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KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) – PDF DOWNLOAD
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- KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:10001 & UP
- PUBLICATION NUMBER: SEAM045102T
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KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP)
KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP)
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
- Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance. Operators and maintenance personnel must always do as follows before beginning operation or maintenance.Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
- Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor.
TABLE OF CONTENTS:
KOMATSU PC158US-2 PC158USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:10001 & UP)
COVER................................................................................................................................ 1 FOREWORD............................................................................................................................. 2 FOREWORD......................................................................................................................... 3 SAFETY INFORMATION............................................................................................................... 6 INTRODUCTION..................................................................................................................... 8 DIRECTIONS OF MACHINE........................................................................................................ 8 PRODUCT INFORMATION.............................................................................................................. 9 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION................................................................................. 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................................................. 9 EMISSION CONTROL INFORMATION LABEL........................................................................................... 10 SERVICE METER LOCATION....................................................................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.................................................................................. 10 CONTENTS............................................................................................................................. 11 SAFETY............................................................................................................................... 15 SAFETY INFORMATION............................................................................................................... 16 POSITION FOR ATTACHING SAFETY LABELS............................................................................................. 18 POSITION FOR ATTACHING SAFETY LABELS......................................................................................... 19 SAFETY LABELS................................................................................................................ 20 SAFETY INFORMATION............................................................................................................... 24 SAFETY RULES................................................................................................................. 24 IF ABNORMALITIES ARE FOUND................................................................................................... 24 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT.......................................................................................... 24 SAFETY EQUIPMENT............................................................................................................. 25 KEEP MACHINE CLEAN........................................................................................................... 25 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................ 25 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................ 25 HANDRAILS AND STEPS.......................................................................................................... 26 CRUSHING OR CUTTING PREVENTION............................................................................................... 27 MOUNTING AND DISMOUNTING..................................................................................................... 27 NO PERSONS ON ATTACHMENTS.................................................................................................... 27 BURN PREVENTION.............................................................................................................. 27 FIRE PREVENTION AND EXPLOSION PREVENTION..................................................................................... 28 ACTION IF FIRE OCCURS........................................................................................................ 29 WINDSHIELD WASHER FLUID...................................................................................................... 29 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............................................................. 29 ATTACHMENT INSTALLATION...................................................................................................... 29 ATTACHMENT COMBINATIONS...................................................................................................... 30 CAB WINDOW GLASSES........................................................................................................... 30 UNAUTHORIZED MODIFICATIONS................................................................................................... 30 SAFETY AT JOBSITE............................................................................................................ 30 WORKING ON LOOSE GROUND...................................................................................................... 30 DISTANCE TO HIGH VOLTAGE CABLES.............................................................................................. 31 ENSURE GOOD VISIBILITY....................................................................................................... 31 VENTILATION FOR ENCLOSED AREA................................................................................................ 32 SIGNALMAN'S SIGNAL AND SIGNS................................................................................................. 32 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................................... 32 ASBESTOS DUST HAZARD PREVENTION.............................................................................................. 32 SAFETY MACHINE OPERATION......................................................................................................... 33 STARTING ENGINE.............................................................................................................. 33 CHECKS BEFORE STARTING ENGINE............................................................................................ 33 SAFETY RULES FOR STARTING ENGINE......................................................................................... 34 STARTING ENGINE IN COLD WEATHER.......................................................................................... 34 OPERATION.................................................................................................................... 35 CHECKS AFTER STARTING ENGINE............................................................................................. 35 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS............................................................................. 35 SAFETY RULES FOR TRAVELING............................................................................................... 36 TRAVELING ON SLOPES...................................................................................................... 37 OPERATIONS ON SLOPES..................................................................................................... 38 PROHIBITED OPERATIONS.................................................................................................... 38 OPERATIONS ON SNOW....................................................................................................... 40 PARKING MACHINE.......................................................................................................... 40 TRANSPORTATION............................................................................................................... 41 LOADING AND UNLOADING.................................................................................................... 41 SHIPPING THE MACHINE..................................................................................................... 42 BATTERY...................................................................................................................... 43 BATTERY HAZARD PREVENTION................................................................................................ 43 STARTING ENGINE WITH BOOSTER CABLES...................................................................................... 44 TOWING....................................................................................................................... 45 SAFETY RULES FOR TOWING.................................................................................................. 45 LIFTING OBJECTS WITH BUCKET.................................................................................................. 46 SAFETY RULES FOR LIFTING OBJECTS......................................................................................... 46 SAFETY MAINTENANCE INFORMATION................................................................................................... 47 WARNING TAG.................................................................................................................. 47 KEEP WORK PLACE CLEAN AND TIDY............................................................................................... 47 APPOINT LEADER WHEN WORKING WITH OTHERS...................................................................................... 47 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................................. 48 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................................... 49 PROPER TOOLS................................................................................................................. 