Komatsu PC138USLC Manual

HYDRAULIC
EXCAVATOR
TEN00189-01
PC138US -8
PC138USLC -8
SERIAL NUMBERS PC138US- 20001
PC138USLC- 20001 and up
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 near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
WARNING
Komatsu has Operation & Maintenance Manuals written
in some other languages. if a foreign language manual
is necessary, contact your local distributor for
availability.
NOTICE

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
Magazine box at rear of cab
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FOREWORD FOREWORD
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FOREWORD
FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
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 words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
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 condition at the top
or left side, and the method of avoiding the hazardous 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 described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
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 questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
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FOREWORD INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Leveling work
Ditching work
Loading work
Demolition work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-168)" for further details.
DIRECTIONS OF MACHINE
(A)
(B)
(C)
(D)
Front
Rear
Left
Right
(E)
(F)
Operator's seat
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.
BREAKING-IN THE NEW MACHINE
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operating the
machine under full load before breaking the machine in can adversely affect the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points when
breaking in the machine.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
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FOREWORD
PRODUCT INFORMATION
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE
This is on the fuel main filter bracket.
EPA: Environmental Protection Agency, U.S.A.
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FOREWORD PRODUCT INFORMATION
SERVICE METER LOCATION
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
DIRECTIONS OF MACHINE 1- 7
BREAKING-IN THE NEW MACHINE 1- 7
PRODUCT INFORMATION 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 8
EPA REGULATIONS, ENGINE NUMBER PLATE 1- 8
SERVICE METER LOCATION 1- 9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 13
SAFETY MACHINE OPERATION 2- 22
STARTING ENGINE 2- 22
OPERATION 2- 24
TRANSPORTATION 2- 30
BATTERY 2- 31
TOWING 2- 33
LIFTING OBJECTS WITH BUCKET 2- 34
SAFETY MAINTENANCE INFORMATION 2- 35
OPERATION 3- 1
MACHINE VIEW ILLUSTRATIONS 3- 2
OVERALL MACHINE VIEW 3- 2
CONTROLS AND GAUGES 3- 3
DETAILED CONTROLS AND GAUGES 3- 5
MONITORING SYSTEM 3- 5
SWITCHES 3- 68
CONTROL LEVERS AND PEDALS 3- 73
SUN ROOF 3- 77
WINDSHIELD 3- 77
SLIDING DOOR 3- 83
EMERGENCY ESCAPE HAMMER 3- 84
CAP WITH LOCK 3- 85
ENGINE HOOD 3- 86
CAB REAR COVER 3- 87
PUMP ROOM DOOR, BATTERY ROOM DOOR 3- 88
DOOR AT FRONT OF TOOL BOX 3- 89
AIR CONDITIONER CONTROLS 3- 90
RADIO 3-103
FUSE 3-108
FUSIBLE LINK 3-109
AUXILIARY ELECTRIC POWER 3-110
CONTROLLERS 3-111
OPERATION MANUAL STORAGE 3-112
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FOREWORD CONTENTS
TOOL BOX 3-112
GREASE PUMP HOLDER 3-112
CUP HOLDER 3-112
ASHTRAY 3-113
FIRE EXTINGUISHER 3-113
MACHINE OPERATIONS AND CONTROLS 3-114
BEFORE STARTING ENGINE 3-114
STARTING ENGINE 3-133
AFTER STARTING ENGINE 3-138
STOPPING THE ENGINE 3-149
MACHINE OPERATION 3-150
STEERING THE MACHINE 3-154
SWINGING 3-156
WORK EQUIPMENT CONTROLS AND OPERATIONS 3-157
WORKING MODE 3-159
PROHIBITED OPERATIONS 3-160
GENERAL OPERATION INFORMATION 3-162
TRAVELING ON SLOPES 3-165
ESCAPE FROM MUD 3-167
RECOMMENDED APPLICATIONS 3-168
BUCKET REPLACEMENT AND INVERSION 3-170
PARKING MACHINE 3-173
MACHINE INSPECTION AFTER DAILY WORK 3-174
LOCKING 3-175
ROAD LINERS 3-176
TRANSPORTATION 3-178
TRANSPORTATION PROCEDURE 3-178
LOADING AND UNLOADING WITH TRAILER 3-179
LIFTING MACHINE 3-186
COLD WEATHER OPERATION 3-188
COLD WEATHER OPERATION INFORMATION 3-188
AFTER DAILY WORK COMPLETION 3-189
AFTER COLD WEATHER SEASON 3-190
LONG TERM STORAGE 3-191
BEFORE STORAGE 3-191
DURING STORAGE 3-192
AFTER STORAGE 3-192
STARTING MACHINE AFTER LONG-TERM STORAGE 3-192
TROUBLES AND ACTIONS 3-193
RUNNING OUT OF FUEL 3-193
PHENOMENA THAT ARE NOT FAILURES 3-193
TOWING THE MACHINE 3-194
LIGHTWEIGHT TOWING HOOK 3-195
SEVERE JOB CONDITION 3-195
DISCHARGED BATTERY 3-196
OTHER TROUBLE 3-201
MAINTENANCE 4- 1
