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Komatsu PC128UU-2 Hydraulic Excavator Operation & Maintenance Manual 5001 and up – PDF DOWNLOAD
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Komatsu PC128UU-2 Hydraulic Excavator Operation & Maintenance Manual
SERIAL NUMBERS : PC128-2 -5001 and up
Book Code: SEAM035500
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Description
Komatsu PC128UU-2 Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu PC128UU-2 Hydraulic Excavator Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavators
Manuals Type: Operation & Maintenance Manual
Machine Model: PC128UU-2
Serial Number: 5001 and up
Book Code: SEAM035500
Language: English
Pages: 279
File Format: Portable Document Format (PDF)
KOMATSU PC128UU-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL 5001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC128UU-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 for the 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 PC128UU-2 Hydraulic Excavator Operation & Maintenance Manual
MAIN MENU............................................................................................................................ 0 COVER PAGE........................................................................................................................... 1 FOREWORD............................................................................................................................. 8 FOREWORD......................................................................................................................... 9 SAFETY INFORMATION............................................................................................................... 10 INTRODUCTION..................................................................................................................... 12 DIRECTIONS OF MACHINE........................................................................................................ 12 PRODUCT INFORMATION.............................................................................................................. 13 MACHINE SERIAL NUMBER PLATE AND ITS LOCATION................................................................................. 13 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION.................................................................................. 13 SERVICE METER LOCATION....................................................................................................... 14 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.................................................................................. 14 CONTENTS............................................................................................................................. 15 SAFETY............................................................................................................................... 19 SAFETY INFORMATION............................................................................................................... 20 POSITION FOR ATTACHING SAFETY LABELS............................................................................................. 22 POSITION FOR ATTACHING SAFETY LABELS......................................................................................... 23 SAFETY LABELS................................................................................................................ 24 SAFETY INFORMATION............................................................................................................... 29 SAFETY RULES................................................................................................................. 29 IF ABNORMALITIES ARE FOUND................................................................................................... 29 WORKING WEAR AND PERSONAL PROTECTIVE ITEMS................................................................................... 29 FIRE EXTINGUISHER AND FIRST AID KIT.......................................................................................... 29 SAFETY EQUIPMENT............................................................................................................. 30 KEEP MACHINE CLEAN........................................................................................................... 30 KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................ 30 LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................ 30 HANDRAILS AND STEPS.......................................................................................................... 31 MOUNTING AND DISMOUNTING..................................................................................................... 32 NO PERSONS ON ATTACHMENT..................................................................................................... 32 BURN PREVENTION.............................................................................................................. 32 FIRE PREVENTION AND EXPLOSION PREVENTION..................................................................................... 33 ACTION IF FIRE OCCURS........................................................................................................ 34 WINDSHIELD WASHER FLUID...................................................................................................... 34 FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION............................................................. 34 ATTACHMENT INSTALLATION...................................................................................................... 34 ATTACHMENT COMBINATIONS...................................................................................................... 35 CAB WINDOW GLASSES........................................................................................................... 35 UNAUTHORIZED MODIFICATIONS................................................................................................... 35 SAFETY AT JOBSITE............................................................................................................ 35 WORKING ON LOOSE GROUND...................................................................................................... 35 DISTANCE AT HIGH VOLTAGE CABLES.............................................................................................. 36 ENSURE GOOD VISIBILITY....................................................................................................... 36 VENTILATION FOR ENCLOSED AREA................................................................................................ 37 SIGNALMAN'S SIGNAL AND SIGNS................................................................................................. 37 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................................................... 37 ASBESTOS DUST HAZARD PREVENTION.............................................................................................. 37 SAFETY MACHINE OPERATION......................................................................................................... 38 BEFORE STARTING ENGINE....................................................................................................... 38 CHECKS BEFORE STARTING ENGINE............................................................................................ 38 SAFETY RULES FOR STARTING ENGINE......................................................................................... 39 STARTING ENGINE IN COLD WEATHER.......................................................................................... 39 AFTER STARTING ENGINE........................................................................................................ 40 CHECKS AFTER STARTING ENGINE............................................................................................. 40 SAFETY RULES FOR CHANGING MACHINE DIRECTIONS............................................................................. 40 SAFETY RULES FOR TRAVELING............................................................................................... 41 TRAVELING ON SLOPES...................................................................................................... 42 OPERATIONS ON SLOPES..................................................................................................... 43 PROHIBITED OPERATIONS.................................................................................................... 43 OPERATIONS ON SNOW....................................................................................................... 45 PARKING MACHINE.......................................................................................................... 45 TRANSPORTATION............................................................................................................... 46 LOADING AND UNLOADING.................................................................................................... 46 SHIPPING THE MACHINE..................................................................................................... 47 BATTERY...................................................................................................................... 48 BATTERY HAZARD PREVENTION................................................................................................ 48 STARTING ENGINE WITH BOOSTER CABLES...................................................................................... 49 TOWING....................................................................................................................... 50 SAFETY RULES FOR TOWING.................................................................................................. 50 LIFTING OBJECTS WITH BUCKET.................................................................................................. 51 SAFETY RULES FOR LIFTING OBJECTS......................................................................................... 51 SAFETY MAINTENANCE INFORMATION................................................................................................... 52 WARNING TAG.................................................................................................................. 52 KEEP WORK PLACE AND CLEAN AND TIDY........................................................................................... 52 APPOINT LEADER WHEN WORKING WITH OTHERS...................................................................................... 52 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................................. 53 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................................................... 54 PROPER TOOLS................................................................................................................. 