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Komatsu Pc138US-2 Pc138USLC-2 Hydraulic Excavator Operation & Maintenance Manual SN 5421,1695 and up – PDF DOWNLOAD
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Komatsu Pc138US-2 Pc138USLC-2 Hydraulic Excavator Operation & Maintenance Manual
Book Code :TEN00076-01
MACHINE MODEL SERIAL NUMBER
PC138US-2 – 5421 and up
PC138USLC-2 – 1695 and up
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Description
Komatsu Pc138US-2 Pc138USLC-2 Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pc138US-2 Pc138USLC-2 Hydraulic Excavator Operation & Maintenance Manual
Model Specification: KOMATSU PC138US-2, PC138USLC-2 HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 293
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PC138US-2 PC138USLC-2 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 5421,1695 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pc138US-2 Pc138USLC-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 Pc138US-2 Pc138USLC-2 Hydraulic Excavator Operation & Maintenance Manual
COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 DIRECTIONS OF MACHINE.................................................................. 8 BREAKING-IN THE NEW MACHINE............................................................ 8 PRODUCT INFORMATION........................................................................ 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 9 ENGINE SERIAL NUMBER PLATE AND ITS LOCATION............................................ 9 EPA NAMEPLATE.......................................................................... 10 SERVICE METER LOCATION................................................................. 10 YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR............................................ 11 CONTENTS....................................................................................... 12 SAFETY......................................................................................... 16 SAFETY INFORMATION......................................................................... 17 SAFETY LABELS.............................................................................. 19 LOCATION OF SAFETY LABELS.............................................................. 20 SAFETY LABELS.......................................................................... 21 SAFETY INFORMATION......................................................................... 26 SAFETY RULES........................................................................... 26 IF PROBLEMS 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 WINDOW GLASSES..................................................................... 31 UNAUTHORIZED MODIFICATIONS............................................................. 31 SAFETY AT JOBSITE...................................................................... 31 WORKING ON LOOSE GROUND................................................................ 32 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.................................................... 35 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..................................... 49 PROPER TOOLS........................................................................... 49 ACCUMULATOR............................................................................ 49 PERSONNEL.............................................................................. 50 ATTACHMENTS............................................................................ 50 WORK UNDER THE MACHINE................................................................. 50 NOISE.................................................................................. 50 WHEN USING HAMMER...................................................................... 50 WELDING WORKS.......................................................................... 51 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..................................................... 52 SAFETY HANDLING HIGH-PRESSURE HOSES.................................................... 52 WASTE MATERIALS........................................................................ 52 AIR CONDITIONER MAINTENANCE............................................................ 52 COMPRESSED AIR......................................................................... 53 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 53 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 FUSIBLE LINK........................................................................... 91 AUXILIARY ELECTRIC POWER............................................................... 91 CONTROLLERS............................................................................ 92 AIR CONDITIONER CONTROLS............................................................... 93 RADIO.................................................................................. 98 OPERATION MANUAL STORAGE...............................................................103 TOOL BOX...............................................................................103 GREASE PUMP HOLDER.....................................................................103 HOT AND COOL BOX.......................................................................103 ASHTRAY................................................................................104 FIRE EXTINGUISHER......................................................................104 MACHINE OPERATIONS AND CONTROLS............................................................105 BEFORE STARTING ENGINE.................................................................105 STARTING ENGINE........................................................................121 AFTER STARTING ENGINE..................................................................126 STOPPING THE ENGINE....................................................................129 MACHINE OPERATION......................................................................130 STEERING THE MACHINE...................................................................134 SWINGING...............................................................................136 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................137 WORKING MODE...........................................................................139 PROHIBITED OPERATIONS..................................................................139 GENERAL OPERATION INFORMATION..........................................................142 TRAVELING ON SLOPES....................................................................144 ESCAPE FROM MUD........................................................................146 RECOMMENDED APPLICATIONS...............................................................147 BUCKET REPLACEMENT AND INVERSION.......................................................149 PARKING MACHINE........................................................................151 MACHINE INSPECTION AFTER DAILY WORK....................................................153 LOCKING................................................................................153 ROAD LINERS............................................................................154 TRANSPORTATION.............................................................................156 TRANSPORTATION PROCEDURE...............................................................156 LOADING AND UNLOADING WITH TRAILER.....................................................156 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 TROUBLES AND ACTIONS.......................................................................169 RUNNING OUT OF FUEL....................................................................169 PHENOMENA THAT ARE NOT FAILURES........................................................169 TOWING THE MACHINE.....................................................................170 LIGHTWEIGHT TOWING HOOK................................................................171 SEVERE JOB CONDITION...................................................................171 DISCHARGED BATTERY.....................................................................172 OTHER TROUBLE..........................................................................176 MAINTENANCE....................................................................................182 MAINTENANCE INFORMATION....................................................................183 OUTLINE OF SERVICE.........................................................................185 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................185 