INSTANT DOWNLOAD
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC128UU-2, PC128US-2, PC138US-2, PC138US-8, PC138USLC-8, PC138USLC-2E0, PC138USLC-10, PC158US-2, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC128UU-2, PC128US-2, PC138US-2, PC138US-8, PC138USLC-8, PC138USLC-2E0, PC138USLC-10, PC158US-2 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM009805 – Hydraulic Excavator PC128UU-2, PC128US-2 Shop Manual.pdf
SEBM018419 – Hydraulic Excavator PC128US-2, PC138US-2, PC138USLC-2E0 Shop Manual.pdf
SEBM018506 – Hydraulic Excavator PC128UU-2 Shop Manual.pdf
SEBM026504 – Hydraulic Excavator PC158US-2 Shop Manual.pdf
SEN01968-12 – Hydraulic Excavator PC138US-8, PC138USLC-8 Shop Manual.pdf
SEN06062-01 – Hydraulic Excavator PC138USLC-10 Shop Manual.pdf
CEAM004200 – Hydraulic Excavator PC128UU-1 avance Operation & Maintenance Manual.pdf
SEAM022200 – Hydraulic Excavator PC128US-1 Operation & Maintenance Manual.pdf
SEAM023300 – Hydraulic Excavator PC128UU-1 Operation & Maintenance Manual.pdf
SEAM035400 – Hydraulic Excavator PC128US-2 Operation & Maintenance Manual.pdf
SEAM035404T – Hydraulic Excavator PC128US-2 Operation & Maintenance Manual.pdf
SEAM035407T – Hydraulic Excavator PC128US-2, PC138USLC-2 Operation & Maintenance Manual.pdf
SEAM035408T – Hydraulic Excavator GALEO PC128US-2, PC138USLC-2 Operation & Maintenance Manual.pdf
SEAM035500 – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual.pdf
SEAM035505T – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual.pdf
SEAM045102T – Hydraulic Excavator PC158US-2, PC158USLC-2 Operation & Maintenance Manual.pdf
SEAM049000T – Hydraulic Excavator GALEO PC128US-2, PC138US-2 Operation & Maintenance Manual.pdf
TEN00003-01 – Hydraulic Excavator PC138US-2, PC138USLC-2E0 Operation & Maintenance Manual.pdf
TEN00075-00 – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual.pdf
TEN00076-01 – Hydraulic Excavator GALEO PC138US-2, PC138USLC-2 Operation & Maintenance Manual.pdf
TEN00189-07 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual.pdf
TEN00495-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual.pdf
TEN00530-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual.pdf
TEN00546-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual.pdf
TEN00604-01 – Hydraulic Excavator PC138USLC-10 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 11,121 pages
File Format: PDF
Language: English
CEAM004200 – Hydraulic Excavator PC128UU-1 avance Operation & Maintenance Manual…..3
COVER…..3
1. INTRODUCTION…..8
2. SAFETY INFORMATION…..9
3. OVERVIEW OF THE EQUIPMENT…..10
3.1 DESIGNATED USES…..10
3.2 FEATURES OF THIS MACHINE…..10
3.3 BREAK-IN…..11
4. MEMO…..12
5. LOCATION OF SERIAL NUMBER PLATES, AND FORM TO ENTER SERIAL NUMBER AND NAME OF THE DISTRIBUTOR…..14
5.1 LOCATION OF SERIAL NUMBER…..14
5.2 LOCATION OF ENGINE SERIAL NUMBER…..14
5.3 FORM FOR ENTERING THE CYLINDER NUMBER AND THE KOMATSU DISTRIBUTOR…..14
6. TABLE OF CONTENTS…..15
SAFETY…..20
7. BASIC PRECAUTIONS…..21
8. PRECAUTIONS FOR OPERATING…..26
8.1 BEFORE STARTING THE ENGINE…..26
8.2 AFTER STARTING THE ENGINE…..28
8.3 TRANSPORT THE VEHICLE…..33
8.4 BATTERY…..34
8.5 TOWING…..35
8.6 BUCKET WITH HOOK…..36
8.6.1 GENERAL PRECAUTIONS…..36
8.6.2 PRECAUTIONS FOR HOISTING OPERATIONS…..38
9. PRECAUTIONS FOR MAINTENANCE…..39
9.1 PRIOR TO PERFORMING MAINTENANCE…..39
9.2 DURING MAINTENANCE…..42
10. WHERE SAFETY LABELS HAVE BEEN ATTACHED…..46
10.1 WHERE SAFETY LABELS ARE LOCATED…..46
OPERATION…..50
11. THE NAME OF EACH PART…..51
11.1 GENERAL DIAGRAM OF THE VEHICLE…..51
11.2 GENERAL VIEW OF CONTROLS AND GAUGES…..52
12. EXPLANATION OF EACH DEVICE…..53
12.1 VEHICLE MONITOR PANEL…..53
12.1.1 A EMERGENCY STOP ITEMS…..55
12.1.2 B GAUGES…..56
12.1.3 C 4 SYSTEMS…..57
12.1.4 D DISPLAY LIGHTS…..59
12.1.5 E BASIC CHECK ITEMS (OPTIONAL)…..59
12.2 SWITCHES…..60
12.3 CONTROL LEVERS / PEDALS…..64
12.4 ENGINE HOOD…..68
12.5 FRONT WINDOW…..69
12.6 SLIDING DOOR…..71
12.7 FUSE BOX…..72
12.8 FUSIBLE LINK…..72
12.9 LOCKING CAP AND COVERS…..73
12.9.1 HOW TO REMOVE AND REPLACE THE LOCKING CAP FOR REFUELING THE FUEL TANK…..73
12.9.2 HOW TO OPEN AND CLOSE COVERS WITH LOCKS…..73
12.10 TOOL BOX…..74
12.11 GREASE GUN HOLDER…..74
12.12 CONTROLLERS…..74
12.13 ASHTRAY (OPTIONAL)…..74
12.14 REAR UNDER VIEW MIRROR (OPTIONAL)…..74
12.15 USING THE CAR RADIO…..75
12.15.1 EXPLANATION OF EACH FEATURE…..75
12.15.2 HOW TO OPERATE THE RADIO…..77
12.15.3 PRECAUTIONS IN USING…..79
12.15.4 SPECIFICATIONS…..79
12.16 USING THE AIR CONDITIONER…..80
12.16.1 USING THE CONTROL PANEL…..80
12.16.2 PRECAUTIONS IN USE…..80
13. OPERATION…..81
13.1 CHECKS BEFORE STARTING THE ENGINE…..81
13.1.1 VISUAL CHECK…..81
13.1.2 CHECKS BEFORE BEGINNING OPERATIONS…..83
13.1.3 ADJUSTMENTS PRIOR TO BEGINNING OPERATIONS…..87
13.1.4 CHECKS AND TASKS TO BE PERFORMED BEFORE STARTING THE ENGINE…..88
13.2 STARTING THE ENGINE…..90
13.2.1 NORMAL STARTING…..90
13.2.2 STARTING IN COLD WEATHER…..91
13.3 CHECKS AND TASKS TO BE PERFORMED AFTER STARTING THE ENGINE…..92
13.4 MOVING THE MACHINE…..95
13.4.1 MOVING THE MACHINE FORWARD…..95
13.4.2 MOVING THE MACHINE BACKWARD…..96
13.5 STEERING THE MACHINE…..97
13.5.1 STEERING (CHANGING THE DIRECTION OF ADVANCE)…..97
13.6 STOPPING THE MACHINE…..99
13.7 SWINGING…..100
13.8 PROHIBITED ACTIONS WHILE OPERATING THE MACHINE…..101
13.9 PRECAUTIONS DURING OPERATION…..104
13.10 PRECAUTIONS WHEN CLIMBING OR DESCENDING SLOPES…..105
13.11 EXTRICATING THE MACHINE FROM MUD…..107
13.11.1 WHEN ONE SIDE IS STUCK…..107
13.11.2 WHEN BOTH SIDES ARE STUCK…..107
13.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR…..108
13.12.1 EXCAVATION OPERATIONS…..108
