Komatsu PC138US-11 Manual

Operation &
Maintenance Manual
WENAM00111
PC138US- 11
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
PC138US- 11 F50001 and up
50001 and up
ORIGINAL INSTRUCTIONS
WARNING
Unsafe use of this machine may cause serious
injury or death. Operators and maintenance
personnel must read this manual before operating
or maintaining this machine. This manual should
be kept inside the cab for reference and periodically
reviewed by all personnel whowill come into
contact with the machine.

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FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).

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READ THIS MANUAL
FOREWORD
READ THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the storing location so that all relevant personnel can
read it at any time.
Keep it in the magazine box rear inside the cab.
If this manual is lost or damaged, contact Komatsu or your Ko-
matsu distributor and tell them about the machine model name
and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial
No., see the machine serial No. plate. In order to arrange the
proper Operation and Maintenance Manual, you will need to
provide the machine model name and the serial No.
This manual uses the International System of Units (SI) for
units of measurement. For reference, units that have been
used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the
latest available information concerning your machine or with questions regarding information contained in this
manual.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it
has been shipped. If this machine has been purchased in another country, it may lack certain safety devices and
specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult your Komatsu distributor before
operating the machine.

FOREWORD
SAFETY INFORMATION
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SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
This signal word indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
This signal word indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury. It may also be used to alert against unsafe practices that may
cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
If precautions described are not observed, the machine may be damaged or the service life
may be reduced.
This word is used for information that is useful to know.

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SAFETY LABELS
FOREWORD
SAFETY LABELS
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using pictograms" to indicate safety procedures.
SAFETY LABELS USING PICTOGRAMS
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown inside
a circle.
Komatsu cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore,
the safety messages in this manual and on the machine may
not include all possible safety precautions.
If any procedures or actions not specifically recommended or
allowed in this manual are used, it is your responsibility to take
the necessary steps to ensure safety
In no event should you engage in prohibited uses or actions de-
scribed in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information availa-
ble at that time. Continuing improvements in the design of this machine can lead to changes in detail which may
not be reflected in this manual
Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for ques-
tions regarding information in this manual.
The numbers in the illustrations correspond to the numbers in ( ) in the text.

FOREWORD
NOISE
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NOISE
Two labels indicating the machine noise level are affixed on the machine.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator’s position is 2.5dB, in accordance with
ISO 11201.
• Sound power level emitted by the machine, measured ac-
cording to ISO 6395 (Dynamic test method, simulated
working cycle).
This is the guaranteed value as specified in European di-
rective 2000/14/EC. This value includes an uncertainty of
1.0 dB.
ISO 6396
2000/14/EC

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VIBRATION LEVELS
FOREWORD
VIBRATION LEVELS
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper-
ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with
ISO 7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.61 m/s2 for right arm and 0.74 m/s2 for left arm according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is
0.39 m/s2 according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
VIBRATION - OPERATING CONDITION
Excavating (Digging-loading-rotating-unloading-rotating)
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
• Tension of crawler (for crawler machines)
• Brake and steering systems
• Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling in good condition
• Remove any large rocks or obstacles
• Fill any ditches and holes
• Site manager should provide machine operators with machine and schedule time to maintain terrain
conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
• Adjust the seat and suspension for the weight and size of the operator
• Wear seat belt
• Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
• When pushing with bucket or blade, avoid sudden loading; load gradually
• Drive around obstacles and rough terrain conditions
• Slow down when it is necessary to go over rough terrain
• Make the curve radius of travelling path as large as possible
• Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
• Reduce speed to prevent bounce
• Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
• Operate the machine only when you are in good health
• Provide breaks to reduce long periods of sitting in the same posture
• Do not jump down from the cab or machine

FOREWORD
VIBRATION LEVELS
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• Do not repeatedly handle and lift loads

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INTRODUCTION
FOREWORD
INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
• Digging work
• Ditching work
• Loading work
• Levelling work
For details of work procedure, see MACHINE OPERATIONS AND CONTROLS “RECOMMENDED APPLICA-
TIONS (3-187)”.
The excavator used in handling operations must conform with current local regulations and be equip-
ped with safety valves and an overload alarm in compliance with EN 474-5.
DEMOLITION WORK
• A demolition machine is a machine based on earth
moving machinery (see EN ISO 6165) and including
equipment and attachment (working tool - e.g. pro-
cessor or breaker) specifically designed to demolish,
cut, loosen, separate, pick up, transport and distribute
component parts of buildings or civil engineering
structures.
• This machine is not prepared for use in Demolition.
• Using this machine in demolition work gives an in-
creased risk of serious injury or death.
• All Komatsu machines that are specifically designed,
and can be used for demolition work, will display the
Komatsu demolition decal.
• If the machine does not display this decal and it is
necessary to carry out demolition work, contact your
distributor for information on demolition machinery compliant with the applicable standards.
k
WARNING
k
WARNING