49 ACCUMULATOR.................................................................................................................. 50 PERSONNEL.................................................................................................................... 50 ATTACHMENTS.................................................................................................................. 50 WORK UNDER THE MACHINE....................................................................................................... 50 NOISE........................................................................................................................ 51 WHEN USING HAMMER............................................................................................................ 51 WELDING WORKS................................................................................................................ 51 REMOVING BATTERY TERMINALS................................................................................................... 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 52 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................ 52 SAFETY RULES FOR HIGH-PRESSURE OIL........................................................................................... 52 SAFETY HANDLING HIGH-PRESSURE HOSES.......................................................................................... 53 WASTE MATERIALS.............................................................................................................. 53 AIR CONDITIONER MAINTENANCE.................................................................................................. 53 COMPRESSED AIR............................................................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................ 54 OPERATION............................................................................................................................ 55 GENERAL VIEW..................................................................................................................... 56 GENERAL VIEW OF MACHINE...................................................................................................... 56 GENERAL VIEW CONTROLS AND GAUGES............................................................................................. 57 EXPLANATION OF COMPONENTS........................................................................................................ 58 MACHINE MONITOR.............................................................................................................. 58 SWITCHES..................................................................................................................... 64 CONTROL LEVERS, PEDALS....................................................................................................... 70 CEILING WINDOW............................................................................................................... 72 FRONT WINDOW................................................................................................................. 73 SLIDING DOOR................................................................................................................. 76 REAR WINDOW.................................................................................................................. 77 HAMMER FOR EMERGENCY ESCAPE.................................................................................................. 77 CAP, COVER WITH LOCK......................................................................................................... 78 ENGINE HOOD.................................................................................................................. 79 CAB REAR COVER............................................................................................................... 80 PUMP ROOM DOOR, BATTERY ROOM DOOR............................................................................................ 81 DOOR AT FRONT OF TOOL BOX.................................................................................................... 82 FUSE......................................................................................................................... 83 FUSIBLELINK.................................................................................................................. 83 POWER SOURCE FOR OPTION...................................................................................................... 84 CONTROLLER................................................................................................................... 84 HANDLING AIR CONDITIONER..................................................................................................... 85 CAR RADIO.................................................................................................................... 88 HANDLING ACCUMULATOR......................................................................................................... 93 OPERATION AND MAINTENANCE MANUAL HOLDER...................................................................................... 94 TOOL COMPARTMENT............................................................................................................. 94 GREASE GUN HOLDER............................................................................................................ 94 ASHTRAY...................................................................................................................... 94 CUP HOLDER................................................................................................................... 95 MACHINE OPERATIONS AND CONTROLS.................................................................................................. 96 BEFORE STARTING ENGINE....................................................................................................... 96 STARTING ENGINE..............................................................................................................110 AFTER STARTING ENGINE........................................................................................................113 STOPPING THE ENGINE..........................................................................................................116 CHECK AFTER SHUT OFF ENGINE..................................................................................................116 MACHINE OPERATION............................................................................................................117 STEERING THE MACHINE.........................................................................................................121 SWINGING.....................................................................................................................123 WORK EQUIPMENT CONTROLS AND OPERATIONS.......................................................................................124 PROHIBITED OPERATIONS........................................................................................................126 GENERAL OPERATION INFORMATION................................................................................................128 TRAVELING ON SLOPES..........................................................................................................129 ESCAPE FROM MUD..............................................................................................................131 RECOMMENDED APPLICATIONS.....................................................................................................132 REPLACEMENT AND INVERSION OF BUCKET..........................................................................................134 PARKING MACHINE..............................................................................................................138 CHECK AFTER FINISHING WORK...................................................................................................139 LOCKING......................................................................................................................140 TRANSPORTATION...................................................................................................................141 TRANSPORTATION PROCEDURE.....................................................................................................141 LOADING AND UNLOADING WITH TRAILER...........................................................................................142 LIFTING MACHINE..............................................................................................................148 COLD WEATHER OPERATION...........................................................................................................150 COLD WEATHER OPERATION INFORMATION...........................................................................................150 AFTER DAILY WORK COMPLETION..................................................................................................152 AFTER COLD WEATHER SEASON....................................................................................................153 LONG TERM STORAGE................................................................................................................154 BEFORE STORAGE...............................................................................................................154 DURING STORAGE...............................................................................................................154 AFTER STORAGE................................................................................................................155 TROUBLESHOOTING..................................................................................................................156 AFTER RUNNING OUT OF FUEL....................................................................................................156 PHENOMENA THAT ARE NOT FAILURES..............................................................................................156 TOWING THE MACHINE...........................................................................................................157 LIGHTWEIGHT TOWING HOOK......................................................................................................157 PRECAUTIONS ON PARTICULAR JOBSITES...........................................................................................157 DISCHARGED BATTERY...........................................................................................................158 OTHER TROUBLE................................................................................................................163 