13.12.2 DITCH DIGGING OPEARTIONS…..108
13.12.3 LOADING OPERATIONS…..108
13.12.4 GRADING OPERATIONS…..108
13.12.5 DITCH DIGGING OPERATIONS FROM THE SIDE…..109
13.12.6 OPERATIONS IN RESTRICTED PLACES…..109
13.13 CHANGING THE BUCKET…..110
13.14 PARKING THE MACHINE…..111
13.15 CHECKS AFTER COMPLETING OPERATION…..112
13.16 STOPPING THE ENGINE…..112
13.17 CHECKS AFTER THE ENGINE HAS BEEN STOPPED…..113
13.18 LOCKING…..113
13.19 USING THE 4 SYSTEMS…..114
13.19.1 THE BUCKET – CAB ACCIDENT PREVENTION DEVICE…..116
13.19.2 USING THE AUTOMATIC CONTROL DEVICE…..118
13.20 USING RUBBER TRACK SHOES (FOR MACHINES SPECIFIED FOR USE WITH RUBBER TRACKS)…..125
13.20.1 HOW TO USE RUBBER TRACK SHOES PROPERLY…..125
13.20.2 CONCERNING THE WARRANTY ON RUBBER TRACK SHOES…..125
13.20.3 PRECAUTIONS IN USING RUBBER TRACK SHOES…..126
13.20.4 PRECAUTIONS IN USE…..127
14. TRANSPORTING…..130
14.1 HOW TO LOAD AND UNLOAD THE VEHICLE…..130
14.2 PRECAUTIONS WHEN CARRYING THINGS…..132
14.3 PRECAUTIONS WHEN TRANSPORTING…..133
15. HANDLING IN COLD WEATHER…..134
15.1 PREPARATION FOR LOW TEMPERATURES…..134
15.1.1 FUEL AND LUBRICATION…..134
15.2 PRECAUTIONS AFTER COMPLETING OPERATIONS…..135
15.3 PREPARING THE CAR HEATER…..136
15.4 AFTER THE COLD WEATHER SEASON IS OVER…..136
16. LONG-TERM STORAGE…..137
16.1 BEFORE STORING THE MACHINE…..137
16.2 DURING STORAGE…..138
16.3 AFTER STORAGE…..138
17. TROUBLESHOOTING…..139
17.1 PHENOMENA THAT ARE NOT BREAKDOWNS…..139
17.2 HOW TO TOW WITH THE MACHINE OR BE TOWED…..141
17.3 HOW TO USE THE HOOK FOR TOWING LIGHT OBJECTS…..141
17.4 PRECAUTIONS FOR SPECIAL JOB SITES…..141
17.5 WHEN THE BATTERY IS DEAD…..142
17.5.1 STARTING THE ENGINE USING BOOSTER CABLES…..143
17.6 WHEN THIS PHENOMENON OCCURS…..146
17.6.1 ELECTRICAL SYSTEM…..146
17.6.2 GENERAL PROBLEMS WITH THE MACHINE…..147
17.6.3 ENGINE…..148
17.6.4 4 SYSTEMS…..150
CHECKS AND MAINTENANCE…..152
18. PRECAUTIONS IN PERFORMING CHECKS AND MAINTENANCE…..153
19. BASIC MAINTENANCE…..156
19.1 ESSENTIAL INFORMATION ON OIL, FUEL AND COOLANT…..156
19.1.1 OIL…..156
19.1.2 FUEL…..158
19.1.3 COOLAND…..158
19.1.4 GREASE…..159
19.1.5 STORING OIL AND FUEL…..159
19.1.6 FILTERS…..159
19.2 SUMMARY OF ELECTRICAL SYSTEM…..160
19.3 SUMMARY OF HYDRAULIC SYSTEM…..161
20. CONSUMABLE SUPPLIES…..162
21. USAGE OF FUEL AND LUBRICATING GREASE ACCORDING TO AMBIENT TEMPERATURE…..163
21.1 FUEL / OIL…..163
21.2 COOLANT…..163
22. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..164
22.1 LIST OF TOOLS NECESSARY…..164
22.2 TORQUE TABLE…..165
23. ABOUT REGULAR REPLACEMENT OF IMPORTANT COMPONENTS…..166
24. LIST OF MAINTENANCE…..168
24.1 MAINTENANCE SCHEDULE…..168
24.2 SERVICE TIME WHEN USING HYDRAULIC BREAKERS…..170
24.1 MAINTENANCE SCHEDULE…..168
25. SERVICE PROCEDURES…..171
25.1 INITIAL SERVICE AFTER 250 HOURS OF OPERATION…..171
25.2 MAINTENANCE THAT IS NOT REGULARLY SCHEDULED…..172
25.2.1 CHECK AND CLEAN OR REPLACE AIR CLEANER…..172
25.2.2 FLUSHING THE COOLING SYSTEM…..174
25.2.3 CHECKING THE ELECTRIC HEATER…..178
25.2.4 CHECK AND TIGHTEN TRACK SHOE BOLTS (STEEL SHOE MACHINES)…..178
25.2.5 CHECK AND ADJUST TRACK TENSION (STEEL TRACK VEHICLES)…..179
25.2.6 CHECKING THE RUBBER TRACK SHOES (MACHINES WITH RUBBER TRACK SHOES)…..182
25.2.7 CHECKING AND ADJUSTING TENSION OF RUBBER TRACK SHOES (FOR MACHINES WITH RUBBER TRACK SHOES)…..184
25.2.8 REPLACING RUBBER TRACKS (FOR MACHINES WITH RUBBER TRACKS)…..186
25.2.9 REPLACING BUCKET TEETH (VERTICAL PIN TYPE)…..189
25.2.10 REPLACING BUCKET TEETH (HORIZONTAL PIN TYPE)…..192
25.2.11 ADJUSTING BUCKET CLEARANCE…..193
25.2.12 CHECKING AND CALIBRATING THE AIR CONDITIONER…..194
25.2.13 CHECK AND REPLENISH WIND SHIELD WASHER FLUID (OPTIONAL)…..195
25.3 CHECKS BEFORE STARTING OPERATIONS…..196
25.3.1 CHECK AND REPLENISH COOLANT LEVEL…..196
25.3.2 CHECK THE OIL IN THE ENGINE OIL PAN AND ADD IF NEEDED…..196
25.3.3 CHECK THE FUEL LEVEL…..197
25.3.4 CHECK AND REPLENISH THE OIL IN THE HYDRAULIC OIL TANK…..198
25.3.5 CHECK THE DUST INDICATOR…..199
25.3.6 CHECK THE ELECTRICAL CIRCUITS…..199
25.4 SERVICE TO BE PERFORMED AFTER EVERY 50 HOURS OF OPERATION…..200
25.4.1 DRAIN WATER AND SEDIMENTS FROM FUEL TANK…..200
25.5 SERVICE TO BE PERFORMED AFTER EVERY 100 HOURS OF OPERATION…..201
25.5.1 GREASING…..201
25.5.2 CHECK AND REPLENISH THE OIL IN THE SWING MACHINERY CASE…..203
25.6 SERVICE TO BE PERFORMED AFTER EVERY 250 HOURS OF OPERATION…..204
25.6.1 CHECK AND REPLENISH THE OIL IN THE FINAL DRIVE CASE…..204
25.6.2 CHECK THE BATTERY FLUID LEVEL…..205
25.6.3 REPLACE THE OIL IN ENGINE OIL PAN AND REPLACE THE ENGINE OIL FILTER CARTRIDGE…..206
25.6.4 REPLACE THE HYDRAULIC FLUID FILTER ELEMENT…..207
25.6.5 CHECK AND ADJUST FAN BELT TENSION…..209
25.6.6 CHECK AND ADJUST THE TENSION OF THE AIR CONDITIONER COMPRESSOR BELT…..210
25.7 SERVICE TO BE PERFORMED AFTER EVERY 500 HOURS OF OPERATION…..211
25.7.1 REPLACE FUEL FILTER CARTRIDGE…..211
25.7.2 CHECK AND REPLENISH THE AMOUNT OF GREASE IN THE SWING PINION…..213
25.7.3 GREASE THE SWING CIRCLE (2 POINTS)…..213
25.7.4 CHECK AND CLEAN RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS…..214
25.7.5 CLEAN AIR CONDITIONER FILTERS…..215
25.8 SERVICE TO BE PERFORMED AFTER EVERY 1000 HOURS OF OPERATION…..216
25.8.1 REPLACE THE OIL IN SWING MACHINERY CASE…..216
25.8.2 REPLACE OIL IN FINAL DRIVE CASE…..217
25.8.3 CHECK ALL TIGHTENERS ON THE TURBOCHARGER…..218
25.8.4 CHECK THE PLAY OF THE TURBOCHARGER ROTOR…..218
25.8.5 GREASE FUEL STOP SOLENOID LINKAGE…..218
25.9 SERVICE TO BE PERFORMED AFTER EVERY 2000 HOURS OF OPERATION…..219
25.9.1 CHECK AND REPLENISH THE OIL IN THE PTO GEAR CASE…..219
25.9.2 …..220
25.9.3 CLEAN AND CHECK THE TURBOCHARGER…..225