FOREWORD
INTRODUCTION
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DIRECTIONS OF MACHINE
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Operator's seat
(F) Sprocket
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
VISIBILITY FROM OPERATOR'S SEAT
The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below.
Proximity visibility
The figure below shows a visibility from the machine at a spot 1.0 m away from outside the machine and 1.5 m
above the ground.
12 m radius visibility
The figure below shows a visibility from the machine for a radius of 12 m. Shaded areas (A) in the figure show
areas, the views of which are blocked when the machine is equipped with the mirrors and other visibility assis-
tant devices. Be fully aware that there is an area where the operator cannot see when operating the machine.

INTRODUCTION
FOREWORD
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Protective structures
This machine is equipped with a structure to protect the operator (ROPS) conforming to ISO12117-2: 2008.

FOREWORD
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
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ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS
EMISSION
About Engine Technology
This engine technology combines a Komatsu Diesel Oxidation Catalyst (KDOC) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Oxidation Catalyst (KDOC): The system makes possible to eliminate the need for regener-
ation and simplifies the engine control system.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).

PRODUCT INFORMATION
FOREWORD
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PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
It is located on the right bottom of the operator's cab.
The design of the nameplate differs according to the district.
LOCATION OF ENGINE NUMBER PLATE
This is on the side of the filler port bracket.

FOREWORD
PRODUCT INFORMATION
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SERVICE METER LOCATION
This is displayed on the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturers name:
Address:
Komatsu Italia Manufacturing S.p.A.
Via Atheste, 4
35042 Este (PD)
Italy
Distributor name
Address
Service Personnel
Phone/Fax

SERIAL PLATE
FOREWORD
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SERIAL PLATE
A
SERIAL NUMBER
E
MACHINE DESIGNATION/TYPE
B
WEIGHT
F
YEAR OF CONSTRUCTION
C
PRODUCT IDENTIFICATION NUMBER
G
ENGINE POWER
D
MANUFACTURER

FOREWORD
DECLARATION OF CONFORMITY
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DECLARATION OF CONFORMITY
The manufacturer:
Komatsu Italia Manufacturing S.p.A.
Via Atheste, 4
35042 Este (PD)
Italy
Declares that this machine:
PC138US-11
Fulfils all the relevant provisions of following EC Directives:
Machine Directive
2006/42/EC
Electro Magnetic Compatibility Directive
2004/108/EC until 19 April 2016
2014/30/EU after 20 April 2016
Outdoor Noise Directive
2000/14/EC amended by 2005/88/EC
Radio Equipment and Telecommunications
Terminal Equipment Directive
1999/5/EC until 12 June 2016
Radio Equipment Directive
2014/53/EU after 13 June 2016

