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Komatsu Pc128Us-2 Hydraulic Excavator Operation & Maintenance Manual SN 6457 And Up – PDF DOWNLOAD
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Komatsu Pc128Us-2 Hydraulic Excavator Operation & Maintenance Manual
Book Code: SEAM035404T
SERIAL NUMBERS PC128US-6457 and up
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Description
Komatsu Pc128Us-2 Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pc128Us-2 Hydraulic Excavator Operation & Maintenance Manual
Model Specification: KOMATSU PC128US-2 HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 263
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PC128US-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 6457 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pc128Us-2 Hydraulic Excavator 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.
TABLE OF CONTENTS:
Komatsu Pc128Us-2 Hydraulic Excavator 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........................................................................................... 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............................................................................................................... 25 SAFETY RULES................................................................................................................. 25 IF ABNORMALITIES ARE FOUND................................................................................................... 25 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................................................................... 25 FIRE EXTINGUISHER AND FIRST AID KIT.......................................................................................... 25 SAFETY EQUIPMENT............................................................................................................. 26 KEEP MACHINE CLEAN........................................................................................................... 26 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................ 26 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................ 26 HANDRAILS AND STEPS.......................................................................................................... 27 CRUSHING OR CUTTING PREVENTION............................................................................................... 28 MOUNTING AND DISMOUNTING..................................................................................................... 28 NO PERSONS ON ATTACHMENTS.................................................................................................... 28 BURN PREVENTION.............................................................................................................. 28 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...................................................................................................... 30 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......................................................................................... 35 STARTING ENGINE IN COLD WEATHER.......................................................................................... 35 OPERATION.................................................................................................................... 36 CHECKS AFTER STARTING ENGINE............................................................................................. 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....................................................................................................... 41 PARKING MACHINE.......................................................................................................... 41 TRANSPORTATION............................................................................................................... 42 LOADING AND UNLOADING.................................................................................................... 42 SHIPPING THE MACHINE..................................................................................................... 43 BATTERY...................................................................................................................... 44 BATTERY HAZARD PREVENTION................................................................................................ 44 STARTING ENGINE WITH BOOSTER CABLES...................................................................................... 45 TOWING....................................................................................................................... 46 SAFETY RULES FOR TOWING.................................................................................................. 46 LIFTING OBJECTS WITH BUCKET.................................................................................................. 47 SAFETY RULES FOR LIFTING OBJECTS......................................................................................... 47 SAFETY MAINTENANCE INFORMATION................................................................................................... 48 WARNING TAG.................................................................................................................. 48 KEEP WORK PLACE CLEAN AND TIDY............................................................................................... 48 APPOINT LEADER WHEN WORKING WITH OTHERS...................................................................................... 48 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................................. 49 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................................... 50 PROPER TOOLS................................................................................................................. 50 ACCUMULATOR.................................................................................................................. 51 PERSONNEL.................................................................................................................... 51 ATTACHMENTS.................................................................................................................. 51 WORK UNDER THE MACHINE....................................................................................................... 51 NOISE........................................................................................................................ 52 WHEN USING HAMMER............................................................................................................ 52 WELDING WORKS................................................................................................................ 52 REMOVING BATTERY TERMINALS................................................................................................... 52 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 53 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................ 53 SAFETY RULES FOR HIGH-PRESSURE OIL........................................................................................... 53 SAFETY HANDLING HIGH-PRESSURE HOSES.......................................................................................... 54 WASTE MATERIALS.............................................................................................................. 54 AIR CONDITIONER MAINTENANCE.................................................................................................. 54 COMPRESSED AIR............................................................................................................... 54 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................ 55 OPERATION............................................................................................................................ 56 GENERAL VIEW..................................................................................................................... 57 GENERAL VIEW OF MACHINE...................................................................................................... 57 GENERAL VIEW CONTROLS AND GAUGES............................................................................................. 58 EXPLANATION OF COMPONENTS........................................................................................................ 59 MACHINE MONITOR.............................................................................................................. 59 SWITCHES..................................................................................................................... 65 CONTROL LEVERS, PEDALS....................................................................................................... 71 FRONT WINDOW................................................................................................................. 