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Komatsu Hydraulic Excavator PC128US-2 PC138USLC-2 Operation & Maintenance Manual SN 7731,1001 and up – PDF DOWNLOAD
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Komatsu Hydraulic Excavator PC128US-2 PC138USLC-2 Operation & Maintenance Manual
Book Code :SEAM035407T
SERIAL NUMBERS :
- PC128US-7731 and up
- PC138USLC-1001 and up
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Description
Komatsu Hydraulic Excavator PC128US-2 PC138USLC-2 Operation & Maintenance Manual
DESCRIPTION:
Komatsu Hydraulic Excavator PC128US-2 PC138USLC-2 Operation & Maintenance Manual
FOREWORD:
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
KOMATSU HYDRAULIC EXCAVATOR PC128US-2 PC138USLC-2 OPERATION & MAINTENANCE MANUAL SN 7731,1001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu Hydraulic Excavator PC128US-2 PC138USLC-2 Operation & Maintenance Manual
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 SERVICE METER LOCATION..................................................... 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................ 10 CONTENTS........................................................................... 11 SAFETY............................................................................. 14 SAFETY INFORMATION............................................................. 15 SAFETY LABELS.................................................................. 17 LOCATION OF SAFETY LABELS.................................................. 18 SAFETY LABELS.............................................................. 19 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........................................................... 24 KEEP MACHINE CLEAN......................................................... 25 KEEP OPERATOR'S COMPARTMENT CLEAN.......................................... 25 LEAVING OPERATOR'S SEAT WITH LOCK.......................................... 25 HANDRAILS AND STEPS........................................................ 26 MOUNTING AND DISMOUNTING................................................... 26 NO PERSONS ON ATTACHMENTS.................................................. 26 DO NOT GET CAUGHT IN ARTICULATED PORTION................................... 26 BURN PREVENTION............................................................ 27 FIRE PREVENTION AND EXPLOSION PREVENTION................................... 27 ACTION IF FIRE OCCURS...................................................... 28 WINDSHIELD WASHER FLUID.................................................... 28 FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............ 28 ATTACHMENT INSTALLATION.................................................... 29 ATTACHMENT COMBINATIONS.................................................... 29 CAB WINDOW GLASSES......................................................... 29 UNAUTHORIZED MODIFICATIONS................................................. 29 SAFETY AT JOBSITE.......................................................... 29 WORKING ON LOOSE GROUND.................................................... 30 DISTANCE TO HIGH VOLTAGE CABLES............................................ 30 ENSURE GOOD VISIBILITY..................................................... 30 VENTILATION FOR ENCLOSED AREA.............................................. 31 SIGNALMAN'S SIGNAL AND SIGNS............................................... 31 EMERGENCY EXIT FROM OPERATOR'S CAB......................................... 31 ASBESTOS DUST HAZARD PREVENTION............................................ 31 SAFETY MACHINE OPERATION....................................................... 32 STARTING ENGINE............................................................ 32 CHECKS BEFORE STARTING ENGINE.......................................... 32 SAFETY RULES FOR STARTING ENGINE....................................... 32 STARTING ENGINE IN COLD WEATHER........................................ 33 OPERATION.................................................................. 34 CHECKS BEFORE OPERATION................................................ 34 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS........................... 34 SAFETY RULES FOR TRAVELING............................................. 35 TRAVELING ON SLOPES.................................................... 36 OPERATIONS ON SLOPES................................................... 37 PROHIBITED OPERATIONS.................................................. 37 OPERATIONS ON SNOW..................................................... 38 PARKING MACHINE........................................................ 39 TRANSPORTATION............................................................. 40 LOADING AND UNLOADING.................................................. 40 SHIPPING THE MACHINE................................................... 40 BATTERY.................................................................... 41 BATTERY HAZARD PREVENTION.............................................. 41 STARTING ENGINE WITH BOOSTER CABLES.................................... 42 TOWING..................................................................... 43 SAFETY RULES FOR TOWING................................................ 43 LIFTING OBJECTS WITH BUCKET................................................ 44 SAFETY RULES FOR LIFTING OBJECTS....................................... 44 SAFETY MAINTENANCE INFORMATION................................................. 45 WARNING TAG................................................................ 45 KEEP WORK PLACE CLEAN AND TIDY............................................. 45 APPOINT LEADER WHEN WORKING WITH OTHERS.................................... 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................ 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................... 46 PROPER TOOLS............................................................... 47 ACCUMULATOR................................................................ 47 PERSONNEL.................................................................. 47 ATTACHMENTS................................................................ 48 WORK UNDER THE MACHINE..................................................... 48 NOISE...................................................................... 48 WHEN USING HAMMER.......................................................... 48 WELDING WORKS.............................................................. 48 REMOVING BATTERY TERMINALS................................................. 49 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION....... 49 DO NOT DISASSEMBLE RECOIL SPRINGS.......................................... 