54 ACCUMULATOR.................................................................................................................. 55 PERSONNEL.................................................................................................................... 55 ATTACHMENTS.................................................................................................................. 55 WORK UNDER THE MACHINE....................................................................................................... 55 NOISE........................................................................................................................ 56 WHEN USING HAMMER............................................................................................................ 56 WELDING WORKS................................................................................................................ 56 REMOVING BATTERY TERMINALS................................................................................................... 56 SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................................... 57 DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................ 57 SAFETY RULES FOR HIGH-PRESSURE OIL........................................................................................... 57 SAFETY HANDLING HIGH-PRESSURE HOSES.......................................................................................... 58 WASTE MATERIALS.............................................................................................................. 58 AIR CONDITIONER MAINTENANCE.................................................................................................. 58 COMPRESSED AIR............................................................................................................... 58 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................ 59 OPERATION............................................................................................................................ 60 GENERAL VIEW..................................................................................................................... 61 GENERAL VIEW OF MACHINE...................................................................................................... 61 GENERAL VIEW CONTROLS AND GAUGES............................................................................................. 62 EXPLANATION OF COMPONENTS........................................................................................................ 63 MACHINE MONITOR.............................................................................................................. 63 4-SYSTEM..................................................................................................................... 68 SWITCHES..................................................................................................................... 71 CONTROL LEVERS, PEDALS....................................................................................................... 76 FRONT WINDOW................................................................................................................. 80 SLIDING DOOR................................................................................................................. 83 REAR WINDOW.................................................................................................................. 84 HAMMER FOR EMERGENCY ESCAPE.................................................................................................. 84 STOW-AWAY TYPE STEP.......................................................................................................... 85 CAP, COVER WITH LOCK......................................................................................................... 87 ENGINE HOOD.................................................................................................................. 88 CAB REAR COVER............................................................................................................... 89 PUMP ROOM DOOR, BATTERY ROOM DOOR............................................................................................ 90 DOOR AT FRONT OF TOOL BOX.................................................................................................... 91 FUSE......................................................................................................................... 92 FUSIBLELINK.................................................................................................................. 92 POWER SOURCE FOR OPTION...................................................................................................... 93 CONTROLLER................................................................................................................... 93 HANDLING AIR CONDITIONER..................................................................................................... 94 CAR RADIO.................................................................................................................... 97 HANDLING ACCUMULATOR.........................................................................................................102 OPERATION AND MAINTENANCE MANUAL HOLDER......................................................................................103 TOOL COMPARTMENT.............................................................................................................103 GREASE GUN HOLDER............................................................................................................103 ASHTRAY......................................................................................................................103 MACHINE OPERATIONS AND CONTROLS..................................................................................................104 BEFORE STARTING ENGINE.......................................................................................................104 STARTING ENGINE..............................................................................................................117 AFTER STARTING ENGINE........................................................................................................120 STOPPING THE ENGINE..........................................................................................................125 CHECK AFTER SHUT OFF ENGINE..................................................................................................125 MACHINE OPERATION............................................................................................................126 STEERING THE MACHINE.........................................................................................................130 SWINGING.....................................................................................................................132 WORK EQUIPMENT CONTROLS AND OPERATIONS.......................................................................................133 PROHIBITED OPERATIONS........................................................................................................135 GENERAL OPERATION INFORMATION................................................................................................139 TRAVELING ON SLOPES..........................................................................................................141 ESCAPE FROM MUD..............................................................................................................143 RECOMMENDED APPLICATIONS.....................................................................................................144 BUCKET REPLACEMENT...........................................................................................................146 PARKING MACHINE..............................................................................................................148 CHECK AFTER FINISHING WORK...................................................................................................149 LOCKING......................................................................................................................150 HANDLING 4-SYSTEM............................................................................................................151 HANDLING ROAD LINER..........................................................................................................165 TRANSPORTATION...................................................................................................................167 TRANSPORTATION PROCEDURE.....................................................................................................167 LOADING AND UNLOADING WITH TRAILER...........................................................................................168 LIFTING MACHINE..............................................................................................................174 COLD WEATHER OPERATION...........................................................................................................176 COLD WEATHER OPERATION INFORMATION...........................................................................................176 AFTER DAILY WORK COMPLETION..................................................................................................178 AFTER COLD WEATHER SEASON....................................................................................................179 LONG TERM STORAGE................................................................................................................180 BEFORE STORAGE...............................................................................................................180 DURING STORAGE...............................................................................................................180 AFTER STORAGE................................................................................................................181 TROUBLESHOOTING..................................................................................................................182 AFTER RUNNING OUT OF FUEL....................................................................................................182 PHENOMENA THAT ARE NOT FAILURES..............................................................................................182 TOWING THE MACHINE...........................................................................................................185 LIGHTWEIGHT TOWING HOOK......................................................................................................185 PRECAUTIONS ON PARTICULAR JOBSITES...........................................................................................185 DISCHARGED BATTERY...........................................................................................................186 