TABLE OF CONTENTS
FOREWORD
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TABLE OF CONTENTS
FOREWORD .......................................................................................................................................................................1-1
READ THIS MANUAL ................................................................................................................................................1-2
SAFETY INFORMATION...........................................................................................................................................1-3
SAFETY LABELS........................................................................................................................................................1-4
NOISE...........................................................................................................................................................................1-5
VIBRATION LEVELS..................................................................................................................................................1-6
VIBRATION - OPERATING CONDITION ........................................................................................................1-6
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE..........................................................................1-6
INTRODUCTION.........................................................................................................................................................1-8
MAIN USE OF MACHINE..................................................................................................................................1-8
DEMOLITION WORK .........................................................................................................................................1-8
DIRECTIONS OF MACHINE.............................................................................................................................1-9
VISIBILITY FROM OPERATOR'S SEAT.........................................................................................................1-9
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION ...........................................................1-11
PRODUCT INFORMATION.....................................................................................................................................1-12
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.........1-12
LOCATION OF ENGINE NUMBER PLATE...................................................................................................1-12
SERVICE METER LOCATION........................................................................................................................1-13
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ......................................................................1-13
SERIAL PLATE .........................................................................................................................................................1-14
DECLARATION OF CONFORMITY....................................................................................................................... 1- 15
SAFETY ...............................................................................................................................................................................2-1
SAFETY........................................................................................................................................................................2-2
SAFETY LABELS........................................................................................................................................................2-4
LOCATION OF SAFETY LABELS....................................................................................................................2-5
CONTENTS OF SAFETY LABELS ..................................................................................................................2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...........................................2-18
PRECAUTIONS BEFORE STARTING OPERATION..................................................................................2-18
PREPARATIONS FOR SAFE OPERATION .................................................................................................2-18
PRECAUTIONS TO PREVENT FIRE............................................................................................................2-19
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE......................................................................2-21
DO NOT GET CAUGHT IN WORK EQUIPMENT........................................................................................2-23
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ................................................................2-23
PROTECTION AGAINST FALLING, FLYING OR INTRUDING OBJECTS .............................................2-24
ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES...................................................2-24
UNAUTHORIZED MODIFICATION................................................................................................................2-24
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ............................................................2-24
PRECAUTIONS RELATED TO CAB GLASS ...............................................................................................2-25
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING .............................................................2-25
PRECAUTIONS FOR OPERATION.......................................................................................................................2-26
PRECAUTIONS FOR JOBSITE .....................................................................................................................2-26
START ENGINE .................................................................................................................................................2-28
PRECAUTIONS FOR OPERATION...............................................................................................................2-30
PRECAUTIONS FOR TRANSPORTATION..................................................................................................2-35
TOWING AND BEING TOWED......................................................................................................................2-36
LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT)....................2-36
LIFTING OBJECTS WITH BUCKETS............................................................................................................2-38
PRECAUTIONS FOR MAINTENANCE.................................................................................................................2-40
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...........................................2-40
PRECAUTIONS FOR CHECK AND MAINTENANCE.................................................................................2-43
PRECAUTIONS FOR DEF......................................................................................................................................2-50
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING ..........................................................2-50
PRECAUTIONS FOR ADDING ......................................................................................................................2-50
PRECAUTIONS FOR STORING....................................................................................................................2-50
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE ..............................................................................2-50
OTHER PRECAUTIONS..................................................................................................................................2-50

FOREWORD
TABLE OF CONTENTS
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OPERATION.......................................................................................................................................................................3-1
GENERAL VIEW ........................................................................................................................................................3-2
MACHINE EQUIPMENT NAME.......................................................................................................................3-2
CAB EQUIPMENT NAMES...............................................................................................................................3-4
CONTROLS AND GAUGES NAMES..............................................................................................................3-5
EXPLANATION OF COMPONENTS.......................................................................................................................3-9
EXPLANATION OF MACHINE MONITOR EQUIPMENT.............................................................................3-9
SWITCHES........................................................................................................................................................3-85
CONTROL LEVERS AND PEDALS ..............................................................................................................3-93
OTHER EQUIPMENT......................................................................................................................................3-98
MACHINE OPERATIONS AND CONTROLS.....................................................................................................3-129
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ..............................................................3-129
METHOD FOR STARTING ENGINE...........................................................................................................3-153
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE.......................................3-158
METHOD FOR STOPPING ENGINE..........................................................................................................3-167
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-
CHINE ..........................................................................................................................................................3-169
METHOD FOR STEERING MACHINE.......................................................................................................3-172
METHOD FOR SWINGING MACHINE.......................................................................................................3-174
METHOD FOR OPERATING WORK EQUIPMENT..................................................................................3-174
HANDLE WORKING MODE.........................................................................................................................3-176
PROHIBITED OPERATIONS .......................................................................................................................3-177
PRECAUTIONS FOR OPERATION............................................................................................................3-182
PRECAUTIONS FOR WORKING ON SLOPE ..........................................................................................3-185
METHOD FOR ESCAPING FROM MUD ...................................................................................................3-186
RECOMMENDED APPLICATIONS.............................................................................................................3-187
RECOMMENDED APPLICATIONS.............................................................................................................3-187
METHOD FOR REPLACING AND INVERTING BUCKET.......................................................................3-189
METHOD FOR PARKING MACHINE..........................................................................................................3-192
METHOD FOR CHECKING AFTER FINISHING WORK .........................................................................3-193
LOCK................................................................................................................................................................3-194
HANDLE AIR CONDITIONER..............................................................................................................................3-199
EXPLANATION OF AIR CONDITIONER EQUIPMENT............................................................................3-200
METHOD FOR OPERATING AIR CONDITIONER ...................................................................................3-204
HANDLE RADIO.....................................................................................................................................................3-211
EXPLANATION OF RADIO EQUIPMENT ..................................................................................................3-211
METHOD FOR CONTROLLING RADIO.....................................................................................................3-213
STOW ANTENNA...........................................................................................................................................3-216
HANDLE ROAD LINERS.......................................................................................................................................3-217
RECOMMENDED USE OF ROAD LINERS...............................................................................................3-217
COMPARISON OF ROAD LINERS AND STEEL SHOES .......................................................................3-217
WARRANTY OF ROAD LINERS .................................................................................................................3-217
PRECAUTIONS WHEN USING ROAD LINERS .......................................................................................3-217
TRANSPORTATION ..............................................................................................................................................3-219
PRECAUTIONS FOR TRANSPORTING MACHINE ................................................................................3-219
SELECT TRANSPORTATION METHOD....................................................................................................3-219
LOADING AND UNLOADING WITH TRAILER..........................................................................................3-220
METHOD FOR LIFTING MACHINE ............................................................................................................3-227
COLD WEATHER OPERATION...........................................................................................................................3-229
COLD WEATHER OPERATION INFORMATION......................................................................................3-229
PRECAUTIONS AFTER DAILY WORK COMPLETION...........................................................................3-230
AFTER COLD WEATHER SEASON ...........................................................................................................3-231
PRECAUTIONS FOR LONG-TERM STORAGE...............................................................................................3-232
PREPARATION FOR LONG-TERM STORAGE........................................................................................3-232
MAINTENANCE DURING LONG-TERM STORAGE................................................................................3-232
STARTING MACHINE AFTER LONG-TERM STORAGE........................................................................3-232
TROUBLES AND ACTIONS.................................................................................................................................3-234
ACTIONS WHEN RUNNING OUT OF FUEL.............................................................................................3-234

