bucket and arm move in the positions indicated in the illustration.

N - Neutral position (no boom or bucket movement) A - Bucket curl back B - Arm lower C - Bucket dump D - Arm raise E - Arm in free float position F - Self leveling (return to dig)

Dual Functional Bucket and Arm Positions •

When the lever is operated in the direction shown in the illustration, a dual function of the bucket and arm can be achieved.

N - Neutral position (no boom or bucket movement) A - Arm lowering - Bucket curling B - Arm lowering - Bucket dumping C - Arm raising - Bucket dumping D - Arm raising - Bucket curling

Multipurpose Bucket Opening Push Button •

•

On machines equipped with a multipurpose (4-in-1) bucket, the bucket is controlled by the push button (12) positioned on the loader control lever.

Press the button to open the bucket; when the button is released, the bucket stops.

Remark This control is also used to activate a hydraulic quick coupling device or other hydraulic attachment.

Multipurpose Bucket Close Push Button •

•

On machines equipped with a multipurpose (4-in-1) bucket, closing the bucket is controlled by the push button (13) positioned on the loader control lever.

Press the button to fold the bucket; when the button is released, the bucket stops.

Remark Do not use the “Arm In Free Float Position” when traveling forward. The bucket will dig in and lift the machine. The float feature should only be used when traveling in reverse, performing grading operations.

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OPERATION

Performing Loading Operations Before performing loading operations, the operator must become familiar with the loader controls and their positions. The operator must also be familiar with all safety issues implicated in these operations. Failure to do so may result in damage to the machine or injury to the operator.

Bucket Position Indicator The bucket position indicator shows the operator the position of the front bucket with respect to the ground. The horizontal position of the bucket, parallel to the ground, is determined by the return of the rod (1) to the reference level (2). If the machine is provided with the automatic RETURN-TO-DIG device, the horizontal, parallel position of the bucket with respect to the ground is determined by the sensor (3) located on the cylinder and is reached when the sensor does not detect the rod (1) any longer. In case of malfunction of the device, check and if necessary carry out the required adjustments. To adjust the sensor, see “Adjusting Automatic Return of Front Bucket to the Digging Position” on page 3-33 (if installed).

Organizing Your Work Area Before starting any loading operations it is important to be sure that your work area is safe and clear of any obstacles or hazards that may hinder your operations, damage the equipment or cause an accident.

• • •

Check the ground to be sure it is level and firm.

Study the loading pattern you will be using. The illustration gives an example of a simple loading pattern used by most operators.

Before starting your operations, sound the horn and be sure all personnel are away from your work area.

Remark When using the declutch button during loader operations, always bring the machine to a full stop before changing speed ranges.

Loading Heaped Material The efficiency of loading the bucket depends on how the operator starts the loading process.

1.

If equipped with the 4-wheel drive feature, engage this feature when loading the bucket to increase loading efficiency.

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OPERATION 2.

Level the bucket and set it on the ground. Shift into a lower speed range and set the machine in 4-wheel drive.

3.

Start moving into the pile from several feet away.

4.

Once the bucket is in the pile, raise the bucket slightly to put weight on the front; begin curling the bucket back while continuing to move into the pile. This will keep the material from falling under the front of the bucket thus losing part of your load.

Remark Avoid allowing the tires to slip when entering a pile; damage to the tires may result.

5.

Once the bucket is full, stop moving into the pile and begin raising the load while continuing to curl the bucket back.

6.

Raise the arm enough to allow the material in the bucket to fall toward the back of the bucket and level off.

7.

Lower the bucket back down to approximately 50 cm (20 in) above the ground and back out of the pile of material.

8.

Proceed slowly and cautiously toward your destination.

Always travel with the load as close to the ground as possible. Remember, the higher you raise the load, the higher the center of gravity on the machine, making your machine unstable and prone to a rollover situation. Always take corners slowly and cautiously. Never raise the load while traveling.

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OPERATION Loading a Truck Bed or Trailer When loading a truck bed or trailer, always start your loading toward the front of the bed. Approach the truck or trailer slowly and cautiously, keeping the load as close to the ground as possible and the front end of the machine parallel with the truck or trailer. At your point of deposit, stop, raise the load, and move toward the truck or trailer slowly. Once you are over the center of the bed, deposit your load; back up far enough to clear the truck or trailer and lower your empty bucket.

Working on Slopes with a Loaded Bucket Working on a slope can be dangerous if safety and some basic precautions are not observed. Respect the following precautions.

•

• •

•

• • •

Always check the work area for snow, landslides, gravel, loose ground and anything that may suddenly modify the work conditions and stability of the machine.

Shift the machine into a low gear range. Do not change gear ranges or press any feature buttons when traveling up or down slopes.

When traveling up the slope, the front loader bucket must always be directed toward the top of the incline.

When traveling down a slope with the bucket loaded, travel with the loaded bucket facing the top of the incline, backing the machine down the incline.

Always keep the bucket at least 50 cm (20 in) above the ground.

Never raise the bucket while traveling on a slope.

Never turn on a slope or travel at an angle on the slope.

Travel up or down the slope at a slow, controllable speed.

Remark If the machine starts to tip with the bucket loaded, lower the bucket and load to the ground immediately to quickly help stabilize the machine and lower the center of gravity.

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OPERATION

Changing the Front Bucket When changing front loader buckets always wear gloves and eye protection. To change the front bucket do this procedure.

1.

Position the bucket and machine on level ground.

2.

Remove the bolts (1) and coupling pins (2).

3.

Exchange the bucket (3), being careful to completely clean the pins and bushings before installing them.

4.

Reinstall the bolts and tighten them in place.

5.

Lubricate all pin locations.

Never use your fingers or hands to line up the pin or bolt holes. If hole alignment is not correct, use a steel drift to line up parts.

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OPERATION

Operating the Backhoe Before performing any backhoe operations the operator must become familiar with the backhoe controls and their locations.

The operator must also learn to perform these operations safely. Failure to do so may result in machine damage, injury or death.

PPC Controls When sitting in the backhoe position, the controls are located to the operator's left and right. In the standard configuration, the left joystick (18) controls the arm and boom swing, while the right joystick (19) controls the boom and bucket. Magnetic, 2-sided, control decals are located in front of each joystick to indicate joystick functions.

The joystick functions can be changed by switching the pattern change valve. Always test the controls before beginning backhoe operations to ensure the joystick functions correspond to the control decals. If necessary, flip decals over to the proper side or change the backhoe control pattern.

To use the backhoe controls, do the following procedure.

1.

With the machine at rest and the engine off, rotate the seat to the backhoe position and adjust seat and armrests to comfortable positions as needed.

2.

Adjust both joysticks to comfortable positions.

3.

Fasten seat belt then start the engine.

4.

Press the control lock button (A) to activate controls (LED off).

5.

Operate backhoe as needed.

6.

When work is completed, stow backhoe in its locked position then press the control lock button (A) to deactivate controls (LED on).

7.

Before rotating the seat to the driving position, return joysticks to the vertical position toward rear window.

Remark Joystick functions are deactivated when the control lock button (A) is in the locked position (LED on).

Adjusting the Backhoe Controls Joysticks may be adjusted to accommodate the operator's size and preference. • •

•

The operator can move the joystick towers forward or backward independently.

Adjustable stops on the floor allow the operator to quickly move joysticks to preferred positions, reducing the need to readjust and reset joystick positions each time the backhoe control is used.

Each joystick also has a wrist support that can be adjusted up or down as needed to improve operator comfort.

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OPERATION Adjusting Joystick Positions To adjust a joystick's position, do this procedure.

1.

Reset tower stop to original position by loosening the knob (4) located on floor in front of joystick tower. Turn knob counterclockwise (B) until it no longer turns. Knob will feel loose during this step.

2.

Press and hold the lever (2) under the wrist support toward the joystick. This unlocks the joystick's tower to move forward and backward.

3.

Slowly move the tower to the desired position then release the lever (2) to lock the tower in place.

4.

To quickly return to this position in the future, set tower stop by turning the knob (4) clockwise (A) until hand tight.

5.

Return joystick towers to the vertical, stow position by pressing and holding the lever (2) then moving both towers away from the operator.

Remark Return joystick towers to the stow position when backhoe controls are not being used to avoid interference when rotating the seat to the driving position.

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WB156/156PS-5

OPERATION Adjusting Wrist Supports To adjust the height of the wrist supports, do this procedure.

1.

Loosen knob (3) by turning it counterclockwise (B) until loose.

2.

Raise or lower the wrist support (A) to the desired position.

3.

Secure wrist support position by turning knob (3) clockwise (C) until hand tight. Do not over tighten!

Remark To reduce fatigue, the operator's arms should rest on the seat's armrests. The wrist supports only provide additional support. Adjust the seat armrests and joystick wrist supports to comfortable positions so the operator's arms are in-line with the armrests, wrist supports and joystick controls.

Adjusting Stow Position (Cab Only) To prevent interference with joysticks when opening and closing the rear window, there should be about 60 mm (2.36 in) clearance between joysticks and the window. If clearance is less than 60 mm (2.36 in), adjust the stow position in the following manner.

1.

Move towers toward operator seat.

2.

Under the floormat, locate stop bolts (E) and nuts (F) between the towers and rear window sill. Loosen nuts.

3.

Move towers toward rear window leaving at least 60 mm clearance.

4.

Adjust stop bolts (E) until snug against towers.

5.

Tighten nuts (F) to secure stop bolts in place.

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OPERATION

Unlocking the Backhoe After adjusting the controls, operate the boom up-down and boom swing joystick controls carefully to relieve the pressure on the safety locks (2) and (3). Once the pressure on the backhoe locks have been released, you are now able to remove the safety lock pin (3) and unlock the backhoe boom (2).

1.

Be sure the machine directional control is set in a neutral position.

2.

Remove outrigger locks and backhoe lock pin (3).

Be careful when removing the lock pin. Never reach over the control levers to remove the pin; you may accidently bump a lever and activate the backhoe work equipment.

3.

Place pin in holding location.

4.

Retract the backhoe locking mechanism.

See “SAFETY LOCK USAGE� on page 2-67.

5.

Sit down and fasten the seat belt snugly around your waist.

6.

Unlock the backhoe controls (2).

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OPERATION

Pattern Change Control Lever Before using the pattern change control lever to change the machine’s operating pattern, lower the work equipment to the ground and stop the engine.

•

•

•

•

•

After changing the control operating pattern and before checking the movements of the machine, make sure that the area is clear of obstacles and that no one is standing in the range of movement of the machine.

After changing the control operating pattern, carry out the first movements slowly and very carefully, to understand the new controls correctly and to avoid any damage or fatal injury that may be caused by incorrect movements.

The pattern change control (20) is positioned on the rear central part of the cab floor and allows the operator to choose the preferred control pattern.

The pattern change control lever (20) has two positions: • ISO PATTERN - Lever in position B (Standard) • KOMATSU PATTERN - Lever in position C (Optional) The control lever (20) is held in place by a safety screw (D). When changing the control pattern, raise the mat and loosen the safety screw (D) to release the lever (20). Select the desired control pattern by rotating the lever (20) and securing it in its place with the safety screw (D). Place the mat back in position.

•

All movements of the boom and the equipment are disabled when the safety button is in the locked position.

•

Before moving the machine, the operator must make sure that the control pattern selected with the lever (20) corresponds to the control pattern indicated on the front part of the respective joysticks. If necessary, flip the magnetic control pattern diagrams over to the correct pattern.

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OPERATION ISO Backhoe Controls ★ Left joystick control lever (single movement) N - Neutral A - Boom swing to the left B - Arm extend C - Boom swing to the right D - Arm retract

★ Right joystick control lever (single movement) N - Neutral A - Bucket curl B - Boom lower C - Bucket open D - Boom raise

Moving the control levers at angles yields two simultaneous movements: ★ Left joystick control lever (combined) N - Neutral A - Arm extend - Boom swing left B - Arm extend - Boom swing right C - Arm retract - Boom swing right D - Arm retract - Boom swing left

★ Right joystick control lever (combined) N - Neutral A - Boom lower - Bucket curl B - Boom lower - Bucket open C - Boom raise - Bucket open D - Boom raise - Bucket curl

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WB156/156PS-5

OPERATION Komatsu Backhoe Controls ★ Left control lever (single movement) N - Neutral A - Boom swing to the left B - Boom lower C - Boom swing to the right D - Boom raise

★ Right control lever (single movement) N - Neutral A - Bucket curl B - Arm extend C - Bucket open D - Arm retract

Moving the control levers at angles yields two simultaneous movements: ★ Left control lever (combined) N - Neutral A - Boom lower and swing to the left B - Boom lower and swing to the right C - Boom raise and swing to the right D - Boom raise and swing to the left

★ Right control lever (combined) N - Neutral A - Arm extend - Bucket curl B - Arm extend - Bucket open C - Arm retract - Bucket open D - Arm retract - Bucket curl Remark Remember the power in the backhoe unit is the breakout feature when excavating or lifting. Do not use the backhoe unit to pick up, reposition or swing the machine to the left or right.

Doing so will damage the swing cylinders or possibly tip the machine over.

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OPERATION

Positioning the Machine Now that you have reviewed the operation of the control levers (joystick), you are ready to excavate with the backhoe unit. These are the final procedures needed to prepare the machine for excavating.

1.

Lay the front bucket flat on the ground.

2.

Lower both outriggers (16 and 17) at the same time lifting the machine evenly and squarely. Be sure both outriggers are completely extended together. Never operate the backhoe without lowering the outriggers and do not lower the outriggers one at a time.

Remark When retracting the outriggers, bring both outriggers up slowly and at the same time, lowering the machine evenly and squarely back down.

★ Proper Position For Using The Backhoe Work Equipment.

3.

Set the throttle at the proper rpm speed (1500 to 1600 rpm).

See “Brakes, Parking Brake, Accelerator, and Throttle Control” on page 2-24.

4.

Position the machine as shown in the illustration above. Lower the bucket (1) to the ground. Continue lowering until the front wheels (2) come off the ground 5 cm (2 in). Be sure both outriggers (3) are firmly on the ground.

5.

Check that your work area and boom swing radius are clear of all obstacles. Before starting your operations, be sure all personnel are outside the working radius.

6.

When you are ready to start your excavation operations, sound the horn.

Remark Call before you dig. See “STARTING YOUR WORK” on page 2-47.

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WB156/156PS-5

OPERATION

Digging Methods

Be careful when excavating a deep trench. The machine is capable of excavating the surface underneath the outriggers thus causing the machine to fall into the excavated trench. Always be aware of this.

• •

To start, position the bucket at a slight penetration angle into the soil shown below in the first illustration on the left.

Begin retracting the arm while raising the boom simultaneously. Take care not to lift the machine when performing this part of the operation. Keep the bucket’s leading edge parallel with the surface being excavated.

• At the end of your stroke or when the bucket is full, curl the bucket while keeping it level with the ground. Raise the boom and lift the arm and bucket out of the excavated site.

• Once the bucket is at clearance height, swing the boom to the right or left depending on your deposit point. Lower the boom and dump the full bucket, extending or retracting the arm if needed.

• When excavating a trench at a depth shown in the illustrations on the right, simultaneously retract the arm, raise the boom and curl the bucket while keeping the leading edge of the bucket at a slight penetration angle into the soil almost parallel with the surface being excavated.

CORRECT The bucket works best with its flat surface or cutting edge tipped down slightly almost parallel to the ground.

INCORRECT The bucket is thrust downward reducing the breakout force and filling the bucket too quickly.

INCORRECT The bucket is pushed upward, lifting the machine thus not filling the bucket.

Sequence 1-2-3 shows the proper way to excavate a trench. Always keep the cutting edge of the bucket tipped down slightly but parallel with the surface being excavated.

WB156/156PS-5

2-65

OPERATION

Changing the Backhoe Bucket Wear gloves and eye protection when changing backhoe buckets.

Change the bucket in this manner.

1.

Position the bucket and machine on level ground.

2.

Remove pin (1) and the arm connection pin (2).

3.

Exchange the bucket, taking care to completely clean the pins and bushings before installing them.

4.

Reinstall the safety stop (3).

5.

Lubricate all pin locations.

Adjusting the Bucket Depending upon what type of excavating operations you will be doing, the bucket can be adjusted to a setting for two positions.

Pos. 1: Normal digging operations ensures more breakout power to the bucket.

Pos. 2: Suitable for operations on vertical walls, ensures the maximum movement and digging height on walls. In this position the breakout force is reduced.

Never use your fingers or hands to line up the pin or bolt holes. If hole alignment is not correct, use a steel drift to line up parts.

2-66

WB156/156PS-5

OPERATION

SAFETY LOCK USAGE When it is necessary to perform maintenance, repairs or to travel on roads, it is important to be aware of the safety locks provided with the machine. It is also important to know how to use these locks and when to use them. Failure to observe these precautions and use the equipped safety equipment may result in a serious accident or injury.

Safety locks should be used when: • Performing any maintenance on the machine •

When traveling on roads

•

When the machine is unattended

Front End Loader Cylinder Lock In illustration (A), the front end loader cylinder lock (1) must be used any time you will be performing maintenance on the machine with the front end loader raised. To use the cylinder lock: 1.

See illustration (B). Remove the cylinder lock assembly pin (2), holding on to the lock unit (1).

2.

Using both hands, lower the lock unit (1) down from its storage position and remove it from the lift arm.

3.

Raise the front end loader unit completely in the air extending the lifting cylinders.

4.

Install the cylinder lock (1) in the position shown in illustration (A), keeping the safety pin boss against the lift cylinder gland nut.

5.

Insert the safety pin (2) completely into the predrilled holes and lock the pin in place with the smaller pin provided.

6.

Slowly lower the front end loader unit until it makes contact with the cylinder lock.

7.

Check to be sure the cylinder lock is securely in place before proceeding with any procedures under the front end loader.

WB156/156PS-5

2-67

OPERATION 8.

Using safety lock (11) in the operator’s cab, lock the loader control before proceeding with any repair or service operations.

9.

When your work is completed, unlock safety lock (11) in the operator’s cab and raise the front end loader up slightly to relieve pressure on the cylinder lock.

10. Carefully remove the small pin and the safety pin (2). With both hands, remove the cylinder lock (1) completely.

11. Lower the front end loader completely to the ground.

12. Re-install the cylinder safety lock (1) in the storage location on the left lift arm shown in illustration (B).

Always keep the cylinder safety lock with the machine. Never use a substitute or damaged cylinder lock. If it is missing or damaged, have it replaced immediately.

2-68

WB156/156PS-5

OPERATION

Backhoe Locks The backhoe locks are used to secure the backhoe unit in a travel position. These locks must be used when traveling with the machine or using the front end loader. To use the backhoe lock: 1.

When the machine is in operation and the backhoe is being operated, the boom lock for the backhoe should be disengaged.

2.

To engage the backhoe boom lock, locate the switch positioned on the left instrument panel. This raises the boom locks.

3.

Fold the arm, boom and bucket up completely.

4.

Once the arm, boom and bucket are folded up completely, press the boom lock switch to lower the boom locking device (2).

5.

