KOMATSU AVANCE PC128UU-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) – PDF DOWNLOAD

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KOMATSU AVANCE PC128UU-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP)

KOMATSU AVANCE PC128UU-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP) – PDF DOWNLOAD:

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KOMATSU AVANCE PC128UU-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP)

• This manual is a guidebook and has been written so that you may use this equipment safely and effectively. Please read this manual and thoroughly understand it prior to operating, inspecting or servicing this equipment. Not following the contents of this manual may lead to incidents which cause serious injury.
• If you lose this manual or if it is soiled or damaged so that it cannot be used, immediately order a replacement manual from Komatsu or your Komatsu dealer. If you sell this equipment to some other party, he sure to give this manual to the new owner. Komatsu provides machines that comply with all applicable regulations and standards of the countries to which they have been shipped.
• if the machine that you purchased was purchased in a different country or from a person or company from another country, it may lack certain safety devices and specifications that are necessary for use in your country.. If there are any questions whether your product complies with the standards and regulations which apply in your country. consult Komatsu or your Komatsu dealer.

TABLE OF CONTENTS:

KOMATSU AVANCE PC128UU-1 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SN:1001 & UP)

MAIN MENU.....................................................................................................  0
COVER.........................................................................................................  1
1. INTRODUCTION...............................................................................................  6
2. SAFETY INFORMATION.........................................................................................  7
3. OVERVIEW OF THE EQUIPMENT..................................................................................  8
	3.1 DESIGNATED USES.......................................................................................  8
	3.2 FEATURES OF THIS MACHINE..............................................................................  8
	3.3 BREAK-IN..............................................................................................  9
4. MEMO....................................................................................................... 10
5. LOCATION OF SERIAL NUMBER PLATES, AND FORM TO ENTER SERIAL NUMBER AND NAME OF THE DISTRIBUTOR.............. 12
	5.1 LOCATION OF SERIAL NUMBER............................................................................. 12
	5.2 LOCATION OF ENGINE SERIAL NUMBER...................................................................... 12
	5.3 FORM FOR ENTERING  THE CYLINDER NUMBER AND THE KOMATSU DISTRIBUTOR.................................... 12
6. TABLE OF CONTENTS.......................................................................................... 13
SAFETY........................................................................................................ 18
7. BASIC PRECAUTIONS.......................................................................................... 19
8. PRECAUTIONS FOR OPERATING.................................................................................. 24
	8.1 BEFORE STARTING THE ENGINE............................................................................ 24
	8.2 AFTER STARTING THE ENGINE............................................................................. 26
	8.3 TRANSPORT THE VEHICLE................................................................................. 31
	8.4 BATTERY............................................................................................... 32
	8.5 TOWING................................................................................................ 33
	8.6 BUCKET WITH HOOK...................................................................................... 34
		8.6.1 GENERAL PRECAUTIONS............................................................................. 34
		8.6.2 PRECAUTIONS FOR HOISTING OPERATIONS............................................................. 36
9. PRECAUTIONS FOR MAINTENANCE................................................................................ 37
	9.1 PRIOR TO PERFORMING MAINTENANCE....................................................................... 37
	9.2 DURING MAINTENANCE.................................................................................... 40
10.  WHERE SAFETY LABELS HAVE BEEN ATTACHED................................................................... 44
	10.1 WHERE SAFETY LABELS ARE LOCATED...................................................................... 44
OPERATION..................................................................................................... 48
11. THE NAME OF EACH PART..................................................................................... 49
	11.1 GENERAL DIAGRAM OF THE VEHICLE....................................................................... 49
	11.2 GENERAL VIEW OF CONTROLS AND GAUGES.................................................................. 50
12. EXPLANATION OF EACH DEVICE................................................................................ 51
	12.1 VEHICLE MONITOR PANEL................................................................................ 51
		12.1.1 A EMERGENCY STOP ITEMS......................................................................... 53
		12.1.2 B GAUGES....................................................................................... 54