25.9.4 CHECK THE ALTERNATOR / STARTER…..225
25.9.5 CHECK AND ADJUST ENGINE VALVE CLEARANCE…..225
25.10 SERVICE TO BE PERFORMED AFTER EVERY 4000 HOURS OF OPERATION…..226
25.10.1 CHECK THE WATER PUMP…..226
26. INSPECTIONS REQUIRED…..227
26.1 BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)…..227
26.1.1 AT LEAST MONTHLY…..227
26.2 CHECKS BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)…..227
26.2.1 AT LEAST MONTHLY…..227
26.2.2 AT LEAST ANNUALLY…..227
SPECIFICATIONS…..228
27. SPECIFICATIONS…..229
OPTIONAL PARTS, ATTACHMENTS…..232
28.GENERAL PRECAUTIONS…..233
28.1 SAFETY PRECAUTIONS…..233
28.2 PRECAUTIONS WHEN ATTACHMENTS ARE INSTALLED…..234
29. USING THE BUCKET WITH HOOK…..235
29.1 CHECKING THE BUCKET WITH HOOK ATTACHED FOR DAMAGE…..235
29.2 OPERATIONS THAT SHOULD NOT BE PERFORMED…..235
29.3 PRECAUTIONS DURING OPERATION…..235
30. USING SEAT BELTS…..238
30.1 SEAT BELTS…..238
30.1.1 FASTENING AND REMOVING SEAT BELTS…..238
30.1.2 ADJUSTING THE BELT LENGTH…..239
31. INFORMATION ON OPTIONAL ATTACHMENTS…..240
31.1 INFORMATION ON OPTIONAL ATTACHMENTS…..240
31.2 ATTACHMENT COMBINATION TABLE…..241
31.3 SELECTING TRACKS…..242
31.4 USING RUBBER PAD TRACKS…..243
31.5 USING THE AUTOMATIC LEVELING DEVICE…..244
31.5.1 EXPLANATION OF EACH DEVICE…..244
31.5.2 USING THE AUTOMATIC FEATURES…..247
31.5.3 TROUBLESHOOTING THE AUTOMATIC LEVELING SYSTEM…..253
31.6 USING THE MONO-BOOM…..254
31.6.1 SERVICE TO BE PERFORMED AFTER EVERY 100 HOURS OF OPERATION…..254
31.7 USING VEHICLES TO WHICH ATTACHMENTS CAN BE INSTALLED (MONO-BOOM)…..256
31.7.1 EXPLANATION OF EACH DEVICE…..256
31.7.2 HYDRAULIC LINES…..258
31.7.3 OPERATION…..260
31.7.4 WHEN USING THE BREAKER…..260
31.7.5 WHEN USING GENERAL ATTACHMENTS SUCH AS CRUSHERS…..261
31.7.6 USING THE ACCUMULATOR…..262
31.7.7 LONG TERM STORAGE…..262
31.7.8 SPECIFICATIONS…..262
31.8 SWITCHING OPERATION PATTERNS (ON MACHINES WHICH HAVE A PATTERN SWITCHING VALVE INSTALLED)…..263
31.8.1 SWITCHING PATTERNS…..263
SEAM022200 – Hydraulic Excavator PC128US-1 Operation & Maintenance Manual…..267
1. INTRODUCTION…..268
2. SAFETY INFORMATION…..269
3. OVERVIEW OF THE EQUIPMENT…..270
4. MEMO…..267
5. LOCATION OF SERIAL NUMBER PLATES, AND FORM TO ENTER SERIAL NUMBER AND NAME OF THE DISTRIBUTOR…..272
6. TABLE OF CONTENTS…..273
SAFETY…..278
7. BASIC PRECAUTIONS…..279
8. PRECAUTIONS FOR OPERATING…..284
8.1 BEFORE STARTING THE ENGINE …..284
8.2 AFTER STARTING THE ENGINE …..286
8.3 TRANSPORT THE VEHICLE …..291
8.4 BATTERY…..292
8.5 TOWING…..293
8.6 PRECAUTIONS FOR HOISTING OPERATIONS…..294
9. PRECAUTIONS FOR MAINTENANCE…..295
9.1 PRIOR TO PERFORMING MAINTENANCE…..295
9.2 DURING MAINTENANCE …..298
10. WHERE SAFETY LABELS HAVE BEEN ATTACHED…..302
10.1 WHERE SAFETY LABELS ARE LOCATED…..302
OPERATION…..306
11. THE NAME OF EACH PART…..307
11.1 GENERAL DIAGRAM OF THE VEHICLE…..307
11.2 GENERAL VIEW OF CONTROLS AND GAUGES…..308
12. EXPLANATION OF EACH DEVICE…..309
12.1 VEHICLE MONITOR PANEL …..309
12.2 SWITCHES …..314
12.3 CONTROL LEVERS/ PEDALS…..318
12.4 ENGINE HOOD …..322
12.5 FRONT WINDOW …..323
12.6 SLIDING DOOR…..325
12.7 HAMMER FOR EMERGENCY ESCAPE…..325
12.8 FUSE BOX …..326
12.9 FUSIBLE LINK…..326
12.10 LOCKING CAP AND COVERS…..327
12.11 MANUAL POCKET…..327
12.12 TOOL BOX …..328
12.13 GREASE GUN HOLDER …..328
12.14 CONTROLLERS …..328
12.15 ASHTRAY …..328
12.16 MIRROR REAR UNDER VIEW …..328
12.17 USING THE CAR RADIO …..329
12.18 USING THE CAR COOLER (if equipped)…..334
13. OPERATION …..335
13.1 CHECKS BEFORE STARTING THE ENGINE …..335
13.2 STARTING THE ENGINE …..344
13.3 CHECKS AND TASKS TO BE PERFORMED AFTER STARTING THE ENGINE …..346
13.4 MOVING THE MACHINE…..348
13.5 STEERING THE MACHINE …..351
13.6 STOPPING THE MACHINE …..353
13.7 SWINGING …..354
13.8 PROHIBITED ACTIONS WHILE OPERATING THE MACHINE …..355
13.9 PRECAUTIONS DURING OPERATION …..358
13.10 PRECAUTIONS WHEN CLIMBING OR DESCENDING SLOPES …..359
13.11 EXTRICATING THE MACHINE FROM MUD …..361
13.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC SHOVEL…..362
13.13 CHANGING THE BUCKET …..363
13.14 PARKING THE MACHINE …..364
13.15 CHECKS AFTER COMPLETING OPERATION …..365
13.16 STOPPING THE ENGINE …..365
13.17 CHECKS AFTER THE ENGINE HAS BEEN STOPPED …..366
13.18 LOCKING …..366
13.19 USING ROAD LINER (FOR MACHINES SPECIFIED FOR USE WITH ROAD LINER)…..367
14. TRANSPORTING…..371
14.1 HOW TO LOAD AND UNLOAD THE VEHICLE …..371
14.2 PRECAUTIONS WHEN CARRYING THINGS…..372
14.3 PRECAUTIONS WHEN TRANSPORTING …..373
14.4 METHOD OF LIFTING MACHINE…..374
15. HANDLING IN COLD WEATHER …..376
15.1 PREPARATION FOR LOW TEMPERATURES …..376
15.2 PRECAUTIONS AFTER COMPLETING OPERATIONS …..377
15.3 PREPARING THE CAR HEATER…..378
15.4 AFTER THE COLD WEATHER SEASON IS OVER…..378
16. LONG-TERM STORAGE …..379
16.1 BEFORE STORING THE MACHINE …..379
16.2 DURING STORAGE …..380
16.3 AFTER STORAGE …..380
17. TROUBLESHOOTING …..381
17.1 PHENOMENA THAT ARE NOT BREAKDOWNS…..381
17.2 HOW TO TOW WITH THE MACHINE OR BE TOWED…..382
17.3 HOW TO USE THE HOOK FOR TOWING LIGHT OBJECTS…..382
17.4 PRECAUTIONS FOR SPECIAL JOB SITES…..382
17.5 WHEN THE BATTERY IS DEAD …..383
17.6 WHEN THIS PHENOMENON OCCURS …..386
CHECKS AND MAINTENANCE…..391
18. PRECAUTIONS IN PERFORMING CHECKS AND MAINTENANCE…..392
19. BASIC MAINTENANCE…..395
19.1 ESSENTIAL INFORMATION ON OIL, FUEL AND COOLANT …..395
19.2 SUMMARY OF ELECTRICAL SYSTEM …..399
19.3 SUMMARY OF HYDRAULIC SYSTEM …..400
20. CONSUMABLE SUPPLIES …..401
21. USAGE OF FUEL AND LUBRICATING GREASE ACCORDING TO AMBIENT TEMPERATURE …..402
21.1 FUEL/OIL…..402
21.2 COOLANT…..402
22. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..403
22.1 LIST OF TOOLS NECESSARY…..403