Once the locking device (2) is set, center the backhoe unit to align the lock pin holes in the backhoe mounting boss.

6.

Remove the centering pin (3) from its holding location and insert it into one of the locking holes in the backhoe mounting boss.

7.

Be sure the pin (3) drops down completely and is flush with the top of the backhoe boss. Keep in mind that once the lock pin (3) is installed, the backhoe assembly will not swing.

8.

Once the pin (3) is in place, lock the backhoe controls.

9.

Move the controls to verify that they are locked.

10. If you will be traveling or using the front end loader for a long period of time, you may want to lock the outriggers in place to avoid possible hydraulic drift.

11. To lock the outriggers, completely raise both outriggers.

12. Install the locking safety cables (6) on both outriggers.

Remark The lock pin and the safety cables must remain with the machine. If they are lost or damaged, they must be replaced.

WB156/156PS-5

2-69

OPERATION

TRAVELING WITH THE MACHINE Before traveling with the machine, it is important to know all the control functions and relevant safety regulations for the area in which you will be traveling. Observe all local and state traffic safety laws. Travel at a safe, controllable speed.

Traveling The operator must be seated with the seat belt fastened snugly around the waist. Position the seat so you are comfortable and able to see all areas around you and have easy access to all controls.

The illustration to the right shows the proper travel posture for the machine. The backhoe must be fully retracted and locked in place as well as both outriggers. See “Backhoe Locks” on page 2-69.

•

Always keep the bucket at least 50 cm (20 in) above the ground.

Be aware of the additional height posed by the backhoe boom. The boom extends 1 m (3 ft) above the canopy and cannot be seen by the operator when the machine is in the travel posture.

• ★ • •

Ensure both brake pedals are locked.

See “Brake Pedals” on page 2-24.

Set the engine at an idle.

Once all personnel are clear of your travel path, place your foot on the brake pedals and release the parking brake.

Never drive up to someone standing in front of your machine’s path of travel. Be sure they are standing to the side and are aware of your approach. If the brakes should fail, the possibility of running someone over becomes greater when they are standing in front of your machine’s path.

•

Select the desired speed range suitable for travel. If you will be traveling in a higher speed range, always start out at a lower speed range and shift up to the higher ranges.

2-70

WB156/156PS-5

OPERATION • •

When you are ready to move, place the directional control lever in the (F) forward or (R) reverse position.

Sound your horn and proceed in the desired travel direction.

If you are traveling in the higher speed ranges and the machine starts to rock forward and backward, slow the machine down to reduce or stop this action. Failure to do so may result in loss of control when traveling.

Traveling on Slopes Operating on damp ground, slopes, or on river banks could cause the machine to slip or possibly roll over. Extreme caution should be observed when traveling in these conditions.

•

•

•

•

•

Travel on slopes with the bucket at a height of 20 to 30 cm (8 to 12 in) above the ground. The loaded bucket should always face the top of the slope.

Avoid changing speed ranges when on a slope. Always set the machine in a low speed range for travel on a slope. Never use the feature buttons when the machine is on a slope. Loss of control may result.

Before traveling up a slope, set the machine in a low speed range.

Check your fuel supply to ensure you do not run out of fuel on the slope. Check your brakes to be sure they are locked together and in good working condition.

Always travel straight up or straight down the slope. Never turn or travel sideways on the slope or incline. Doing so may cause the machine to roll over.

Always be aware of your travel surfaces. Wet leaves, grass or mud may hinder your control.

WB156/156PS-5

2-71

OPERATION •

• •

•

• •

When traveling up a slope with an empty bucket, travel with the bucket curled upward at a height of 20 to 30 cm (8 to 12 in) above the ground.

If the machine should lose control or slide, lower the bucket to the ground immediately to help stabilize the machine.

Never shift into Neutral when on a slope.

When traveling down a slope with an empty bucket, travel with the bucket curled downward at a height of 20 to 30 cm (8 to 12 in) above the ground.

If the machine loses control or slides, lower the bucket to the ground immediately to help stabilize the machine.

Never shift into Neutral when on a slope.

Traveling or Working in Swampy or Wet Areas If you will be traveling or working in areas where the machine will be immersed in water, always check water depth, ground stability and current flow first.

Do not operate the machine in water deeper than 50 cm (20 in). A depth deeper than 50 cm (20 in) may damage the machine.

After you have completed your work or travel through water or muddy areas, always clean the machine and lubricate any components that may have been immersed in mud or water.

2-72

WB156/156PS-5

OPERATION

PARKING THE MACHINE The Komatsu backhoe is designed to be parked in a secure manner.

Whether you leave the machine for a short or long period of time, it is important to use all the security features provided with your machine.

Parking for Short Periods of Time If you are leaving the machine for a short period of time, find a flat, level surface to park on.

1.

Lower the work equipment to the ground and place the directional control in the (N) neutral position.

2.

Turn the engine off and remove the ignition key.

3.

Set the parking brake.

Parking for Long Periods of Time The danger of having a child or an unauthorized person tampering with the machine while unattended for a long period of time is quite possible. To avoid an accident, follow the same procedures as described above.

The machine is equipped with a series of key-operated locks. It is important that these locks work properly and are used when the machine is unattended for a long period of time.

You are responsible for the security of your equipment when it is unattended. Properly locking and securing the equipment will help protect it from unauthorized access.

Parking Posture

The above illustration shows the proper parking posture. It is important to lower all work equipment and neutralize their controls. This includes front end loader, backhoe unit and outriggers.

Once the work equipment is lowered, lock the controls. See “SAFETY LOCK USAGE� on page 2-67.

WB156/156PS-5

2-73

OPERATION

Parking on an Incline Parking on slopes, hills or any kind of an incline is not recommended.

If at all possible, park the machine on a flat, level surface. However, this is sometimes not possible and if you must park on a slope, do so in this manner.

1.

Lower the front end loader and dig the cutting edge into the ground several inches. Be sure the bucket is tipped forward to help keep the digging force in a downward position.

2.

Move the control lever into the “Free Float� position.

3.

Place blocks under both front and rear wheels to help secure the machine in place.

4.

When setting the backhoe on the ground, dig the bucket teeth into the ground to help hold the machine in place. Do not raise the back end of the machine up when doing this procedure.

Never park the machine with the wheels off the ground. The danger of the machine dropping onto someone becomes possible when the machine is unattended. Always lower the work equipment and machine to the ground fully when parking the machine.

2-74

WB156/156PS-5

OPERATION

TRANSPORTING THE MACHINE Before transporting the machine, be sure what you are using to transport the machine is capable of supporting the weight of the machine. It must be wide enough and rated for the load.

Loading and Securing the Machine 1.

Be sure the area where you will be loading the machine is flat and dry.

2.

Check the ramps and support surface for damage, weak spots, missing boards or excess wear. If these surfaces look unsafe, too weak or unstable, do not load the machine. Be sure the loading equipment and transportation equipment are in good condition and rated for your load.

3.

Locate the tie down and transportation brackets on the machine.

Be sure they are in good condition.

4.

While preparing to load the machine, verify that loading ramps are no higher than 15°.

5.

Position the machine squarely with the ramps. Raise the loader bucket high enough to clear all surfaces.

6.

Travel up the ramp at a slow speed in low range. Position the bucket (1) facing forward and travel straight up the ramp.

7.

Once the machine has been loaded, rest the front bucket on the floor; set the machine in neutral and set the parking brake.

8.

Lower the backhoe (2) to the floor and set all control locks, including the backhoe lock pin. See “PARKING THE MACHINE” on page 2-73.

9.

Turn the ignition key off and remove the key.

Secure the machine with tie-downs/chains (4) at the anchor points shown in illustrations above.

To help keep the machine in position, place blocks (3) in front and behind the front and rear wheels for extra support. Protect the exhaust stack (5) from moisture if needed.

WB156/156PS-5

2-75

OPERATION

LIFTING THE MACHINE

Use a crane properly rated to handle the machine’s weight and size. The person operating the crane to lift the machine MUST be a qualified crane operator.

• • • • •

Do not lift the machine with a person in the cab or on the machine.

Use a wire rope that has ample strength for the weight of the machine being lifted. The operating weight of the WB156/ 156PS-5 is 7,498 kg (16,530 lb).

Keep the machine horizontal when lifting it.

Never enter the area under or around a raised machine. There is danger that the machine may lose its balance.

Before lifting the machine, take the following steps to prevent the machine from unexpectedly moving.

• Set the parking brake lever to the LOCK position.

• If equipped with telescopic arm, lock the sliding arm to prevent accidental extension.

• Engage the backhoe boom safety coupling.

• Press the work equipment control switch to the LOCK position.

• Insert the backhoe lock pin to lock the backhoe arm in position.

• Connect outriggers safety cables.

When lifting the machine, the wire rope must be fitted correctly or the machine may fall and cause serious injury or even death.

Remark The lifting procedure applies to machines with standard specifications.

The method of lifting may differ depending on the attachments and options installed.

For details about lifting a machine that does not conform to standard specifications, contact your Komatsu distributor.

LIFTING POSITION MARKS

2-76

WB156/156PS-5

OPERATION

LIFTING PROCEDURE ★ Machine must be on firm, level ground.

1.

Start the engine. Make sure the machine is horizontal; then set the work equipment to the travel posture (A).

(A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 50 cm (16 - 20 in)

2.

The telescopic arm is equipped with a safety element (6) that locks the sliding arm (2) when it is completely retracted and prevents any accidental extension. The safety element (6), held in its seat by the retainer (7), must be inserted to prevent the extension of the arm as shown in Figure A. For more details, see "Safety Devices" in the "OPTIONS, ATTACHMENTS" section.

3.

Raise and center the backhoe boom and engage the safety coupling.

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.

WB156/156PS-5

2-77

OPERATION 5.

Install the lock pin.

When installing the backhoe lock pin, be careful not to get caught between the backhoe frame and boom. Never reach over the backhoe controls to install the lock pin. There is the possibility that you may bump one of the control levers causing the backhoe work equipment to move; or you may lose your balance and fall into the work equipment. Always install the lock pin while standing on the ground.

6.

Connect the safety cables to prevent accidental lowering of the outriggers.

7.

Use wire ropes and slings that match the weight of the machine.

The operating weight of the WB156/156PS-5 is 7,498 kg (16,530 lb). Wind the wire rope and fix it to the lifting points as shown in "Lifting Position Marks."

Remark Use protectors so that the wire ropes do not break at sharp edges or narrow places.

Use threaders and bars having sufficient width so that the slings and wire ropes do not touch the machine.

8.

Clear the area of unwarranted personnel. Make sure enough ground guides are available to keep the area clear.

9.

Lift the machine about 100 - 200 mm (4 - 8 in) above the ground.

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.

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.

2-78

WB156/156PS-5

OPERATION

EMERGENCY RECOVERY The machine is equipped with emergency recovery hooks for emergency recovery only. The machine is not designed to be towed in any manner, especially by the loader or backhoe unit. These hooks are only for temporary use to get the machine into a secure area so the proper repairs can be made.

How to Move the Machine If the machine gets stuck, breaks down, or runs out of fuel and cannot be moved under its own power, it is important to follow some simple procedures: • •

• •

Place all the controls in neutral and disengage the 4-wheel drive system before moving the machine.

Using the recovery hooks and towing cables rated at F=6200 dN (13,938 lb), tow the machine just far enough to carry out essential repairs.

Never tow the machine at an angle; always tow the machine in a straight line.

Be sure the tow cables are the same length when towing.

Never stand next to the tow lines when towing the machine. The cable or chain could break, causing injury. Always stay clear of towing equipment.

WB156/156PS-5

2-79

OPERATION

PRECAUTIONS DURING SEASONAL CHANGES Where temperature changes are drastic or seasonal, especially in colder climates, it is necessary to take some countermeasures to limit any damage resulting from low or extremely high temperatures.

Cold Seasons When the end of the work day approaches, especially during extremely cold weather, it is important to follow these steps to assure a good start-up the next work day.

• • • • •

Remove any mud or water from the machine, especially the undercarriage area.

Park the machine in a protected area, if possible.

Drain any condensation from filters and water traps. See “Draining Water Separator” on page 3-37.

If possible, remove the battery and store it in a warmer location if temperatures will be extremely cold.

Always allow the machine additional time to warm up during cold seasons. See “Warming Up the Machine” on page 244.

Fuel and Lubricants • •

In colder climates, it is advisable to use winterized fuel ASTM D975 N 1 when ambient temperatures are below -10°C (14°F). (Do not mix gasoline with diesel fuel. This will damage the fuel system.)

Replace the engine oil with a suitable viscosity oil for the climate.

See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

Coolant The required standards for permanent antifreeze are SAE-J1034 and Federal Standard O-A-548D. See “Changing Coolant” on page 3-64.

Never mix antifreezes or add additives to the cooling system.

Remark Never use flammable liquids in the cooling system.

2-80

WB156/156PS-5

OPERATION Battery When ambient temperatures decrease, the battery capacity decreases accordingly and if the battery charge is low, the electrolyte may freeze. Keep the battery completely charged and insulated to protect it from low temperatures so that the machine can be started without problems the following day.

To avoid explosions due to the presence of gas, do not create sparks, smoke or have open flames near the battery.

To measure the specific gravity of the electrolyte refer to the following table.

Electrolyte Temperature Percentage of Charge

20°C (68°F)

0°C (32°F)

-10°C (14°F)

-20°C (-4°F)

100%

1.28

1.29

1.30

1.31

90%

1.26

1.27

1.28

1.29

80%

1.24

1.25

1.26

1.27

75%

1.23

1.24

1.25

1.26

Warm Seasons • • •

At the end of the cold season, change the lubricants and fuel back to the warm-climate-rated fluids. Make sure the fan belts are in good condition and the radiator fins are clean.

If you have worked in an area where road salts were used during the winter, thoroughly wash your machine to remove these corrosive deposits.

The required standards for permanent antifreeze are SAE-J1034 and Federal Standard O-A-548D. Be sure the coolant antifreeze is at the proper lever and setting for your climate. See “Changing Coolant” on page 3-64. Never mix antifreezes or add additives to the cooling system.

Remark Never use flammable liquids or “water only” in the cooling system.

WB156/156PS-5

2-81

OPERATION

TROUBLESHOOTING Always contact your Komatsu distributor when you have to carry out any troubleshooting procedures. If the problem or failure is not listed in the troubleshooting section, contact your Komatsu distributor immediately and the problem checked.

Battery

•

When checking or handling the batteries, stop the engine and turn the ignition switch to the OFF position before making repairs.

•

Before starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery.

•

The battery generates hydrogen gas, so there is danger of explosion. Do not bring lighted cigarettes near the battery or do anything that will cause sparks.

•

Battery electrolyte is diluted sulfuric acid and will attack your clothes and skin. If it gets on your clothes or on your skin, wash it off immediately with large quantities of water. If it gets in your eyes, flush your eyes with large quantities of fresh water and consult a doctor immediately.

•

When handling batteries, always wear protective goggles and rubber gloves.

Servicing • • • •

• •

If battery tops are badly corroded, clean with diluted baking soda and warm water solution.

Before charging or servicing the battery, disconnect the cable from the negative terminal of the battery.

The unusually high voltage will damage the alternator.

To avoid gas explosions while charging the battery, cover the battery caps with rags soaked in a baking soda solution. If electrolyte temperature exceeds 45°C (113°F), stop charging for a while. Turn off the charger as soon as the battery is charged.

Overcharging the battery may cause overheating, decreasing the quantity of electrolyte or damaging the electrode plates.

When adding fluids to the battery, use distilled, non-mineral-based water and do not overfill the battery. Always wear protective clothing when servicing the battery.

Remark If you accidentally swallow battery acid, drink a large quantity of water or milk, beaten egg white or vegetable oil and if available, take anti-acid substances like magnesia, bicarbonate, etc. Call a doctor or a poison treatment center immediately.

2-82

WB156/156PS-5

OPERATION Removal and Installation When removing the battery follow this procedure.

1.

Turn the starting switch to the “OFF� position.

2.

Wait at least one minute.

3.

Turn off the battery disconnect switch.

4.

Disconnect the ground (negative) cable.

5.

Disconnect the positive cable.

Remark If a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks.

When installing the battery, the ground cable should be connected to the ground terminal as the last step. These illustrations show the proper removal and installation order.

WB156/156PS-5

2-83

OPERATION

Starting the Engine with Booster Cables

•

When starting the engine with a booster cable, always wear safety glasses and rubber gloves.

•

When connecting the cables, never cross the positive (+) and negative (-) terminals.

•

Be careful not to let the machines touch each other; sparks from the contact could ignite the hydrogen gas.

•

Make sure the booster cable connections are correct.

•

The final connection should be at the engine block of the problem machine. Sparks will be generated when this is done, so connect to a place as far as possible from the battery.

•

Use care when removing the cables from the machine that has been started. To avoid a hydrogen explosion, do not allow the cable ends to contact each other or the machine.

Accessing the Battery To access the battery you must open the tool and battery box using the ignition key.

Connecting the Booster Cables Keep the starting switch in the OFF position. Connect the booster cable as follows, in the order of the numbers marked.

1.

Make sure that the ignition switches on the operating machine and the non-operating machine are both in the OFF position.

2.

Connect one clamp of the booster cable (A) to the positive terminal (1) of the non-operating machine.

3.

Connect the other clamp of booster cable (A) to the positive terminal (2) of the operating machine.

4.

Connect one clamp of booster cable (B) to the negative terminal (3) of the operating machine.

5.

Connect the clamp of booster cable (B) to the engine block (4) of the engine to be started.

2-84

WB156/156PS-5

OPERATION Starting the Engine

Never jump-start the engine at the starter. Accidental movement of the machine may cause injury or even death.

Always start the engine with the starting switch in the cab.

• • •

Make sure the clamps are firmly connected to the battery terminals.

Start the operating machine and run it at a high idle.

Turn the starting switch on the non-operating machine to the “START” position and start the engine. If the engine does not start, wait two minutes before trying again.

Disconnecting the Booster Cables After the engine has started, disconnect the booster cables in the reverse order in which they were connected.

1.

Remove one clamp of booster cable (B) from the engine block (4) on the non-operating machine.

2.

Remove the other clamp of booster cable (B) from the negative terminal (3) on the operating machine.

3.

Remove one clamp of booster cable (A) from the positive terminal on the operating machine (2).

4.

Remove the other clamp of booster cable (A) from the engine block on the problem machine (1).