ELECTRIC SYSTEM MAINTENANCE............................................................188 WEAR PARTS.................................................................................189 WEAR PARTS LIST........................................................................189 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................190 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................191 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....192 TIGHTENING TORQUE SPECIFICATIONS...........................................................193 TIGHTENING TORQUE LIST.................................................................193 SAFETY CRITICAL PARTS......................................................................194 SAFETY CRITICAL PARTS LIST.............................................................194 MAINTENANCE SCHEDULE.......................................................................195 MAINTENANCE SCHEDULE CHART.............................................................195 MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.............................................196 MAINTENANCE PROCEDURE......................................................................197 INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS).........................197 WHEN REQUIRED..........................................................................198 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.......................................198 CLEAN INSIDE OF COOLING SYSTEM.....................................................202 CHECK AND TIGHTEN TRACK SHOE BOLTS.................................................205 CHECK AND ADJUST TRACK TENSION.....................................................206 CHECK ROAD LINERS..................................................................208 REPLACE ROAD LINERS................................................................208 CHECK ELECTRICAL INTAKE AIR HEATER.................................................208 REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...........................................209 REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE).........................................212 ADJUST BUCKET CLEARANCE............................................................213 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.........................................214 CHECK AND MAINTENANCE AIR CONDITIONER..............................................215 CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER..........................216 REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (IF EQUIPPED)................217 WASH WASHABLE FLOOR................................................................218 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................221 CHECK BEFORE STARTING..................................................................223 EVERY 50 HOURS MAINTENANCE.............................................................224 DRAIN WATER FROM FUEL TANK.........................................................224 EVERY 100 HOURS MAINTENANCE............................................................225 LUBRICATING........................................................................225 CHECK SWING MACHINERY CASE OIL, ADD OIL............................................226 EVERY 250 HOURS MAINTENANCE............................................................227 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................227 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................228 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................230 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................231 EVERY 500 HOURS MAINTENANCE............................................................232 LUBRICATING........................................................................232 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................234 REPLACE FUEL FILTER CARTRIDGE......................................................235 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................236 LUBRICATE SWING CIRCLE.............................................................236 CLEAN, CHECK RADIATOR FINS, AIR COOLER FINS, OIL COOLER FINS, CONDENSER FINS.......236 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.........................................237 REPLACE BREATHER ELEMENT IN HYDRAULIC TANK.........................................239 EVERY 1000 HOURS MAINTENANCE...........................................................240 CHANGE OIL IN SWING MACHINERY CASE.................................................240 CHANGE OIL IN FINAL DRIVE CASE.....................................................241 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................242 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.........................................242 CHECK PLAY TURBOCHARGER ROTOR......................................................242 EVERY 2000 HOURS MAINTENANCE...........................................................243 CHECK PTO GEAR CASE, ADD OIL.......................................................243 CLEAN HYDRAULIC TANK STRAINER......................................................244 CLEAN, CHECK TURBOCHARGER..........................................................244 CHECK ALTERNATOR, STARTING MOTOR...................................................244 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................244 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)......245 EVERY 4000 HOURS MAINTENANCE...........................................................249 CHECK WATER PUMP...................................................................249 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)..........................................249 EVERY 5000 HOURS MAINTENANCE...........................................................250 CHANGE OIL IN HYDRAULIC TANK.......................................................250 SPECIFICATIONS.................................................................................252 SPECIFICATIONS.............................................................................253 ATTACHMENTS, OPTIONS...........................................................................256 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................257 SAFETY FIRST...........................................................................257 ATTACHMENT INSTALLATION................................................................258 BUCKET WITH HOOK...........................................................................259 HOOK CONDITION.........................................................................259 PROHIBITED OPERATIONS..................................................................259 AIR CONDITIONER............................................................................260 AIR CONDITIONER CONTROL PANEL..........................................................260 AIR CONDITIONER CONTROLS...............................................................265 AIR CONDITIONER MAINTENANCE............................................................265 MACHINE READY FOR ATTACHMENT...............................................................266 LOCATIONS..............................................................................266 HYDRAULIC CIRCUIT......................................................................269 ATTACHMENT REMOVAL AND INSTALLATION....................................................270 ATTACHMENT OPERATIONS..................................................................274 LONG TERM STORAGE......................................................................277 SPECIFICATIONS.........................................................................277 ATTACHMENT GUIDE...........................................................................278 OTHER ATTACHMENTS......................................................................278 ATTACHMENT COMBINATIONS................................................................279 SELECTION OF TRACK SHOES...............................................................280 RECOMMENDED ATTACHMENT OPERATIONS..........................................................281 HYDRAULIC BREAKER......................................................................281 CRUSHER................................................................................286 INDEX..........................................................................................290
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