22.2 TORQUE TABLE …..404
23. ABOUT REGULAR REPLACEMENT OF IMPORTANT COMPONENTS…..405
24. LIST OF MAINTENANCE…..408
24.1 MAINTENANCE SCHEDULE…..408
24.2 SERVICE TIME WHEN USING HYDRAULIC BREAKERS …..410
25. SERVICE PROCEDURES …..411
25.1 INITIAL SERVICE AFTER 250 HOURS OF OPERATION …..411
25.2 MAINTENANCE THAT IS NOT REGULARLY SCHEDULED…..412
25.3 CHECKS BEFORE STARTING OPERATIONS…..429
25.4 SERVICE TO BE PERFORMED AFTER EVERY 50 HOURS OF OPERATION …..433
25.5 HOURS OF OPERATION 100 AFTER EVERY SERVICE TO BE PERFORMED …..434
25.6 SERVICE TO BE PERFORMED AFTER EVERY 250 HOURS OF OPERATION …..437
25.7 SERVICE TO BE PERFORMED AFTER EVERY 500 HOURS OF OPERATION …..443
25.8 SERVICE TO BE PERFORMED AFTER EVERY 1000 HOURS OF OPERATION …..449
25.9 SERVICE TO BE PERFORMED AFTER EVERY 2000 HOURS OF OPERATION …..452
25.10 SERVICE TO BE PERFORMED AFTER EVERY 4000 HOURS OF OPERATION …..459
26. INSPECTIONS REQUIRED…..460
26.1 BEFORE BEGINNING WORK (Checks prior to starting operations)…..460
26.2 CHECKS BEFORE BEGINNING WORK (Checks prior to starting operations)…..460
SPECIFICATIONS…..461
27. SPECIFICATIONS…..462
OPTIONAL PARTS, ATTACHMENTS…..465
28. GENERAL PRECAUTIONS …..466
28.1 SAFETY PRECAUTIONS …..466
28.2 PRECAUTIONS WHEN ATTACHMENTS ARE INSTALLED …..467
29. USING SEAT BELTS …..468
29.1 SEAT BELTS …..468
30. INFORMATION ON OPTIONAL ATTACHMENTS …..470
30.1 INFORMATION ON OPTIONAL ATTACHMENTS…..470
30.2 ATTACHMENT COMBINATION TABLE…..471
30.3 SELECTING TRACKS …..472
30.4 USING VEHICLES TO WHICH ATTACHMENTS CAN BE INSTALLED (MONO- BOOM) …..473
SEAM023300 – Hydraulic Excavator PC128UU-1 Operation & Maintenance Manual…..481
1. INTRODUCTION…..483
2. SAFETY INFORMATION…..484
3. OVERVIEW OF THE EQUIPMENT…..485
4. MEMO…..481
5. LOCATION OF SERIAL NUMBER PLATES, AND FORM TO ENTER SERIAL NUMBER AND NAME OF THE DISTRIBUTOR…..487
6. TABLE OF CONTENTS…..488
SAFETY…..492
7. BASIC PRECAUTIONS…..493
8. PRECAUTIONS FOR OPERATING…..498
8.1 BEFORE STARTING THE ENGINE …..498
8.2 AFTER STARTING THE ENGINE …..500
8.3 TRANSPORT THE VEHICLE …..505
8.4 BATTERY …..506
8.5 TOWING …..507
8.6 PRECAUTIONS FOR HOISTING OPERATIONS …..508
9. PRECAUTIONS FOR MAINTENANCE…..509
9.1 PRIOR TO PERFORMING MAINTENANCE…..509
9.2 DURING MAINTENANCE…..512
10. WHERE SAFETY LABELS HAVE BEEN ATTACHED…..516
10.1 WHERE SAFETY LABELS ARE LOCATED …..516
OPERATION…..520
11. THE NAME OF EACH PART…..521
11.1 GENERAL VIEW OF THE VEHICLE…..521
11.2 GENERAL VIEW OF CONTROLS AND GAUGES …..522
12. EXPLANATION OF EACH DEVICE…..523
12.1 VEHICLE MONITOR PANEL…..523
12.2 SWITCHES…..530
12.3 CONTROL LEVERS/ PEDALS…..534
12.4 ENGINE HOOD…..538
12.5 FRONT WINDOW…..539
12.6 SLIDING DOOR …..541
12.7 HAMMER FOR EMERGENCY ESCAPE…..541
12.8 FUSE BOX…..542
12.9 FUSIBLE LINK…..542
12.10 LOCKING CAP AND COVERS …..543
12.11 MANUAL POCKET …..543
12.12 TOOL BOX…..544
12.13 GREASE GUN HOLDER…..544
12.14 CONTROLLERS…..544
12.15 ASHTRAY (if equipped)…..544
12.16 REAR UNDER VIEW MIRROR…..544
12.17 USING THE CAR RADIO …..545
12.18 USING THE CAR COOLER (if equipped)…..550
13. OPERATION…..551
13.1 CHECKS BEFORE STARTING THE ENGINE…..551
13.2 STARTING THE ENGINE…..560
13.3 CHECKS AND TASKS TO BE PERFORMED AFTER STARTING THE ENGINE…..562
13.4 MOVING THE MACHINE…..565
13.5 STEERING THE MACHINE…..568
13.6 STOPPING THE MACHINE…..570
13.7 SWINGING …..571
13.8 PROHIBITED ACTIONS WHILE OPERATING THE MACHINE …..572
13.9 PRECAUTIONS DURING OPERATION …..575
13.10 PRECAUTIONS WHEN CLIMBING OR DESCENDING SLOPES…..576
13.11 EXTRICATING THE MACHINE FROM MUD …..578
13.12 OPERATIONS THAT CAN BE PERFORMED WITH THE HYDRAULIC EXCAVATOR …..579
13.13 CHANGING THE BUCKET …..581
13.14 PARKING THE MACHlNE …..582
13.15 CHECKS AFTER COMPLETING OPERATION…..583
13.16 STOPPING THE ENGINE…..583
13.17 CHECKS AFTER THE ENGINE HAS BEEN STOPPED …..584
13.18 LOCKING …..584
13.19 USING THE 4 SYSTEMS…..585
13.20 USING ROAD LINER (FOR MACHINES SPECIFIED FOR USE WITH ROAD LINER) …..595
14. TRANSPORTATION…..599
14.1 HOW TO LOAD AND UNLOAD THE VEHICLE…..599
14.2 PRECAUTIONS WHEN CARRYING THINGS …..600
14.3 PRECAUTIONS WHEN TRANSPORTING…..601
14.4 METHOD OF LIFTING MACHINE…..602
15. HANDLING IN COLD WEATHER…..604
15.1 PREPARATION FOR LOW TEMPERATURES …..604
15.2 PRECAUTIONS AFTER COMPLETING OPERATIONS…..605
15.3 PREPARING THE CAR HEATER…..606
15.4 AFTER THE COLD WEATHER SEASON IS OVER…..606
16. LONG-TERM STORAGE…..607
16.1 BEFORE STORING THE MACHINE…..607
16.2 DURING STORAGE…..608
16.3 AFTER STORAGE…..608
17. TROUBLESHOOTING…..609
17.1 PHENOMENA THAT ARE NOT BREAKDOWNS…..609
17.2 HOW TO TOW WITH THE MACHINE OR BE TOWED …..611
17.3 HOW TO USE THE HOOK FOR TOWING LIGHT OBJECTS …..611
17.4 PRECAUTIONS FOR SPECIAL JOB SITES …..611
17.5 WHEN THE BATTERY IS DEAD…..612
17.6 WHEN THIS PHENOMENON OCCURS…..616
CHECKS AND MAINTENANCE…..622
18. PRECAUTIONS IN PERFORMING CHECKS AND MAINTENANCE…..623
19. BASIC MAINTENANCE…..626
19.1 ESSENTIAL INFORMATION ON OIL, FUEL AND COOLANT …..626
19.2 SUMMARY OF ELECTRICAL SYSTEM…..630
19.3 SUMMARY OF HYDRAULIC SYSTEM…..630
20. CONSUMABLE SUPPLIES…..631
21. USE OF FUEL COOLANT AND LUBRICATING GREASE ACCORDING TO AMBIENT TEMPERATURE…..632
21.1 FUEL/ OIL…..632
21.2 COOLANT…..632
22. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..636
22.1 LIST OF TOOLS NECESSARY …..636
22.2 TORQUE TABLE …..637
23. ABOUT REGULAR REPLACEMENT OF IMPORTANT COMPONENTS…..638
24. LIST OF MAINTENANCE…..641
24.1 MAINTENANCE SCHEDULE…..641
24.2 SERVICE TIME WHEN USING HYDRAULIC BREAKERS …..643
25. SERVICE PROCEDURES…..644
25.1 INITIAL SERVICE AFTER 250 HOURS OF OPERATION …..644
25.2 MAINTENANCE THAT IS NOT REGULARLY SCHEDULED…..645