WB156/156PS-5

2-85

OPERATION

Electrical Circuits Trouble Lights do not work properly even with the engine running at high rpms:

Possible Cause

Remedy

• •

Check and repair terminal connections Adjust fan belt tension (See “EVERY 250 HOURS MAINTENANCE” on page 3-46)

Faulty alternator Faulty cables Serpentine belt worn or damaged

• • •

Replace alternator Check and repair cables Replace belt

•

Defective alternator

•

Replace alternator

Starter does not operate when the ignition key is turned to the “START” position:

• • •

Faulty cables Low battery charge Blown engine start fuse

• • •

Check condition of cables Check battery charge state Replace fuse and check system

Starter drive chatters:

• • •

Low battery charge Faulty cables Battery charge insufficient

• • •

Check battery charge state Check condition of cables Charge the battery

Starter cranks slowly:

• •

Faulty cables Battery charge insufficient

• •

Check condition of cables Charge the battery

Starter cuts out while cranking the engine:

• •

Faulty cables Battery charge insufficient

• •

Check condition of cables Charge the battery

Engine oil pressure light does not work with the ignition key in the “ON” position and the engine not running:

• •

Bad bulb Defective pressure sensor

• •

Replace bulb Replace sensor

Alternator light does not work with the ignition key in the “ON” position and the engine not running:

• •

Bad bulb Faulty cables

• •

Replace bulb Check condition of cables

•

Faulty cables

Lights come on intermittently with the engine running:

•

Poor fan belt tension

Alternator charge indicator does not go out with the engine running and engine speed is increased:

• • •

Alternator is very noisy:

Hydraulic System Trouble

Pump is very noisy:

Equipment control levers do not return to the neutral position:

Work equipment moves very slowly:

2-86

Possible Cause

Remedy

• • •

Low oil in tank Faulty pump Incorrect hydraulic fluid

• • •

Add oil Repair or replace Change hydraulic oil

•

Broken return spring or sized spool

•

Replace spring or check condition of valve body

• • •

Faulty pump Pressure valve defective or stuck Dirty filter or strainer

• • •

Repair or replace Calibrate or replace Replace filter, clean strainer

WB156/156PS-5

OPERATION

Braking System Trouble

Possible Cause

Remedy

Braking irregular for both wheels:

• • • •

Worn brake disks No fluid in master cylinder Air in braking system Faulty master cylinder

• • • •

Replace Top off and purge system Purge the system Replace

Braking not regular on one side only:

• • •

Air in braking system Brake disk worn Faulty master cylinder

• • •

Purge the system Replace Replace

Transmission Trouble

Possible Cause

Remedy

• •

Top off Clean element and seat

• • •

Oil level Clutch pressure adjusting valve stuck open Faulty delivery pump Worn clutch shaft or piston rings Clutch pump stuck open

• • •

Replace Replace rings Clean

Pump delivery insufficient:

• • •

Oil level Suction filter clogged Faulty pump

• • •

Top off Clean filter Replace

System overheating:

• • • • • •

Damaged rings Faulty pump Oil level Dirty heat exchanger Damaged heat exchanger Faulty torque converter

• • • • • •

Dissemble and clean Replace Top off Clean Repair or replace Replace

Noisy converter:

• •

Faulty pump Damaged bearings

• •

Replace Remove and replace

Lack of power:

• •

Low engine rpm causing stall Overheating

• •

Check engine See overheating remedies

• • Low pressure in clutch:

WB156/156PS-5

2-87

OPERATION

Engine Trouble

Possible Cause

Remedy

Oil pressure light remains on even with the engine at high idle:

• • •

Oil level too low Oil filter plugged Incorrect oil for the season

• • •

Top off Change oil and filter Change oil

Cooling system overheating:

• • • • • •

Coolant low due to leaks Fan belt slipping Cooling system blocked Radiator fins damaged Faulty thermostat Radiator cap defective

• • • • • •

Top off and repair Check belt tension Flush cooling system Repair or clean Replace Replace

Temperature gauge stuck at “H”:

•

Faulty temperature indicator

•

Replace

Temperature does not show proper gauge reading:

• •

Faulty thermostat Faulty gauge

• •

Replace Replace

Engine cranks but does not start:

• • •

No fuel Air in fuel system Low compression

• • •

Refuel Bleed system Adjust valve clearance

White or light blue exhaust gases:

• •

Too much oil in oil pan Unstable fuel

• •

Correct the oil level Change to suitable fuel

Exhaust gases are black:

• • •

Air cleaner clogged Faulty injectors or injection pump Low compression

• • •

Clean or replace Replace Adjust valve clearance

Popping noise heard at exhaust stack:

•

Faulty injectors

•

Replace injectors

Abnormal engine noise:

• • • •

Improper fuel Cetane rating Overheating Damaged exhaust muffler Excessive valve clearance

• • • •

Change fuels See “temperature indication” Replace Adjust valves

2-88

WB156/156PS-5

3MAINTENANCE

WB156/156PS-5

3-1

MAINTENANCE

MAINTENANCE INFORMATION • • • • • •

• • • • • •

• • • • • • •

• •

3-2

Before opening the engine hood, engage safety locks of both the front loader and backhoe.

If it is necessary to check the hydraulic oil level in the reservoir, arrange the machine in the transport position.

See “SAFETY LOCK USAGE” on page 2-67.

Only perform operations with the machine on firm and level ground, after applying the parking brake.

Use Komatsu genuine oils and greases. Choose oils suitable for the ambient temperature.

Use clean oils and greases. Keep the oil and grease containers clean. Keep any foreign matter away from oils and greases.

Always keep the machine clean. This makes it easier to locate any part causing problems. Keep the grease fittings, the breathers and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into or on them.

Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least 40-50°C (104-122° F) before draining the liquids.

After changing the oil or the filters, check if metal particles are present. If you find large quantities of metal particles, contact your Komatsu distributor.

Check and change the oil while parked in a clean location to prevent any impurities from getting into the tank or container.

Before carrying out any maintenance operation, hang the warning plates on the ignition switch, control levers, and cab doors, to prevent anyone from starting the engine by mistake.

When performing maintenance operations, always adhere to the precautions indicated on safety plates applied on the machine.

Instructions for welding.

• Turn ignition key to the “OFF” position, wait at least one minute, then turn off the battery disconnect switch.

• Disconnect the battery (first negative cable and then positive cable).

• Disconnect the alternator.

• Do not apply more than 200V continuously.

• Connect the welder’s ground cable within 1 m (3 ft) from the point on which welding will take place.

• Avoid putting gaskets and bearings between the welding area and ground cable. Gaskets and bearings are poor grounding surfaces and it is possible that arcing could weld bearings together.

• Shield areas around the welding area with weld blankets or something similar to avoid damage from spatter.

Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids.

When O-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all O-rings and gaskets with new ones. Fit the O-rings and gaskets correctly when reassembling.

Avoid keeping loose objects or tools in your pockets. They may fall out and drop into the machine, especially when you open covers and work on the machine while bending over it.

When washing the machine, do not direct a high-pressure water jet onto the radiator and heat exchanger.

When washing the machine, protect electric system connectors and avoid getting the starting switch wet.

Before starting work in mud, in rain, on seashores, or river banks, perform general lubrication. Wash the machine immediately after work to protect components from rust. Lubricate equipment joints more frequently than usual.

When working at dusty work sites, proceed as follows: • Check the air cleaner for any clogging and clean it more frequently than usual.

• Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.

• Change the diesel oil filter more frequently than usual.

• Clean the electrical components, especially the starter and the alternator, to avoid any accumulation of dust.

Never mix oils of different brands.

Do not top off with oil different from the oil presently in the machine. If necessary, drain all the oil and fill the tank with new of a different brand.

WB156/156PS-5

MAINTENANCE

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to the regulations in force.

• If it burns, combustible material of some components may become extremely dangerous. For this reason, avoid any contact of burnt material with your skin or eyes and do not inhale the fumes.

Maintenance Notes • Use only Komatsu genuine replacement parts.

• Do not mix different types of oil.

• Unless specified otherwise, oils and coolant used by Komatsu before delivery of the machine are listed in the table.

Item

Specifications

•

Engine oil

SAE 10W-30 API classification CI-4

•

Hydraulic system oil

SAE 10W-30 API classification CI-4

•

Biodegradable hydraulic system oil (Only for machines in which the synthetic biodegradable oil type HEES (not of plant origin) is used).

PAKELO GEOLUBE HYDRAULIC EP-46

Hydraulic transmission oil

GM DEXRON® II D

•

Axle oil (front and rear)

SHELL: CALTEX: CHEVRON: TEXACO: MOBILE

•

Brake system oil

GM DEXRON® II D

•

DONAX TD RPM TRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TEXTRAN TDH OIL MOBILFLUID 422 or 424

Ambient temperature above -10° C (14° F): ASTM D975 no. 2 diesel oil •

Fuel Ambient temperature below -10° C (14° F): ASTM D975 no. 1 diesel oil

•

Radiator coolant

Permanent, ethylene glycol-based antifreeze, with corrosion inhibitor for protection down to -36° C (-33° F)

GM DEXRON II® D (GM DEXRON® is a registered trademark of General Motors Corporation)

WB156/156PS-5

3-3

MAINTENANCE

Engine Maintenance Engine Oil •

Engine oil must be selected very carefully since it lubricates the engine, which is the machine’s heart; the following main maintenance operations are required for engine oil.

1.

2.

3.

Daily, check the oil level.

Check condition of the oil with periodic analysis.

Periodic oil changes.

Coolant •

Engine coolant keeps the engine at the correct temperature and ensures optimal operating conditions; check coolant level in the expansion tank daily and top off if necessary.

The quantity of antifreeze to be added to the coolant depends on the minimum temperature in the place where the machine is working.

Refer to the following table.

•

Quantity of Antifreeze to be Added to the Water °C

-4

-6

-9

-12

-16

-20

-26

-32

-36

°F

25

21

15

10

3

-4

-15

-26

-33

Liter

1.4

2.1

2.8

3.5

4.2

4.9

5.6

6.3

7

US gal

0.37

0.55

0.74

0.92

1.11

1.29

1.48

1.66

1.85

Liter

12.6

11.9

11.2

10.5

9.8

9.1

8.4

7.7

7

US gal

3.33

3.15

2.96

2.78

2.59

2.41

2.22

2.04

1.85

Minimum ambient temperature

Quantity of antifreeze

Quantity of water

• • •

Use water which has a low mineral content.

Do not use corrosion inhibitors containing soluble oil, since they damage the rubber couplings.

In case of doubt, contact your Komatsu distributor.

Fuel • • • •

Always use fuel suitable for the engine. Fuels with different specifications may damage the engine or reduce its power.

Always refuel at the end of the work day.

When refueling, make sure that there is no water on the fuel drum cover and be careful not to draw condensation from the drum bottom.

If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.

Hydraulic System Maintenance • •

Be extremely careful when performing maintenance on the hydraulic system, since the oil can be very hot.

The system is pressurized not only during work, but also at the end of work.

The following maintenance operations are required for the hydraulic system.

A. Check the oil level in the tank daily.

B. Periodically change the oil filter.

C. Change the oil and clean the suction filter periodically.

•

3-4

Always bleed (purge) the system after changing the oil filter and the oil.

WB156/156PS-5

MAINTENANCE • • 1.

2.

3.

When a component is removed from the circuit, check the gaskets and O-rings; change them if they are damaged.

When a cylinder or a component of the hydraulic system is removed, after reassembly bleed the system by doing these steps.

Start the engine and let it idle.

Make all the cylinders perform four to five movements, stopping them at approximately 100 mm (4 in) from the end of their stroke.

Slowly make all the cylinders reach the end of their stroke for three to four times.

Carrying Out KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other problems.

We strongly recommend that you use this service. The oil analysis is carried out at actual cost, so the cost is low. The results of the analysis are reported together with recommendations which will reduce repair costs and machine downtime.

KOWA Analysis Items Measurement of density of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of iron, copper, and other metal wear particles in the oil.

Measurement of quantity of particles This uses a PQI (Particle Quantifier Index) machine to measure the quantity of large iron particles (larger than 5 microns) in the oil, which enables the early detection of failures.

Others Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.

WB156/156PS-5

3-5

MAINTENANCE

Electrical System Maintenance • •

If the cables are wet or their insulating material is damaged, the electrical system may short, which could result in machine malfunctions.

The following maintenance operations are required for the electrical system.

A. Check the alternator belt tension.

B. Check the alternator belt for damage or breakage.

C. Check the battery electrolyte level.

• • • • •

Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component with characteristics different from those specified and approved by Komatsu.

Be careful to keep the electric system dry.

When working on seashores, river banks, or lakes, protect the jack plugs from corrosion.

Do not connect any optional device to the fuses, ignition switch, battery, relays, etc. For the installation of any optional equipment, contact your Komatsu distributor.

If any electric welding needs to be done, disconnect the battery and the alternator.

Lubrication • • •

Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and the noise that may be produced if the articulations are dry.

Lubricate with grease or oil.

The following maintenance operations are required for the components that need lubricating.

A. Check the fluid and lubricant levels.

B. Change oil at recommended intervals.

C. Inject grease through the grease fittings.

• • •

3-6

Use only the specified lubricants, according to the ambient temperature.

Always clean the grease fittings before injecting grease and remove any excess grease after lubrication; this cleaning operation must be performed with extreme care on the revolving parts.

Keep the lubricants at the correct levels; avoid excessive or insufficient quantities.

WB156/156PS-5

MAINTENANCE

WEAR PARTS LIST • • •

The parts subject to wear such as filters, bucket teeth, etc., must be replaced according to the periodic maintenance intervals prescribed or when they reach their wear limit.

The timely change of these parts ensures economical use of the machine.

Use only Komatsu genuine parts, which alone can guarantee excellent quality and interchangeability.

Item

Description

Qty

Change Interval

Hydraulic oil filter

Cartridge

1

Every 500 hours

Engine oil filter

Cartridge

1

Every 500 hours

Fuel filter

Cartridge

1

Every 500 hours

Converter oil filter

Cartridge

1

Every 1,000 hours

Air cleaner

Main cartridge Safety cartridge

1 1

When required When required

Front bucket

Teeth Screw Nut

AR AR AR

When required When required When required

Backhoe bucket

Center teeth Screw Nut Right tooth Left tooth Screw Side screw Nut

AR AR AR 1 1 AR 4 AR

When required When required When required When required When required When required When required When required

WB156/156PS-5

3-7

MAINTENANCE

FUEL, COOLANT, AND LUBRICANTS Proper Selection According to the Ambient Temperature Ambient Temperature Reservoir

Kind of fluid

-22 -30

-4 -20

14 -10

32 0

50 10

68 20

Capacity 86 30

104 40

122째F 50째 C

Specified

Refill

SAE 15W-40

9 liter (2.4 US gal) Aspirated engine

9 liter (2.4 US gal) Aspirated engine

SAE 30

150 liter (39.6 US gal)

92 liter (24.3 US gal)

150 liter (39.6 US gal)

92 liter (24.3 US gal)

Front axle: Differential

6.5 liter (1.7 US gal)

6.5 liter (1.7 US gal)

Final reduction gear (ea.)

1 liter (0.26 US gal)

1 liter (0.26 US gal)

Rear axle: Differential

14.5 liter (3.8 US gal)

14.5 liter (3.8 US gal)

Final reduction gear (ea.)

1.5 liter (0.4 US gal)

1.5 liter (0.4 US gal)

SAE 5W-30 Engine oil pan

SAE 10W 30

SAE 5W Hydraulic system

SAE 10W Oil API CI-4

SAE 10W-30

Hydraulic system with biodegradable oil

See page 3-12

(See Note 1)

Hydraulic transmission

GM DEXTRON II D

20 liter (5.3 US gal)

17 liter (4.5 US gal)

Brake system

GM DEXTRON II D

0.8 liter (0.2 US gal)

0.8 liter (0.2 US gal)

130 liter (34.4 US gal)

-

14 liter (3.7 US gal)

-

Fuel tank

Diesel fuel

ASTM D975 No. 1 ASTM D975 No. 2

Cooling system

Coolant

Tthylene Glycol Base

OPTION FOR VERY COLD AREAS: If the temperature exceeds 10째 C (50째 F), contact your Komatsu distributor for advice on the type of oil to be used.

3-8

WB156/156PS-5

MAINTENANCE

Grease Lubrication Points

Consistency

Type

Articulations, grease fittings

NLGI 2

See note 2

Note 1: For axle oil, use only the following recommended oils.

SHELL: DONAX TD CALTEX: RPM TRACTOR HYDRAULIC FLUID CHEVRON: TRACTOR HYDRAULIC FLUID TEXACO: TEXTRAN TDH OIL MOBIL: MOBILFLUID 422 or 424 Note 2: The recommended lubricating grease is No.2 multipurpose lithium grease with 3% molybdenum disulfide (Lithio EP + MoS2).

Fuel •

•

• •

When fuel sulphur content is less than 0.5%, change oil in the oil pan at the stated periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.

Fuel Sulphur Content

Change Interval of Oil in Engine Oil Pan

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

When starting the engine when the atmospheric temperature is lower than 0°C (32°F), be sure to use the SAE10W, SAE20W-20 and SAE10W-30 engine oil, even though the atmospheric temperature goes up to 10°C (18°F) more or less in the day time.

There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 10W-40), but be sure to add single grade oil that matches the temperature in the table.

Use Komatsu genuine oil which has been specifically formulated and approved for use in the engine, hydraulic work equipment, transmission, axles, and brakes.

Specified capacity: Refill capacity:

Total amount of oil including oil for components and oil in piping Amount of oil needed to refill system during normal inspection and maintenance

ASTM: SAE: API:

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

WB156/156PS-5

3-9

MAINTENANCE

APPROVED SYNTHETIC LUBRICANTS (HEES) Our machines can be filled with Hydraulic Environmental Ester Synthetic (HEES) oil not of plant origin. Use of oils indicated in the following table is authorized and recommended.

Supplier

HEES Oil

KOMATSU

---

AGIP

ARNICA S 46

ARAL

HEF 46 vitam

AVIA

SYNTOFLUID N 46

BP

BIOHYD SE-S 46

CONDAT

CONDAT D 46 K

ELF

HYDRELF BIO 46

ESSO

HYDRAULIKOIL HE 46

FINA

BIOYIDRAN TMP 46 SE 46

FUCHS

PLANTOHYD S 46

KENDALL

SYNTH NATURA 46 HV

KUWAIT PETROLEUM K8

HOLBEIN 46

MOBIL

EAL SYNDRAULIC

MOBIL (USA)

ENVIROSYN 46 H

PAKELO

GEOLUBE HYDRAULIC EP-46

PANOLIN

HLP SYNTH 46

SHELL

NATURELLE HFE-46

TAMOIL

GREEN HYDRO SAFETY 46

TEXACO

HYDRA 46

TOTAL

EQUIVIS BIO 46

VAVOLINE

UNISYN HLP 32/68

• Do not mix hydraulic environmental ester synthetic (HEES) oil with ordinary hydraulic oils. When the temperature increases, insoluble compounds are generated which are deposited on the filters and clog them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil).

• HEES oil can be used only in the hydraulic system; it cannot be used for the endothermic motor, the transmissions, the braking system, etc.

• Before introducing HEES oil in the hydraulic system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordinary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work equipment. Wait until the oil reaches a temperature of at least 40°C (104°F), then start moving the equipment so that all the parts of the system are filled with oil. Stop the engine and check the oil level. See “Checking Hydraulic Oil Level” on page 3-37.

3-10

WB156/156PS-5

MAINTENANCE

LUBRICATION DIAGRAMS General View •

For lubrication procedures for single points. See “MAINTENANCE SCHEDULE” on page 3-22.