49 SAFETY RULES FOR HIGH-PRESSURE OIL......................................... 49 SAFETY HANDLING HIGH-PRESSURE HOSES........................................ 50 WASTE MATERIALS............................................................ 50 AIR CONDITIONER MAINTENANCE................................................ 50 COMPRESSED AIR............................................................. 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................. 50 OPERATION.......................................................................... 52 MACHINE VIEW ILLUSTRATIONS..................................................... 53 OVERALL MACHINE VIEW....................................................... 53 CONTROLS AND GAUGES........................................................ 54 DETAILED CONTROLS AND GAUGES................................................... 55 MONITORING SYSTEM.......................................................... 55 SWITCHES................................................................... 67 CONTROL LEVERS AND PEDALS.................................................. 72 SUN ROOF................................................................... 75 WINDSHIELD................................................................. 76 SLIDING DOOR............................................................... 81 EMERGENCY ESCAPE HAMMER.................................................... 81 CAP WITH LOCK.............................................................. 83 ENGINE HOOD................................................................ 84 CAB REAR COVER............................................................. 85 PUMP ROOM DOOR,BATTERY ROOM DOOR........................................... 86 DOOR AT FRONT OF TOOL BOX.................................................. 87 FUSE....................................................................... 88 FUSIBLELINK................................................................ 89 CONTROLLERS................................................................ 89 AIR CONDITIONER CONTROLS................................................... 90 RADIO...................................................................... 96 ACCUMULATOR................................................................101 OPERATION MANUAL STORAGE...................................................102 TOOL BOX...................................................................102 GREASE PUMP HOLDER.........................................................102 HOT AND COOL BOX...........................................................102 ASHTRAY....................................................................103 FIRE EXTINGUISHER..........................................................103 MACHINE OPERATIONS AND CONTROLS................................................104 BEFORE STARTING ENGINE.....................................................104 STARTING ENGINE............................................................120 AFTER STARTING ENGINE......................................................124 STOPPING THE ENGINE........................................................127 CHECK AFTER SHUT OFF ENGINE................................................127 MACHINE OPERATION..........................................................128 STEERING THE MACHINE.......................................................132 SWINGING...................................................................134 WORK EQUIPMENT CONTROLS AND OPERATIONS.....................................135 WORKING MODE...............................................................137 PROHIBITED OPERATIONS......................................................138 GENERAL OPERATION INFORMATION..............................................140 TRAVELING ON SLOPES........................................................142 ESCAPE FROM MUD............................................................144 RECOMMENDED APPLICATIONS...................................................145 BUCKET REPLACEMENT AND INVERSION...........................................147 PARKING MACHINE............................................................149 MACHINE INSPECTION AFTER DAILY WORK........................................150 LOCKING....................................................................150 ROAD LINERS................................................................151 TRANSPORTATION.................................................................153 TRANSPORTATION PROCEDURE...................................................153 LOADING AND UNLOADING WITH TRAILER.........................................154 LIFTING MACHINE............................................................160 COLD WEATHER OPERATION.........................................................162 COLD WEATHER OPERATION INFORMATION.........................................162 AFTER DAILY WORK COMPLETION................................................164 AFTER COLD WEATHER SEASON..................................................164 LONG TERM STORAGE..............................................................165 BEFORE STORAGE.............................................................165 DURING STORAGE.............................................................165 AFTER STORAGE..............................................................165 TROUBLES AND ACTIONS...........................................................166 RUNNING OUT OF FUEL........................................................166 PHENOMENA THAT ARE NOT FAILURES............................................166 TOWING THE MACHINE.........................................................167 LIGHTWEIGHT TOWING HOOK....................................................167 SEVERE JOB CONDITION.......................................................167 DISCHARGED BATTERY.........................................................168 OTHER TROUBLE..............................................................172 MAINTENANCE........................................................................177 MAINTENANCE INFORMATION........................................................178 LUBRICANTS, COOLANT AND FILTERS................................................180 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................180 ELECTRIC SYSTEM MAINTENANCE................................................182 WEAR PARTS.....................................................................183 WEAR PARTS LIST............................................................183 LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS....................................184 PROPER SELECTION...........................................................184 TIGHTENING TORQUE SPECIFICATIONS...............................................188 TIGHTENING TORQUE LIST.....................................................188 