		12.1.3 C 4 SYSTEMS.................................................................................... 55
		12.1.4 D DISPLAY LIGHTS............................................................................... 57
		12.1.5 E BASIC CHECK ITEMS (OPTIONAL)................................................................. 57
	12.2 SWITCHES............................................................................................. 58
	12.3 CONTROL LEVERS / PEDALS.............................................................................. 62
	12.4 ENGINE HOOD.......................................................................................... 66
	12.5 FRONT WINDOW......................................................................................... 67
	12.6 SLIDING DOOR......................................................................................... 69
	12.7 FUSE BOX............................................................................................. 70
	12.8 FUSIBLE LINK......................................................................................... 70
	12.9 LOCKING CAP AND COVERS............................................................................... 71
		12.9.1 HOW TO REMOVE AND REPLACE THE LOCKING CAP FOR REFUELING THE FUEL TANK.......................... 71
		12.9.2 HOW TO OPEN AND CLOSE COVERS WITH LOCKS........................................................ 71
	12.10 TOOL BOX............................................................................................ 72
	12.11 GREASE GUN HOLDER................................................................................... 72
	12.12 CONTROLLERS......................................................................................... 72
	12.13 ASHTRAY (OPTIONAL).................................................................................. 72
	12.14 REAR UNDER VIEW MIRROR (OPTIONAL)................................................................... 72
	12.15 USING THE CAR RADIO................................................................................. 73
		12.15.1 EXPLANATION OF EACH FEATURE................................................................... 73
		12.15.2 HOW TO OPERATE THE RADIO...................................................................... 75
		12.15.3 PRECAUTIONS IN USING.......................................................................... 77
		12.15.4 SPECIFICATIONS................................................................................ 77
	12.16 USING THE AIR CONDITIONER........................................................................... 78
		12.16.1 USING THE CONTROL PANEL....................................................................... 78
		12.16.2 PRECAUTIONS IN USE............................................................................ 78
13. OPERATION................................................................................................. 79
	13.1 CHECKS BEFORE STARTING THE ENGINE.................................................................... 79
		13.1.1 VISUAL CHECK................................................................................... 79
		13.1.2 CHECKS BEFORE BEGINNING OPERATIONS............................................................. 81
		13.1.3 ADJUSTMENTS PRIOR TO BEGINNING OPERATIONS...................................................... 85
		13.1.4 CHECKS AND TASKS TO BE PERFORMED BEFORE STARTING THE ENGINE.................................... 86
	13.2 STARTING THE ENGINE.................................................................................. 88
		13.2.1 NORMAL STARTING................................................................................ 88
		13.2.2 STARTING IN COLD WEATHER....................................................................... 89
	13.3 CHECKS AND TASKS TO BE PERFORMED AFTER STARTING THE ENGINE........................................... 90
	13.4 MOVING THE MACHINE................................................................................... 93
		13.4.1 MOVING THE MACHINE FORWARD..................................................................... 93
		13.4.2 MOVING THE MACHINE BACKWARD.................................................................... 94
	13.5 STEERING THE MACHINE................................................................................. 95
		13.5.1 STEERING (CHANGING THE DIRECTION OF ADVANCE)................................................... 95
	13.6 STOPPING THE MACHINE................................................................................. 97
	13.7 SWINGING............................................................................................. 98
	13.8 PROHIBITED ACTIONS WHILE OPERATING THE MACHINE....................................................... 99
	13.9 PRECAUTIONS DURING OPERATION.........................................................................102
	13.10 PRECAUTIONS WHEN CLIMBING OR DESCENDING SLOPES......................................................103
	13.11 EXTRICATING THE MACHINE FROM MUD....................................................................105
		13.11.1 WHEN ONE SIDE IS STUCK........................................................................105
		13.11.2 WHEN BOTH SIDES ARE STUCK.....................................................................105
	13.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR.......................................106
		13.12.1 EXCAVATION OPERATIONS.........................................................................106
		13.12.2 DITCH DIGGING OPEARTIONS......................................................................106
		13.12.3 LOADING OPERATIONS............................................................................106
		13.12.4 GRADING OPERATIONS............................................................................106
		13.12.5 DITCH DIGGING OPERATIONS FROM THE SIDE........................................................107