Remark Use only recommended oil and grease. See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

WB156/156PS-5

3-11

MAINTENANCE

Multipurpose Bucket and Pallet Forks • • •

Points indicated are symmetrical and must be lubricated every 10 hours.

The fork sliding bars and safety pins must be lubricated with grease only to protect them from oxidation.

Fork joints (A) must be lubricated only if the forks are used.

3-12

WB156/156PS-5

MAINTENANCE

Telescopic Arm •

Points indicated are symmetrical and must be lubricated every 10 hours.

WB156/156PS-5

3-13

MAINTENANCE

TORQUE SPECIFICATIONS Torque List

If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts. This will cause failure of the machine or problems with operation.

Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Torque of Bolts

Thread Diameter of Bolt

Width across Flat

mm

mm

N•m

lbf ft

6

10

11.8 - 14.7

8.70 - 10.84

8

13

27 - 34

19.91 - 25.07

10

17

59 - 74

43.51 - 54.57

12

19

98 - 123

72.28 - 90.72

14

22

153 - 190

112.84 - 140.13

16

24

235 - 285

173.32 - 210.20

18

27

320 - 400

236.02 - 295.02

20

30

455 - 565

335.59 - 416.72

22

32

610 - 765

449.91 - 564.23

24

36

785 - 980

578.98 - 722.81

27

41

1150 - 1440

848.19 - 1062.09

30

46

1520 - 1910

1121.09 - 1408.74

33

50

1960 - 2450

1445.62 - 1807.02

36

55

2450 - 3040

1807.02 - 2242.19

39

60

2890 - 3630

2131.55 - 2677.35

3-14

WB156/156PS-5

MAINTENANCE

Thread Diameter of Bolt

Width across Flat

mm

mm

N•m

lbf ft

6

10

5.9 - 9.8

4.35 - 7.22

8

13

13.7 - 23.5

10.10 - 17.33

10

14

34.3 - 46.1

25.29 - 34.00

12

27

74.5 - 90.2

54.94 - 66.52

Torque of Hose Nuts Use these torques for hose nuts.

Thread Diameter

Width across Flat

Tightening Torque

mm

mm

N•m

lbf ft

02

14

19

19.6 - 29.4

14.5 - 21.7

03

18

24

29.4 - 68.6

21.7 - 50.6

04

22

27

58.9 - 98.1

44.4 - 72.4

05

24

32

107.9 - 166.7

79.6 - 123.0

06

30

36

147.1 - 205.9

108.5 - 151.9

10

33

41

147.1 - 245.1

108.5 - 180.8

12

36

46

196.2 - 294.2

144.7 - 217.0

14

42

55

245.2 - 343.2

180.9 - 253.1

Nominal No.

Torque of Split Flange Bolts Use these torques for split flange bolts.

Thread Diameter

Width across Flat

mm

mm

N•m

kgm

10

14

59 - 74

43.51 - 54.57

12

17

98 - 123

72.28 - 90.72

16

22

235 - 285

173.32 - 210.20

WB156/156PS-5

Tightening Torque

3-15

MAINTENANCE Torque for Flared Nuts Use these torques for flared part of nut.

Thread Diameter

Width across Flat

Tightening Torque

mm

mm

N•m

lbf ft

14

19

24.5 ± 4.9

18.0 ± 3.6

18

24

49 ± 19.6

36.1 ± 14.4

22

27

78.5 ± 19.6

57.8 ± 14.4

24

32

137.3 ± 29.4

101.2 ± 21.6

30

36

176.5 ± 29.4

130.1 ± 21.6

33

41

196.1 ± 49

144.6 ± 36.1

36

46

245.2 ± 49

180.8 ± 36.1

42

55

294.2 ± 49

216.9 ± 36.1

Torque for O-Ring Boss Piping Joints ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque in this table.

Thread Diameter

Width across Flat

mm

mm

Norminal No.

3-16

02

14

03, 04

20 Varies depending on type of connector.

Tightening Torque (N•m {lbf ft}) Range

Target

35 - 63 {25.81 - 46.46}

44 {32.45}

84 - 132 {61.95 - 97.35}

103 {75.96}

128 - 186 {94.40 - 137.18}

157 {115.79}

05, 06

24

10, 12

33

363 - 480 {267.73 - 354.02}

422 {311.25}

14

42

746 - 1010 {550.22 - 744.93}

883 {651.26}

WB156/156PS-5

MAINTENANCE Torque for O-Ring Boss Plugs ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque in this table.

Tightening Torque (N•m {lbf lb})

Thread Diameter

Width across Flat

mm

mm

Range

Target

08

08

14

5.88 - 8.82 {4.33 - 6.50}

7.35 {5.42}

10

10

17

9.8 - 12.74 {7.22 - 9.39}

11.27 {8.31}

12

12

19

14.7 - 19.6 {10.84 - 14.45}

17.64 {13.01}

14

14

22

19.6 - 24.5 {14.45 - 18.07}

22.54 {16.62}

16

16

24

24.5 - 34.3 {18.07 - 25.29}

29.4 {21.68}

18

18

27

34.3 - 44.1 {25.29 - 32.52}

39.2 {28.91}

20

20

30

44.1 - 53.9 {32.52 - 39.75}

49.0 {36.14}

24

24

32

58.8 - 78.4 {43.36 - 57.82}

68.6 {50.59}

30

30

32

93.1 - 122.5 {68.66 - 90.35}

107.8 {79.50}

33

33

_

107.8 - 147.0 {79.50 - 108.42}

124.4 {91.75}

36

36

36

127.4 - 176.4 {93.96 - 130.10}

151.9 {112.03}

42

42

_

181.3 - 240.1 {133.72 - 177.08}

210.7 {155.40}

52

52

_

274.4 - 367.5 {202.38 - 271.05}

323.4 {238.52}

Norminal No.

Torque for Hoses (Taper Seal Type and Face Seal Type) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil.

Tightening Torque (N•m {lbf ft}) Nominal Size of Hose

Width across Flats

02

19

Taper Seal Type

Face Seal Type

Nominal Thread Thread Size Size - Threads per (mm) Inch, Thread Series

Root Diameter (mm) (Reference)

Range

Target

34 - 54 {25.0 - 39.8}

44 {32.4}

-

9/16 - 18UN

14.3

34 - 63 {25.0 - 46.4}

44 {32.4}

14

-

-

22

54 - 93 {39.8 - 68.5}

74 {54.5}

-

11/16 -16UN

17.5

24

59 - 98 {43.5 - 72.2}

78 57.5}

18

-

-

04

27

84 - 132 {61.9 - 97.3}

103 {75.9}

22

13/16 - 16UN

20.6

05

32

128 - 186 {94.4 - 137.1}

157 {115.7}

24

1 - 14UNS

25.4

06

36

177 - 245 {130.5 - 180.7} 216 {159.3}

30

1 3/16 - 12UN

30.2

(10)

41

177 - 245 {130.5 - 180.7} 216 {159.3}

33

-

-

(12)

46

197 - 294 {145.3 - 216.8} 245 {180.7}

36

-

-

(14)

55

246 - 343 {181.4 - 252.9} 294 {216.8}

42

-

-

03

WB156/156PS-5

3-17

MAINTENANCE

3-18

WB156/156PS-5

MAINTENANCE

PERIODIC REPLACEMENT OF COMPONENTS To ensure safety while driving and using the machine, the operator must carry out all periodic maintenance operations prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the following pages, which are especially related to safety and fire prevention rules. These components are subject to wear and because it is particularly difficult to evaluate their condition through simple periodic maintenance, after a certain period it is advisable to change them regardless of their condition, in order to maintain their efficiency. Repair or replace these components immediately in case of failures or abnormalities, even if the time interval prescribed for their change (replacement) has not elapsed yet.

If the hose clamps show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses.

In addition to periodic replacement of the components listed on the following pages, the inspections described in the table should be performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute any other required measure.

Type of check

Check item

Check before starting

Leakage from joints, grease fittings, hydraulic hoses, or fuel lines

Periodic check (monthly check)

Leakage from joints, fittings, hydraulic hoses, or fuel lines.

Damaged hydraulic or fuel lines (cracks, wear and tear)

Periodic check (annual check)

Leakage from joints, fittings, hydraulic hoses/fuel lines.

Deteriorated, twisted, damaged hydraulic hoses/fuel lines (cracks, wear and tear) or in contact with other parts of the machine

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MAINTENANCE

SAFETY CRITICAL PARTS Fuel Supply System ★ Parts related to safety Components that Require Periodic Replacing

• •

Qty

Fuel line (Fuel tank - precleaner)

1

Fuel line (Precleaner - fuel pump)

1

Fuel line (Fuel pump - fuel filter)

1

Fuel line (Fuel filter - injection pump)

1

Fuel line (Fuel filter - fuel tank)

1

Fuel recovery line (Injection pump - fuel filter)

1

Fuel recovery line (Injector - fuel filter)

1

Fuel recovery line (Between the injectors)

3

Fuel recovery plug

1

Replacement Interval

Every 2 years or 4,000 hours, whichever occurs first

For serial numbers and quantity of components that periodically need replacement, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced.

When replacing hoses, always change O-rings, gaskets, and analogous components.

Delivery / Return Hydraulic System ★ Parts related to safety Components that Require Periodic Replacing

• •

Qty

Hydraulic hose (Hydraulic pump - iron tube)

1

Hydraulic hose (Iron tube - backhoe distributor)

1

Hydraulic hose (Iron tube - loader distributor)

1

Hydraulic hose (Hydraulic pump - backhoe distributor)

1

Hydraulic hose (Loader distributor - backhoe distributor)

1

Replacement Interval

Every 2 years or 4,000 hours, whichever occurs first

For serial numbers and quantity of components that periodically need replacement, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced.

When replacing hoses, always change O-rings, gaskets, and analogous components.

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MAINTENANCE

Delivery / Return Hydraulic System ★ Parts related to safety Components that Require Periodic Replacing

Qty

Hydraulic hose (Cylinders - Loader arm)

1

Hydraulic hose (Cylinders - Loader bucket)

1

Hydraulic hose (Cylinders - Multi-purpose bucket)

1

Hydraulic hose (Cylinders - Backhoe boom)

1

Hydraulic hose (Cylinders - Backhoe arm)

1

Replacement Interval

Every 2 years or 4,000 hours, whichever occurs first

Hydraulic hose (Cylinders - Backhoe bucket)

• •

For serial numbers and quantity of components that periodically need replacement, consult the replacement parts manual section regarding the components connected with safety and components that must be periodically replaced.

When replacing hoses, always change O-rings, gaskets, and analogous components.

Seat Belt System ★ Parts related to safety Components that Require Periodic Replacing

Qty

Replacement Interval

Seat belt (see “Seat Belt Inspection” on page 1-19 for inspection details)

1

Every 3 years after the start of usage or 5 years after the date of manufacture or at first sign of wear or damage.

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MAINTENANCE

MAINTENANCE SCHEDULE Maintenance Schedule Chart SERVICE ITEM

PAGE

INITIAL 50 HOURS SERVICE (for Machines with HEES Oil Only) 1. Every 50 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 2. Replace hydraulic tank oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 INITIAL 250 HOURS SERVICE 1. Every 250 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 2. Change front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 3. Change rear axle oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 4. Change hydraulic system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 5. Replace hydraulic transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 6. Check engine valve clearance, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 7. Change hydraulic tank oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 INITIAL 500 HOURS SERVICE (for Machines with HEES Oil Only) 1. Every 500 hours maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 2. Change hydraulic oil and clean suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 WHEN REQUIRED 1. Check, clean or replace engine air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 2. Check, clean cab air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 3. Clean air recirculation filter (for machines with air conditioners only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 4. Check level in windshield washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 5. Check windshield wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 6. Lubricate cab door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 7. Bleed brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 8. Check, adjust front wheel toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 9. Check, adjust parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 10. Check, adjust brake pedal stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 11. Adjust automatic return of front bucket to the digging position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 CHECK BEFORE STARTING 1. Various checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 2. Check fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 3. Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

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MAINTENANCE 4. Check engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 5. Check hydraulic oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 6. Drain water from fuel water separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 EVERY 10 HOURS SERVICE 1. Grease lubricating joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 EVERY 50 HOURS SERVICE 1. Previous maintenance - 10 hours service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 2. Check radiator fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 3. Check brake system oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 4. Lubricate drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 5. Lubricate front axle joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 6. Check tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 7. Check electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 EVERY 250 HOURS SERVICE 1. Previous maintenance - 10 and 50 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 2. Check serpentine belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3. Check A/C compressor belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 4. Clean outside of radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 5. Check battery electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 6. Check front axle oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 7. Check rear axle oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 8. Check transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 9. Check wheel lug nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 EVERY 500 HOURS SERVICE 1. Previous maintenance - 10, 50 and 250 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 2. Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 3. Change engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 4. Change hydraulic tank oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 5. Change fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 6. Drain fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 7. Drain hydraulic oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 EVERY 1000 HOURS SERVICE 1. Previous maintenance - 10, 50, 250 and 500 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 2. Change front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

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MAINTENANCE 3. Change rear axle oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 4. Change transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 5. Change transmission filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 6. Check and adjust engine valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 EVERY 2000 HOURS SERVICE 1. Previous maintenance - 10, 50, 250, 500 and 1000 hours service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 2. Change hydraulic system oil and clean suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 3. Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65 4. Change braking system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 5. Check alternator and starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 6. Check alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 7. Check A/C cooling gas quantity (only for machines with air conditioner). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

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MAINTENANCE

Initial 50 Hours Maintenance Remark ONLY FOR MACHINES IN WHICH HYDRAULIC ENVIRONMENTAL ESTER SYNTHETIC (HEES) OIL IS USED. The following maintenance operation must be performed after the first 50 hours of operation together with maintenance operations to be initiated “Every 50 Hours Maintenance” on page 3-42.

• HYDRAULIC OIL TANK FILTER CHANGE ★ For further details on the various maintenance operations, see “Every 500 Hours Maintenance” on page 3-51.

Initial 250 Hours Maintenance Perform the following maintenance after the first 250 hours together with those to be initiated “Every 250 Hours Maintenance” on page 3-46.

• FRONT AXLE OIL CHANGE • REAR AXLE OIL CHANGE • HYDRAULIC TRANSMISSION OIL CHANGE • HYDRAULIC TRANSMISSION OIL FILTER CHANGE • ENGINE VALVE CLEARANCE CHECK AND ADJUSTMENT • HYDRAULIC OIL TANK FILTER CHANGE ★ See “Every 500 Hours Maintenance” on page 3-51. ★ See “Every 1000 Hours Maintenance” on page 3-58.

For checks and adjustments, contact your Komatsu distributor.

Initial 500 Hours Maintenance Remark ONLY FOR MACHINES IN WHICH HYDRAULIC ENVIRONMENTAL ESTER SYNTHETIC (HEES) OIL IS USED. The following maintenance operation must be performed after the first 500 hours of operation, together with maintenance operations to be initiated. See “Every 500 Hours Maintenance” on page 3-51.

• HYDRAULIC OIL CHANGE AND SUCTION FILTER CLEANING ★ For further details on various maintenance operations, see “Every 2000 Hours Maintenance” on page 3-62.

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MAINTENANCE

When Required Cleaning or Changing Engine Air Filters

• Remove the air filter only after stopping the engine. Do not start the engine if the air filter is open.

• Wear safety goggles during the cleaning operations.

The air filtering system consists of a primary filtering element with considerable capacity and a secondary cartridge that ensures additional safety protection. The primary element can be cleaned with compressed air, while the safety cartridge can only be changed. The filter must be cleaned when the clogging warning light (A), positioned on the side dashboard, comes on or flashes. To reach the air filter, lift the loader arm; engage the mechanical safety lock; and open the engine hood. See “SAFETY LOCK USAGE” on page 2-67.

Clean the primary element 1.

2.

Release the safety retainer (1), moving it toward the outside.

Turn the cover (2) counterclockwise by approximately 12.5°.

3.

4.

Lift the cover (2) and extract the filtering element (3).

Slightly strike the filtering element (3) on the palm of your hand, in such a way as to remove the dust. Blow compressed air on the inner surface, keeping the air jet at a distance of approximately 15 cm (5.9 in). Be careful to keep the pressure in the 58 - 72.5 psi range.

After the cleaning operations, inspect the filtering surface for damage by introducing a lamp into the cartridge and carefully checking the gaskets of the front seals. If the cartridge is damaged, replace it.

5.

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MAINTENANCE 6.

Carefully clean the inside of the filter housing (4), taking care to prevent foreign bodies from getting into the suction duct.

7.

Put back the filtering element (3), making sure that it fits perfectly in its seat.

Put back the cover (2), turning it clockwise by approximately 12.5°. Make sure that the cover (2) is perfectly locked and make sure that the ejector (5) is positioned vertically on the lower part.

8.

9.

Once the whole has been assembled, push the safety retainer (1) toward the inside. • If the clogging warning light comes on after the engine starts, it is necessary to change the primary filtering element and the safety cartridge. • Change the primary filtering element after six cleaning operations or after one year. Every time the primary filtering element is replaced, the safety cartridge must be replaced, too.

Change the safety cartridge 1.

2.

3.

4.

5.

Remove the primary element (3).

Remove the safety cartridge (6) and replace it with a new one.

Once the safety cartridge (6) has been installed inside the filter housing (4), make sure that it fits perfectly in its seat.

Reassemble the whole as described in steps 7 and 8 in the previous procedure, making sure that all the filter components are perfectly secured.

Push the safety lock (1) towards the inside.

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MAINTENANCE Checking and Cleaning Cab Air Filter

Wear safety goggles during the cleaning operations.

The air suction for the ventilation of the cab is protected by a filter positioned on the right side of the cab. This filter blocks all the impurities contained in the air and must be cleaned whenever a decrease in air circulation is observed. The filter can be reached from the outside of the cab.

1.

Remove the four screws (1); remove the outer guard (2); and extract the filtering element (3).

2. Hit the element slightly on the palm of your hand to eliminate the dust. Blow compressed air on its surfaces, keeping the jet at a distance of about 15 cm (6 in) and making sure that the pressure does not exceed 65 psi.

3. Carefully clean the filter housing, taking care to prevent any foreign body from getting into the suction duct, then reassemble the unit. ★ If the filtering element is excessively clogged or damaged, replace it with a new one.

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MAINTENANCE Cleaning Air Recirculation Filter ★ Only for machines with an air conditioner.

Wear safety goggles during the cleaning operations.

If the machine is provided with an air conditioning system, in addition to the external filter there is also an internal filter (3) for internal air recirculation. This filter holds the impurities present in the air and must be cleaned whenever a decrease in air circulation is observed. The filter can be reached from the inside of the cab.

1.

Open the door (1) of the storage compartment; remove the container (2); and extract the filtering element (3).

2. Hit the element slightly on the palm of your hand to eliminate the dust. Blow compressed air on its surfaces, keeping the jet at a distance of about 15 cm (6 in) and making sure that the pressure does not exceed 65 psi.

