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KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM035408T) – PDF DOWNLOAD
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- KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:SEAM035408T
- SERIAL NUMBERS:
PC128US-8269 and up
PC138USLC-1047 and up
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KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM035408T)
KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM035408T) – PDF DOWNLOAD:
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KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM035408T)
- 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. If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable reoulations and standards ofthe countrv to which it has been shipped. If this machine has been purcnased in another country or purchased trom someone in anotner country, It may lack certain safety devices 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 vour countrv. consult Komatsu or vour Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATSU GALEO PC128US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (SEAM035408T)
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 AND ITS LOCATION......................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................. 10 CONTENTS............................................................................ 11 SAFETY.............................................................................. 15 SAFETY INFORMATION.............................................................. 16 SAFETY LABELS............................................................... 18 LOCATION OF SAFETY LABELS............................................... 19 SAFETY LABELS........................................................... 20 SAFETY INFORMATION.......................................................... 26 SAFETY RULES............................................................ 26 IF ABNORMALITIES ARE FOUND.............................................. 26 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.............................. 26 FIRE EXTINGUISHER AND FIRST AID KIT..................................... 26 SAFETY EQUIPMENT........................................................ 26 KEEP MACHINE CLEAN...................................................... 27 KEEP OPERATOR'S COMPARTMENT CLEAN....................................... 27 LEAVING OPERATOR'S SEAT WITH LOCK....................................... 27 HANDRAILS AND STEPS..................................................... 28 MOUNTING AND DISMOUNTING................................................ 28 NO PERSONS ON ATTACHMENTS............................................... 28 DO NOT GET CAUGHT IN ARTICULATED PORTION................................ 28 BURN PREVENTION......................................................... 29 FIRE PREVENTION AND EXPLOSION PREVENTION................................ 29 ACTION IF FIRE OCCURS................................................... 30 WINDSHIELD WASHER FLUID................................................. 30 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION........ 30 ATTACHMENT INSTALLATION................................................. 31 ATTACHMENT COMBINATIONS................................................. 31 CAB WIDOW GLASSES....................................................... 31 UNAUTHORIZED MODIFICATIONS.............................................. 31 SAFETY AT JOBSITE....................................................... 31 WORKING ON LOOSE GROUND................................................. 31 DISTANCE TO HIGH VOLTAGE CABLES......................................... 32 ENSURE GOOD VISIBILITY.................................................. 32 VENTILATION FOR ENCLOSED AREA........................................... 33 SIGNALMAN'S SIGNAL AND SIGNS............................................ 33 EMERGENCY EXIT FROM OPERATOR'S CAB...................................... 33 ASBESTOS DUST HAZARD PREVENTION......................................... 33 SAFETY MACHINE OPERATION.................................................... 34 STARTING ENGINE......................................................... 34 CHECKS BEFORE STARTING ENGINE....................................... 34 SAFETY RULES FOR STARTING ENGINE.................................... 34 STARTING ENGINE IN COLD WEATHER..................................... 34 OPERATION............................................................... 36 CHECKS BEFORE OPERATION............................................. 36 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................ 36 SAFETY RULES FOR TRAVELING.......................................... 37 TRAVELING ON SLOPES................................................. 38 OPERATIONS ON SLOPES................................................ 39 PROHIBITED OPERATIONS............................................... 39 OPERATIONS ON SNOW.................................................. 40 PARKING MACHINE..................................................... 41 TRANSPORTATION.......................................................... 42 LOADING AND UNLOADING............................................... 42 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...................... 48 PROPER TOOLS............................................................ 49 ACCUMULATOR............................................................. 49 PERSONNEL............................................................... 49 ATTACHMENTS............................................................. 50 WORK UNDER THE MACHINE.................................................. 50 NOISE................................................................... 50 WHEN USING HAMMER....................................................... 50 WELDING WORKS........................................................... 50 REMOVING BATTERY TERMINALS.............................................. 51 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.... 51 DO NOT DISASSEMBLE RECOIL SPRINGS....................................... 51 SAFETY RULES FOR HIGH-PRESSURE OIL...................................... 51 SAFETY HANDLING HIGH-PRESSURE HOSES..................................... 52 WASTE MATERIALS......................................................... 52 AIR CONDITIONER MAINTENANCE............................................. 52 COMPRESSED AIR.......................................................... 52 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................... 