Komatsu PC138US-8 & PC138USLC-8 Excavator Operation and Maintenance Manual – TEN00189-01 PDF

Description

Komatsu PC138US-8 and PC138USLC-8 Excavator Operation and Maintenance Manual

This Komatsu PC138US-8 & PC138USLC-8 Excavator Operation and Maintenance Manual is the complete document supplied with the machine, published under form number TEN00189-01. It covers both the PC138US-8 and the longer-undercarriage PC138USLC-8 Galeo hydraulic excavators in standard and blade specification, and it is written for the operator, the field mechanic and the maintenance planner alike. Everything in it applies directly to these two machines — the layout of the cab, the monitor, the switch panel, the daily checks, the service intervals and the exact fluid and torque values are all specific to this model, not a generic excavator guide.

The manual runs the full length of the machine’s working life: from the first 100-hour break-in period through the daily walk-around, the 100 / 250 / 500 / 1000 / 2000 / 4000 / 5000 and 8000-hour maintenance milestones, and on to long-term storage. The Komatsu PC138US-8 PC138USLC-8 Excavator Operation and Maintenance Manual is the reference you keep in the magazine box at the rear of the cab, and it is the one the maintenance interval chart on the machine monitor is built around.

File Details

• Manual type: Operation and Maintenance Manual
• Brand: Komatsu
• Models covered: PC138US-8, PC138USLC-8 (Galeo hydraulic excavator, standard and blade specification)
• Engine: Komatsu SAA4D95LE-5 diesel engine
• Document number: TEN00189-01
• Language: English
• Page count: 375 pages
• File format: PDF
• Publication date: 03-07 (March 2007), printed in Japan

Chapters Covered

• Foreword — how to use the manual, manual storage location, warranty statement
• Safety Information — signal words, safety labels using words and pictograms
• Introduction and Directions of Machine — front, rear, left, right conventions and machine orientation
• Breaking-In the New Machine — procedures for the first 100 hours
• Product Information — product identification number (PIN) plate, EPA regulations and engine number plate, service meter location, machine serial number record
• Safety — location of safety labels, full safety label reproductions with part numbers
• General Precautions — safety rules, working wear, fire extinguisher and first aid kit, keeping the machine clean, handrails and steps, mounting and dismounting, burn prevention, fire and explosion prevention, working on loose ground, distance to high voltage cables, ventilation, signalman signals, asbestos dust prevention
• Safety Machine Operation — starting engine, checks before starting, operation, transportation, battery, towing, lifting objects with bucket
• Safety Maintenance Information — warning tag, workplace tidiness, two workers for maintenance when the engine is running, proper tools, accumulator and gas spring, work under the machine, high-pressure oil, high fuel pressure, high voltage, waste materials, compressed air, periodic replacement of safety critical parts
• Operation — machine view illustrations, controls and gauges, detailed controls and gauges, monitoring system, meter display and pilot display, emergency / caution / basic check monitors, switches, function switches, working mode selector, travel speed selector, wiper and washer, buzzer cancel, air conditioner controls, radio, fuse and fusible link, auxiliary electric power, controllers, operation manual storage, tool box, grease pump holder, cup holder, ashtray, fire extinguisher
• Machine Operations and Controls — before starting engine, walk-around checks, checks before starting, starting engine (normal and cold weather), after starting engine, engine warm-up, hydraulic equipment warm-up, stopping the engine, machine operation, steering, swinging, work equipment controls and operations, working mode, prohibited operations, general operation information, traveling on slopes, escape from mud, recommended applications, bucket replacement and inversion, parking, machine inspection after daily work, locking, road liners, transportation
• Transportation — transportation procedure, loading and unloading with trailer, securing the machine, lifting machine, stowing the radio antenna
• Cold Weather Operation — fuel and lubricants, cooling system coolant, battery care, after daily work completion, after cold weather season
• Long Term Storage — before storage, during storage, after storage, starting the machine after long-term storage
• Troubles and Actions — running out of fuel and bleeding air, phenomena that are not failures, towing the machine, lightweight towing hook, severe job conditions, discharged battery, charging, starting engine with booster cables, other trouble charts for electrical system, chassis and engine, electronic control system error codes
• Maintenance Information — service meter reading, Komatsu genuine parts and lubricants, dust jobsite handling, hydraulic system air bleeding, checks after inspection and maintenance
• Outline of Service — factory-fill oils and coolants, handling oil, fuel, coolant, grease, KOWA oil analysis and sampling
• Wear Parts — wear parts list with part numbers and replacement frequency
• Recommended Fuel, Coolant, and Lubricant — ambient temperature selection tables, specified and refill capacities
• Tightening Torque Specifications — standard torque tables by bolt and hose size
• Safety Critical Parts — periodic replacement list with intervals
• Maintenance Schedule — full schedule chart and hydraulic breaker maintenance intervals
• Maintenance Procedure — when required items, every 100 / 250 / 500 / 1000 / 2000 / 4000 / 5000 / 8000 hours service
• Specifications — machine weight, dimensions, travel and swing speeds, working ranges
• Attachments and Options — bucket with hook, machine ready for attachment, attachment guide and combinations, track shoe selection, recommended attachment operations, KOMTRAX
• Index