3. Carefully clean the filter housing, taking care to prevent any foreign matter from getting into the suction duct.

4. Put back the filtering element (3) and the container of the storage compartment (2), then close the door (1). ★ If the filtering element is excessively clogged or damaged, replace it with a new one.

Checking the Level in Windshield Washer Reservoir •

The reservoir (1) is positioned inside the engine compartment and contains windshield washer fluid for the front and rear windshields. Make sure that the reservoir is always filled with fluid. If necessary, add automotive windshield washer fluid.

• Be careful to prevent dust from getting into the reservoir. ★ Do not use the antifreezes used in engine cooling systems.

Checking Windshield Wiper Blades • •

• •

The windshield wiper blades should be checked (while the windshield wipers are off) by verifying the condition of the windshield.

If any lines are left on the windshield after washing and wiping it, this means that the scraping wire has deteriorated and it is necessary to change the blades.

To ensure optimal operation of the windshield wiper, it is advisable to change the blades at least once a year. Change the blades more frequently if the machine works in difficult environmental conditions.

Always keep the windows clean, removing any residue of dirt, grease or other substances, since these may prevent the regular operation of the windshield wiper.

WB156/156PS-5

3-29

MAINTENANCE Lubricating Cab Door Hinges The cab door hinges should be lubricated when a squealing noise is heard on opening or closing the cab door or when signs of oxidation are found on the shoulder washers or on the pivots.

The lubrication procedure consists of injecting grease into the nipples provided on the hinge axes. ★ For further information on the grease to use, see “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

Bleeding Brake System

• Oil spilled on the floor may cause it to become slippery; immediately clean any dirty area.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

This operation is important, since it ensures the braking efficiency and power of the machine.

1.

Disconnect the brake pedals, so that they are independent of each other.

2. Apply a small pipe for the collection of the oil to the drain screws (1).

3. Remove the front guard (2) and the cap (3) from the reservoir (4).

4. Make sure that the oil in the braking system reaches the maximum level.

5. Press the left brake pedal thoroughly and, keeping it pressed, loosen the drain screw (1) of the corresponding brake until the pedal reaches the end of stroke. Use a 13 mm wrench.

6. While keeping the pedal completely pressed, tighten the drain screw (1).

7. Release the brake pedal; wait a few seconds; and repeat steps 5 and 6 until no air bubbles can be seen in the oil that flows out of the drain screw (1).

8. Carry out the same operations for the right pedal.

9. After bleeding the circuit, start the machine and check the braking efficiency; if necessary, bleed the circuit again.

10. Put back the front guard (2).

• When bleeding the system, apply a small pipe to the screws (1), in order to collect the oil.

• The bleeding procedure must be carried out for both braking units, disconnecting the pedals from each other.

• Frequently check the oil level in the braking system and service whenever the oil is near the minimum level.

• To top off, use only new oil of the prescribed type.

3-30

WB156/156PS-5

MAINTENANCE Checking and Adjusting Front Wheel Toe-in •

• • •

•

This check must be done according to time intervals scheduled by the operator, since any abnormality regarding the wheel toe-in is due to impacts or vibrations, depending on type of material handled by the machine.

Another reason for performing this check is to examine the front tires for excessive wear.

The machine has been designed with a toe-in equal to 0 mm.

Every adjustment must restore this value and must be carried out on tie rods (1) after loosening nuts (2) that lock them. Use 27 and 19 mm wrenches.

During this check and the relevant adjustment, it is advisable to also check the condition of the ball joints (3). If considerable slack is observed, immediately replace them.

WB156/156PS-5

3-31

MAINTENANCE Checking and Adjusting Parking Brake

During running-in, check efficiency of parking brake after the first 500 hours of operation.

Check condition • •

Tire pressure as prescribed Dry, compact road surface, with approximately 11° 20’ (1/5) grade

• 1.

2.

Machine in operating condition Start the engine.

Align the machine in a straight traveling position and proceed up the slope with 1/5 grade, with an empty bucket.

3.

Stop the machine by applying brake pedal; shift the directional control lever to neutral position (N); and stop the engine.

Apply the parking brake (lock position); slowly release the brake pedal; and make sure that the machine does not move.

4.

3-32

WB156/156PS-5

MAINTENANCE Adjustment 1.

2.

With engine off, release the brake lever and rotate lever end (2) by giving it two or three counterclockwise turns.

Start the engine and check again.

Checking the Braking Efficiency • •

During running-in, check the braking efficiency after the first 100 hours of operation.

Perform check with the machine positioned on firm and flat ground, making sure that there are no people or obstacles in the vicinity.

This check must be carried out after setting the work equipment in the travel or transport position, and engaging all safety locks.

1. Connect tandem brake pedals (2) with pin (1).

2. Start the engine and release the parking brake.

3. Engage 2nd gear and forward gear.

4. Accelerate until reaching the maximum speed.

5. Press the brake pedals. The machine must brake smoothly on a straight line and the tension of pedals must be constant. Otherwise, contact your Komatsu distributor.

WB156/156PS-5

3-33

MAINTENANCE Checking and Adjusting Brake Pedal Stroke Perform this check when working on adjusting the brake pedal stroke to eliminate or prevent any problems.

1.

2.

3.

4.

Insert connection pin (1) in order to couple the pedals.

By adjusting the end-of-stroke rubber pads (2), position the pedals in correspondence with measure “A” = 325 mm (12.8 in); secure the pads in this position. Use a 13 mm wrench.

Lower the pedals to measure “A” 306 mm (12 in).

Adjust brake pump rods (3) until they touch the pumping pistons, lock them in this position. Use a 22 mm wrench.

Adjusting Automatic Return of Front Bucket to the Digging Position The device for automatic return of the front bucket to the digging position automatically brings the front bucket to the loading position when it is lowered to the ground. The sensor is positioned on the right dumping cylinder and determines the horizontal position of the bucket in relation to the ground after bucket dumping control has reached end of stroke and the electromagnet of the distributor rod has been operated. ★ See “OPERATING THE FRONT END LOADER AND BACKHOE” on page 2-45. ★ The sensor must be positioned at a distance of 2 - 4 mm (0.0780.157 in) from the sliding rod.

3-34

WB156/156PS-5

MAINTENANCE

Checks Before Starting Various Checks

• Dirt, oil, and fuel in hot areas of the engine compartment may cause fires and damage the machine.

• Check to see if there are leaks, and perform any necessary repairs immediately.

• If this occurs repeatedly, contact your Komatsu distributor.

Before starting the engine, check the following: • Check for loose screws or nuts.

• Check for oil, fuel or coolant leakage.

• Check for worn equipment.

• Check condition of wheel rims, and condition and wear of the tires.

• Check condition and efficiency of instruments and warning lights on the dashboard, working lights and direction indicators.

The other general checks concerning safety and functionality: • Integrity of seat belt system. See “Seat Belt Inspection” on page 1-19.

• Soundness and legibility of warning plates and decals.

• Cleanliness of ladders and handrails used to reach the driver’s seat and cleanliness inside the operator’s compartment.

Checking Fuel Level

• When refueling, avoid spilling fuel to prevent any risk of fire. If some fuel should inadvertently be spilled, clean the dirty area immediately.

• Fuel is flammable; do not smoke when refueling.

• Place the fuel nozzle into the filler.

• •

To check the fuel level (1), use the indicator provided on the dashboard; do not fill the tank completely.

Leave space for fuel expansion.

Remark • It is advisable to refuel after work, in order to avoid the formation of condensation.

• After refueling, tighten the filler cap (2) thoroughly and lock the tank.

WB156/156PS-5

3-35

MAINTENANCE Checking Coolant Level

Do not remove the radiator cap to check coolant level. The coolant must be checked with the engine cold, through the expansion tank.

•

•

•

• •

The coolant level can be checked in expansion tank (1) with the engine cold. Coolant must be between the MIN and MAX lower marks.

The check must be performed through the hole positioned on the right side of the engine hood. The coolant level must be above the MIN lower mark.

If the level is near the lower limit of the MIN mark, fill the tank with coolant. If the level decreases considerably and constantly, check the radiator, engine, and radiator body for leaks.

Also check the fluid level in the radiator.

Expansion tank (1) can be reached after opening the engine hood.

The upper MIN and MAX marks indicate the expansion level of the coolant at operating temperature.

Checking Engine Oil Level

• After the machine is stopped, the engine is very hot.

• Let the engine cool down before performing any check.

• Hot engines may cause burns.

•

Dipstick (1) can be reached through an opening in the right side of the engine hood.

• The check must be performed when the engine is cold and the machine parked on level ground.

• The oil level can be checked on the graduated dipstick (1) and must be between MIN and MAX marks. If the level is near the MIN mark, top off with oil suitable for the ambient temperature, as prescribed in the lubricant chart. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

If it is necessary to check the oil level during or soon after work, stop engine and wait for 15 minutes before checking.

3-36

WB156/156PS-5

MAINTENANCE Checking Hydraulic Oil Level

• The oil level in the hydraulic system must be checked when the oil is cold and the machine positioned on level ground in the lubricating position.

• If it is necessary to top off, stop engine and then eliminate the residual pressures present in the work equipment (move the controls more than once) and in the tank by slowly loosening filling cap (2).

• •

•

The oil level must be visible through gauge (1) on the tank and must be filled between the MIN and MAX marks.

If level is near the MIN mark, top off by adding the prescribed hydraulic oil through filler (2). See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

Reinstall the filler cap. Use a 24 mm hexagon wrench.

• When adding oil, do not exceed the MAX level. This would damage the hydraulic system and cause oil to flow out.

• If a constant or abnormal decrease of the oil level is observed, thoroughly check the hydraulic system, the pistons and pump for leaks.

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3-37

MAINTENANCE Draining Water Separator

• The fuel is flammable. Do not use exposed flames and do not smoke while draining the water separator.

• If fuel spills, wipe it up immediately.

This operation serves to drain the condensation and must be done with a full tank in order to prevent air from entering the fuel supply system.

• Condensation must be drained at the end of work, before the engine has completely cooled down, in order to prevent freezing if the temperature gets very low.

• The water separator can be reached after opening the engine hood.

• Condensation is drained by loosening plug (1) and waiting until only clear diesel fuel flows out. Use a 13 mm wrench.

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WB156/156PS-5

MAINTENANCE

Every 10 Hours Maintenance Lubricating Joints (Grease Fittings)

• Clean the grease fittings before attaching the grease pump.

• After lubrication, remove all the contaminated grease that may have spread out of the fittings.

• If the machine is used in difficult conditions, perform these operations more frequently than usual.

This maintenance operation must be done with the front bucket resting on the ground, and backhoe equipment completely extended and resting on the ground, as indicated in the graphic.

Use the prescribed grease pump/grease. See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8 and “LUBRICATION DIAGRAMS” on page 3-11. ★ As a general rule, each cylinder is provided with two grease fittings positioned on the couplings and that each pin serving as fulcrum point for movement is provided with at least one grease fitting.

WB156/156PS-5

3-39

MAINTENANCE Joint Lubrication Points Front Loader Lubrication Locations

3-40

1

Tie rod - bucket coupling pin

2 Points

2

Bucket fulcrum pin

2 Points

3

Lever fulcrum pin

2 Points

4

Tie rod - lever coupling pin

2 Points

5

Bucket cylinder head pin

2 Points

6

Lift cylinder head pin

2 Points

7

Lift cylinder base pin

2 Points

8

Arm fulcrum pin

2 Points

9

Bucket cylinder base pin

2 Points

10

Multipurpose bucket fulcrum pin (option)

2 Points

11

Multipurpose bucket cylinder base pin (option)

2 Points

12

Multipurpose bucket cylinder head pin (option)

2 Points

WB156/156PS-5

MAINTENANCE Backhoe Lubrication Locations

13

Stabilizer cylinder pin

2 Points

14

Stabilizer arm fulcrum pin

2 Points

15

Boom swing cylinder base pin

4 Points

16

Boom swing fulcrum pin

2 Points

17

Stabilizer foot fulcrum pin

2 Points

18

Stabilizer ram pin

2 Points

19

Boom fulcrum pin

2 Points

20

Boom swing cylinder head pin

2 Points

21

Lift cylinder head pin

1 Points

22

Arm cylinder base pin

1 Points

23

Lift cylinder base pin

1 Points

24

Arm cylinder head pin

1 Points

25

Arm fulcrum pin

1 Points

26

Bucket cylinder base pin

1 Points

27

Bucket cylinder head pin

1 Points

28

Tie rod - lever coupling pin

2 Points

29

Tie rod - bucket coupling pin

2 Points

30

Lever fulcrum pin

1 Points

31

Bucket fulcrum pin

1 Points

32

Telescopic arm cylinder base pin (optional)

1 Points

33

Telescopic arm cylinder head pin (optional)

1 Points

WB156/156PS-5

3-41

MAINTENANCE

Every 50 Hours Maintenance Perform the following operations together with those to be every 10 HOURS.

Checking Radiator Fluid Level

• Perform this check with the machine parked on level ground and the loader arm raised with the safety lock engaged.

• Do not remove the radiator cap when the fluid is hot. The fluid may spray out of the radiator and cause burns.

• Loosen the cap slowly to release the pressure before removing it.

• •

The radiator cap can be reached after opening the engine hood.

Remove the cap (1) and make sure that the fluid is very near the filling hole. ★ If the level of fluid in the radiator is low and the expansion tank is filled with coolant, check the cap tightness and make sure that there are no air leaks from the coupling that connects the radiator and expansion tank. If the problem persists, contact your Komatsu distributor.

3-42

WB156/156PS-5

MAINTENANCE Checking Brake System Oil Level •

This operation must be carried out when the warning light (1) on the front instrument panel comes on.

•

The brake fluid reservoir (2) can be reached after removing the front guard (3).

•

This is a visual check and, if necessary, the reservoir must be serviced with the prescribed fluid until reaching the MAX mark. ★ Use new oil only. ★ If constant and considerable leaks are observed, it is advisable to contact a Komatsu distributor to have the system checked and the necessary repairs carried out.

WB156/156PS-5

3-43

MAINTENANCE Lubricating Drive Shafts •

Lubrication must be done after carefully cleaning the grease fittings, by attaching the grease pump and using the prescribed grease. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• Once lubrication has been completed, make sure that all the points have been lubricated. Remove the contaminated grease that may have spread out of the joints.

3-44

WB156/156PS-5

MAINTENANCE Lubricating Front Axle Joints •

Lubrication points (1) of the wheel joints are indicated in the photo. The points are located in symmetrical positions, while the central joint is lubricated by means of a grease fitting (2) positioned on the frame.

• Lubrication must be done after carefully cleaning the grease fittings, by attaching the grease pump and using the prescribed grease. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• Once lubrication has been done, remove the contaminated grease that may have spread out of the joints and central coupling.

Checking Tire Pressure

• Inflate the tires only after positioning them in a protection cage.

• To inflate the tire, stand beside the external belt.

• Do not exceed the prescribed tire pressures.

Standard Front Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 x 17.5 Pressure. . . . . . . . . . . . . . . . . . . . . . 3.31 ± 5 kg/cm2 (47.1±1 psi) Standard Rear Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5L x 24 Pressure. . . . . . . . . . . . . . . . . . . . . . 1.88 ± 5 kg/cm2 (26.7±1 psi) • •

This check is indispensable to preserve the tires, keep them efficient over time and make them last longer.

While checking the tire pressure, check conditions of the tread and sidewalls.

★ Tire pressure may vary based on tire, ballast, and road conditions.

Refer to the markings on the tire’s sidewall for pressures suitable for your tire.

Checking Electrical System

• It the fuses are corroded, oxidized or not fitted properly, replace them with fuses having the same capacity. Before changing a fuse, make sure that the ignition key is in the “OFF” position.

• If there are signs of short circuits on the cables, find the causes and repair them; always contact your Komatsu distributor for troubleshooting.

Make sure that there are no disconnected cables or signs of short circuits in the electrical system. Check that all the cables are securely tightened to their respective terminals. Tighten any loose cables. Check the following: • Battery • Starter • Alternator

WB156/156PS-5

3-45

MAINTENANCE

Every 250 Hours Maintenance Perform the following operations together with those to be done every 10 and 50 HOURS.

Checking Serpentine Belt • • •

Carry out this checking and maintenance operation when the engine is cold.

The belt (4) can be reached after opening the engine hood.

This check is visual, must be carried out with cold engine, and consists of inspecting the belt for cuts, frays and cracks. If you find any of these defects, have the belt changed by a Komatsu distributor.

Checking A/C Compressor Belt Tension ★ Only for machines with an air conditioner • The compressor belt can be reached after opening the engine hood.

• The check is manual and consists of exerting pressure on the belt (1) at the center of the section between the compressor (2) and the pulley (3).

• If the pressure exerted is approximately 10 kg, the resulting deflection must be approximately 5 - 6 mm. When the belt is new, the resulting deflection must be approximately 4 mm.

• If the belt is worn or its condition is questionable, change it and check the tension again after a few hours of operation.

3-46

WB156/156PS-5

MAINTENANCE Cleaning Outside of Radiator

• Compressed air, steam or water directed at a person may cause injuries.

• Always wear safety goggles and safety shoes.

To clean the outside of the radiator, it is first necessary to loosen the screws (2) and remove the guard (1) from the front of the engine hood.

Use a 17 mm hex wrench.

•

The cleaning must be carried out using a compressed air jet and, if necessary, with a low pressure water or steam washing cycle. The specific detergents available on the market can certainly be used, provided that the instructions given on the package are followed and that the washed parts are carefully dried. After washing, put back the front guard (1).

• The condenser (3), must be cleaned at the same time as the radiator.

• The condenser (3), must be cleaned with a jet of compressed air and, if necessary, with a low-pressure water or steam washing cycle. The specific products available on the market can certainly be used, provided that the instructions given on the package are followed and that the washed parts are carefully dried. ★ Do not use products containing even a small quantity of oily substances, since these facilitate the adhesion of dust, which affects the heat exchange adversely. ★ Clean the outside of the radiator whenever the radiator is dirty with oil, diesel oil and greasy or oily substances.

WB156/156PS-5

3-47

MAINTENANCE Checking Battery Electrolyte

• Check the level with the machine parked on flat ground.

• Check the level only after stopping the engine and if necessary add distilled water only before starting work.

• Always wear safety goggles and waterproof gloves.

• To prevent gas explosions, do not use exposed flames.

• Do not smoke.

• Avoid producing sparks due to short circuits.

• The battery electrolyte is dangerous. If it comes in contact with your eyes or skin, rinse with plenty of water and consult a doctor without delay.

• • •

★ • ★ ★ ★

The battery (1) can be reached after removing the cover (5), and the fastening screws (3). Use a 17 mm hexagon wrench.

The electrolyte level in each cell must be about 6 mm (0.24 in) above the plate edge; if necessary, add distilled water only.

To reach the filling holes of the cells, first remove guard (4). If, on the contrary, the level is low because some fluid has been spilled, add sulfuric acid, after having diluted it until reaching the concentration suitable for the ambient temperature.

See “Checking Battery Electrolyte” on page 3-48.

After checking the battery electrolyte, reinstall guard (4) and cover (5) with fastening screws (3).

It is advisable to add distilled water before starting work, in order to prevent freezing.

