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PC138US-11
Komatsu PC138US-11 User Manual
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1-1
WEN
AM00
111
FO
REWORD
Komatsu recommends that any service parts used
for
maintenance,
repair
o
r
replacement of em
ission control systems b
e genuine new
Komatsu or Ko
-
matsu approved rebu
ilt parts or as
semblies or oth
ers parts of equival
ent
quality, and that the eng
ine be serviced by
an authorized Ko
matsu distribu
-
tor. Failure to follow t
hese recom
mendations cou
ld result in ineff
ective serv
-
ice, damage to the p
roduct or safety risks
(including personal
injury or
dea
th).
1
3
Table of Contents
Table of Contents
17
Read this Manual
3
Safety Information
4
Safety Labels
5
Noise
6
Vibration Levels
7
Vibration - Operating Condition
7
Guide to Reduce Vibration Levels on Machine
7
Introduction
9
Main Use of Machine
9
Demolition Work
9
Directions of Machine
10
Visibility from Operator's Seat
10
Engine Technology to Conform Exhaust Gas Emission
12
Product Information
13
Location of Product Identification Number (Pin)/Machine Serial No. Plate
13
Location of Engine Number Plate
13
Service Meter Location
14
Your Machine Serial Numbers and Distributor
14
Serial Plate
15
Declaration of Conformity
16
Table of Contents
17
Safety Labels
24
Location of Safety Labels
25
Contents of Safety Labels
26
General Precautions Common to Operation and Maintenance
38
Preparations for Safe Operation
38
Ensure Safe Operation
38
Understand the Machine
38
Precautions for Safety-Related Equipment
38
Inspect Machine
38
Wear Well-Fitting Clothes and Protective Equipment
38
Keep Machine Clean
38
Precautions before Starting Operation
38
If any Problem Is Found
39
Actions if Fire Occurs
39
Precautions for Inside Operator's Compartment
39
Provide Fire Extinguisher and First Aid Kit
39
Precautions to Prevent Fire
39
Prevent Fire
40
Precautions When Getting on or off Machine
41
Use Handrails and Steps When Getting on or off Machine
41
No Jumping on or off Machine
41
Emergency Exit from Operator's Cab
42
Precautions When Leaving Machine
42
Precautions When Standing up from Operator's Seat
42
No People on Attachments
42
Lifting of Personnel Prohibited
42
Do Not Get Caught in Work Equipment
43
Precautions Related to Protective Structures
43
Electromagnetic Interference
43
Protection against Falling, Flying or Intruding Objects
44
Actions in the Event of Damage to Safety Structures
44
Unauthorized Modification
44
Precautions Related to Attachments and Options
44
Precautions When Running Engine Inside Building
45
Precautions Related to Cab Glass
45
Precautions for Operation
46
Precautions for Jobsite
46
Investigate and Confirm Jobsite Conditions
46
Precautions When Working on Loose Ground
46
Do Not Go Close to High-Voltage Cables
46
Ensure Good Visibility
47
Check Signs and Signalman's Signals
47
Beware of Asbestos Dust
47
Checks and Adjustment before Starting Engine
48
Use Warning Tags
48
Start Engine
48
Precautions When Starting Engine
49
In Cold Weather
49
Start Engine with Jumper Cables
49
Precautions for Operation
50
Checks before Operation
50
Precautions When Traveling in Forward or Reverse and Swinging
50
Precautions When Traveling
51
Precautions When Traveling on Slopes
52
Precautions When Operating on Slopes
53
Prohibited Operations
53
Precautions When Operating on Snow or Frozen Surfaces
54
Precautions When Parking Machine
54
Precautions for Transportation
55
Precautions When Loading and Unloading
55
Towing and Being Towed
56
Lifting Objects with Bucket Link Lifting Device (Optional Equipment)
56
Precautions for Towing and Being Towed
56
Safety Rules for Lifting Objects
56
Safety Rules for Lifting Objects
58
Lifting Objects with Buckets
58
Only Authorized Personnel
60
Stability
60
Appoint Leader When Working with Others
60
Precautions for Maintenance
60
Select Suitable Place for Inspection and Maintenance
60
Keep Work Place Clean and Tidy
60
Display Warning Tag During Inspection and Maintenance
60
Precautions before Starting Inspection and Maintenance
60
Guards
61
End of Service Life
61
Stop Engine before Carrying out Inspection and Maintenance
61
Two Workers for Maintenance When Engine Is Running
61
Precautions When Installing, Removing, or Storing Attachments
62
Precautions for Working at High Places
62
Precautions When Working on Machine
62
Precautions for Check and Maintenance
63
Precautions When Working under Machine or Work Equipment
63
Use Proper Tools
63
Turn Battery Disconnect Switch to off Position
63
Precautions for Welding
63
Handle Battery
64
Precautions When Using Hammer
64
Precautions for High-Pressure Oil
65