25.3 CHECKS BEFORE STARTING OPERATIONS…..662
25.4 SERVICE TO BE PERFORMED AFTER EVERY 50 HOURS OF OPERATION …..666
25.5 SERVICE TO BE PERFORMED AFTER EVERY 100 HOURS OF OPERATION…..667
25.6 SERVICE TO BE PERFORMED AFTER EVERY 250 HOURS OF OPERATION …..670
25.7 SERVICE TO BE PERFORMED AFTER EVERY 500 HOURS OF OPERATION…..676
25.8 SERVICE TO BE PERFORMED AFTER EVERY 1000 HOURS OF OPERATION…..682
25.9 SERVICE TO BE PERFORMED AFTER EVERY 2000 HOURS OF OPERATION…..685
25.10 SERVICE TO BE PERFORMED AFTER EVERY 4000 HOURS OF OPERATION…..692
26. INSPECTIONS REQUIRED…..693
26.1 BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)…..693
26.2 CHECKS BEFORE BEGINNING WORK (CHECKS PRIOR TO STARTING OPERATIONS)…..693
SPECIFICATIONS…..694
27. SPECIFICATIONS…..695
OPTIONAL PARTS, ATTACHMENTS…..698
28. GENERAL PRECAUTIONS…..699
28.1 SAFETY PRECAUTIONS…..699
28.2 PRECAUTIONS WHEN ATTACHMENTS ARE INSTALLED…..700
29. USING SEAT BELTS …..701
29.1 SEAT BELTS…..701
30. INFORMATION ON OPTIONAL ATTACHMENTS…..703
30.1 INFORMATION ON OPTIONAL ATTACHMENTS…..703
30.2 ATTACHMENT COMBINATION TABLE…..704
30.3 SELECTING TRACKS…..705
30.4 USING THE AUTOMATIC LEVELING DEVICE…..706
SEAM035400 – Hydraulic Excavator PC128US-2 Operation & Maintenance Manual…..719
COVER…..719
1. FOREWORD…..722
2. SAFETY INFORMATION…..723
3. INTRODUCTION…..724
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..725
5. CONTENTS…..727
SAFETY…..731
6. GENERAL PRECAUTIONS…..732
7. PRECAUTIONS DURING OPERATION…..741
7.1 BEFORE STARTING ENGINE…..741
7.2 AFTER STARTING ENGINE…..743
7.3 TRANSPORTATION…..751
7.4 BATTERY…..753
7.5 TOWING…..755
7.6 BUCKET WITH HOOK…..756
8. PRECAUTIONS FOR MAINTENANCE…..757
8.1 BEFORE CARRYING OUT MAINTENANCE…..757
8.2 DURING MAINTENANCE…..762
9. POSITION FOR ATTACHING SAFETY LABELS…..769
9.1 POSITION FOR ATTACHING SAFETY LABELS…..769
OPERATION…..775
10. GENERAL VIEW…..776
10.1 GENERAL VIEW OF MACHINE…..776
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…..777
11. EXPLANATION OF COMPONENTS…..778
11.1 MACHINE MONITOR…..778
11.2 SWITCHES…..785
11.3 CONTROL LEVERS, PEDALS…..790
11.4 CEILING WINDOW…..793
11.5 FRONT WINDOW…..794
11.6 SLIDING DOOR…..796
11.7 REAR WINDOW…..797
11.8 HAMMER FOR EMERGENCY ESCAPE…..797
11.9 CAP, COVER WITH LOCK…..798
11.10 ENGINE HOOD…..799
11.11 CAB REAR COVER…..799
11.12 PUMP ROOM DOOR, BATTERY ROOM DOOR…..800
11.13 DOOR AT FRONT OF TOOL BOX…..800
11.14 FUSE…..801
11.15 FUSIBLE LINK…..801
11.16 POWER SOURCE FOR OPTION…..802
11.17 CONTROLLER…..802
11.18 HANDLING AIR CONDITIONER…..803
11.19 CAR RADIO…..808
11.20 TOOL COMPARTMENT…..812
11.21 GREASE GUN HOLDER…..812
11.22 ASHTRAY…..812
11.23 HANDLING ACCUMULATOR…..812
11.24 OPERATION AND MAINTENANCE MANUAL HOLDER…..813
12. OPERATION…..814
12.1 CHECK BEFORE STARTING ENGINE…..814
12.2 STARTING ENGINE…..825
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…..828
12.4 MOVING MACHINE OFF…..830
12.5 STEERING MACHINE…..833
12.6 STOPPING MACHINE…..835
12.7 SWINGING…..836
12.8 OPERATION OF WORK EQUIPMENT…..837
12.9 PROHIBITIONS FOR OPERATION…..838
12.10 PRECAUTIONS FOR OPERATION…..841
12.11 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…..842
12.12 HOW TO ESCAPE FROM MUD…..844
12.13 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…..845
12.14 REPLACEMENT AND INVERSION OF BUCKET…..847
12.15 PARKING MACHINE…..849
12.16 CHECK AFTER FINISHING WORK…..850
12.17 STOPPING ENGINE…..851
12.18 CHECK AFTER STOPPING ENGINE…..852
12.19 LOCKING…..852
12.20 HANDLING ROAD LINER…..853
13. TRANSPORTATION…..855
13.1 TRANSPORTATION PROCEDURE…..855
13.2 LOADING, UNLOADING WORK WITH TRAILERS…..856
13.3 METHOD OF LIFTING MACHINE…..862
14. COLD WEATHER OPERATION…..863
14.1 PRECAUTIONS FOR LOW TEMPERATURE…..863
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…..865
14.3 AFTER COLD WEATHER…..865
15. LONG-TERM STORAGE…..866
15.1 BEFORE STORAGE…..866
15.2 DURING STORAGE…..867
15.3 AFTER STORAGE…..867
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…..867
16. TROUBLESHOOTING…..868
16.1 AFTER RUNNING OUT OF FUEL…..868
16.2 PHENOMENA THAT ARE NOT FAILURES…..868
16.3 METHOD OF TOWING MACHINE…..869
16.4 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…..869
16.5 PRECAUTIONS ON PARTICULAR JOBSITES…..870
16.6 IF BATTERY IS DISCHARGED…..870
16.7 OTHER TROUBLE…..875
MAINTENANCE…..879
17. GUIDES TO MAINTENANCE…..880
18. OUTLINES OF SERVICE…..883
18.1 OUTLINE OF OIL, FUEL, COOLANT…..883
18.2 OUTLINE OF ELECTRIC SYSTEM…..886
18.3 OUTLINE OF HYDRAULIC SYSTEM…..887
19. WEAR PARTS LIST…..888
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..889
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..893
21.1 TORQUE LIST…..893
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..894
23. MAINTENANCE SCHEDULE CHART…..896
23.1 MAINTENANCE SCHEDULE CHART…..896
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…..898
24. SERVICE PROCEDURE…..899
24.1 INITIAL 250 HOURS SERVICE…..899
24.2 WHEN REQUIRED…..900
24.3 CHECK BEFORE STARTING…..922
24.4 EVERY 50 HOURS SERVICE…..923
24.5 EVERY 100 HOURS SERVICE…..924
24.6 EVERY 250 HOURS SERVICE…..926
24.7 EVERY 500 HOURS SERVICE…..931
24.8 EVERY 1000 HOURS SERVICE…..936
24.9 EVERY 2000 HOURS SERVICE…..938
24.10 EVERY 4000 HOURS SERVICE…..940
24.11 EVERY 5000 HOURS SERVICE…..941
SPECIFICATIONS…..942
25. SPECIFICATIONS…..943
OPTIONS, ATTACHMENTS…..945
26. GENERAL PRECAUTIONS…..946
26.1 PRECAUTIONS RELATED TO SAFETY…..946
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..947
27. HANDLING BUCKET WITH HOOK…..948
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..948
27.2 PROHIBITED OPERATIONS…..948
27.3 PRECAUTIONS DURING OPERATIONS…..948