OTHER TROUBLE................................................................................................................191 MAINTENANCE .........................................................................................................................196 MAINTENANCE INFORMATION..........................................................................................................197 LUBRICANTS, COOLANT AND FILTERS..................................................................................................200 OIL..........................................................................................................................200 ELECTRIC SYSTEM MAINTENANCE..................................................................................................202 WEAR PARTS LIST..................................................................................................................203 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................................................204 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.............................................................................204 TIGHTENING TORQUE SPECIFICATIONS.................................................................................................208 TIGHTENING TORQUE LIST.......................................................................................................208 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................................209 SAFETY CRITICAL PARTS........................................................................................................209 MAINTENANCE SCHEDULE.............................................................................................................210 MAINTENANCE SCHEDULE CHART...................................................................................................210 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...................................................................................212 MAINTENANCE PROCEDURE............................................................................................................213 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...............................................................213 REPLACE FUEL FILTER CARTRIDGE............................................................................................213 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................................213 WHEN REQUIRED................................................................................................................214 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................................214 CLEAN INSIDE OF COOLING SYSTEM...........................................................................................217 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................................220 CHECK AND ADJUST TRACK TENSION...........................................................................................222 CHECK ROAD LINER MACHINES EQUIPPED WITH ROAD LINER)......................................................................224 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................224 REPLACE BUCKET TEETH (VERTICAL PIN TYPE..................................................................................225 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...............................................................................228 ADJUST BUCKET CLEARANCE..................................................................................................229 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................................230 CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...........................................231 WASHING WASHABLE FLOOR...................................................................................................232 BLEEDING AIR FROM HYDRAULIC SYSTEM.......................................................................................234 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..............................................................236 CHECK BEFORE STARTING........................................................................................................237 EVERY 50 HOURS MAINTENANCE...................................................................................................238 DRAIN WATER AND SEDIMENT FROM FUEL TANK..................................................................................238 EVERY 100 HOURS MAINTENANCE..................................................................................................239 LUBRICATING..............................................................................................................239 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL........................................................................241 EVERY 250 HOURS MAINTENANCE..................................................................................................242 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................................242 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................................243 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................................244 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT.................................................................245 EVERY 500 HOURS MAINTENANCE..................................................................................................247 REPLACE FUEL FILTER CARTRIDGE............................................................................................247 CHECK SWING PINION GREASE LEVEL, ADD GREASE.............................................................................248 LUBRICATE SWING CIRCLE (2 POINTS)........................................................................................248 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)....249 CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)......250 REPLACE HYDRAULIC FILTER ELEMENT.........................................................................................251 EVERY 1000 HOURS MAINTENANCE.................................................................................................252 CHANGE OIL IN SWING MACHINERY CASE.......................................................................................252 CHANGE OIL IN FINAL DRIVE CASE...........................................................................................253 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...............................................................................253 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................................................253 CHECK FAN BELT TENSION AND REPLACE FAN BELT..............................................................................253 EVERY 2000 HOURS MAINTENANCE.................................................................................................254 CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL................................................................................254 CLEAN HYDRAULIC TANK STRAINER............................................................................................255 CLEAN, CHECK TURBOCHARGER................................................................................................255 CHECK ALTERNATOR, STARTING MOTOR.........................................................................................255 CHECK ENGINE VALVE CLEARANCE ADJUST......................................................................................255 EVERY 4000 HOURS MAINTENANCE.................................................................................................256 CHECK WATER PUMP.........................................................................................................256 EVERY 5000 HOURS MAINTENANCE.................................................................................................257 CHANGE OIL IN HYDRAULIC TANK.............................................................................................257 SPECIFICATIONS.......................................................................................................................259 SPECIFICATIONS...................................................................................................................260 ATTACHMENTS AND OPTIONS..............................................................................................................262 GENERAL PRECAUTIONS..............................................................................................................263 PRECAUTIONS RELATED TO SAFETY................................................................................................263 PRECAUTIONS WHEN INSTALLING ATTACHMENTS......................................................................................265 HANDLING BUCKET WITH HOOK........................................................................................................266 CHECKING FOR DAMAGE TO BUCKET WITH HOOK......................................................................................266 PROHIBITED OPERATIONS........................................................................................................266 HANDLING CAR HEATER..............................................................................................................267 EXPLANATION OF COMPONENTS....................................................................................................267 PREPARING CAR HEATER.........................................................................................................267 LOCATION OF FIRE EXTINGUISHER................................................................................................268 INTRODUCTION OF ATTACHMENTS......................................................................................................269 SPECIFICATION, USE...........................................................................................................269 ATTACHMENT INSTALLATION COMBINATION TABLE........................................................................................270 ATTACHMENT COMBINATIONS......................................................................................................270 RECOMMENDED ATTACHMENT OPERATIONS................................................................................................271 HYDRAULIC BREAKER............................................................................................................271 INDEX................................................................................................................................276
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