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Komatsu Pc138US-2, Pc138USLC-2E0 Hydraulic Excavator Operation & Maintenance Manual SN 4501, 1501 and up – PDF DOWNLOAD
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Komatsu Pc138US-2, Pc138USLC-2E0 Hydraulic Excavator Operation & Maintenance Manual
Book Code : TEN00003-01
SERIAL NUMBERS
- PC138US-2 4501 and up
- PC138USLC-2E0 1501 and up
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Description
Komatsu Pc138US-2, Pc138USLC-2E0 Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu Pc138US-2, Pc138USLC-2E0 Hydraulic Excavator Operation & Maintenance Manual
Model Specification: KOMATSU PC138US-2, PC138USLC-2E0 HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 285
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU PC138US-2, PC138USLC-2E0 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL SN 4501, 1501 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Pc138US-2, Pc138USLC-2E0 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-2E0 Hydraulic Excavator Operation & Maintenance Manual
MAIN MENU...................................................................................... 0 COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 DIRECTIONS OF 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.................................................................................. 99 ACCUMULATOR............................................................................104 OPERATION MANUAL STORAGE...............................................................105 TOOL BOX...............................................................................105 GREASE PUMP HOLDER.....................................................................105 HOT AND COOL BOX.......................................................................105 ASHTRAY................................................................................106 FIRE EXTINGUISHER......................................................................106 MACHINE OPERATIONS AND CONTROLS............................................................107 BEFORE STARTING ENGINE.................................................................107 STARTING ENGINE........................................................................123 AFTER STARTING ENGINE..................................................................128 STOPPING THE ENGINE....................................................................131 MACHINE OPERATION......................................................................132 STEERING THE MACHINE...................................................................136 SWINGING...............................................................................138 WORK EQUIPMENT CONTROLS AND OPERATIONS.................................................139 WORKING MODE...........................................................................141 PROHIBITED OPERATIONS..................................................................142 GENERAL OPERATION INFORMATION..........................................................144 TRAVELING ON SLOPES....................................................................146 ESCAPE FROM MUD........................................................................148 RECOMMENDED APPLICATIONS...............................................................149 BUCKET REPLACEMENT AND INVERSION.......................................................151 PARKING MACHINE........................................................................153 MACHINE INSPECTION AFTER DAILY WORK....................................................155 ROAD LINERS............................................................................156 TRANSPORTATION.............................................................................158 TRANSPORTATION PROCEDURE...............................................................158 LOADING AND UNLOADING WITH TRAILER.....................................................158 LIFTING MACHINE........................................................................164 COLD WEATHER OPERATION.....................................................................166 COLD WEATHER OPERATION INFORMATION.....................................................166 AFTER DAILY WORK COMPLETION............................................................168 AFTER COLD WEATHER SEASON..............................................................168 LONG TERM STORAGE..........................................................................169 BEFORE STORAGE.........................................................................169 DURING STORAGE.........................................................................169 AFTER STORAGE..........................................................................169 TROUBLES AND ACTIONS.......................................................................170 RUNNING OUT OF FUEL....................................................................170 PHENOMENA THAT ARE NOT FAILURES........................................................170 TOWING THE MACHINE.....................................................................171 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 REPLACE FUEL FILTER CARTRIDGE......................................................237 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..............................217 WASH WASHABLE FLOOR................................................................218 BLEEDING AIR FROM HYDRAULIC SYSTEM.................................................221 METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT........................223 CHECK BEFORE STARTING..................................................................225 EVERY 50 HOURS MAINTENANCE.............................................................226 DRAIN WATER FROM FUEL TANK.........................................................226 EVERY 100 HOURS MAINTENANCE............................................................227 LUBRICATING........................................................................227 CHECK SWING MACHINERY CASE OIL, ADD OIL............................................228 EVERY 250 HOURS MAINTENANCE............................................................229 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.......................................229 CHECK LEVEL OF BATTERY ELECTROLYTE.................................................230 CHECK AND ADJUST COOLING FAN BELT TENSION..........................................232 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................233 EVERY 500 HOURS MAINTENANCE............................................................234 LUBRICATING........................................................................234 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................236 REPLACE FUEL FILTER CARTRIDGE......................................................237 CHECK SWING PINION GREASE LEVEL, ADD GREASE........................................238 LUBRICATE SWING CIRCLE.............................................................238 CLEAN, CHECK RADIATOR FINS, AIR COOLER FINS, OIL COOLER FINS, CONDENSER FINS.......238 CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS.........................................239 EVERY 1000 HOURS MAINTENANCE...........................................................241 CHANGE OIL IN SWING MACHINERY CASE.................................................241 CHANGE OIL IN FINAL DRIVE CASE.....................................................242 REPLACE HYDRAULIC OIL FILTER ELEMENT...............................................243 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.........................................243 CHECK PLAY TURBOCHARGER ROTOR......................................................243 EVERY 2000 HOURS MAINTENANCE...........................................................244 CHECK PTO GEAR CASE, ADD OIL.......................................................244 CLEAN HYDRAULIC TANK STRAINER......................................................245 CLEAN, CHECK TURBOCHARGER..........................................................245 CHECK ALTERNATOR, STARTING MOTOR...................................................245 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................245 EVERY 4000 HOURS MAINTENANCE...........................................................246 CHECK WATER PUMP...................................................................246 EVERY 5000 HOURS MAINTENANCE...........................................................247 CHANGE OIL IN HYDRAULIC TANK.......................................................247 SPECIFICATIONS.................................................................................248 SPECIFICATIONS.............................................................................249 ATTACHMENTS, OPTIONS...........................................................................252 ATTACHMENTS AND OPTIONS - GENERAL INFORMATION..............................................253 SAFETY FIRST...........................................................................253 ATTACHMENT INSTALLATION................................................................254 BUCKET WITH HOOK...........................................................................255 HOOK CONDITION.........................................................................255 PROHIBITED OPERATIONS..................................................................255 AIR CONDITIONER............................................................................256 AIR CONDITIONER CONTROL PANEL..........................................................256 AIR CONDITIONER CONTROLS...............................................................261 AIR CONDITIONER MAINTENANCE............................................................261 MACHINE READY FOR ATTACHMENT...............................................................262 LOCATIONS..............................................................................262 HYDRAULIC CIRCUIT......................................................................265 ATTACHMENT REMOVAL AND INSTALLATION....................................................266 ATTACHMENT OPERATIONS..................................................................270 LONG TERM STORAGE......................................................................273 SPECIFICATIONS.........................................................................273 ATTACHMENT GUIDE...........................................................................274 OTHER ATTACHMENTS......................................................................274 ATTACHMENT COMBINATIONS................................................................275 SELECTION OF TRACK SHOES...............................................................276 RECOMMENDED ATTACHMENT OPERATIONS..........................................................277 HYDRAULIC BREAKER......................................................................277 INDEX..........................................................................................282
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