28. HANDLING CAR HEATER…..949
28.1 EXPLANATION OF COMPONENTS…..949
28.2 PREPARING CAR HEATER…..949
29. MACHINES READY FOR ATTACHMENTS…..950
29.1 EXPLANATION OF COMPONENTS…..950
29.2 HYDRAULIC CIRCUIT…..952
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…..953
29.4 OPERATION…..955
29.5 LONG-TERM STORAGE…..956
29.6 SPECIFICATIONS…..956
30. INTRODUCTION OF ATTACHMENTS…..957
30.1 SPECIFICATION, USE…..957
30.2 ATTACHMENT INSTALLATION COMBINATION TABLE…..958
31. EXTENDING MACHINE SERVICE LIFE…..959
31.1 HYDRAULIC BREAKER…..959
SEAM035404T – Hydraulic Excavator PC128US-2 Operation & Maintenance Manual…..965
COVER…..965
FOREWORD…..966
FOREWORD…..967
SAFETY INFORMATION…..970
INTRODUCTION…..972
DIRECTIONS OF MACHINE…..972
PRODUCT INFORMATION…..973
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..973
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..973
EMISSION CONTROL INFORMATION LABEL…..974
SERVICE METER LOCATION…..974
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..974
CONTENTS…..975
SAFETY…..979
SAFETY INFORMATION…..980
POSITION FOR ATTACHING SAFETY LABELS…..982
POSITION FOR ATTACHING SAFETY LABELS…..983
SAFETY LABELS…..984
SAFETY INFORMATION…..989
SAFETY RULES…..989
IF ABNORMALITIES ARE FOUND…..989
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..989
FIRE EXTINGUISHER AND FIRST AID KIT…..989
SAFETY EQUIPMENT…..990
KEEP MACHINE CLEAN…..990
KEEP OPERATOR'S COMPARTMENT CLEAN…..990
LEAVING OPERATOR'S SEAT WITH LOCK…..990
HANDRAILS AND STEPS…..991
CRUSHING OR CUTTING PREVENTION…..992
MOUNTING AND DISMOUNTING…..992
NO PERSONS ON ATTACHMENTS…..992
BURN PREVENTION…..992
FIRE PREVENTION AND EXPLOSION PREVENTION…..993
ACTION IF FIRE OCCURS…..994
WINDSHIELD WASHER FLUID…..994
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..994
ATTACHMENT INSTALLATION…..994
ATTACHMENT COMBINATIONS…..995
CAB WIDOW GLASSES…..995
UNAUTHORIZED MODIFICATIONS…..995
SAFETY AT JOBSITE…..995
WORKING ON LOOSE GROUND…..995
DISTANCE TO HIGH VOLTAGE CABLES…..996
ENSURE GOOD VISIBILITY…..996
VENTILATION FOR ENCLOSED AREA…..997
SIGNALMAN'S SIGNAL AND SIGNS…..997
EMERGENCY EXIT FROM OPERATOR'S CAB…..997
ASBESTOS DUST HAZARD PREVENTION…..997
SAFETY MACHINE OPERATION…..998
STARTING ENGINE…..998
CHECKS BEFORE STARTING ENGINE…..998
SAFETY RULES FOR STARTING ENGINE…..999
STARTING ENGINE IN COLD WEATHER…..999
OPERATION…..1000
CHECKS AFTER STARTING ENGINE…..1000
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..1000
SAFETY RULES FOR TRAVELING…..1001
TRAVELING ON SLOPES…..1002
OPERATIONS ON SLOPES…..1003
PROHIBITED OPERATIONS…..1003
OPERATIONS ON SNOW…..1005
PARKING MACHINE…..1005
TRANSPORTATION…..1006
LOADING AND UNLOADING…..1006
SHIPPING THE MACHINE…..1007
BATTERY…..1008
BATTERY HAZARD PREVENTION…..1008
STARTING ENGINE WITH BOOSTER CABLES…..1009
TOWING…..1010
SAFETY RULES FOR TOWING…..1010
LIFTING OBJECTS WITH BUCKET…..1011
SAFETY RULES FOR LIFTING OBJECTS…..1011
SAFETY MAINTENANCE INFORMATION…..1012
WARNING TAG…..1012
KEEP WORK PLACE CLEAN AND TIDY…..1012
APPOINT LEADER WHEN WORKING WITH OTHERS…..1012
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..1013
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..1014
PROPER TOOLS…..1014
ACCUMULATOR…..1015
PERSONNEL…..1015
ATTACHMENTS…..1015
WORK UNDER THE MACHINE…..1015
NOISE…..1016
WHEN USING HAMMER…..1016
WELDING WORKS…..1016
REMOVING BATTERY TERMINALS…..1016
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..1017
DO NOT DISASSEMBLE RECOIL SPRINGS…..1017
SAFETY RULES FOR HIGH-PRESSURE OIL…..1017
SAFETY HANDLING HIGH-PRESSURE HOSES…..1018
WASTE MATERIALS…..1018
AIR CONDITIONER MAINTENANCE…..1018
COMPRESSED AIR…..1018
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1019
OPERATION…..1020
GENERAL VIEW…..1021
GENERAL VIEW OF MACHINE…..1021
GENERAL VIEW CONTROLS AND GAUGES…..1022
EXPLANATION OF COMPONENTS…..1023
MACHINE MONITOR…..1023
SWITCHES…..1029
CONTROL LEVERS, PEDALS…..1035
FRONT WINDOW…..1039
SLIDING DOOR…..1042
REAR WINDOW…..1043
HAMMER FOR EMERGENCY ESCAPE…..1043
CAP, COVER WITH LOCK…..1044
ENGINE HOOD…..1045
CAB REAR COVER…..1046
PUMP ROOM DOOR, BATTERY ROOM DOOR…..1047
DOOR AT FRONT OF TOOL BOX…..1048
FUSE…..1049
FUSIBLELINK…..1049
POWER SOURCE FOR OPTION…..1050
CONTROLLER…..1050
HANDLING AIR CONDITIONER…..1051
CAR RADIO…..1054
HANDLING ACCUMULATOR…..1059
OPERATION AND MAINTENANCE MANUAL HOLDER…..1060
TOOL COMPARTMENT…..1060
GREASE GUN HOLDER…..1060
ASHTRAY…..1060
MACHINE OPERATIONS AND CONTROLS…..1061
BEFORE STARTING ENGINE…..1061
STARTING ENGINE…..1074
AFTER STARTING ENGINE…..1077
STOPPING THE ENGINE…..1080
CHECK AFTER SHUT OFF ENGINE…..1080
MACHINE OPERATION…..1081
STEERING THE MACHINE…..1085
SWINGING…..1087
WORK EQUIPMENT CONTROLS AND OPERATIONS…..1088
PROHIBITED OPERATIONS…..1090
GENERAL OPERATION INFORMATION…..1094
TRAVELING ON SLOPES…..1095
ESCAPE FROM MUD…..1097
RECOMMENDED APPLICATIONS…..1098
REPLACEMENT AND INVERSION OF BUCKET…..1100
PARKING MACHINE…..1104
CHECK AFTER FINISHING WORK…..1105
LOCKING…..1106
HANDLING ROAD LINER…..1107
TRANSPORTATION…..1109
TRANSPORTATION PROCEDURE…..1109
LOADING AND UNLOADING WITH TRAILER…..1110
LIFTING MACHINE…..1116
COLD WEATHER OPERATION…..1118
COLD WEATHER OPERATION INFORMATION…..1118
AFTER DAILY WORK COMPLETION…..1120
AFTER COLD WEATHER SEASON…..1121
LONG TERM STORAGE…..1122
BEFORE STORAGE…..1122
DURING STORAGE…..1122
AFTER STORAGE…..1123
TROUBLESHOOTING…..1124
AFTER RUNNING OUT OF FUEL…..1124
PHENOMENA THAT ARE NOT FAILURES…..1124
TOWING THE MACHINE…..1125
LIGHTWEIGHT TOWING HOOK…..1125
PRECAUTIONS ON PARTICULAR JOBSITES…..1125
DISCHARGED BATTERY…..1126
OTHER TROUBLE…..1131
MAINTENANCE…..1135
MAINTENANCE INFORMATION…..1136
