Komatsu PC158US-2 Hydraulic Excavator Shop Manual SEBM026504 PDF

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Komatsu PC158US-2 Hydraulic Excavator Shop Manual SEBM026504 – PDF DOWNLOAD

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Komatsu PC158US-2 Hydraulic Excavator Shop Manual SEBM026504 – PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC158US-2 Hydraulic Excavator Shop Manual SEBM026504 – PDF DOWNLOAD

• MACHINE MODEL           SERIAL NUMBER
  PC158US-2                         10001 and up

COVER . 1
CONTENTS 2
01 GENERAL 26
SPECIFICATION DIMENSION DRAWINGS 27
SPECIFICATIONS 29
WEIGHT TABLE 32
LIST OF LUBRICANTS AND WATER 34
10 STRUCTURE AND FUNCTION . 36
PTO . 37
RADIATOR AND OIL COOLER . 38
POWER TRAIN . 40
SWING CIRCLE 41
SWING MACHINERY . 42
FINAL DRIVE . 43
TRACK FRAME・RECOIL SPRING . 44
HYDRAULIC COMPONENT LAYOUT 45
VALVE CONTROL . 47
HYDRAULIC TANK AND FILTER . 49
HYDRAULIC PUMP (PISTON PUMP) 50
PC-EPC VALVE 71
CONTROL VALVE . 74
CLSS 84
SELF PRESSURE REDUCING VALVE 121
CENTER SWIVEL JOINT .128
TRAVEL MOTOR 129
SWING MOTOR .137
SOLENOIL VALVE 144
PPC ACCUMULATOR .146
ACCUMULATOR FOR BREAKER .147
PPC VALVE .148
WORK EQUIPMENT 159
AIR CONDITIONER PIPING 160
ELECTRIC COMPONENT LAYOUT .161
ENEGINE CONTROL .165
ELECTRIC CONTROL SYSTEM .173
MONITOR SYSTEM 189
20 TESTING ANS ADJUSTING 194
STANDARD VALUE TABLE 195
STANDARD VALUE TABLE FOR ENGINE .195
STANDARD VALUE TABLE FOR CHASSIS 196
STANDARD VALUE TABLE FOR ELECTRICAL PARTS .204
TESTING AND ADJUSTING .208
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 209
MEASURING ENGINE SPEED 210
MEASURING EXHAUST COLOR .211
ADJUSTING VALVE CLEARANCE .212
MEASURING BLOW-BY PRESSURE 213
MEASURING ENGINE OIL PRESSURE .214
TESTING AND ADJUSTING FUEL INJECTION TIMEING 214
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR .215
ADJUSTING ENGINE SPEED SENSOR .215
ADJUSTING FUEL CONTROL CABLE 216
ADJUSTING ENGINE STOP SOLENOLD LINKAGE INSPECTION .217
TESTING CLEARANCE OF SWING CIRCLE BEARING .218
CHECKING WEAR OF SPROCKET .219
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION .220
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING,TRAVEL CIRCUIT 221
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE) .224
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE .226
TESTING AND ADJUSTING CONTROL CICUIT OIL PRESSURE .229
TESTING SOLENIOD VALVE OUTPOUT PRESSURE .230
MEASURING PPC VALVE OUTPUT PRESSURE .231
ADJUSTING PPC VALVE .232
TESTING AND ADJUSTING TRAVEL DEVIATION 233
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT .234
MEASURING OIL LEAKAGE OF SWING MOTOR 235
MEASURING OIL LEAKAGE OF TRAVEL MOTOR .235
BLEEDING AIR 236
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT .238
RELEASING REMAINING PRESSURE IN HYDRAULIC TANK 238
PROCEDURE FOR CHECKIG DIODE .239
PM CLINIC INSPECTION TABLE 240
TROUBLESHOOTING .242
POINTS TO REMEMBER WHEN TROUBLESHOOTING .243
SEQUENCE OF EVENTS IN TROUBLESHOOING 244
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 245
CHECEKS BEFORE TROUBLESHOOTING 253
CONNECTOR TYPES AND MOUNTING LOCATIONS 254
CONNECTOR ARRANGEMENT DIAGRAM .256