		13.12.6 OPERATIONS IN RESTRICTED PLACES...............................................................107
	13.13 CHANGING THE BUCKET.................................................................................108
	13.14 PARKING THE MACHINE.................................................................................109
	13.15 CHECKS AFTER COMPLETING OPERATION...................................................................110
	13.16 STOPPING THE ENGINE.................................................................................110
	13.17 CHECKS AFTER THE ENGINE HAS BEEN STOPPED............................................................111
	13.18 LOCKING.............................................................................................111
	13.19 USING THE 4 SYSTEMS.................................................................................112
		13.19.1 THE BUCKET - CAB ACCIDENT PREVENTION DEVICE...................................................114
		13.19.2 USING THE AUTOMATIC CONTROL DEVICE............................................................116
	13.20 USING RUBBER TRACK SHOES (FOR MACHINES SPECIFIED FOR USE WITH RUBBER TRACKS)........................123
		13.20.1 HOW TO USE RUBBER TRACK SHOES PROPERLY........................................................123
		13.20.2 CONCERNING THE WARRANTY ON RUBBER TRACK SHOES.................................................123
		13.20.3 PRECAUTIONS IN USING RUBBER TRACK SHOES.......................................................124
		13.20.4 PRECAUTIONS IN USE............................................................................125
14. TRANSPORTING..............................................................................................128
	14.1 HOW TO LOAD AND UNLOAD THE VEHICLE...................................................................128
	14.2 PRECAUTIONS WHEN CARRYING THINGS.....................................................................130
	14.3 PRECAUTIONS WHEN TRANSPORTING........................................................................131
15. HANDLING IN COLD WEATHER..................................................................................132
	15.1 PREPARATION FOR LOW TEMPERATURES.....................................................................132
		15.1.1 FUEL AND LUBRICATION...........................................................................132
	15.2 PRECAUTIONS AFTER COMPLETING OPERATIONS..............................................................133
	15.3 PREPARING THE CAR HEATER.............................................................................134
	15.4 AFTER THE COLD WEATHER SEASON IS OVER................................................................134
16. LONG-TERM STORAGE.........................................................................................135
	16.1 BEFORE STORING THE MACHINE...........................................................................135
	16.2 DURING STORAGE.......................................................................................136
	16.3 AFTER STORAGE........................................................................................136
17. TROUBLESHOOTING...........................................................................................137
	17.1 PHENOMENA THAT ARE NOT BREAKDOWNS....................................................................137
	17.2 HOW TO TOW WITH THE MACHINE OR BE TOWED..............................................................139
	17.3 HOW TO USE THE HOOK FOR TOWING LIGHT OBJECTS.........................................................139
	17.4 PRECAUTIONS FOR SPECIAL JOB SITES....................................................................139
	17.5 WHEN THE BATTERY IS DEAD.............................................................................140
		17.5.1 STARTING THE ENGINE USING BOOSTER CABLES.......................................................141
	17.6 WHEN THIS PHENOMENON OCCURS..........................................................................144
		17.6.1 ELECTRICAL SYSTEM..............................................................................144
		17.6.2 GENERAL PROBLEMS WITH THE MACHINE..............................................................145
		17.6.3 ENGINE.........................................................................................146
		17.6.4  4 SYSTEMS.....................................................................................148
CHECKS AND MAINTENANCE........................................................................................150
18. PRECAUTIONS IN PERFORMING CHECKS AND MAINTENANCE..........................................................151
19. BASIC MAINTENANCE.........................................................................................154
	19.1 ESSENTIAL INFORMATION ON OIL, FUEL AND COOLANT.......................................................154
		19.1.1 OIL............................................................................................154
		19.1.2 FUEL...........................................................................................156
		19.1.3 COOLAND........................................................................................156
		19.1.4 GREASE.........................................................................................157
		19.1.5 STORING OIL AND FUEL...........................................................................157
		19.1.6 FILTERS........................................................................................157
	19.2 SUMMARY OF ELECTRICAL SYSTEM.........................................................................158
	19.3 SUMMARY OF HYDRAULIC SYSTEM..........................................................................159
20. CONSUMABLE SUPPLIES.......................................................................................160