SAFETY CRITICAL PARTS..........................................................189 SAFETY CRITICAL PARTS LIST.................................................189 MAINTENANCE SCHEDULE...........................................................190 MAINTENANCE SCHEDULE CHART.................................................190 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.................................191 MAINTENANCE PROCEDURE..........................................................192 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).............192 CHECK ENGINE VALVE CLEARANCE,ADJUST....................................192 WHEN REQUIRED..............................................................193 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT............................193 CLEAN INSIDE OF COOLING SYSTEM.........................................197 CHECK AND TIGHTEN TRACK SHOE BOLTS.....................................200 CHECK AND ADJUST TRACK TENSION.........................................201 ROAD LINERS-CHECK......................................................203 REPLACE ROAD LINERS....................................................203 CHECK ELECTRICAL INTAKE AIR HEATER.....................................203 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...............................204 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).............................207 ADJUST BUCKET CLEARANCE................................................208 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID..............................209 CHECK AND ADJUST AIR CONDITIONER.......................................210 CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RALL AND ROLLER...............211 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (IF EQUIPPED)....212 WASHING WASHABLE FLOOR.................................................213 BLEEDING AIR FROM HYDRAULIC SYSTEM.....................................216 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT............218 CHECK BEFORE STARTING......................................................220 EVERY 50 HOURS MAINTENANCE.................................................221 DRAIN WATER FROM FUEL TANK.............................................221 EVERY 100 HOURS MAINTENANCE................................................222 LUBRICATING............................................................222 SWING MACHINERY CASE OIL-CHECK/ADD.....................................224 EVERY 250 HOURS MAINTENANCE................................................225 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL............................225 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................226 ENGINE CRANKCASE OIL AND FILTER CARTRIDGE-CHANGE/REPLACE...............228 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION,ADJUST...................229 EVERY 500 HOURS MAINTENANCE................................................230 REPLACE FUEL FILTER CARTRIDGE..........................................230 CHECK SWING PINION GREASE LEVEL,ADD GREASE.............................231 LUBRICATE SWING CIRCLE.................................................231 CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS AND CONDENSER FINS...........231 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER.............232 REPLACE HYDRAULIC OIL FILTER ELEMENT...................................234 EVERY 1000 HOURS MAINTENANCE...............................................235 CHANGE OIL IN SWING MACHINERY CASE.....................................235 CHANGE OIL IN FINAL DRIVE CASE.........................................236 FAN BELT-INSPECT/REPLACE...............................................236 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.............................236 CHECK PLAY OF TURBOCHARGER ROTOR.......................................236 EVERY 2000 HOURS MAINTENANCE...............................................237 CHECK PTO GEAR CASE,ADD OIL............................................237 HYDRAULIC OIL TANK STRAINER-CLEAN......................................238 CLEAN,CHECK TURBOCHARGER...............................................238 CHECK ALTERNATOR,STARTING MOTOR........................................238 CHECK ENGINE VALVE CLEARANCE,ADJUST....................................238 EVERY 4000 HOURS MAINTENANCE...............................................239 CHECK WATER PUMP.......................................................239 EVERY 5000 HOURS MAINTENANCE...............................................240 CHANGE OIL IN HYDRAULIC TANK...........................................240 SPECIFICATIONS.....................................................................241 SPECIFICATIONS.................................................................242 ATTACHMENTS,OPTIONS................................................................245 ATTACHMENTS AND OPTIONS-GENERAL INFORMATION....................................246 SAFETY FIRST...............................................................246 ATTACHMENT INSTALLATION....................................................247 BUCKET WITH HOOK...............................................................248 HOOK CONDITION.............................................................248 PROHIBITED OPERATIONS......................................................248 AIR CONDITIONER................................................................249 AIR CONDITIONER CONTROL PANEL..............................................249 AIR CONDITIONER CONTROLS...................................................254 AIR CONDITIONER MAINTENANCE................................................254 MACHINE READY FOR ATTACHMENT...................................................255 LOCATIONS..................................................................255 HYDRAULIC CIRCUIT..........................................................258 ATTACHMENT REMOVAL AND INSTALLATION........................................259 ATTACHMENT OPERATIONS......................................................263 LONG TERM STORAGE..........................................................266 SPECIFICATIONS.............................................................266 ATTACHMENT GUIDE...............................................................267 OTHER ATTACHMENT...........................................................267 ATTACHMENT COMBINATIONS....................................................268 RECOMMENDED ATTACHMENT OPERATIONS..............................................269 HYDRAULIC BREAKER..........................................................269 INDEX..............................................................................274
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