MAINTENANCE INFORMATION 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
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FOREWORD
CONTENTS
ELECTRIC SYSTEM MAINTENANCE 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
TIGHTENING TORQUE SPECIFICATIONS 4- 12
TIGHTENING TORQUE LIST 4- 12
SAFETY CRITICAL PARTS 4- 13
SAFETY CRITICAL PARTS LIST 4- 13
MAINTENANCE SCHEDULE 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER 4- 16
MAINTENANCE PROCEDURE 4- 17
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 46
EVERY 100 HOURS MAINTENANCE 4- 47
EVERY 250 HOURS MAINTENANCE 4- 49
EVERY 500 HOURS MAINTENANCE 4- 56
EVERY 1000 HOURS MAINTENANCE 4- 65
EVERY 2000 HOURS MAINTENANCE 4- 71
EVERY 4000 HOURS MAINTENANCE 4- 75
EVERY 5000 HOURS MAINTENANCE 4- 77
EVERY 8000 HOURS MAINTENANCE 4- 79
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS AND OPTIONS 6- 1
ATTACHMENTS AND OPTIONS - GENERAL INFORMATION 6- 2
SAFETY FIRST 6- 2
ATTACHMENT INSTALLATION 6- 3
BUCKET WITH HOOK 6- 4
HOOK CONDITION 6- 4
PROHIBITED OPERATIONS 6- 4
MACHINE READY FOR ATTACHMENT 6- 5
LOCATIONS 6- 5
HYDRAULIC CIRCUIT 6- 8
ATTACHMENT REMOVAL AND INSTALLATION 6- 9
ATTACHMENT OPERATIONS 6- 13
LONG TERM STORAGE 6- 17
SPECIFICATIONS 6- 17
ATTACHMENT GUIDE 6- 18
ATTACHMENT COMBINATIONS 6- 19
TRACK SHOES SELECTION 6- 20
RECOMMENDED ATTACHMENT OPERATIONS 6- 21
HYDRAULIC BREAKER 6- 21
HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 26
BASIC PRECAUTIONS 6- 26
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 4
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
SAFETY INFORMATION
Safety rules 2- 13
If problems are found 2- 13
Working wear and personal protective items 2- 13
Fire extinguisher and first aid kit 2- 13
Safety equipment 2- 13
Keep machine clean 2- 14
Keep operator's compartment clean 2- 14
Leaving operator's seat with lock 2- 14
Handrails and steps 2- 15
Precautions when working in high place 2- 15
Mounting and dismounting 2- 15
No persons on attachments 2- 15
Do not get caught in articulated portion 2- 16
Burn prevention 2- 16
Fire prevention and explosion prevention 2- 17
Action if fire occurs 2- 17
Windshield washer fluid 2- 18
Falling objects, flying objects and intruding objects prevention 2- 18
Attachment installation 2- 18
Attachment combinations 2- 18
Cab window glasses 2- 18
Unauthorized modifications 2- 19
Safety at jobsite 2- 19
Working on loose ground 2- 19
Distance to high voltage cables 2- 19
Ensure good visibility 2- 20
Ventilation for enclosed area 2- 20
Signalman's signal and signs 2- 21
Emergency exit from operator's cab 2- 21
Asbestos dust hazard prevention 2- 21
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SAFETY SAFETY
SAFETY MACHINE OPERATION 2- 22
STARTING ENGINE 2- 22
Checks before starting engine 2- 22
Safety rules for starting engine 2- 23
Starting engine in cold weather 2- 23
OPERATION 2- 24
Checks before operation 2- 24
Safety rules for changing machine directions 2- 24
Safety rules for traveling 2- 25
Traveling on slopes 2- 26
Operations on slopes 2- 27
Prohibited operations 2- 27
Operations on snow 2- 29
Parking machine 2- 29
TRANSPORTATION 2- 30
Loading and unloading 2- 30
Shipping the machine 2- 30
BATTERY 2- 31
Battery hazard prevention 2- 31
Starting engine with booster cables 2- 32
TOWING 2- 33
Safety rules for towing 2- 33
LIFTING OBJECTS WITH BUCKET 2- 34
Safety rules for lifting objects 2- 34
SAFETY MAINTENANCE INFORMATION 2- 35
Warning Tag 2- 35
Keep Work Place Clean and Tidy 2- 35
Appoint Leader when Working with Others 2- 35
Stop Engine Before Carrying Out Maintenance 2- 36
Two Workers for Maintenance when Engine is Running 2- 37
Proper Tools 2- 37
Accumulator, Gas spring 2- 38
Personnel 2- 38
Attachments 2- 38
Work Under the Machine 2- 38
Noise 2- 38
When Using Hammer 2- 39
Welding Works 2- 39
Removing Battery Terminals 2- 39
Safety First when Using High-pressure Grease to Adjust Track Tension 2- 39
Do Not Disassemble Recoil Springs 2- 39
Safety Rules for High-pressure Oil 2- 40
Precaution for High Fuel Pressure 2- 40
Safety Handling High-pressure Hoses 2- 40
Precaution for High Voltage 2- 40
Waste Materials 2- 41
Air Conditioner Maintenance 2- 41
Compressed Air 2- 41
Periodic Replacement of Safety Critical Parts 2- 41
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)
(2) Caution before operating (09802-03000)
(3) Caution for leaving operator's seat (09654-03001)
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SAFETY SAFETY LABELS SAFETY SAFETY LABELS
(4) Caution for going close to electric cables (09801-03001)
(5) Caution for operating pattern (09822-03000)
Standard machine
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