Precautions for High-Temperature Coolant
65
Precautions for High-Temperature Parts
65
Precautions for High-Temperature Oil
65
Precautions for High-Pressure Fuel
66
Handle High-Pressure Hoses and Piping
66
Precautions for High Voltage
66
Precautions for Noise
66
Handle Accumulator and Gas Spring
67
Precautions for High-Pressure Grease When Adjusting Track Tension
67
Do Not Disassemble Recoil Spring
67
Precautions for Compressed Air
68
Maintenance of Air Conditioner
68
Chemical Hazard
68
Precautions for Disposing of Waste Materials
68
Method for Selecting Window Washer Fluid
68
Periodic Replacement of Defined Life Parts
68
Precautions for Fire Hazard and Leakage
70
Other Precautions
70
General Character and Precautions for Handling
70
Precautions for Storing
70
Precautions for Adding
70
Precautions for Def
70
Operation
71
General View
72
Machine Equipment Name
72
Cab Equipment Names
74
Controls and Gauges Names
75
Explanation of Components
79
Explanation of Machine Monitor Equipment
79
Switches
155
Control Levers and Pedals
163
Other Equipment
168
Machine Operations and Controls
199
Checks and Adjustment before Starting Engine
199
Method for Starting Engine
223
Method for Operations and Checks after Starting Engine
228
Method for Stopping Engine
237
Method for Starting Machine (Travel Forward and Reverse) and Stopping Machine
239
Method for Steering Machine
242
Method for Swinging Machine
244
Method for Operating Work Equipment
244
Handle Working Mode
246
Prohibited Operations
247
Precautions for Operation
252
Precautions for Working on Slope
255
Method for Escaping from Mud
256
Recommended Applications
257
Method for Replacing and Inverting Bucket
259
Method for Parking Machine
262
Method for Checking after Finishing Work
263
Lock
264
Handle Air Conditioner
269
Explanation of Air Conditioner Equipment
270
Method for Operating Air Conditioner
274
Handle Radio
281
Explanation of Radio Equipment
281
Method for Controlling Radio
283
Stow Antenna
286
Warranty of Road Liners
287
Precautions When Using Road Liners
287
Comparison of Road Liners and Steel Shoes
287
Recommended Use of Road Liners
287
Handle Road Liners
287
Transportation
289
Precautions for Transporting Machine
289
Select Transportation Method
289
Loading and Unloading with Trailer
290
Method for Lifting Machine
297
Cold Weather Operation
299
Cold Weather Operation Information
299
Precautions after Daily Work Completion
300
After Cold Weather Season
301
Precautions for Long-Term Storage
302
Preparation for Long-Term Storage
302
Maintenance During Long-Term Storage
302
Starting Machine after Long-Term Storage
302
Troubles and Actions
304
Actions When Running out of Fuel
304
Phenomena that Are Not Failures
304
Precautions for Towing Machine
305
Precautions for Severe Job Condition
306
Precautions for Discharged Battery
307
Other Trouble
311
Maintenance
317
Fresh and Clean Lubricants
318
Welding Instructions
318
Precautions for Refilling Oil or Fuel
318
Check Drained Oil and Used Filter
318
Precautions for Adding Def
318
Always Use Clean Washer Fluid
318
Komatsu Genuine Lubricants
318
Komatsu Genuine Replacement Parts
318
Check Service Meter Reading
318
Precautions for Maintenance
318
Dusty Jobsites
319
Avoid Mixing Oil
319
Lock Inspection Covers
319
Bleed Air from Hydraulic Circuit
319
Precautions When Installing Hydraulic Hoses
319
Checks after Inspection and Maintenance
319
Fuel and Lubricants to Match the Ambient Temperature
319
Outline of Maintenance
320
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
320
Handle Electrical Components
324
Standard Tightening Torque for Bolts and Nuts
325
Maintenance Schedule
327
Maintenance Schedule Table
327
Maintenance Interval for Hydraulic Breaker
328
Maintenance Procedure
329
Method for Checking, Cleaning and Replacing Air Cleaner
329
When Required
329
Method for Cleaning Inside of Cooling System
334
Method for Checking Looseness and Tightening Track Shoe Bolts
338
Method for Checking and Adjusting Track Tension
339
Method for Checking Looseness and Tightening Road Liner Shoe Bolts
339
Method for Checking Road Liner
340
Method for Replacing Bucket Teeth (Vertical Pin Type)
341
Method for Replacing Road Liner
341
Method for Replacing Bucket Teeth (Horizontal Pin Type)
344
Method for Adjusting Bucket Clearance
345
Method for Checking and Maintenance Air Conditioner
346
Method for Checking Window Washer Fluid Level, Adding Fluid
346
Method for Checking, Cleaning and Lubricating Slide Door Rail and Roller
348
Method for Checking Stopper Clearance in Opening Front Door Is up
349
Method for Replacing Additional Filter Element for Breaker
349
Method for Washing Washable Floor