TABLE OF CONTENTS
FOREWORD
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PHENOMENA THAT ARE NOT FAILURES .............................................................................................. 3-234
PRECAUTIONS FOR TOWING MACHINE ............................................................................................... 3-235
PRECAUTIONS FOR SEVERE JOB CONDITION................................................................................... 3-236
PRECAUTIONS FOR DISCHARGED BATTERY ..................................................................................... 3-237
OTHER TROUBLE ........................................................................................................................................ 3-241
MAINTENANCE ..................................................................................................................................................................4-1
PRECAUTIONS FOR MAINTENANCE...................................................................................................................4-2
CHECK SERVICE METER READING ..............................................................................................................4-2
KOMATSU GENUINE REPLACEMENT PARTS............................................................................................4-2
KOMATSU GENUINE LUBRICANTS ................................................................................................................4-2
ALWAYS USE CLEAN WASHER FLUID.........................................................................................................4-2
FRESH AND CLEAN LUBRICANTS .................................................................................................................4-2
CHECK DRAINED OIL AND USED FILTER...................................................................................................4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL..........................................................................................4-2
PRECAUTIONS FOR ADDING DEF ............................................................................................................... 4- 2
WELDING INSTRUCTIONS..............................................................................................................................4-2
DO NOT DROP THINGS INSIDE MACHINE..................................................................................................4-2
BURN PREVENTION .........................................................................................................................................4-2
DUSTY JOBSITES..............................................................................................................................................4-3
AVOID MIXING OIL ............................................................................................................................................4-3
LOCK INSPECTION COVERS.........................................................................................................................4-3
BLEED AIR FROM HYDRAULIC CIRCUIT.....................................................................................................4-3
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES.......................................................................4-3
CHECKS AFTER INSPECTION AND MAINTENANCE................................................................................4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE .................................................4-3
OUTLINE OF MAINTENANCE .................................................................................................................................4-4
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..........................................................4-4
HANDLE ELECTRICAL COMPONENTS ........................................................................................................4-8
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS .........................................................................4-9
MAINTENANCE SCHEDULE..................................................................................................................................4-11
MAINTENANCE SCHEDULE TABLE............................................................................................................4-11
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.......................................................................4-12
MAINTENANCE PROCEDURE..............................................................................................................................4-13
WHEN REQUIRED...........................................................................................................................................4-13
CHECKS BEFORE STARTING ......................................................................................................................4-39
EVERY 100 HOURS MAINTENANCE...........................................................................................................4-39
EVERY 250 HOURS MAINTENANCE...........................................................................................................4-41
EVERY 500 HOURS MAINTENANCE...........................................................................................................4-47
EVERY 1000 HOURS MAINTENANCE.........................................................................................................4-55
EVERY 2000 HOURS MAINTENANCE.........................................................................................................4-63
EVERY 4000 HOURS MAINTENANCE.........................................................................................................4-73
EVERY 4500 HOURS MAINTENANCE.........................................................................................................4-76
EVERY 5000 HOURS MAINTENANCE.........................................................................................................4-76
EVERY 8000 HOURS MAINTENANCE.........................................................................................................4-78
EVERY 9000 HOURS MAINTENANCE.........................................................................................................4-78
SPECIFICATIONS ..............................................................................................................................................................5-1
SPECIFICATIONS ......................................................................................................................................................5-2
SPECIFICATIONS: PC138US-11.....................................................................................................................5-2
EXPLANATION OF LIFT CAPACITY CHART ........................................................................................................5-4
ATTACHMENTS AND OPTIONS .....................................................................................................................................6-1
PRECAUTIONS FOR USING ATTACHMENT AND OPTIONS ...........................................................................6-2
PRECAUTIONS WHEN SELECTING..............................................................................................................6-2
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY.............................................6-2
PRECAUTIONS WHEN REMOVING AND INSTALLING.............................................................................6-2
PRECAUTIONS WHEN USING........................................................................................................................6-2
QUICK COUPLER SYSTEM.....................................................................................................................................6-4
HANDLING QUICK COUPLER.........................................................................................................................6-4
2-PIECE BOOM...........................................................................................................................................................6-7