75 SLIDING DOOR................................................................................................................. 78 REAR WINDOW.................................................................................................................. 79 HAMMER FOR EMERGENCY ESCAPE.................................................................................................. 79 CAP, COVER WITH LOCK......................................................................................................... 80 ENGINE HOOD.................................................................................................................. 81 CAB REAR COVER............................................................................................................... 82 PUMP ROOM DOOR, BATTERY ROOM DOOR............................................................................................ 83 DOOR AT FRONT OF TOOL BOX.................................................................................................... 84 FUSE......................................................................................................................... 85 FUSIBLELINK.................................................................................................................. 85 POWER SOURCE FOR OPTION...................................................................................................... 86 CONTROLLER................................................................................................................... 86 HANDLING AIR CONDITIONER..................................................................................................... 87 CAR RADIO.................................................................................................................... 90 HANDLING ACCUMULATOR......................................................................................................... 95 OPERATION AND MAINTENANCE MANUAL HOLDER...................................................................................... 96 TOOL COMPARTMENT............................................................................................................. 96 GREASE GUN HOLDER............................................................................................................ 96 ASHTRAY...................................................................................................................... 96 MACHINE OPERATIONS AND CONTROLS.................................................................................................. 97 BEFORE STARTING ENGINE....................................................................................................... 97 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................................................................................................130 TRAVELING ON SLOPES..........................................................................................................131 ESCAPE FROM MUD..............................................................................................................133 RECOMMENDED APPLICATIONS.....................................................................................................134 REPLACEMENT AND INVERSION OF BUCKET..........................................................................................136 PARKING MACHINE..............................................................................................................140 CHECK AFTER FINISHING WORK...................................................................................................141 LOCKING......................................................................................................................142 HANDLING ROAD LINER..........................................................................................................143 TRANSPORTATION...................................................................................................................145 TRANSPORTATION PROCEDURE.....................................................................................................145 LOADING AND UNLOADING WITH TRAILER...........................................................................................146 LIFTING MACHINE..............................................................................................................152 COLD WEATHER OPERATION...........................................................................................................154 COLD WEATHER OPERATION INFORMATION...........................................................................................154 AFTER DAILY WORK COMPLETION..................................................................................................156 AFTER COLD WEATHER SEASON....................................................................................................157 LONG TERM STORAGE................................................................................................................158 BEFORE STORAGE...............................................................................................................158 DURING STORAGE...............................................................................................................158 AFTER STORAGE................................................................................................................159 TROUBLESHOOTING..................................................................................................................160 AFTER RUNNING OUT OF FUEL....................................................................................................160 PHENOMENA THAT ARE NOT FAILURES..............................................................................................160 TOWING THE MACHINE...........................................................................................................161 LIGHTWEIGHT TOWING HOOK......................................................................................................161 PRECAUTIONS ON PARTICULAR JOBSITES...........................................................................................161 DISCHARGED BATTERY...........................................................................................................162 OTHER TROUBLE................................................................................................................167 MAINTENANCE..........................................................................................................................171 MAINTENANCE INFORMATION..........................................................................................................172 LUBRICANTS, COOLANT AND FILTERS..................................................................................................175 OUTLINE OF OIL, FUEL, COOLANT................................................................................................175 ELECTRIC SYSTEM MAINTENANCE..................................................................................................177 HANDLING HYDRAULIC SYSTEM....................................................................................................177 WEAR PARTS LIST..................................................................................................................179 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................................................180 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.............................................................................180 TIGHTENING TORQUE SPECIFICATIONS.................................................................................................184 TIGHTENING TORQUE LIST.......................................................................................................184 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................................185 SAFETY CRITICAL PARTS........................................................................................................185 MAINTENANCE SCHEDULE.............................................................................................................186 MAINTENANCE SCHEDULE CHART...................................................................................................186 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...................................................................................188 MAINTENANCE PROCEDURE............................................................................................................189 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...............................................................189 WHEN