MAINTENANCE..........................................................................................................................167 MAINTENANCE INFORMATION..........................................................................................................168 OUTLINE OF SERVICE...............................................................................................................171 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................................................171 ELECTRIC SYSTEM MAINTENANCE..................................................................................................175 HANDLING HYDRAULIC SYSTEM....................................................................................................175 WEAR PARTS LIST..................................................................................................................176 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................................................177 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................................178 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..........................................179 TIGHTENING TORQUE SPECIFICATIONS.................................................................................................180 TIGHTENING TORQUE LIST.......................................................................................................180 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................................181 SAFETY CRITICAL PARTS........................................................................................................181 MAINTENANCE SCHEDULE.............................................................................................................182 MAINTENANCE SCHEDULE CHART...................................................................................................182 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...................................................................................184 MAINTENANCE PROCEDURE............................................................................................................185 INITIAL 250 HOURS MAINTENANCE(ONLY AFTER THE FIRST 250 HOURS)................................................................185 WHEN REQUIRED................................................................................................................186 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................186 CLEAN INSIDE OF COOLING SYSTEM...........................................................................................189 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................192 CHECK AND ADJUST TRACK TENSION...........................................................................................193 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................194 REPLACE BUCKET TEETH (VERTICAL PIN TYPE).................................................................................195 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................198 ADJUST BUCKET CLEARANCE..................................................................................................199 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................200 CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...........................................201 REPLACE ADDITIONAL BREAKER FILTER ELEMENT(IF EQUIPPED)...................................................................202 WASHING WASHABLE FLOOR...................................................................................................203 BLEEDING AIR FROM HYDRAULIC SYSTEM.......................................................................................205 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..............................................................207 CHECK BEFORE STARTING........................................................................................................208 EVERY 50 HOURS MAINTENANCE...................................................................................................209 DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................209 EVERY 100 HOURS MAINTENANCE..................................................................................................210 LUBRICATING..............................................................................................................210 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.........................................................................212 EVERY 250 HOURS MAINTENANCE..................................................................................................213 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................213 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................214 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................216 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................................................217 EVERY 500 HOURS MAINTENANCE..................................................................................................219 REPLACE FUEL FILTER CARTRIDGE............................................................................................219 CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................220 LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................220 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....221 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......222 REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................223 EVERY 1000 HOURS MAINTENANCE.................................................................................................224 CHANGE OIL IN SWING MACHINERY CASE.......................................................................................224 CHANGE OIL IN FINAL DRIVE CASE...........................................................................................225 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................225 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................225 CHECK FAN BELT TENSION AND REPLACE FAN BELT..............................................................................225 EVERY 2000 HOURS MAINTENANCE.................................................................................................226 CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL................................................................................226 CLEAN HYDRAULIC TANK STRAINER............................................................................................227 CLEAN, CHECK TURBOCHARGER................................................................................................227 CHECK ALTERNATOR, STARTING MOTOR.........................................................................................227 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................227 EVERY 4000 HOURS MAINTENENCE.................................................................................................228 CHECK WATER PUMP.........................................................................................................228 EVERY 5000 HOURS MAINTENANCE.................................................................................................229 CHANGE OIL IN HYDRAULIC TANK.............................................................................................229 SPECIFICATIONS.......................................................................................................................231 SPECIFICATIONS...................................................................................................................232 ATTACHMENTS AND OPTIONS..............................................................................................................234 GENERAL PRECAUTIONS..............................................................................................................235 PRECAUTIONS RELATED TO SAFETY................................................................................................235 PRECAUTIONS WHEN INSTALLING ATTACHMENTS......................................................................................237 HANDLING CAR HEATER..............................................................................................................238 EXPLANATION OF COMPONENTS....................................................................................................238 PREPARING CAR HEATER.........................................................................................................238 MACHINES READY FOR ATTACHMENTS...................................................................................................239 EXPLANATION OF COMPONENTS....................................................................................................239 HYDRAULIC CIRCUIT............................................................................................................242 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE....................................................................................243 OPERATION....................................................................................................................245 LONG TERM STORAGE............................................................................................................247 SPECIFICATIONS...............................................................................................................247 INTRODUCTION OF ATTACHMENTS......................................................................................................248 SPECIFICATION, USE...........................................................................................................248 ATTACHMENT INSTALLATION COMBINATION TABLE........................................................................................249 ATTACHMENT COMBINATIONS......................................................................................................249 RECOMMENDED ATTACHMENT OPERATIONS................................................................................................250 HYDRAULIC BREAKER............................................................................................................250 INDEX................................................................................................................................255
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