FOREWORD
TABLE OF CONTENTS
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2-PIECE BOOM COMPONENTS.....................................................................................................................6-7
2-PIECE BOOM CONTROL PEDAL ...............................................................................................................6-7
METHOD FOR LUBRICATING 2-PIECE BOOM...........................................................................................6-8
PREPARATION FOR STORAGE AND LIFTING MACHINE......................................................................6-10
SPECIFICATIONS............................................................................................................................................6-11
EXPLANATION OF LIFT CAPACITY CHART..............................................................................................6-13
HANDLE BUCKET WITH HOOK ...........................................................................................................................6-15
PRECAUTIONS FOR OPERATION..............................................................................................................6-15
HANDLE MACHINE READY FOR INSTALLATION OF ATTACHMENT..........................................................6-16
EXPLANATION OF COMPONENTS.............................................................................................................6-16
METHOD FOR CHANGING OVER AND CONNECTING HYDRAULIC CIRCUIT OF MACHINES
READY FOR INSTALLATION OF ATTACHMENT..................................................................................6-19
METHOD FOR REMOVING AND INSTALLING ATTACHMENT..............................................................6-20
METHOD FOR OPERATING ATTACHMENT..............................................................................................6-26
LONG-TERM STORAGE ................................................................................................................................6-29
SPECIFICATIONS............................................................................................................................................6-29
ATTACHMENTS AND OPTIONS...........................................................................................................................6-30
INSTALL ATTACHMENT.................................................................................................................................6-30
TRACK SHOES SELECTION.........................................................................................................................6-31
RECOMMENDED ATTACHMENT OPERATIONS..............................................................................................6-33
HYDRAULIC BREAKER..................................................................................................................................6-33
KomVision..................................................................................................................................................................6-38
PRECAUTIONS WHEN USING KomVision .................................................................................................6-38
MACHINE MONITOR EQUIPMENT NAME .................................................................................................6-38
EXPLANATION OF MACHINE MONITOR EQUIPMENT...........................................................................6-39
WARNING DISPLAY........................................................................................................................................6-40
CAMERA SYSTEM CAUTION LAMP............................................................................................................6-41
CAMERA CONTROLLER CAUTION LAMP.................................................................................................6-41
MONITOR DISPLAY........................................................................................................................................6-41
MONITOR DISPLAY SELECTOR SWITCH .................................................................................................6-44
CAMERA IMAGE SELECTOR SWITCH.......................................................................................................6-45
METHOD FOR CHECKING BEFORE STARTING .....................................................................................6-45
METHOD FOR CHECKING CAMERA VISIBILITY .....................................................................................6-46
TROUBLES AND ACTIONS...........................................................................................................................6-46
REPLACEMENT PARTS...................................................................................................................................................7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS....................................................................................7-2
DEFINED LIFE PARTS LIST ............................................................................................................................7-2
CONSUMABLE PARTS.............................................................................................................................................7-3
CONSUMABLE PARTS LIST............................................................................................................................7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....................................................................................7-4
LUBRICATION CHART......................................................................................................................................7-4
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE................................................................................................................................................................7-6
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .................7-7
INDEX..................................................................................................................................................................................8-1