LUBRICANTS, COOLANT AND FILTERS…..1139
OUTLINE OF OIL, FUEL, COOLANT…..1139
ELECTRIC SYSTEM MAINTENANCE…..1141
HANDLING HYDRAULIC SYSTEM…..1141
WEAR PARTS LIST…..1143
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..1144
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…..1144
TIGHTENING TORQUE SPECIFICATIONS…..1148
TIGHTENING TORQUE LIST…..1148
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1149
SAFETY CRITICAL PARTS…..1149
MAINTENANCE SCHEDULE…..1150
MAINTENANCE SCHEDULE CHART…..1150
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..1152
MAINTENANCE PROCEDURE…..1153
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..1153
WHEN REQUIRED…..1154
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..1154
CLEAN INSIDE OF COOLING SYSTEM…..1157
CHECK AND TIGHTEN TRACK SHOE BOLTS…..1160
CHECK AND ADJUST TRACK TENSION…..1162
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)…..1164
CHECK ELECTRICAL INTAKE AIR HEATER…..1164
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..1165
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..1168
ADJUST BUCKET CLEARANCE…..1169
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..1170
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..1171
REPLACE ADDITIONAL BREAKER FILTER ELEMENT (IF EQUIPPED)…..1172
WASHING WASHABLE FLOOR…..1173
BLEEDING AIR FROM HYDRAULIC SYSTEM…..1175
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..1177
CHECK BEFORE STARTING…..1178
EVERY 50 HOURS MAINTENANCE…..1179
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..1179
EVERY 100 HOURS MAINTENANCE…..1180
LUBRICATING…..1180
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..1182
EVERY 250 HOURS MAINTENANCE…..1183
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..1183
CHECK LEVEL OF BATTERY ELECTROLYTE…..1184
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..1185
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..1186
EVERY 500 HOURS MAINTENANCE…..1188
REPLACE FUEL FILTER CARTRIDGE…..1188
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..1189
LUBRICATE SWING CIRCLE (2 POINTS)…..1189
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..1190
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..1191
REPLACE HYDRAULIC FILTER ELEMENT…..1192
EVERY 1000 HOURS MAINTENANCE…..1193
CHANGE OIL IN SWING MACHINERY CASE…..1193
CHANGE OIL IN FINAL DRIVE CASE…..1194
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..1194
CHECK PLAY OF TURBOCHARGER ROTOR…..1194
CHECK FAN BELT TENSION AND REPLACE FAN BELT…..1194
EVERY 2000 HOURS MAINTENANCE…..1195
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…..1195
CLEAN HYDRAULIC TANK STRAINER…..1196
CLEAN, CHECK TURBOCHARGER…..1196
CHECK ALTERNATOR, STARTING MOTOR…..1196
CHECK ENGINE VALVE CLEARANCE, ADJUST…..1196
EVERY 4000 HOURS MAINTENENCE…..1197
CHECK WATER PUMP…..1197
EVERY 5000 HOURS MAINTENANCE…..1198
CHANGE OIL IN HYDRAULIC TANK…..1198
SPECIFICATIONS…..1200
SPECIFICATIONS…..1201
ATTACHMENTS AND OPTIONS…..1203
GENERAL PRECAUTIONS…..1204
PRECAUTIONS RELATED TO SAFETY…..1204
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..1206
HANDLING BUCKET WITH HOOK…..1207
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..1207
PROHIBITED OPERATIONS…..1207
HANDLING CAR HEATER…..1208
EXPLANATION OF COMPONENTS…..1208
PREPARING CAR HEATER…..1208
MACHINES READY FOR ATTACHMENTS…..1209
EXPLANATION OF COMPONENTS…..1209
HYDRAULIC CIRCUIT…..1212
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…..1213
OPERATION…..1215
LONG-TERM STORAGE…..1217
SPECIFICATIONS…..1217
INTRODUCTION OF ATTACHMENTS…..1218
SPECIFICATION, USE…..1218
ATTACHMENT INSTALLATION COMBINATION TABLE…..1219
ATTACHMENT COMBINATIONS…..1219
RECOMMENDED ATTACHMENT OPERATIONS…..1220
HYDRAULIC BREAKER…..1220
INDEX…..1225
SEAM035407T – Hydraulic Excavator PC128US-2, PC138USLC-2 Operation & Maintenance Manual…..1228
COVER…..1228
FOREWORD…..1229
FOREWORD…..1230
SAFETY INFORMATION…..1233
INTRODUCTION…..1235
DIRECTIONS OF MACHINE…..1235
PRODUCT INFORMATION…..1236
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..1236
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..1236
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…..1237
SERVICE METER LOCATION…..1237
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..1237
CONTENTS…..1238
SAFETY…..1241
SAFETY INFORMATION…..1242
SAFETY LABELS…..1244
LOCATION OF SAFETY LABELS…..1245
SAFETY LABELS…..1246
SAFETY INFORMATION…..1251
SAFETY RULES…..1251
IF ABNORMALITIES ARE FOUND…..1251
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..1251
FIRE EXTINGUISHER AND FIRST AID KIT…..1251
SAFETY EQUIPMENT…..1251
KEEP MACHINE CLEAN…..1252
KEEP OPERATOR'S COMPARTMENT CLEAN…..1252
LEAVING OPERATOR'S SEAT WITH LOCK…..1252
HANDRAILS AND STEPS…..1253
MOUNTING AND DISMOUNTING…..1253
NO PERSONS ON ATTACHMENTS…..1253
DO NOT GET CAUGHT IN ARTICULATED PORTION…..1253
BURN PREVENTION…..1254
FIRE PREVENTION AND EXPLOSION PREVENTION…..1254
ACTION IF FIRE OCCURS…..1255
WINDSHIELD WASHER FLUID…..1255
FALLING OBJECTS,FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..1255
ATTACHMENT INSTALLATION…..1256
ATTACHMENT COMBINATIONS…..1256
CAB WINDOW GLASSES…..1256
UNAUTHORIZED MODIFICATIONS…..1256
SAFETY AT JOBSITE…..1256
WORKING ON LOOSE GROUND…..1257
DISTANCE TO HIGH VOLTAGE CABLES…..1257
ENSURE GOOD VISIBILITY…..1257
VENTILATION FOR ENCLOSED AREA…..1258
SIGNALMAN'S SIGNAL AND SIGNS…..1258
EMERGENCY EXIT FROM OPERATOR'S CAB…..1258
ASBESTOS DUST HAZARD PREVENTION…..1258
SAFETY MACHINE OPERATION…..1259
STARTING ENGINE…..1259
CHECKS BEFORE STARTING ENGINE…..1259
SAFETY RULES FOR STARTING ENGINE…..1259