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 259
T-BRANCH BOX AND T-BRANCH TABLE .281
METHOD OF USING TROUBLESHOOTING CHARTS 283
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM 285
TROUBLESHOTING OF CONTROLLER, ELECTRICAL SYSTEM .288
RELATED ELECTRICAL CIRCUIT DIAGRMS FOR ELECTRICAL SYSTEM 289
E-1 ABNORMALITY IN PC-EPC SYSTEM 292
a) SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER .293
b) TEERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 294
E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM .296
a) EVEN WHEN SAFETY LOCK LEVER IS SET TO FREE, NO WORK EQUIPMENT, TRAVEL, SWING MOVE 296
b) EVEN WHEN SAFETY LOCK LEVER IS SET TO LOCK, WORK EQUIPMENT, TRAVEL, SWING MOVE .296
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM .298
a) EVEN WHEN SWING LOCK SWITCH IS TURNED OFF, UPPWE STRUCTURE DOSE NOT SWING 298
b) EVEN WHEN SWING LOCK SWITCH IS TURNED TO LOCK, UPPER STRUCTURE SWINGS 299
E-4 ABNORMALTY TRAVEL SPEED SOLENOID SYSTEM .300
a) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO HI, TRAVEL SPEED DOES NOT CHANGE TO HIGH SPEED .300
b) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO LO, TRACEL SPEED DOES NOT CHANGE TO LOW SPEED 301
E-5 DEFECTIVE RUNNING SPEED AUTO SPEED CHANGE SYSTEM 302
a) MAIN PUMP PRESSURE SENSOR SYSTEM .302
b) ENGINE ROTATION SENSOR SYSTEM 302
E-6 DEFECTIVE ENGINE STARTING SYSTEM TROUBLESHOOTING MODE .304
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM .308
TABLE OF FAILURE MODES AND CAUSES .309
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER 311
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS .312
H-3 NO WORK EQUIPMENT, TRAVEK, SWING MIVE .313
H-4 ABNORMAIL NOISE GENERATED (AROND PUMP) 314
H-5 FAIN CONTROL ABILITY IS POOR OR RESPONSE IS POOR 314
H-6 BOOM IS SLOW OR LACKS POWER .315
H-7 ARM IS SLOW OR LACKS POWER .316
H-8 BUCKET IS SLOW OR LACKS POWER .316
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE 317
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM,ARM, OR BUCKET) 317
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING) 317
H-12 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDENTLY, OTHER WORK EQUIPMENT MOVES 318
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITN LARGER LOAD IS SLOW 318
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 319
H-15 IN SWING OR WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 319
H-16 TRAVEL DEVIATION .320
a) DEVIATION IS EXCESSIVE DURING NORMAL TRAVEL 320
b) DEVIATION IS EXCESSIVE WHEN STARTING .320
H-17 TRAVEL SPEED IS SLOW .321
H-18 STEERING IS DIFFICULT TO TUEN OR LACKS POWER .322
H-19 TRAVEL SPEED DOES NOT SWITCH .324
H-20 TRAVEL DOES DOES NOT MOVE (ONE SIDE ONLY) 324
H-21 UPPER STRUVTURE DOES NOT SWING .325
a) DOES NOT SWING IN EITHER DIRECTION (LIFT AND RIGHT) 325
b) DOES NOT SEING IN ONE DIRECTION ONLY (LEFT AND RIGHT) 325
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW 326
a) ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT) 326
b) ACCELERATION IS POOR OR SWING SPEED IS SLOW (ONE DIRECTION ONLY) .326
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING 327
a) EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT) (WHEN OPERATION OF CONTROL VALVE SPOOL, PPC CIRCUIT THROTTLE IS NORMAL) 327
b) EXCESSIVE OVERRUN WHEN STOPPING SWING (ONE DIRECTION ONLY) .327
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) .328
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 328
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING .329
a) WHEN SWING HOLDING BRAKE IS ACTUATED .329
b) WHEN SWING HOLDING BRAKE IS RELEASED .329
TROUBLESHOOTING OF MACHINE MONOTOR SYSTEM .330
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM .331
M-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON 332
M-2 DISPLAY DOES NOT GO OUT AFTER COMPLETION OF SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON .333
M-3 SOME ITEMS DO NOT LIGHT UP DURING DELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON .333
a) NO GAUGES (FUEL LEVEL, ENGINE WATER TEMPERATURE) LIGTH UP PREHEATING PILOT LAMP DOES NOT LIGHT UP 333
b) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERLY CHARGE) DO NOT LIGTH UP .333
M-4 CHARGE CAUTION LAMP DOES NOT LIGHT UP WHENSTARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE) .334
M-5 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE) .335
M-6 PRSHEATING PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT HEAT .336
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN WNGINE IS RUNNING .337
M-8 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 338
M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE .339
a) AFTER ENGINE IS STARTED, TEMPERATURE REMAINS AT BLTTOM LEVEL AND DOES NOT MOVE .339
b) AFTER ENGINE IS STARTED, TEMPERATURE IMMEDIATELY GOES UP (THERE IS NO OVERHEATING BUT GAUGE ENTERS RED RANGE) 339
M-10 ABNORMALITY IN FUEL GAUGE 340
a) NO SEGMENTS ON FUEL GAUGE LIGHT UP .340
b) FUEL LEVEL HAS GONE BUT FUEL GAUGE REMAINS AT FULL TANK DISPLAY 340
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT GIVE FULL TANK DISPLAY .341
M-11 DEFECTIVE OPERATION OF ALARM BUZZER 342
a) BUZZER DOES NOT SOUND 342
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 342
M-12 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING 343
a) WHEN BATTERY CHARGE CAUTION LAMP DOES LIGHT UP .343
b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP .343
M-13 NIGHT LIGHTING DOES NOT LIGHT UP .344
a) GAUGE LIGHTING DOES NOT LIGHT UP .344
b) SERVICE METER LIGHTING DOES NOT LIGHT UP .344
M-14 HEATER DOES NOT WORK .345
a) NEITHER HI NOR LO WORK .345
b) ONLY LO DOES NOT WORK 345
c) ONLY HI DOES NOT WORK 345
TROUBLESHOOTING OF ENGINE (S MODE) 347
MERHOD OF USING TROUBLESHOOTING CHARTS 348
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) .352
S-2 ENGINE DOES NOT START .354
(1) ENGINE DOES NOT TURN 354
(2) ENGINE TURN BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) .355
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 356
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 357
S-4 ENGINE STOPS DURING OPERATIONS 358
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) .359
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) .360
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 361