350
Method for Checking Gas Spring
352
Method for Bleeding Air from Hydraulic Circuit
353
Checks before Starting
355
Every 100 Hours Maintenance
355
Method for Lubricating Work Equipment
355
Method for Checking Oil Level in Swing Machinery Case, Adding Oil
356
Every 250 Hours Maintenance
357
Method for Checking Oil Level in Final Drive Case, Adding Oil
357
Method for Changing Oil in Large Capacity Final Drive Case
358
Method for Checking Battery Electrolyte Level
359
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
361
Every 500 Hours Maintenance
363
Method for Lubricating
363
Method for Replacing Fuel Prefilter Cartridge
366
Method for Checking Swing Pinion Grease Level, Adding Grease
368
Method for Lubricating Swing Circle
368
Method for Checking and Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Air Conditioner Condenser Fins
369
Method for Cleaning Air Conditioner Fresh/Recirc Air Filters
370
Every 1000 Hours Maintenance
371
Method for Replacing Hydraulic Oil Filter Element
371
Method for Change Oil in Swing Machinery Case
372
Method for Changing Oil in Final Drive Case
373
Method for Changing Oil in Large Capacity Final Drive Case
374
Method for Checking Oil Level in Pto Gear Case, Adding Oil
375
Method for Replacing Fuel Main Filter Cartridge
376
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
378
Method for Replacing Def Tank Breather Element
378
Method for Replacing Hydraulic Tank Breather Element
378
Every 2000 Hours Maintenance
379
Method for Checking Fan Belt Tension and Replacing Fan Belt
379
Method for Cleaning Hydraulic Tank Strainer
380
Method for Checking and Releasing Nitrogen Gas Charge Pressure in Accumula- Tor (for Control Circuit)
381
Method for Checking Alternator and Starting Motor
384
Method for Checking and Adjusting Engine Valve Clearance
384
Method for Replacing Kccv Filter Element
384
Method for Replacing Def Filter
387
Every 4000 Hours Maintenance
389
Replace Defined Life Parts
389
Method for Checking Water Pump
390
Method for Replacing Accumulator (for Control Circuit)
390
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
391
Every 4500 Hours Maintenance
392
Every 5000 Hours Maintenance
392
Method for Changing Oil in Hydraulic Tank
392
Method for Cleaning Def Tank
392
Replace Kccv Hose
392
End of Service Life
394
Every 8000 Hours Maintenance
394
Every 9000 Hours Maintenance
394
Method for Replacing Def Hose
394
Method for Replacing Engine High-Pressure Piping Clamp
394
Method for Replacing Fuel Spray Prevention Cap
394
Specifications
395
Specifications: Pc138Us-11
396
Explanation of Lift Capacity Chart
398
Attachments and Options
401
Precautions for Using Attachment and Options
402
Precautions When Removing and Installing
402
Precautions When Selecting
402
Precautions When Using
402
Read the Operation and Maintenance Manual Thoroughly
402
Handling Quick Coupler
404
Quick Coupler System
404
2-Piece Boom
407
2-Piece Boom Components
407
2-Piece Boom Control Pedal
407
Method for Lubricating 2-Piece Boom
408
Preparation for Storage and Lifting Machine
410
Specifications
411
Explanation of Lift Capacity Chart
413
Handle Bucket with Hook
415
Precautions for Operation
415
Explanation of Components
416
Handle Machine Ready for Installation of Attachment
416
Method for Changing over and Connecting Hydraulic Circuit of Machines Ready for Installation of Attachment
419
Method for Removing and Installing Attachment
420
Method for Operating Attachment
426
Long-Term Storage
429
Specifications
429
Attachments and Options
430
Install Attachment
430
Track Shoes Selection
431
Hydraulic Breaker
433
Recommended Attachment Operations
433
Komvision
438
Machine Monitor Equipment Name
438
PRECAUTIONS WHEN USING Komvision
438
Explanation of Machine Monitor Equipment
439
Warning Display
440
Camera Controller Caution Lamp
441
Camera System Caution Lamp
441
Monitor Display
441
Monitor Display Selector Switch
444
Camera Image Selector Switch
445
Method for Checking before Starting
445
Method for Checking Camera Visibility
446
Troubles and Actions
446
Replacement Parts
447
Defined Life Parts List
448
Periodic Replacement of Defined Life Parts
448
Consumable Parts
449
Consumable Parts List
449
Lubrication Chart
450
Recommended Fuel, Coolant, and Lubricant
450
Method for Using Fuel, Coolant and Lubricants According to Ambient Temperature
452
Recommended Brands and Qualities Other than Komatsu Genuine Oils
453
Index
454
4
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Komatsu PC138US-11 Specifications
General
Brand
Komatsu
Model
PC138US-11
Category
Excavators
Language
English
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