52 OPERATION........................................................................... 54 MACHINE VIEW ILLUSTRATIONS...................................................... 55 OVERALL MACHINE VIEW........................................................ 55 CONTROLS AND GAUGES......................................................... 56 DETAILED CONTROLS AND GAUGES.................................................... 57 MONITORING SYSTEM........................................................... 57 SWITCHES.................................................................... 69 CONTROL LEVERS AND PEDALS................................................... 74 SUN ROOF.................................................................... 77 WINDSHIELD.................................................................. 78 SLIDING DOOR................................................................ 83 EMERGENCY ESCAPE HAMMER..................................................... 83 CAP WITH LOCK............................................................... 85 ENGINE HOOD................................................................. 86 CAB REAR COVER.............................................................. 87 PUMP ROOM DOOR, BATTERY ROOM DOOR........................................... 88 DOOR AT FRONT OF TOOL BOX................................................... 89 FUSE........................................................................ 90 FUSIBLELINK................................................................. 91 CONTROLLERS................................................................. 91 AIR CONDITIONER CONTROLS.................................................... 92 RADIO....................................................................... 98 ACCUMULATOR.................................................................103 OPERATION MANUAL STORAGE....................................................104 TOOL BOX....................................................................104 GREASE PUMP HOLDER..........................................................104 HOT AND COOL BOX............................................................104 ASHTRAY.....................................................................105 FIRE EXTINGUISHER...........................................................105 MACHINE OPERATIONS AND CONTROLS.................................................106 BEFORE STARTING ENGINE......................................................106 STARTING ENGINE.............................................................122 AFTER STARTING ENGINE.......................................................127 STOPPING THE ENGINE.........................................................130 CHECK AFTER SHUT OFF ENGINE.................................................130 MACHINE OPERATION...........................................................131 STEERING THE MACHINE........................................................135 SWINGING....................................................................137 WORK EQUIPMENT CONTROLS AND OPERATIONS......................................138 WORKING MODE................................................................140 PROHIBITED OPERATIONS.......................................................141 GENERAL OPERATION INFORMATION...............................................143 TRAVELING ON SLOPES.........................................................145 ESCAPE FROM MUD.............................................................147 RECOMMENDED APPLICATIONS....................................................148 BUCKET REPLACEMENT AND INVERSION............................................150 PARKING MACHINE.............................................................152 MACHINE INSPECTION AFTER DAILY WORK.........................................153 LOCKING.....................................................................153 ROAD LINERS.................................................................154 TRANSPORTATION..................................................................156 TRANSPORTATION PROCEDURE....................................................156 LOADING AND UNLOADING WITH TRAILER..........................................157 LIFTING MACHINE.............................................................163 COLD WEATHER OPERATION..........................................................165 COLD WEATHER OPERATION INFORMATION..........................................165 AFTER DAILY WORK COMPLETION.................................................167 AFTER COLD WEATHER SEASON...................................................167 LONG TERM STORAGE...............................................................168 BEFORE STORAGE..............................................................168 DURING STORAGE..............................................................168 AFTER STORAGE...............................................................168 TROUBLESHOOTING.................................................................169 RUNNING OUT OF FUEL.........................................................169 PHONOMENA THAT ARE NOT FAILURES.............................................169 TOWING THE MACHINE..........................................................170 LIGHTWEIGHT TOWING HOOK.....................................................170 SEVERE JOB CONDITION........................................................170 DISCHARGED BATTERY..........................................................171 OTHER TROUBLE...............................................................175 MAINTENANCE.........................................................................180 MAINTENANCE INFORMATION.........................................................181 LUBRICANTS, COOLANT AND FILTERS.................................................183 HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC.........................183 ELECTRIC SYSTEM MAINTENANCE.................................................185 WEAR PARTS .....................................................................186 WEAR PARTS LIST.............................................................186 LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS......................................187 PROPER SELECTION............................................................187 TIGHTENING TORQUE SPECIFICATIONS................................................191 TIGHTENING TORQUE LIST......................................................191 SAFETY CRITICAL PARTS...........................................................192 SAFETY CRITICAL PARTS LIST..................................................192 