Before reinstalling the cell plugs, make sure that the breather holes are not clogged.

Make sure that the connection terminals are not oxidized; if necessary, clean them and cover them with anti-oxidation grease.

3-48

WB156/156PS-5

MAINTENANCE Checking Front Axle Oil Levels Differential •

This visual check is used to verify if the lubricant reaches hole (1).

If necessary, top off using the prescribed oil. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• Level hole (1) must also be used as the filler hole. Use a 17 mm wrench.

Planetary •

Conduct this check with each reduction gear positioned with the plug on the horizontal axis.

• If necessary, move the machine slightly until the specific position for a precise check is reached.

• This visual check serves to verify if the lubricant reaches hole (2).

If this does not occur, add the prescribed oil. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• Use a 17 mm wrench.

Checking Rear Axle Oil Levels Differential •

This check is used to verify if the lubricant reaches hole (1). If necessary, top off using the prescribed oil. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• Level hole (1) must be used also as filler hole. Use a ½ inch square wrench.

WB156/156PS-5

3-49

MAINTENANCE Transmission Oil Level

• The level must be checked with the engine running and the transmission oil at operating temperature. Be very careful in order to avoid burns.

• If it is necessary to add oil, stop the engine before opening the engine hood. Set the parking brake to “ON” in order to prevent possible injury from unexpected machine movement. Never rely on the directional control lever alone to keep the machine from moving; it can unexpectedly roll or move under power, resulting in death or serious injury.

•

Dipstick (1) can be reached through the opening on the right side of the engine hood, which is protected by inspection cover.

• The level must be checked with the engine running at 800 - 1000 rpm and with the transmission oil at operating temperature.

• The oil must always reach the maximum level mark, or very near it.

• To add oil, use the dipstick (1) filler tube and the prescribed oil. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

• After checking the oil level, close inspection cover and lock it.

Checking Wheel Lug Nut Torque •

This check is used to verify that driving torque of the wheel lug nuts on the hubs are correct.

• The driving torque must be checked by means of a torque wrench (1) set according to the values indicated in the paragraph. ★ See “TORQUE SPECIFICATIONS” on page 3-14.

• Use a 27 mm wrench for the front wheels and a 32 mm wrench for the rear wheels. ★ Do not increase the specified driving torque; keep it within the prescribed ranges. ★ When the driving torque must be checked, do not lubricate the thread.

3-50

WB156/156PS-5

MAINTENANCE

Every 500 Hours Maintenance Perform these operations together with those every 10, 50 and 250 HOURS.

Changing Engine Oil

• Change the oil with the machine parked on level ground and the loader arm raised, with the safety lock engaged.

• After the machine has been operated, the engine oil is very hot and may cause burns; let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil.

• Oil that spills during the change makes the ground slippery. Use anti-slip shoes and immediately remove any trace of oil from the floor.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to antipollution regulations in force.

When changing engine oil, also change the filter. ★ See “Changing Engine Oil Filter” on page 3-52.

Required: Container to hold the drained oil.

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9l (2.4 gal) 1.

2.

3.

4.

Open the engine hood.

Remove the oil pan drain plug (1). Collect used oil in a container.

Use a 19 mm wrench.

While the oil flows out, remove filler cap (2), so that oil can flow freely.

Change the engine oil filter.

5.

Tighten engine oil pan drain plug (1) and add the exact quantity of new oil, using dipstick (3) to make sure that the oil reaches the MAX level.

6. Reinstall filler cap (2). Start the engine and let it run for five minutes, and then shut it down. Check the oil level again and add oil, if necessary.

7. Close the engine hood. ★ Use oil suitable for the ambient temperature. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

WB156/156PS-5

3-51

MAINTENANCE Changing Engine Oil Filter

• Immediately following machine operation, engine oil is very hot and may cause burns. Let the engine cool down until it reaches a temperature of 40-45°C (104-113°F) before draining the oil.

• Oil that spills during changes makes the ground slippery. Use anti-slip shoes and immediately remove any trace of oil from the floor.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

• 1.

Replace the oil filter every time the oil is changed.

Unscrew and remove the old filter (1), using the special wrench that is provided.

2. Clean the contact surface between the gasket and the filter support (2).

3. Fill the new filter with engine oil, lubricate the gasket, and carefully screw it on.

4. Give another half turn by hand.

5. Start the engine. Make sure that there are no leaks and that the oil pressure warning light goes out. ★ Do not use the wrench to further tighten the filter. The filter may be damaged and cause an oil leak.

3-52

WB156/156PS-5

MAINTENANCE Changing Hydraulic Tank Oil Filter On machines using containing Hydraulic Environmental Ester Synthetic (HEES) oil, the hydraulic tank oil filter must be changed after the first 500 hours of operation and successively every 2000 hours, and in any case at least once a year.

Required: Container to hold the drained hydraulic oil.

Hydraulic Tank Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 l (10.8 gal) •

After stopping the engine, with the machine in the correct position for the performance of maintenance operations, eliminate the residual pressure from the equipment (by moving the controls more than once) and from the tank (by slowly loosening the filler cap).

• Let the oil cool down until it reaches 40-45°C (104-113°F) before carrying out this maintenance operation.

• If any oil spilled, wipe it up immediately in order to prevent the surface from getting slippery.

• Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of according to the regulations in force.

1. Open the engine hood and slowly loosen the filler cap (1) to release any residual pressure from the tank, then remove it. ★ See “SAFETY LOCK USAGE” on page 2-67.

2.

3.

Place the container under the plug (3) positioned on the hydraulic pump intake flange and remove it. Let the oil flow out. Use a 27 mm wrench.

Loosen the clamps and disconnect the intake coupling (4).

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3-53

MAINTENANCE 4.

5.

6.

7.

8.

9.

Loosen and remove the screws (5) and remove the flange (6), complete with gasket (7) and filter (8).

Clean the strainer (8) using light solvents (kerosene, diesel oil, etc.); dry the strainer with low-pressure compressed air (maximum 43.5 psi). • Carefully check the filtering element grid and if it is not in perfect condition, change it.

Position the gasket (7) and put back the flange (6) complete with filter (8).

Connect the intake coupling (4) and secure it with the clamps.

Change the drain filter.

Put back the drain plug (3) and fill the oil tank with the prescribed oil until it reaches the correct level.

10. Raise the front mat and remove the cover (9). Use a 13 mm wrench.

11. Loosen the bleeder plug (10), positioned on the hydraulic pump, until no air bubbles can be observed in the oil that flows out (use a 19 mm hex wrench). Tighten the bleeder plug (10) and put back the cover (9).

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WB156/156PS-5

MAINTENANCE 12. Put back the filler cap (1), start the engine and operate the machine making each piston move several times in order to bleed the system. Stop the machine in the maintenance position, check the oil level again and service if necessary. Always use oil of the prescribed type. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

13. Close the engine hood.

★ Do not start the engine when the tank is empty, since this would certainly damage the pump. ★ In machines equipped with a demolition hammer, hydraulic oil deteriorates more rapidly than in machines used for simple digging operations. ★ Perform the oil change according to the indications given in the table to the right.

WB156/156PS-5

3-55

MAINTENANCE Changing Fuel Filter

• Replace the filter element once the engine has cooled down to 40-45°C (104-113°F).

• During this procedure, fuel may spill; clean spills immediately to prevent any slipping or fire.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

After opening the engine hood, locate the fuel filter and fuel lift pump on the left side of the engine.

Fuel Filter 1.

2.

3.

4.

5.

6.

Clean external surfaces of the engine and attached components near the fuel filter to prevent dirt and contamination from entering the fuel circuit.

Unscrew the old filter (1).

Wipe the inside of the fuel filter head (5).

Fill the filter with clean diesel fuel, then lubricate the gasket on the new filter (1) with clean lubricating engine oil. This minimizes air in fuel lines and reduces time needed to bleed the circuit.

Install the new filter onto the head until the gasket contacts the filter head surface. Tighten the fuel filter an additional 1/2 to 3/4 of a turn, or follow instructions provided with the new fuel filter.

Bleed the fuel supply circuit.

Bleeding The Circuit 1.

2.

Loosen the fuel delivery line (3) entering the filter head.

Pump the lever on the right side of the fuel lift pump until a steady flow of fuel without air bubbles comes out of the loosened fuel line.

3. Tighten the fuel delivery line (3) then loosen the fuel supply line (4) on the opposite side of the filter head.

4. Again, pump the lever on the fuel lift pump until a steady flow of fuel without bubbles comes out of the loosened fuel line.

5. Tighten the fuel supply line (4).

6. Clean any fuel spills, then start the engine. ★ Do not let the starter run for more than 30 seconds. If the engine does not start, wait at least two minutes before repeating the starting procedure. ★ If the fuel tank is run dry or drained, bleed the system. ★ If the engine starts normally but later stops, runs rough, misfires, or creates excessive smoke, check for air in the fuel lines. In addition to bleeding the fuel circuit as described above, it may be necessary to bleed air from the fuel lines running from the fuel lift pump to the injector pump to the fuel injectors. Also check that all fuel lines and the fuel filter are secured tightly. Check for possible leaks around the siphon tubes on the fuel tank.

3-56

WB156/156PS-5

MAINTENANCE Draining Fuel Tank

• When draining the fuel tank, avoid spilling fuel, since this may cause fires.

• If some fuel is accidentally spilled, clean the dirty area immediately to prevent slipping and fires.

Required: Container to hold the drained fuel.

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41l (10.8 gal) •

This operation is used to remove impurities and condensation from the tank.

•

Remove lower plug (1) and wait until clean fuel flows out. Use a 17 mm wrench. ★ The tank must be drained before starting the engine, with temperatures exceeding 0°C (32°F); when the temperature is below 0°C (32°F), the tank must be drained at the end of work or with the machine at operating temperature, to prevent condensation from freezing. Any condensation and impurities that may have accumulated inside the tank must be eliminated before refueling.

Draining Hydraulic Oil Tank ★ Only for machines using Hydraulic Environmental Ester Synthetic (HEES) oil

• Stop the engine and place the machine in the correct position to perform maintenance operations. Eliminate residual pressure from the equipment (by moving the controls more than once) and from the tank (by slowly loosening the filling cap).

• Let the oil cool down until it reaches 40-45°C (104-113°F) before performing any maintenance.

• Immediately clean any oil spills and wipe excess oil from area.

Required: Container to hold the drained oil.

Hydraulic Tank Oil . . . . . . . . . . . . . . . . . . . . . . . . 41l (10.8 gal) This operation is used to get rid of condensation accumulated on the tank bottom to flow out of the tank itself.

1. Loosen filler cap (1) to release residual pressure from the tank.

2. Remove drain plug (2) and let condensation flown out of the tank completely, using a 27 mm wrench.

3. Reinstall filler cap (1). ★ Draining the tank must be done at temperatures exceeding 0°C (32°F), before starting the engine. When the temperature is below 0°C (32°F), the hydraulic oil tank must be drained at the end of work, or when the temperature of the machine is sufficiently high, to prevent condensation from freezing.

WB156/156PS-5

3-57

MAINTENANCE

Every 1000 Hours Maintenance Perform these operations together with those initiated every 10, 50, 250, and 500 HOURS.

Changing Front Axle Oil

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Required: Container to hold the drained oil.

Front Axle Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 l (2.0 gal) Perform this operation with the machine positioned on level ground and at operating temperature, so that the oil is fluid and can be easily drained, which facilitates the elimination of any suspended solid particles.

Differential 1.

2.

3.

Place the container under the drain plug. Remove drain plug (2) and let the oil flow out completely. While the oil flows out, remove plug (1). Use a 17 mm wrench.

Once the oil has been drained, reinstall plug (2) and pour oil of the appropriate type through hole (1), until the level corresponding to the lower edge of the hole itself is reached.

Reinstall plug (1).

Planetary 1.

2.

3.

4.

5.

Move the machine until plug (3) is in a low position on the vertical axis.

Place the container under the drain plug (3). Remove plug (3) using a 17 mm wrench and let the oil flow out.

Once the oil has been drained, move the machine until plug (3), which serves also as a level indicator, is positioned on the horizontal axis.

Pour oil of the appropriate type through the hole until the lower edge of the hole itself is reached.

Reinstall plug (3).

★ Move the machine both forward and backward. Stop it to check the oil level again. ★ Always use oil of the appropriate type.

See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

3-58

WB156/156PS-5

MAINTENANCE Changing the Rear Axle Oil

Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Required: Container of to hold the drained oil.

Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 l (3.8 gal) Perform this operation with the machine positioned on level ground and at operating temperature, so that the oil is fluid and can drain easily, which facilitates elimination of any suspended solid particles.

Differential 1.

2.

3.

Place container under drain plug (2) and remove it. Let the used oil flow out completely. While the oil flows out, remove plug (1), using a ½ inch square wrench.

Once the oil has been drained, reinstall plug (2) and pour oil of the appropriate type through hole (1), until the level corresponding to the lower edge of the hole itself is reached. ★ With this operation both axle shafts are filled with oil. Before checking the level and replacing the plug, wait a few minutes in order to permit the uniform distribution of oil.

Install plug (1).

Planetary 1.

2.

3.

4.

5.

Move the machine until drain plug (3) is in low position on the vertical axis.

Place container under plug (3) and remove it. Let the oil flow out.

Use a ½ inch square wrench.

After draining the oil, move the machine until plug (3), which is also a level indicator, is positioned on the horizontal axis.

Pour oil of appropriate type through the hole until it reaches the lower edge of the hole itself.

Reinstall plug (3).

. ★ Move the machine both forward and backward and then stop it.

Check the levels again. ★ Always use oil of the appropriate type.

See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

WB156/156PS-5

3-59

MAINTENANCE Changing Transmission Oil •

Change the oil while the machine is parked on level ground and the loader arm is raised with the safety lock engaged.

• The transmission oil must be drained at operating temperature, which is very high, and may cause severe burns; wear insulating gloves, goggles and safety shoes.

• Immediately clean any spilled or excess oil from the area.

• Oils, filters, the coolant and the battery are considered special waste and must be collected and disposed of according to the regulations in force.

• On new machines, change the hydraulic transmission oil after the first 250 hours of operation and successively every 1000 hours. ★ When changing the transmission oil, also change the filter.

Required: Container to hold the drained oil.

Power Shuttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2l (5.3 gal) Power Shift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0l (7.4 gal) 1.

With the machine at operating temperature, stop the engine, open the engine hood and extract the dipstick (1). ★ See “SAFETY LOCK USAGE” on page 2-67.

2. Place a container under the drain plug (1) and remove the plug. Let the oil flow into a container with suitable capacity. Use a ½ inch square wrench.

3.

4.

Remove the filter (3) and replace it with a new one.

Replace the plug (1) and add oil until reaching the MIN level on the dipstick (2).

5. Start the engine and let it idle to fill the converter and the internal circuits.

6. While the engine is idling, add oil until reaching the MIN level again.

7. When the oil reaches a temperature of approximately 50°C (122°F), add oil until reaching the MAX mark. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

8. Close the engine hood.

3-60

WB156/156PS-5

MAINTENANCE Changing Transmission Filter

• After operating the machine, the transmission unit is very hot and may cause burns. Let the machine cool down before changing the filter.

• Oil that spills during filter replacement may cause the floor to become slippery; use anti-social shoes and immediately remove any trace of oil from the floor and transmission unit.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Change the filter every time the transmission oil is changed.

1.

2.

3.

4.

Raise the front mat and remove cover (1) using a 13 mm wrench.

Unscrew and remove filter (2) with the special wrench provided.

Clean the contact surface between the gasket and filter support (3).

Lubricate the gasket; fit it in its seat; and screw filter on thoroughly until it touches the gasket.

5. Give it another half turn by hand.

6. Start the engine; let it idle to let the oil warm up until it reaches operating temperature.

7. Add oil until it reaches the MAX mark on dipstick (1). ★ See “Transmission Oil Level” on page 3-50. ★ Always top off with suitable oil. See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

8. Reinstall cover (1).

Checking and Adjusting Engine Valve Clearance ★ Since the check and adjustment of the engine valve clearance requires special tools, have these operations performed by your Komatsu distributor.

WB156/156PS-5

3-61

MAINTENANCE

Every 2000 Hours Maintenance Perform these operations together with those to be performed every 10, 50, 250, 500, and 1000 HOURS.

Changing Hydraulic System Oil and Cleaning Suction Filter •

For machines containing Hydraulic Environmental Ester Synthetic (HEES) oil, replace oil after the first 500 hours of operation and successively every 2000 hours, or at least once a year.

• After stopping the engine, with the machine positioned so that maintenance can be performed (see illustration), release residual pressure from the work equipment system (by operating the controls more than once) and from the tank (by slowly loosening the filler cap).

• Let the oil cool down until it reaches 40-45°C (104-113°F) before performing any maintenance.

• Immediately clean any oil spills and wipe excess oil from the area.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Required: Container to hold drained hydraulic oil.

Hydraulic System Oil . . . . . . . . . . . . . . . . . . . . . . 97l (25.6 gal) 1.

Open the engine hood and slowly loosen the filler cap (1) to release any residual pressure from the tank, then remove it. ★ See “SAFETY LOCK USAGE” on page 2-67.

2. Place container under the drain plug (2) and remove plug. Let the oil flow out, gathering it into a container with suitable capacity.

Use a 41 mm wrench.

3.

4.

Remove the plug (3) positioned on the hydraulic pump intake flange and let the oil flow out, gathering it into a container with suitable capacity. Use a 27 mm wrench.

Loosen the clamps and disconnect the intake coupling (4).

3-62

WB156/156PS-5

MAINTENANCE 5.

6.

Loosen and remove the screws (5) and remove the flange (6), complete with gasket (7) and filter (8).

Clean the filter (8) using light solvents (kerosene, diesel oil, etc.); dry the filter with low-pressure compressed air (maximum 43.5 psi).

7.

8.

Open the battery box door and remove cover (1).

Remove the hydraulic filter (2) and replace with a new filter.

9.

Change the oil filter. See “Changing Hydraulic Tank Oil Filter� on page 3-53.

10. Replace the drain plugs (2) and (3) and fill the oil tank with the prescribed oil until reaching the correct level.

11. Raise the front mat and remove the cover (9). Use a 13 mm wrench.

WB156/156PS-5

3-63

MAINTENANCE 12. Loosen the bleeder plug (10), positioned on the hydraulic pump, until no air bubbles can be observed in the oil that flows out (use a 19 mm hex wrench). Tighten the bleeder plug (10) and put back the cover (9).

13. Put back the filler cap (1), start the engine and operate the machine making each piston move several times in order to bleed the system.

14. Stop the machine in maintenance position, check the oil level again and top off if necessary. Always use oil of the prescribed type. ★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

15. Close the engine hood.

★ Do not start the engine when the tank is empty tank, this will damage the pump. ★ In machines equipped with a demolition hammer, hydraulic oil deteriorates more rapidly than in machines used for simple digging operations. ★ Perform the oil change according to the indications given in the table.