21. USAGE OF FUEL AND LUBRICATING GREASE ACCORDING TO AMBIENT TEMPERATURE.....................................161
	21.1 FUEL / OIL...........................................................................................161
	21.2 COOLANT..............................................................................................161
22. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS............................................................162
	22.1 LIST OF TOOLS NECESSARY..............................................................................162
	22.2 TORQUE TABLE.........................................................................................163
23. ABOUT REGULAR REPLACEMENT OF IMPORTANT COMPONENTS.........................................................164
24. LIST OF MAINTENANCE.......................................................................................166
	24.1 MAINTENANCE SCHEDULE.................................................................................166
	24.2 SERVICE TIME WHEN USING HYDRAULIC BREAKERS...........................................................168
	24.1 MAINTENANCE SCHEDULE.................................................................................166
25. SERVICE PROCEDURES........................................................................................169
	25.1 INITIAL SERVICE AFTER 250 HOURS OF OPERATION.........................................................169
	25.2 MAINTENANCE THAT IS NOT REGULARLY SCHEDULED..........................................................170
		25.2.1 CHECK AND CLEAN OR REPLACE AIR CLEANER.........................................................170
		25.2.2 FLUSHING THE COOLING SYSTEM....................................................................172
		25.2.3 CHECKING THE ELECTRIC HEATER...................................................................176
		25.2.4 CHECK AND TIGHTEN TRACK SHOE BOLTS (STEEL SHOE MACHINES).......................................176
		25.2.5 CHECK AND ADJUST TRACK TENSION (STEEL TRACK VEHICLES)..........................................177
		25.2.6 CHECKING THE RUBBER TRACK SHOES (MACHINES WITH RUBBER TRACK SHOES).............................180
		25.2.7 CHECKING AND ADJUSTING TENSION OF RUBBER TRACK SHOES (FOR MACHINES WITH RUBBER TRACK SHOES)....182
		25.2.8 REPLACING RUBBER TRACKS (FOR MACHINES WITH RUBBER TRACKS)......................................184
		25.2.9 REPLACING BUCKET TEETH (VERTICAL PIN TYPE).....................................................187
		25.2.10 REPLACING BUCKET TEETH (HORIZONTAL PIN TYPE)..................................................190
		25.2.11 ADJUSTING BUCKET CLEARANCE....................................................................191
		25.2.12 CHECKING AND CALIBRATING THE AIR CONDITIONER..................................................192
		25.2.13 CHECK AND REPLENISH WIND SHIELD WASHER FLUID (OPTIONAL).......................................193
	25.3 CHECKS BEFORE STARTING OPERATIONS....................................................................194
		25.3.1 CHECK AND REPLENISH COOLANT LEVEL..............................................................194
		25.3.2 CHECK THE OIL IN THE ENGINE OIL PAN AND ADD IF NEEDED..........................................194
		25.3.3 CHECK THE FUEL LEVEL...........................................................................195
		25.3.4 CHECK AND REPLENISH THE OIL IN THE HYDRAULIC OIL TANK..........................................196
		25.3.5 CHECK THE DUST INDICATOR.......................................................................197
		25.3.6 CHECK THE ELECTRICAL CIRCUITS..................................................................197
	25.4 SERVICE TO BE PERFORMED AFTER EVERY 50 HOURS OF OPERATION............................................198
		25.4.1 DRAIN WATER AND SEDIMENTS FROM FUEL TANK.......................................................198
	25.5 SERVICE TO BE PERFORMED AFTER EVERY 100 HOURS OF OPERATION...........................................199
		25.5.1 GREASING.......................................................................................199
		25.5.2 CHECK AND REPLENISH THE OIL IN THE SWING MACHINERY CASE........................................201
	25.6 SERVICE TO BE PERFORMED AFTER EVERY 250 HOURS OF OPERATION...........................................202
		25.6.1 CHECK AND REPLENISH THE OIL IN THE FINAL DRIVE CASE............................................202
		25.6.2 CHECK THE BATTERY FLUID LEVEL..................................................................203
		25.6.3 REPLACE THE OIL IN ENGINE OIL PAN AND REPLACE THE ENGINE OIL FILTER CARTRIDGE..................204
		25.6.4 REPLACE THE HYDRAULIC FLUID FILTER ELEMENT.....................................................205
		25.6.5 CHECK AND ADJUST FAN BELT TENSION..............................................................207
		25.6.6 CHECK AND ADJUST THE TENSION OF THE AIR CONDITIONER COMPRESSOR BELT............................208
	25.7 SERVICE TO BE PERFORMED AFTER EVERY 500 HOURS OF OPERATION...........................................209
		25.7.1 REPLACE FUEL FILTER CARTRIDGE..................................................................209
		25.7.2 CHECK AND REPLENISH THE AMOUNT OF GREASE IN THE SWING PINION...................................211
		25.7.3 GREASE THE SWING CIRCLE (2 POINTS).............................................................211
		25.7.4 CHECK AND CLEAN RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS..............................212
		25.7.5 CLEAN AIR CONDITIONER FILTERS..................................................................213
	25.8 SERVICE TO BE PERFORMED AFTER EVERY 1000 HOURS OF OPERATION..........................................214
		25.8.1 REPLACE THE OIL IN SWING MACHINERY CASE........................................................214