REQUIRED................................................................................................................190 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................190 CLEAN INSIDE OF COOLING SYSTEM...........................................................................................193 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................196 CHECK AND ADJUST TRACK TENSION...........................................................................................198 CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER).....................................................................200 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................200 REPLACE BUCKET TEETH (VERTICAL PIN TYPE).................................................................................201 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................204 ADJUST BUCKET CLEARANCE..................................................................................................205 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................206 CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...........................................207 REPLACE ADDITIONAL BREAKER FILTER ELEMENT (IF EQUIPPED)..................................................................208 WASHING WASHABLE FLOOR...................................................................................................209 BLEEDING AIR FROM HYDRAULIC SYSTEM.......................................................................................211 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..............................................................213 CHECK BEFORE STARTING........................................................................................................214 EVERY 50 HOURS MAINTENANCE...................................................................................................215 DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................215 EVERY 100 HOURS MAINTENANCE..................................................................................................216 LUBRICATING..............................................................................................................216 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.........................................................................218 EVERY 250 HOURS MAINTENANCE..................................................................................................219 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................219 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................220 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................221 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................................................222 EVERY 500 HOURS MAINTENANCE..................................................................................................224 REPLACE FUEL FILTER CARTRIDGE............................................................................................224 CHECK SWING PINION GREASE LEVEL, ADD GREASE..............................................................................225 LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................225 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....226 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......227 REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................228 EVERY 1000 HOURS MAINTENANCE.................................................................................................229 CHANGE OIL IN SWING MACHINERY CASE.......................................................................................229 CHANGE OIL IN FINAL DRIVE CASE...........................................................................................230 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................230 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................230 CHECK FAN BELT TENSION AND REPLACE FAN BELT..............................................................................230 EVERY 2000 HOURS MAINTENANCE.................................................................................................231 CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL................................................................................231 CLEAN HYDRAULIC TANK STRAINER............................................................................................232 CLEAN, CHECK TURBOCHARGER................................................................................................232 CHECK ALTERNATOR, STARTING MOTOR.........................................................................................232 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................................232 EVERY 4000 HOURS MAINTENENCE.................................................................................................233 CHECK WATER PUMP.........................................................................................................233 EVERY 5000 HOURS MAINTENANCE.................................................................................................234 CHANGE OIL IN HYDRAULIC TANK.............................................................................................234 SPECIFICATIONS.......................................................................................................................236 SPECIFICATIONS...................................................................................................................237 ATTACHMENTS AND OPTIONS..............................................................................................................239 GENERAL PRECAUTIONS..............................................................................................................240 PRECAUTIONS RELATED TO SAFETY................................................................................................240 PRECAUTIONS WHEN INSTALLING ATTACHMENTS......................................................................................242 HANDLING BUCKET WITH HOOK........................................................................................................243 CHECKING FOR DAMAGE TO BUCKET WITH HOOK......................................................................................243 PROHIBITED OPERATIONS........................................................................................................243 HANDLING CAR HEATER..............................................................................................................244 EXPLANATION OF COMPONENTS....................................................................................................244 PREPARING CAR HEATER.........................................................................................................244 MACHINES READY FOR ATTACHMENTS...................................................................................................245 EXPLANATION OF COMPONENTS....................................................................................................245 HYDRAULIC CIRCUIT............................................................................................................248 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE....................................................................................249 OPERATION....................................................................................................................251 LONG-TERM STORAGE............................................................................................................253 SPECIFICATIONS...............................................................................................................253 INTRODUCTION OF ATTACHMENTS......................................................................................................254 SPECIFICATION, USE...........................................................................................................254 ATTACHMENT INSTALLATION COMBINATION TABLE........................................................................................255 ATTACHMENT COMBINATIONS......................................................................................................255 RECOMMENDED ATTACHMENT OPERATIONS................................................................................................256 HYDRAULIC BREAKER............................................................................................................256 INDEX................................................................................................................................261
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