3-64

WB156/156PS-5

MAINTENANCE Changing Coolant

• After the machine has been operated, the coolant is very hot and under pressure and may cause serious burns. Let the engine cool down until it reaches approximately 40-45°C (104-113°F) before changing the coolant.

• Slowly loosen the radiator cap, in order to release the residual pressure.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Required: Container to hold the drained coolant.

Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14l (3.7 gal) The following operations refer to changing permanent coolants, if the coolant is water or water with antifreeze, which are used according to the season, it is necessary to flush the cooling system in order to eliminate any encrustation.

1. Open engine hood.

2. Loosen and remove upper radiator cap (1).

3.

4.

Place a container under the radiator drain cock (2) (see Figure A); and open drain cock. Loosen drain valve (3) positioned on the filter carrier head. The coolant will flow out; collect it in a container with suitable capacity. Use a 12 mm wrench.

Close radiator drain cock (2) (see Figure B); tighten valve (3) on the filter carrier head, and fill the radiator with new coolant.

★ See “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

5. Start engine and let it idle for a few minutes. Check the coolant level again and add coolant, if necessary. Reinstall upper radiator cap (1).

WB156/156PS-5

3-65

MAINTENANCE 6.

Fill the expansion tank until the maximum level is reached, then close the engine hood.

3-66

WB156/156PS-5

MAINTENANCE Changing Brake System Oil

• Oil spills on the floor may cause it to become slippery; immediately clean any dirty area.

• Oils, filters, coolant, and the battery are considered special waste and must be collected and disposed of according to all antipollution regulations in force.

Before changing the brake system oil, it is advisable to brake a few times in order to warm the oil up to increase the viscosity and facilitate draining. Changing oil and bleeding the brake system must be done with the machine positioned on level ground with the parking brake set.

1. Attach a small hose (for collection of the oil) to drain screws (1) and loosen them, using a 13 mm wrench.

2. Remove front guard (2) and cap (3).

3. Operate the tandem brake pedals (connected to each other) until oil in tank (3) runs out.

4. Fill tank (3) with new oil and keep pumping. Fill tank (3) more than once, until the used oil (about 0.8 liters {1.7 US pint}) has been completely purged. Bleed the residual air. ★ See “Bleeding Brake System” on page 3-30. ★ For details on oil to be used see “FUEL, COOLANT, AND LUBRICANTS” on page 3-8.

Checking the Alternator and the Starter This procedure must be carried out by qualified personnel. Have this operation performed by your Komatsu distributor.

Changing the Alternator Belt This procedure must be carried out by qualified personnel. Have this operation performed by your Komatsu distributor.

Checking the A/C Cooling Gas Quantity ★ Only for machines with an air conditioner Specific equipment is required to check the coolant. Have this maintenance operation carried out only by specialized personnel; contact your Komatsu distributor.

WB156/156PS-5

3-67

MAINTENANCE

MAINTENANCE WHEN USING DEMOLITION HAMMER Hydraulic oil used in the machines provided with a demolition hammer deteriorates more quickly than oil used in normal digging machines. It is advisable to consult the following maintenance plan.

Changing Hydraulic Oil Filter For new machines, change the filter after the first 100 and 150 hours of operation. For successive changes, adhere to the schedule provided in table.

If the machine contains Hydraulic Environmental Ester Synthetic (HEES) oil, the filter must be changed after the first 50 hours of operation.

Changing Hydraulic Oil Change hydraulic oil in the tank according to intervals shown on table.

On machines containing Hydraulic Environmental Ester Synthetic (HEES) oil, change oil after the first 500 hours of operation. For successive changes, adhere to the schedule provided on table.

3-68

WB156/156PS-5

MAINTENANCE

LONG TERM STORAGE Before Storage

• When draining the fuel, do not smoke or have exposed flames near the machine.

• Place a container under the machine to collect the fuel and prevent it from spilling.

• If some fuel spills, clean the dirty surface immediately.

★ To protect cylinder rods when the machine is not used, position work equipment as shown. This prevents cylinder rods from rusting.

If the machine must be stored for a long period, it is advisable to put it in a sheltered place. Take the following precautions to keep all its components sound and efficient.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Clean the machine thoroughly, repainting it where necessary in order to prevent oxidation.

Insert supports under the axles to avoid overloading them, and to avoid any deformation of the tire sidewalls.

Drain and change all fluids of the hydraulic system and lubricants (axles, reduction gears, converter, and engine).

Change all filtering elements (air cleaner, engine oil filter, hydraulic system filters, diesel oil filter).

Drain the coolant and replace it with a corrosion inhibitor (permanent fluid).

Drain the fuel and fill the tank with at least 10 liters (2.6 US gal) of special washing and protecting fuel.

Let the engine run for about 10 minutes to eliminate the residual fuel from the filters, injection pump, and entire fuel supply system. This procedure prevents the injection pump and injectors from seizing. Stop the engine and refuel with diesel fuel.

Remove the battery according to the battery removal instructions. See “Removal and Installation” on page 2-80. Check the electrolyte level and make sure that the battery charge is sufficient. Store battery in a room with suitable temperature and periodically recharge it.

Grease the hydraulic cylinder rods.

Seal the end of the exhaust pipe and fuel tank cap.

Move the machine controls to the neutral position and engage the mechanical safety locks of the equipment controls.

Hang a warning notice on the steering wheel to indicate the condition of the machine.

Lock the cab doors, fuel tank cap, engine hood and battery box. On canopy machines, install anti-vandalism guards.

WB156/156PS-5

3-69

MAINTENANCE

During Storage

If it is necessary to carry out a rust-prevention treatment while the machine is kept indoors, open the doors and windows to increase ventilation and avoid any hazardous fumes.

Start engine and move the machine a short distance once a month, so a new oil film covers all moving parts and surfaces of components. Also, charge the battery if necessary.

After Storage ★ If the machine is stored without carrying out the monthly rust-prevention treatment, have maintenance performed by your Komatsu distributor.

When using the machine after a long period of inactivity, do the following steps.

1.

2.

3.

4.

5.

Remove seals from the exhaust pipe and fuel tank.

Check all fluid levels (engine oil, coolant, fuel, hydraulic system oil).

Make sure that the battery charge is sufficient; install the battery; then turn on the battery disconnect switch.

Disconnect the engine stop solenoid.

Turn the ignition key directly to the start position and keep it there until the engine oil pressure warning light goes out.

This operation starts the circulation of lubricating oil and carries out a first lubrication cycle.

6. Reconnect the stop solenoid valve and start the engine. Let the engine run at accelerated speed (approximately 1200 rpm) for about 15 minutes.

7. While the engine is warming up, check the tire pressure and remove the protection grease from the hydraulic cylinder rods.

8. Before moving the machine, make sure that the instruments, lights, direction indicators, and brake stoplight work properly.

9. Warm up the hydraulic cylinders by slowly moving all the work equipment as soon as possible.

10. Move at low speed and brake a few times in order to increase the oil viscosity and allow the braking surfaces to seat.

3-70

WB156/156PS-5

MAINTENANCE

MEMORANDUM

WB156/156PS-5

3-71

MAINTENANCE

3-72

WB156/156PS-5

4SPECIFICATIONS

WB156/156PS-5

4-1

SPECIFICATIONS

SPECIFICATIONS Machine Dimensions and Weights

4-2

WB156/156PS-5

SPECIFICATIONS

A

Maximum height

4230 mm (13 ft 11in)

M

Transport length

7504 mm (24 ft 7 in)

B

Hinge pin height

3367 mm (11 ft 1 in)

N

Dumping height (SAE) -with retracted telescopic arm -with extended telescopic arm

3761 mm (12 ft 4 in) 3747 mm (12 ft 4 in) 4435 mm (14 ft 7 in)

C

Overall height, ROPS Cab

2935 mm (9 ft 8 in)

O

Maximum digging height -with extended telescopic arm

5525 mm (18 ft 2 in) 6136 mm (20 ft 2 in)

D

Maximum dumping height

2622 mm (8 ft 7 in)

P

Digging depth (2 ft level bottom) -with extended telescopic arm

4670 mm (15 ft 4 in) 5916 mm (19 ft 5 in)

E

Reach at maximum height and 45° dump angle

750 mm (2 ft 5 in)

Q

Reach at maximum height -with extended telescopic arm

3046 mm (10 ft) 4239 mm (13 ft 11 in)

F

Dumping angle

45°

R

Maximum reach from swing center -with extended telescopic arm

6034 mm (19 ft 10 in) 7164 mm (23 ft 6 in)

G

Rollback angle

45°

S

Maximum digging depth -with extended telescopic arm

4725 mm (15 ft 6 in) 5970 mm (19 ft 7 in)

H

Digging depth

138 mm (5.4 in)

T

Digging reach

2320 mm (7 ft 7 in)

I

Bucket reach (transport)

2023 mm (6 ft 8 in)

U

Rear tread

1800 mm (5 ft 11 in)

J

Ground clearance

430 mm (1 ft 5 in)

V

Front tread

1874 mm (6 ft 2 in)

K

Wheel base

2175 mm (7 ft 2 in)

W

Overall width (with bucket)

2356 mm (7 ft 9 in)

L

Backhoe swing center distance

1175 mm (3 ft 10 in)

X

Backhoe transport height -with telescopic arm

3676 mm (12 ft 1 in) 3746 mm (12 ft 4 in)

WB156/156PS-5

4-3

SPECIFICATIONS

Standard Arm

Lift capacity figures (dN) comply with SAE J31.

Unit is equipped with standard equipment and 600 mm (24 inch) back hoe bucket.

4-4

WB156/156PS-5

SPECIFICATIONS

Retracted Telescopic Arm

Lift capacity figures (dN) comply with SAE J31.

Unit is equipped with standard equipment and 600 mm (24 inch) back hoe bucket.

WB156/156PS-5

4-5

SPECIFICATIONS

Extended Telescopic Arm

Lift capacity figures (dN) comply with SAE J31.

Unit is equipped with standard equipment and 600 mm (24 inch) back hoe bucket.

4-6

WB156/156PS-5

SPECIFICATIONS

MACHINE SYSTEMS SPECIFICATIONS Engine Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Komatsu S4D102LE-2 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water-cooled, in line 4-cycle Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharged Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 mm x 135 mm (4.49 in x 5.31 in) Piston displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 ltr (275 in3) Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18:1 • Horsepower rating @ 2200 rpm (WB156-5/WB156PS-5) Gross horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 kW (99 HP) Net horsepower @ 2200 rpm (SAE J 1349) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.8 kW (95 HP) Maximum torque @ 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 N·m (305 ft/lbs) Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double elements and dust evacuator, condition indicator • Lubrication system Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, force-lubrication Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow • Cooling system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator coolant cooled system • Starting system Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric motor with air pre-heating system for cold climate

Electrical System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ah (860 CCA) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 A Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 kw

Service Refill Capacities Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 l (2.4 gal) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 l (3.7 gal) Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 l (39.6 gal) Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 l (10.8 gal) Hydraulic system capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 l (25.6 gal) Front axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 l (2.0 gal) Rear axle oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 l (3.8 gal) Transmission oil, Power Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2 l (5.3 gal) Transmission oil, Power Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.0 l (7.4 gal)

Standard Tires Front tire, 14 x 17.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31±5 kg/cm2 (47.1±1 psi) Rear tire, 19.5L x 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.88±5 kg/cm2 (26.7±1 psi)

WB156/156PS-5

4-7

SPECIFICATIONS

Transmission •

WB156-5 Shifting between 2WD and 4WD is achieved through an electro-hydraulic system. The transmission is operated through a torque converter and a power shift reversing shuttle; the mechanical 4-speed gearbox is synchronized. ★ Calculated with 19.5Lx24 tires and engine at 2200 rpm.

FORWARD

REVERSE

Gears

1st

2nd

3rd

4th

1st

2nd

3rd

4th

km/h

6.3

11.4

21.3

37.8

6.3

11.4

21.3

37.8

mph

3.9

7.1

13.2

23.5

3.9

7.1

13.2

23.5

•

WB156PS-5 Electronically-controlled, 4-wheel drive, full powershift transmission. Twist Grip or EGMTM (Electronic Gear Management) gear controls for changing driving direction and gears at full power without disengaging the drive.

Twist Grip Controls in manual mode. ★ Calculated with 19.5Lx24 tires and engine at 2200 rpm.

FORWARD

REVERSE

Gears

1st

2nd

3rd

4th

1st

2nd

3rd

4th

km/h

6.5

12.0

23.0

40.0

6.35

12.0

23.0

-

mph

4.0

7.5

14.3

24.9

4.0

7.5

14.3

-

Total Mass Maximum total mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,298 kg (16,090 lb)

Standard Bucket Capacity Bucket breakout force (ISO 6015) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,126 kg (13,505 lb) Arm breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,915 kg (8,631 lb) Front bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(SAE) 1.03 m3 (1.35 yd3) Backhoe bucket capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SAE) 0.20 m3 (0.24 yd3)

Loader Standard bucket width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2356 mm (7 ft 9 in) Standard bucket capacity (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.95m3 (1.25 yd3) Standard bucket weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454 kg (1,000 lb) Lifting capacity at maximum height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3900 kg (8,598 lb) Lifting capacity at ground level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5000 kg (11,020 lb) Breakout force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 kg (13,224 lb)

4-8

WB156/156PS-5

5OPTIONS, ATTACHMENTS

WB156/156PS-5

5-1

OPTIONS, ATTACHMENTS

AUTHORIZED OPTIONAL EQUIPMENT

•

Komatsu machines can be provided with optional equipment in addition to the standard equipment. If optional equipment is installed and used, carefully read the relevant operation manual and respect the instructions given therein.

•

Use only optional or special equipment recommended and approved by Komatsu and in compliance with the requirements indicated in the table.

•

Komatsu cannot be held liable for any injury, accident or product failure resulting from the installation and use of unauthorized equipment.

Precautions Regarding Safety The installation of optional accessories and equipment, other than those authorized by Komatsu, shortens the life of the machine and may also cause safety problems.

It is advisable to contact a Komatsu distributor before installing any accessory that is not mentioned in this operation and maintenance manual.

In case of failure to comply with these instructions, Komatsu declines any responsibility for accidents or damage.

•

When removing or installing any equipment, take the following precautions and be careful to ensure that operations are carried out in total safety.

• • • • • • • •

Carry out installation and removal on a firm and flat surface.

When the operations are carried out by two or more operators, decide the communication signals in advance and obey them during work.

Use a crane to handle objects weighing more than 25 kg (55 lb).

Always support any heavy object before removing it. When lifting heavy parts, be mindful of the object’s center of gravity.

It is dangerous to carry out any operation with suspended loads. Always position the load on a suitable support and make sure that it is stable.

When installing or removing any equipment, make sure that it is stable and cannot fall down.

Never stand under loads being lifted by a crane.

Choose a safe position, where you do not run any risk in case the load should fall.

When using optional equipment, be sure all non-authorized personnel are at least 12 m (40 ft) away from your work location.

Remark Specialized personnel are required to operate cranes. Do not allow unskilled personnel to use cranes.

For further details regarding installation and removal operations, contact your Komatsu distributor.

5-2

WB156/156PS-5

OPTIONS, ATTACHMENTS

Precautions Regarding the Installation of Equipment

•

The installation of long work equipment reduces the stability of the machine.

If it is necessary to travel up or down a slope, proceed very carefully since the machine may lose its balance and overturn.

•

When work equipment with overall dimensions exceeding those of the standard equipment is installed, be particularly careful, since more space is necessary for the movements of the equipment and of the machine.

Optional Equipment Measurements ★ Specific weight of the material handling = 1.8 tons/cu.m

Front End Loader Max. Dimensions

Max. Weight kg (lb)

Width mm (inch)

Height mm (inch)

Max. SAE Capacity cu. m (cu. yd.)

Max. Operating Pressure bar. (psi)

Max. Flow Rate per Minute

Front bucket

450 (992)

2320 (91.4)

940 (37)

1.1 (1.44)

—

—

Multipurpose bucket

750 (1654)

2340 (92.1)

1015 (40)

1.00 (1.30)

200 (2844)

75 liters (19.8 gpm)

Lifting forks on bucket

190 (419)

● ●

● ●

❑ ❑

—

—

Pallet forks

320 (706)

1800 (70.8)

800 (31.5)

❑ ❑

—

—

Equipment

WB156/156PS-5

5-3

OPTIONS, ATTACHMENTS Backhoe Unit

Equipment

Max. Weight kg (lb)

Max. Dimensions

Max. SAE Capacity cu. m (cu. yd.)

Max. Operating Pressure bar. (psi)

Max. Flow Rate per Minute

Backhoe bucket

200 (441)

930 (36.6)

— —

0.305 (0.40)

— —

— —

Ditch-cleaning bucket

220 (485)

1600 (63)

— —

0.250 (0.33)

— —

— —

Trapezoidal bucket

190 (419)

2100 (82.6)

900 (35.4)

0.300 (0.40)

— —

— —

Hydraulic hammer

450 (992)

— —

— —

— —

160 (2320)

80 (21.2)

Drill

360 (794)

800❊ (31.5)❊

2000▲ (78.7)▲

— —

200 (2844)

120 (31.7)

Clamshell bucket

350 (772)

650 (25.6)

1800 (70.8)

0.200 (0.26)

200 (2844)

120 (31.7)

● - Fork length 1140 mm (44.9 in) ❑ - Maximum capacity 2000 kg (4409 lb) ❊ - Measurement referenced to the tool diameter ▲ - Measurement referenced to the tool length

5-4

WB156/156PS-5

OPTIONS, ATTACHMENTS

FRONT EQUIPMENT QUICK COUPLING DEVICES All coupling and uncoupling operations must be performed on a flat, firm surface. Before beginning work operations, be sure the equipment installed is in good working order and installed correctly.

Manual Control Quick Coupling 1.

Rotate the lock lever handle (1) to unlock the fulcrum pin.

2. Position the machine so the support cradle is perpendicular to the equipment being installed.

3.

Operate the bucket control lever so the fixed coupling pins (3) are positioned under the upper seating surface (4) on the bucket (5).

4.

Raise the arm (6) to engage the pins (3) in the upper seats (4) on the bucket (5). When in place, raise the bucket slightly.

5.

Rotate the lock lever handle (1) to lock the fulcrum pin and hook up the safety restraint (7).

6.

Lube all fittings after installation.

WB156/156PS-5

5-5

OPTIONS, ATTACHMENTS

MULTIPURPOSE BUCKET (4-IN-1) Attach the multipurpose bucket to the front end loader in the same manner as a general purpose bucket or coupler. With the bucket lowered to the ground, proceed in the following manner.

1.

Turn off the engine. Operate the controls to relieve pressure in the system.

2.

Connect couplings (8) and (9) to the auxiliary hydraulic lines on the loader arms.

Always wear a face shield and gloves to protect your face and hands from hydraulic oil or metal chips.

3.

Once the couplings are installed, start the engine and operate the control lever (7).

4.

Open and close buttons (6) and (5).

5.

Turn the engine off and check for any leaks.

★ See “OPERATING THE FRONT END LOADER AND BACKHOE” on page 2-45.

•

5-6

The bucket is opened and closed using two hydraulic cylinders (1).