		25.8.2 REPLACE OIL IN FINAL DRIVE CASE................................................................215
		25.8.3 CHECK ALL TIGHTENERS ON THE TURBOCHARGER.......................................................216
		25.8.4 CHECK THE PLAY OF THE TURBOCHARGER ROTOR.......................................................216
		25.8.5 GREASE FUEL STOP SOLENOID LINKAGE..............................................................216
	25.9 SERVICE TO BE PERFORMED AFTER EVERY 2000 HOURS OF OPERATION..........................................217
		25.9.1 CHECK AND REPLENISH THE OIL IN THE PTO GEAR CASE...............................................217
		25.9.2 ...............................................................................................218
		25.9.3 CLEAN AND CHECK THE TURBOCHARGER...............................................................223
		25.9.4 CHECK THE ALTERNATOR / STARTER.................................................................223
		25.9.5 CHECK AND ADJUST ENGINE VALVE CLEARANCE........................................................223
	25.10 SERVICE TO BE PERFORMED AFTER EVERY 4000 HOURS OF OPERATION.........................................224
		25.10.1 CHECK THE WATER PUMP..........................................................................224
26. INSPECTIONS REQUIRED......................................................................................225
	26.1 BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)..........................................225
		26.1.1 AT LEAST MONTHLY...............................................................................225
	26.2 CHECKS BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)...................................225
		26.2.1 AT LEAST MONTHLY...............................................................................225
		26.2.2 AT LEAST ANNUALLY..............................................................................225
SPECIFICATIONS................................................................................................226
27. SPECIFICATIONS............................................................................................227
OPTIONAL PARTS, ATTACHMENTS...................................................................................230
28.GENERAL PRECAUTIONS........................................................................................231
	28.1 SAFETY PRECAUTIONS...................................................................................231
	28.2 PRECAUTIONS WHEN ATTACHMENTS ARE INSTALLED...........................................................232
29. USING THE BUCKET WITH HOOK................................................................................233
	29.1 CHECKING THE BUCKET WITH HOOK ATTACHED FOR DAMAGE....................................................233
	29.2 OPERATIONS THAT SHOULD NOT BE PERFORMED..............................................................233
	29.3 PRECAUTIONS DURING OPERATION.........................................................................233
30. USING SEAT BELTS..........................................................................................236
	30.1 SEAT BELTS...........................................................................................236
		30.1.1 FASTENING AND REMOVING SEAT BELTS..............................................................236
		30.1.2 ADJUSTING THE BELT LENGTH......................................................................237
31. INFORMATION ON OPTIONAL ATTACHMENTS.......................................................................238
	31.1 INFORMATION ON OPTIONAL ATTACHMENTS..................................................................238
	31.2 ATTACHMENT COMBINATION TABLE.........................................................................239
	31.3 SELECTING TRACKS.....................................................................................240
	31.4 USING RUBBER PAD TRACKS..............................................................................241
	31.5 USING THE AUTOMATIC LEVELING DEVICE..................................................................242
		31.5.1 EXPLANATION OF EACH DEVICE.....................................................................242
		31.5.2 USING THE AUTOMATIC FEATURES...................................................................245
		31.5.3 TROUBLESHOOTING THE AUTOMATIC LEVELING SYSTEM..................................................251
	31.6 USING THE MONO-BOOM..................................................................................252
		31.6.1 SERVICE TO BE PERFORMED AFTER EVERY 100 HOURS OF OPERATION.....................................252
	31.7 USING VEHICLES TO WHICH ATTACHMENTS CAN BE INSTALLED (MONO-BOOM).....................................254
		31.7.1 EXPLANATION OF EACH DEVICE.....................................................................254
		31.7.2 HYDRAULIC LINES................................................................................256
		31.7.3 OPERATION......................................................................................258
		31.7.4 WHEN USING THE BREAKER.........................................................................258
		31.7.5 WHEN USING GENERAL ATTACHMENTS SUCH AS CRUSHERS................................................259
		31.7.6 USING THE ACCUMULATOR..........................................................................260
		31.7.7 LONG TERM STORAGE..............................................................................260
		31.7.8 SPECIFICATIONS.................................................................................260
	31.8 SWITCHING OPERATION PATTERNS (ON MACHINES WHICH HAVE A PATTERN SWITCHING VALVE INSTALLED)............261
		31.8.1 SWITCHING PATTERNS.............................................................................261

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