MAINTENANCE SCHEDULE............................................................193 MAINTENANCE SCHEDULE CHART..................................................193 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................194 MAINTENANCE PROCEDURE...........................................................195 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)..............195 WHEN REQUIRED...............................................................196 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................196 CLEAN INSIDE OF COOLING SYSTEM..........................................200 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................203 CHECK AND ADJUST TRACK TENSION..........................................204 REPLACE ROAD LINERS.....................................................206 CHECK ELECTRICAL INTAKE AIR HEATER......................................206 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)................................207 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)..............................210 ADJUST BUCKET CLEARANCE.................................................211 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................212 CHECK AND ADJUST AIR CONDITIONER........................................213 CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER................214 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT...................215 WASH WASHABLE FLOOR.....................................................216 BLEEDING AIR FROM HYDRAULIC SYSTEM......................................219 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT.............221 CHECK BEFORE STARTING.......................................................223 EVERY 50 HOURS MAINTENANCE..................................................224 DRAIN WATER AND SEDIMENT FROM FUEL TANK.................................224 EVERY 100 HOURS MAINTENANCE.................................................225 LUBRICATING.............................................................225 SWING MACHINERY CASE OIL-CHECK/ADD......................................227 EVERY 250 HOURS MAINTENANCE.................................................228 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................228 CHECK LEVEL OF BATTERY ELECTROLYTE......................................229 ENGINE CRANKCASE OIL AND FILTER CARTRIDGE-CHANGE/REPLACE................231 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION,ADJUST....................232 EVERY 500 HOURS MAINTENANCE.................................................233 REPLACE FUEL FILTER CARTRIDGE...........................................233 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................234 LUBRICATE SWING CIRCLE .................................................234 CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS AND CONDENSER FINS............234 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER..............235 REPLACE HYDRAULIC OIL FILTER ELEMENT....................................237 EVERY 1000 HOURS MAINTENANCE................................................238 CHANGE OIL IN SWING MACHINERY CASE......................................238 CHANGE OIL IN FINAL DRIVE CASE..........................................239 FAN BELT-INSPECT/REPLACE................................................239 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................239 CHECK PLAY TURBOCHARGER ROTOR...........................................239 EVERY 2000 HOURS MAINTENANCE................................................240 CHECK PTO GEAR CASE,ADD OIL.............................................240 CLEAN HYDRAULIC TANK STRAINER...........................................241 CLEAN, CHECK TURBOCHARGER...............................................241 CHECK ALTERNATOR, STARTING MOTOR........................................241 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................241 EVERY 4000 HOURS MAINTENENCE................................................242 CHECK WATER PUMP........................................................242 EVERY 5000 HOURS MAINTENANCE................................................243 CHANGE OIL IN HYDRAULIC TANK............................................243 SPECIFICATIONS......................................................................244 SPECIFICATIONS..................................................................245 ATTACHMENTS,OPTIONS.................................................................248 ATTACHMENTS AND OPTIONS-GENERAL INFORMATION.....................................249 SAFETY FIRST................................................................249 ATTACHMENT INSTALLATION.....................................................250 BUCKET WITH HOOK................................................................251 HOOK CONDITION..............................................................251 PROHIBITED OPERATIONS.......................................................251 AIR CONDITIONER.................................................................252 AIR CONDITIONER CONTROL PANEL...............................................252 AIR CONDITIONER CONTROLS....................................................257 AIR CONDITIONER MAINTENANCE.................................................257 MACHINES READY FOR ATTACHMENTS..................................................258 LOCATIONS...................................................................258 HYDRAULIC CIRCUIT...........................................................261 ATTACHMENT REMOVAL AND INSTALLATION.........................................262 ATTAMHMENT OPERATIONS.......................................................266 LONG TERM STORAGE...........................................................269 SPECIFICATIONS..............................................................269 ATTACHMENT GUIDE................................................................270 OTHER ATTACHMENT............................................................270 ATTACHMENT COMBINATIONS.....................................................271 SELECTION OF TRACK SHOES....................................................272 RECOMMENDED ATTACHMENT OPERATIONS...............................................273 HYDRAULIC BREAKER...........................................................273 INDEX...............................................................................278
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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