Read end to end, the Komatsu PC138US-8 PC138USLC-8 service and operation manual gives a technician the full picture of the machine rather than a single slice of it. The operation half explains what every lever, pedal, switch and monitor reading on the PC138US-8 and PC138USLC-8 actually does, how the working modes P, E, L, B and ATT change machine behaviour, how the auto-deceleration and turbo protect functions behave, and how to travel, swing and dig safely on level ground and on slopes. The maintenance half then takes over with the service intervals, the greasing points, the oil and filter change procedures, the track tension adjustment, the bucket tooth replacement and bucket clearance adjustment, and the accumulator and gas spring checks. In between sits the reference material that keeps the whole thing accurate — fluid capacities, tightening torques, safety critical part replacement intervals, and the error code chart for the electronic control system. It is a single document that covers normal operation, scheduled service and the troubleshooting path when something is not behaving as it should.

What This Manual Lets You Do

With this manual on hand you can carry out the complete daily pre-start inspection routine without guessing which items belong in it, run the engine and hydraulic warm-up procedures correctly in cold weather, and set the working mode to match the job. You can perform the scheduled maintenance at every interval up to 8000 hours using the exact procedures, greasing points and torque values Komatsu specifies, rather than relying on a general excavator service routine that may not match the PC138US-8 or PC138USLC-8. You can bleed the fuel system after running dry, bleed air from the hydraulic circuit after a repair, adjust track tension safely, replace bucket teeth on either vertical or horizontal pin type buckets, and work through the electrical, chassis and engine troubleshooting charts when a fault appears. You can also read the monitor user codes and understand what each one tells you about the pump control system, swing brake system, engine controller, throttle system and sensor circuits. For transport days, the manual gives the loading, unloading, securing and lifting procedures with the angles and block placements that keep the machine stable.

Why the Correct Procedures Matter

Komatsu designed the PC138US-8 and PC138USLC-8 around specific fluid grades, service intervals and operating limits. Using the wrong hydraulic oil, skipping a filter change, or running the engine hard before the warm-up is complete will shorten the life of the pump, the cylinders and the engine itself. The correct torque on track shoe bolts, the correct track deflection, the correct bucket clearance and the correct antifreeze mix ratio all have real consequences. This operation and maintenance manual is where those numbers live. It also carries the safety material — the warning tags, the lock lever procedure, the high-pressure oil and high-pressure fuel precautions, the accumulator handling rules and the safety label locations — that keep the person working on the machine out of harm’s way.

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Instant PDF Delivery

The Komatsu PC138US-8 PC138USLC-8 Excavator Operation and Maintenance Manual is delivered as an instant PDF download immediately after payment. There is no shipping, no waiting for a physical book and no separate order to track. The file opens on any device — laptop, tablet or phone — and any page can be printed for the workshop, the cab or the service truck. Keep one copy on the machine and one in the office, and search the file directly when you need a torque value, a capacity or a service interval without paging through a paper book with greasy hands.