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) .362
S-9 OIL BECOMES CONTAMINATED QUICKLY 363
S-10 FUEL CONSUMPTION IS EXCESSIVE 364
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 365
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) .366
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) .367
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) .368
S-15 ABNORMAL NOISE IS MADE .369
S-16 VIBRATION IS EXCESSIVE .370
30 DISASSEMBLY AND ASSEMBLY .371
METHOD OF USING MANUAL 373
PRECAUTIONS WHEN CARRYING OUT OPERATION .374
SPECIAL TOOL LIST .376
SKETCHES OF SPECIAL TOOL 379
ENGINE, MAIN PUMP .380
REMOVAL .380
INSTALLATION 381
REDIATOR, HYDRAULIC OIL COOLER 382
REMOVAL .382
INSTALLATION 383
FUEL TANK .384
REMOVAL AND INSTALLATION 384
CENTER SWIVEL JOINT .385
REMOVAL AND INSTALLATION 385
DISASSEMBLY AND ASSEMBLY 386
FINAL DRIVE, TRAVEL MOTOR .387
REMOVAL AND INSTALLATION 387
FINAL DRIVE .388
DISASSEMBLY .388
ASSEMBLY 391
SWING MOTOR, SWING MACHINERY 397
REMOVAL AND INSTALLATION 397
SWING MACHINERY .398
DISASSEMBLY .398
ASSEMBLY 401
REVOLVIND FRAME .405
REMVOAL .405
INSTALLATION 406
SWING CIRCLE 407
REMOVAL AND INSTALATION .407
RECOIL SPRING .408
DISASSEMBLY .408
ASSEMBLY 409
IDLER .410
ASSEMBLY 410
TRACK ROLLER 412
ASSEMBLY 412
TRACK SHOE 414
REMOVAL AND INSTALLATION 414
HYDRAULIC TANK 415
REMOVAL .415
INSTALLATION 416
MAIN PUMP .417
REMOVAL .417
INSTALLATION 418
CONTROL VALVE .419
REMOVAL .419
INSTALLATION 420
DISASSEMBLY .421
ASSEMBLY 426
LS SELECTION VALVE 431
DISASSEMBLY AND ASSEMBLY 431
PRESSURE COMPENSATION VALVE .432
DISASSEMBLY .432
ASSEMBLY 434
MIAN RELIEF VALVE .436
DISASSEMBLY .436
ASSEMBLY 437
WORK EQUIPMENT PPC VALVE (FOE BOOM, BUCKET, ARM, SWING CONTROL) .438
DISADDEMBLY .438
ASSEMBLY 439
TRAVEL PPC VALVE 440
DISASSEMBLY .440
ASSEMBLY 441
HYDRAULIC CYLINDER 442
DISASSEMBLY .442
ASSEMBLY 445
WORK EQUIPMENT 449
REMOVAL .449
INSTALLATION 450
OPERATOR CAB 451
REMOVAL .451
INSTALLATION 452
OPERATOR’S CAB GLASS (STUCK GLASS) 453
REMOVAL .454
INSTALLATION 455
FRONT WINDOW 465
REMVOAL AND INSTALLATION 465
FLOOR FRAME .466
REMOVAL .466
INSTALLATION 467
AIRCONDITIONER COMPRESSOR .468
REMOVAL AND INSTALLATION 468
AIRCONDITIONER CONDENSER 469
REMOVAL AND INSTALLATION 469
AIRCONDITIONER UNIT .470
REMOVAL .470
INSTALLATION 471
COUNTERWEIGHT .472
REMOVAL AND INSTALLATION 472
40 MAINTENANCE STANDARD .473
SWING MACHINERY .474
FINAL DRIVE .476
SWING CIRCLE 478
TRACK FRAME, RECOIL SPRING 479
IDLER .480
CARRIER ROLLER .482
TRACK ROLLER 484
SPRICKET 486
TRACK SHOE 487
HYDRAULIC PUMP 491
PC-EPC VALVE 492
CONTROL VALVE .493
SELF PRESSURE REDUCTUIN VALVE .502
TRAVEL MOTOR 503
SWING MOTOR .504
SOLENOID VALVE 505
CENTER SWIVEL JOINT .506
PPC VALVE .507
HYDRAULIC CYLINDER 510
WORK EQUIPMENT 512
DIMENSION OF WORK EQUIPMENT .514
90 OTHERS .518
HYDRAULIC CIRCUIT DIAGRAM .519
ELECTRIC CIRCUIT DIAGRAM (1/2) 520
ELECTRIC CIRCUIT DIAGRAM (2/2) 521

DESCRIPTION:

Komatsu PC158US-2 Hydraulic Excavator Shop Manual SEBM026504 – PDF DOWNLOAD

• MACHINE MODEL           SERIAL NUMBER
  PC158US-2                         10001 and up

G.B 26/12/24