WB156/156PS-5

OPTIONS, ATTACHMENTS

Bucket Operation The multipurpose bucket can be used for several applications. It eliminates the need for specific equipment. This bucket offers the option of a load-and-scoop bucket as well as a dozer blade for grading and trench filling purposes. A set of optional lifting forks can be installed for material handling purposes.

Description • • •

The bucket jaws (4) can be opened to unload materials or used as a dozer blade for filling trenches.

The multipurpose bucket is equipped with a tooth protection casing (3).

Use buttons (5) and (6) to control the bucket jaws.

Bucket Uses The multipurpose bucket can be used for the following applications: • Loading heaped material (see “Loading Heaped Material” on page 2-53) • Unloading on high surfaces by opening the bucket instead of rolling it forward • Grasping logs or objects • Filling trenches and grading

The bucket is also equipped with an indicator (10) to show the position of the upper part of the bucket.

WB156/156PS-5

5-7

OPTIONS, ATTACHMENTS

PALLET FORKS Remark For the characteristics, see table “Optional Equipment Measurements” on page 5-3.

•

Before lifting the load, make sure that the position of its center (G) complies with the distances indicated in the figure below. Furthermore, the load must always be centered with respect to the forks. Non-compliance with these rules may cause serious damage and even death.

•

Before handling any load, verify the capacity of the forks. The allowed load is generally stamped on the forks.

Description • •

5-8

The forks are usually applied to the 4-in-1 bucket. When they are not used, they must be overturned towards the back of the machine (in storage postion) and secured with the safety pins provided.

The pallet forks (1) make it possible to use the machine as a normal lift truck. The controls to lift and oscillate them are the same as used to control the standard bucket. The distance between the pallet forks can be varied to adapt them to the load to be handled; to do this, make them slide on the coupling bar (2).

WB156/156PS-5

OPTIONS, ATTACHMENTS

Safety Devices •

•

Two safety pins (3) are provided to keep the forks in the overturned position when the machine travels on roads and during work.

Slide the forks towards the outside of the bucket, turn them over and insert them in the supports (5) as shown in Figure B.

Using the Forks

•

Before working with the forks, the operator must evaluate the increased dimensions of the machine and learn how to use the fork controls.

•

The forks protrude beyond the bucket outline and therefore it is necessary to be very careful when maneuvering the machine, especially in reduced spaces.

•

After inserting the forks in the skid or material, but before lifting the load, move the forks in such a way as to lift their prongs and therefore prevent the load from slipping.

•

Be careful of the grasping points when overturning the forks for use or storage. Improper handling may injure or sever your hands or feet.

•

If possible, this operation should be carried out by two people.

•

Use the lifting, oscillation and shifting controls slowly and smoothly, in order to avoid vibrations that may cause the load to move.

•

Maintain the greatest possible distance between the prongs.

•

The forks must always rest on the blade and be positioned between two teeth, in order to prevent them from slipping laterally.

WB156/156PS-5

5-9

OPTIONS, ATTACHMENTS Preparing the Pallet Forks for Use 1.

Overturn the forks toward the front part of the machine.

2.

Lift the bucket and operate the control lever in such a way as to swing it forward until releasing the forks.

3.

Move the forks (1) sidewards to widen or narrow the distance between them according to the width of the load to be handled.

4.

Fold the bucket and maneuver the lifting arm until the forks are in the horizontal position.

5.

Lubricate the fork rotation pins (4-in-1 bucket and pallet forks).

Overturning the Forks 1.

Remove the safety pins (4) and the pins (3).

2.

When not needed, the forks may be arranged in stow position.

Slide the forks toward the outside of the bucket, overturn them and insert them in the supports (5) as shown in Figure B.

3.

Replace the pins (3) and the safety pins (4).

4.

Make sure that when they are overturned in stow position, the forks are firmly secured inside their respective supports (5). If any slack should be observed between the forks and the safety pin (3), immediately carry out the necessary adjustment in the following manner.

•

•

Release the stop nut (10) and loosen the adjusting screw (11) while taking up the slack between the fork and the safety pin (3). Use a 22 mm hex wrench.

After the adjustment, tighten the stop nut (10) thoroughly. If the adjusting screw (11) is excessively worn, replace it at once.

.

•

The check and adjustment of the forks must be carried out on both sides, with the forks at rest. Do not hesitate to adjust the forks as soon as the presence of a slack is noticed.

Non-compliance with these instructions may lead to dangerous situations for the operator and cause serious damage to the machine.

•

Before carrying out any movement with the machine, make sure that the safety pins (4) are correctly inserted.

5-10

WB156/156PS-5

OPTIONS, ATTACHMENTS Removing the Forks

Pay the utmost attention when removing the forks, the supports and the bar, in order not to crush or possibly sever your hands or feet.

1.

Maneuver the lifting arm and swing the bucket until the forks (1) rest on the ground in horizontal position.

2.

Remove the safety pins (6) and the pins (7).

3.

If the supports (8) must be removed: • •

Loosen and remove the screws (9) that fasten the slide bar (2).

Hold one of the supports (8) and withdraw the slide bar (2); repeat the same operation for the other support.

Installing the Forks To install the pallet forks, repeat the procedure described for the removal in the reverse order, taking the same precautions.

Maintenance No specific maintenance operation is required for this device, except for the occasional greasing of the slide bar and of the fork fulcrum pin. ★ See “Multipurpose Bucket and Pallet Forks” on page 3-12.

WB156/156PS-5

5-11

OPTIONS, ATTACHMENTS

BACKHOE TELESCOPIC ARM The optional telescopic arm makes it possible to perform operations outside the normal backhoe radius, such as grading, ditch cleaning and using optional attachments.

Description This structure is designed with an external hollow arm (1) and an inner arm (2) that slides on V-shaped guides. This arm is extended or retracted hydraulically.

Control •

Use buttons (4) and (5), located on the right joystick lever, to move the telescopic arm.

• The movements of the main equipment remain unchanged. ★ See “Control Lever Positions” on page 2-52.

Movements of the telescopic arm are as follows: • Retract the arm by pressing push button (4); the arm stops when the button is released.

• Extend the arm by pressing push button (5); the arm stops when the button is released.

Remark The telescopic arm controls are locked when the joystick lock switch (11) is in Lock (illuminated) position.

5-12

WB156/156PS-5

OPTIONS, ATTACHMENTS

Safety Devices •

•

•

The telescopic arm is equipped with a safety element (6) that locks the sliding arm (2) when it is completely retracted and prevents any accidental extension of the same.

The safety element (6), held in its seat by the retainer (7), must be inserted to prevent the extension of the arm as shown in Figure A in the following situations: • When it is necessary to travel on roads or cover considerable distances • When the backhoe is not used In operating conditions, the safety element (6) must be positioned as shown in Figure B.

Using the Telescopic Arm

•

Before releasing and extending the arm, make sure that the stabilizers rest on firm ground.

•

If possible, work with the backhoe centered on the guides and unload the material as near the machine as possible.

•

If it is necessary to work with a misaligned backhoe or with the backhoe completely shifted on the guides, operate slowly when swinging the arm to unload the material on the misaligned side, since in these conditions the machine may lose stability.

•

Do not use the arm retracting cylinder to increase the bucket tearing force when digging.

WB156/156PS-5

5-13

OPTIONS, ATTACHMENTS

Maintenance The telescopic arm requires two maintenance operations: • Lubrication of the joints; see “LUBRICATION DIAGRAMS” on page 3-11 • Adjustment of the slide guide (8) slack, which must be carried out occasionally, when impacts or vibrations are noticed during work

Adjusting the Guide Slack

•

When leaving the operator’s seat during the adjustment of the guides, remove the ignition key.

•

Adjust the screws and guides one by one.

•

Do not place tools in the space between the safety locks and the arm.

1.

Position the machine on flat ground and lower the stabilizers.

2.

Lift the boom, fold the bucket completely and extend the telescopic part (7) completely.

3.

Fold the arm until the slide guides (8) are perpendicular to the ground, and in any case, positioned so that the extending part is completely free and does not overload the guides.

4.

Stop the engine.

5.

Check the side on which the adjusting screws (9) of the guides protrude more. Adjust by working on this side only.

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OPTIONS, ATTACHMENTS

If the adjusting screws (9) protrude to the same extent on the two sides, the operation described at step 6 can be carried out either on the right or on the left side.

6.

Loosen the four lock nuts (10) and tighten the adjusting screws (9) thoroughly, taking up the slack completely. Use a 27 mm and an 8 mm hex wrench.

7.

Starting from the central positions, loosen the adjusting screws (9) by 270° (3/4 turn) and lock them with the lock nuts (10).

8. Start the machine; extend and retract the telescopic arm more than once to make sure that it slides correctly.

•

The wear limit allowed for the rubber blocks is represented by the minimum engagement of the adjusting screws (9) in the lock nuts; the rubber blocks must be replaced when the heads of the screws (9) are 5 mm back with respect to the lock nuts (10).

•

When taking up the slack, avoid excessive pressures in order to prevent the guides from seizing.

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OPTIONS, ATTACHMENTS

DEMOLITION HAMMER PIPING The machine can be fitted for the application of a Komatsu-compatible demolition hammer on the backhoe unit. This hammer is used for breaking up concrete, asphalt or rocks. The geometry of the tool must be defined according to the nature of the materials to be broken and the type of work to be carried out.

Description •

The arrangement includes the fixed connection of the hydraulic delivery line (2) and return line (3) with the hammer (4).

Control • •

•

In the version with servo controls, the hammer is operated by the small pedal (5) positioned on the cab floor.

The movements of the levers described in “Operating the Backhoe” on page 2-57 (version with servo controls) remain unchanged.

The hammer is operated by pressing the foot-operated button (5), since in this way pressurized oil is conveyed into the circuit; when the foot-operated button (5) is released, the oil flow is interrupted and the hammer stops.

Remark The demolition arm control is inhibited when the safety button is in locking position.

See “Side Instrument and Controls” on page 2-10.

This configuration includes also the fixed installation of rigid or flexible pipes, more precisely a delivery (2) and a drain (3) pipe that convey/discharge the oil necessary for the operation of the hammer and reach the proximity of the hammer connection (4).

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OPTIONS, ATTACHMENTS

Rules for Hammer Usage

When using the hammer attachment, always wear eye and hearing protection.

Never allow anyone to stand near you while using the hammer.

•

Make sure that the position of the hammer is correct with respect to the material to be broken. Be sure it is as perpendicular as possible and the arm thrust is sufficient, so that the full power of the hammer can be achieved.

•

Keep constant downward pressure on the hammer tool as it penetrates the material to be broken. This means raising the wheels approximately 5 cm (2 in) off the ground. Be careful not to swing or move the machine when performing this operation.

•

When working on very hard materials, it is important not to keep hitting the same point for more than 30 seconds. Hit the same point for a few seconds and then change position frequently, in order to facilitate the breaking process.

Remark Remember the power in the backhoe unit is the breakout feature when using this tool. Do not use the backhoe unit to reposition or swing the machine to the left or right. Doing so will damage the swing cylinders or possibly tip the machine over.

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OPTIONS, ATTACHMENTS •

To facilitate the sliding of the tool on its seat, check the thrust direction and always correct the hitting position of the hammer by using the bucket and arm control.

Remark Do not use the demolition hammer with the bucket cylinder at the end of its stroke; always leave a minimum space of 5 cm (2 in).

•

Always be sure that the arm at its optimal position to avoid harmful or useless strokes.

Avoid the Following Uses •

Gathering or moving materials with the demolition hammer

•

Rotating the boom while using the hammer

Remark Remember the power in the backhoe unit is the breakout feature when using this tool. Do not use the backhoe unit to reposition or swing the machine to the left or right. Doing so will damage the swing cylinders or possibly tip the machine over.

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OPTIONS, ATTACHMENTS •

Moving the tool back and forth while breaking the material or using the tool as a pry bar between the broken material

•

Working with the hammer in a horizontal position or even with the greater inclination of the machine

•

Striking the ground with the hammer bit

•

Lifting the machine with the demolition hammer

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OPTIONS, ATTACHMENTS

Installing the Hammer

•

The machine must be parked on a level surface, with the front equipment resting on the ground.

•

For the installation, the hammer must be positioned horizontally, with the bit directed towards the machine.

•

When the coupling pins are removed or installed, chips may come off; always use gloves, goggles and helmet.

•

The change of the equipment must be carried out by two operators, who must decide together the words and signals to be used during work.

•

Avoid using your fingers to align the holes; they may be injured or severed.

•

Before carrying out any operation on the hydraulic circuit, eliminate the residual pressure from the equipment circuits by moving the controls more than once and the pressure from the tank by slowly loosening the filler cap.

•

If any oil has spilled, wipe it up immediately to prevent a slippery surface.

For the installation of the demolition hammer, it is necessary to connect the mechanical constraints of the backhoe bucket as described in “Changing The Backhoe Bucket” on page 2-66 and to carry out the hydraulic connections using the pipes provided.

After connecting the mechanical constraints, do the hydraulic connections.

1. Stop the engine and move the hydraulic controls in all directions, in order to completely release the residual pressure present in the circuits of the machine.

2.

Press the hammer control pedal to release the pressure present in the hammer delivery pipe.

3.

Eliminate the residual pressure in this manner.

A. With the engine at rest, turn the ignition key to position “I.” B. Press the PPC locking button and make sure that the LED is off (release position). ★

See “Side Instrument and Controls” on page 2-10.

C. Shift the backhoe control levers a few times and press the hammer control pedal.

D. Turn the ignition key to position “O.”

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OPTIONS, ATTACHMENTS 4.

Remove the plugs of the machine pipes and of the hammer flexible pipes. Use 32, 36, 38 and 41 mm hex wrenches.

5.

Connect the right pipe to the coupling (1) and the left pipe to the coupling (2), making sure that the sizes of the pipe fittings are as required.

When connecting the pipes, be careful to prevent any impurities from getting into them.

6.

Start the machine and raise the demolition hammer, positioning it vertically.

7.

Stop the machine again and lubricate the joints. See “LUBRICATION DIAGRAMS” on page 3-11. Lubricate the hammer according to the specific operation and maintenance manual.

8.

Before starting work, check the tightness of the circuit.

•

Wear thick gloves and safety goggles during this check.

•

To check the system for leaks, use a piece of cardboard or a wooden board.

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OPTIONS, ATTACHMENTS

Removing the Hammer 1.

Stop the engine and move the hydraulic controls in all directions in order to completely release the residual pressure present in the circuits of the machine.

2.

Press the hammer control pedal to release the pressure present in the hammer delivery pipe.

3.

Disconnect the hammer delivery and return pipes. Use 32, 36, 38 and 41 mm hex wrenches.

4.

Fit the pipe sealing plugs, complete with the relevant gaskets.

•

Make sure that the plugs are properly tightened and that there are no leakages; if the circuit is inadvertently pressurized, small leakages can be turned into thin jets that may perforate the skin or injure the eyes.

•

Always wear thick gloves and safety goggles to carry out this check.

•

To check the system for leaks, use a piece of cardboard or a wooden board.

5. Disconnect the hammer from the mechanical constraints, as described in “Changing the Backhoe Bucket” on page 2-66.

Using the Hammer See the manufacturer’s manual.

If the machine is provided with a telescopic arm, do not extend the arm when a hammer is installed.

Maintenance The hydraulic system does not require any maintenance operation and inspection other than those prescribed for the machine in “MAINTENANCE WHEN USING DEMOLITION HAMMER” on page 3-67.

Regarding the maintenance operations required for the hammer, see the specific operation manual.

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OPTIONS, ATTACHMENTS

HYDRAULIC JACK HAMMER PIPING Due to the fact that the machine may be equipped with off-tractor hydraulics, a jack hammer or similar approved tool may be used. This option eliminates the need for an independent power source when using some power tools.

Description • • •

The machine can be provided with the delivery (1) and return (2) couplings for the use of a manual hydraulic jack hammer.

The connection to the machine is made up of two flexible lines (3).

The circuit is separated from the normal circuits by a solenoid valve and activated by a switch positioned on the dash board.

Control • • •

Pressing the switch once energizes the solenoid and allows the system to operate. If the switch is pressed a second time, the system is disengaged.

When the system is in operation, the switch is illuminated.

For operation of the jack hammer, see the manual provided with the tool.

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OPTIONS, ATTACHMENTS

Connecting and Removing the Jack Hammer

Connection and removal of the hammer must be carried out with the machine in the parked position, parking brake set, and all safety locks engaged.

Connecting the Jack Hammer 1.

Stop the engine and neutralize all hydraulic controls to relieve any pressure on the system.

2.

Turn the ignition switch to the “I” position and press the switch to release any residual pressure from the hammer.

3.

Make sure that the couplings are clean and free from dirt or debris. Carefully install the couplings.

4.

Turn the switch off and start the engine.

5.

Engage the switch and increase engine rpm to the required setting in the tool operation manual.

Disconnecting the Jack Hammer 1.

Press the button to disengage the solenoid and shut the hydraulics down.

2.

Stop the engine and neutralize all hydraulic controls to relieve any pressure on the system.

3.

Turn the ignition switch to the “I” position and press the switch to release any residual pressure from the hammer.

4.

Turn the switch off.

5.

Disconnect the tool and cap all connection openings

Using the Jack Hammer For operation of the jack hammer, see the manufacturer’s manual provided with the tool.

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OPTIONS, ATTACHMENTS

LOAD STABILIZER SYSTEM (LSS) (RIDE CONTROL OPTIONAL)

Never operate the load stabilizer system while using the backhoe.

The load stabilizer system (LSS) improves the performance of the machine during travel, regardless of the type of terrain and of the bucket load. It reduces the oscillations while traveling and while carrying loads, at the same time increasing productivity and the operator’s comfort. It also reduces to a minimum the impact forces to which the machine may be subjected. When the load stabilizer system is in operation, the loader pressure in low position is limited to that supplied by the weight of the arm and the bucket. The bucket weight is hydraulically cushioned when the machine is moving. To activate the load stabilizer system (LSS), press the switch positioned on the side instrument panel.

Remark If the machine is equipped with safety valves on the front loader, make sure that they are disconnected.

When the operation of the system is not required any longer, move the switch back to the neutral position (LED off).

Load Stabilizer System (LSS) Accumulator

•

Contact your Komatsu distributor if it is necessary to repair or change the accumulator for the load stabilizer system.

•

Failure to comply with this instruction may cause serious injury and even death.

Pressurizing the Load Stabilizer System (LSS) 1.

Every time you start the machine or after pauses lasting more than 30 minutes, press the upper part of the switch (16), and at the same time, lift the loader to the end of stroke, thus reaching the maximum pressure in the system; in this condition, release the switch (16).

Remark • This operation pressurizes the LSS system and ensures optimal performance.

• The release of the switch (16) and its automatic return to the neutral position interrupt the pressurization of the system, but don't connect the system.

2.

To connect the system, lower the loader and press the lower part of the switch (16), which remains in this position and comes on to confirm that the system is activated.

3.

The system can be disconnected by moving the switch (16) to the neutral position (warning light off).

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OPTIONS, ATTACHMENTS

MEMORANDUM

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