STARTING ENGINE IN COLD WEATHER…..1260
OPERATION…..1261
CHECKS BEFORE OPERATION…..1261
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..1261
SAFETY RULES FOR TRAVELING…..1262
TRAVELING ON SLOPES…..1263
OPERATIONS ON SLOPES…..1264
PROHIBITED OPERATIONS…..1264
OPERATIONS ON SNOW…..1265
PARKING MACHINE…..1266
TRANSPORTATION…..1267
LOADING AND UNLOADING…..1267
SHIPPING THE MACHINE…..1267
BATTERY…..1268
BATTERY HAZARD PREVENTION…..1268
STARTING ENGINE WITH BOOSTER CABLES…..1269
TOWING…..1270
SAFETY RULES FOR TOWING…..1270
LIFTING OBJECTS WITH BUCKET…..1271
SAFETY RULES FOR LIFTING OBJECTS…..1271
SAFETY MAINTENANCE INFORMATION…..1272
WARNING TAG…..1272
KEEP WORK PLACE CLEAN AND TIDY…..1272
APPOINT LEADER WHEN WORKING WITH OTHERS…..1272
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..1273
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..1273
PROPER TOOLS…..1274
ACCUMULATOR…..1274
PERSONNEL…..1274
ATTACHMENTS…..1275
WORK UNDER THE MACHINE…..1275
NOISE…..1275
WHEN USING HAMMER…..1275
WELDING WORKS…..1275
REMOVING BATTERY TERMINALS…..1276
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..1276
DO NOT DISASSEMBLE RECOIL SPRINGS…..1276
SAFETY RULES FOR HIGH-PRESSURE OIL…..1276
SAFETY HANDLING HIGH-PRESSURE HOSES…..1277
WASTE MATERIALS…..1277
AIR CONDITIONER MAINTENANCE…..1277
COMPRESSED AIR…..1277
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1277
OPERATION…..1279
MACHINE VIEW ILLUSTRATIONS…..1280
OVERALL MACHINE VIEW…..1280
CONTROLS AND GAUGES…..1281
DETAILED CONTROLS AND GAUGES…..1282
MONITORING SYSTEM…..1282
SWITCHES…..1294
CONTROL LEVERS AND PEDALS…..1299
SUN ROOF…..1302
WINDSHIELD…..1303
SLIDING DOOR…..1308
EMERGENCY ESCAPE HAMMER…..1308
CAP WITH LOCK…..1310
ENGINE HOOD…..1311
CAB REAR COVER…..1312
PUMP ROOM DOOR,BATTERY ROOM DOOR…..1313
DOOR AT FRONT OF TOOL BOX…..1314
FUSE…..1315
FUSIBLELINK…..1316
CONTROLLERS…..1316
AIR CONDITIONER CONTROLS…..1317
RADIO…..1323
ACCUMULATOR…..1328
OPERATION MANUAL STORAGE…..1329
TOOL BOX…..1329
GREASE PUMP HOLDER…..1329
HOT AND COOL BOX…..1329
ASHTRAY…..1330
FIRE EXTINGUISHER…..1330
MACHINE OPERATIONS AND CONTROLS…..1331
BEFORE STARTING ENGINE…..1331
STARTING ENGINE…..1347
AFTER STARTING ENGINE…..1351
STOPPING THE ENGINE…..1354
CHECK AFTER SHUT OFF ENGINE…..1354
MACHINE OPERATION…..1355
STEERING THE MACHINE…..1359
SWINGING…..1361
WORK EQUIPMENT CONTROLS AND OPERATIONS…..1362
WORKING MODE…..1364
PROHIBITED OPERATIONS…..1365
GENERAL OPERATION INFORMATION…..1367
TRAVELING ON SLOPES…..1369
ESCAPE FROM MUD…..1371
RECOMMENDED APPLICATIONS…..1372
BUCKET REPLACEMENT AND INVERSION…..1374
PARKING MACHINE…..1376
MACHINE INSPECTION AFTER DAILY WORK…..1377
LOCKING…..1377
ROAD LINERS…..1378
TRANSPORTATION…..1380
TRANSPORTATION PROCEDURE…..1380
LOADING AND UNLOADING WITH TRAILER…..1381
LIFTING MACHINE…..1387
COLD WEATHER OPERATION…..1389
COLD WEATHER OPERATION INFORMATION…..1389
AFTER DAILY WORK COMPLETION…..1391
AFTER COLD WEATHER SEASON…..1391
LONG TERM STORAGE…..1392
BEFORE STORAGE…..1392
DURING STORAGE…..1392
AFTER STORAGE…..1392
TROUBLES AND ACTIONS…..1393
RUNNING OUT OF FUEL…..1393
PHENOMENA THAT ARE NOT FAILURES…..1393
TOWING THE MACHINE…..1394
LIGHTWEIGHT TOWING HOOK…..1394
SEVERE JOB CONDITION…..1394
DISCHARGED BATTERY…..1395
OTHER TROUBLE…..1399
MAINTENANCE…..1404
MAINTENANCE INFORMATION…..1405
LUBRICANTS, COOLANT AND FILTERS…..1407
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..1407
ELECTRIC SYSTEM MAINTENANCE…..1409
WEAR PARTS…..1410
WEAR PARTS LIST…..1410
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..1411
PROPER SELECTION…..1411
TIGHTENING TORQUE SPECIFICATIONS…..1415
TIGHTENING TORQUE LIST…..1415
SAFETY CRITICAL PARTS…..1416
SAFETY CRITICAL PARTS LIST…..1416
MAINTENANCE SCHEDULE…..1417
MAINTENANCE SCHEDULE CHART…..1417
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..1418
MAINTENANCE PROCEDURE…..1419
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..1419
CHECK ENGINE VALVE CLEARANCE,ADJUST…..1419
WHEN REQUIRED…..1420
CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT…..1420
CLEAN INSIDE OF COOLING SYSTEM…..1424
CHECK AND TIGHTEN TRACK SHOE BOLTS…..1427
CHECK AND ADJUST TRACK TENSION…..1428
ROAD LINERS-CHECK…..1430
REPLACE ROAD LINERS…..1430
CHECK ELECTRICAL INTAKE AIR HEATER…..1430
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..1431
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..1434
ADJUST BUCKET CLEARANCE…..1435
CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID…..1436
CHECK AND ADJUST AIR CONDITIONER…..1437
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RALL AND ROLLER…..1438
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (IF EQUIPPED)…..1439
WASHING WASHABLE FLOOR…..1440
BLEEDING AIR FROM HYDRAULIC SYSTEM…..1443
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..1445
CHECK BEFORE STARTING…..1447
EVERY 50 HOURS MAINTENANCE…..1448
DRAIN WATER FROM FUEL TANK…..1448
EVERY 100 HOURS MAINTENANCE…..1449
LUBRICATING…..1449
SWING MACHINERY CASE OIL-CHECK/ADD…..1451
EVERY 250 HOURS MAINTENANCE…..1452
CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL…..1452
CHECK LEVEL OF BATTERY ELECTROLYTE…..1453
ENGINE CRANKCASE OIL AND FILTER CARTRIDGE-CHANGE/REPLACE…..1455
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION,ADJUST…..1456
EVERY 500 HOURS MAINTENANCE…..1457
REPLACE FUEL FILTER CARTRIDGE…..1457
CHECK SWING PINION GREASE LEVEL,ADD GREASE…..1458
LUBRICATE SWING CIRCLE…..1458
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS AND CONDENSER FINS…..1458
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER…..1459
REPLACE HYDRAULIC OIL FILTER ELEMENT…..1461
EVERY 1000 HOURS MAINTENANCE…..1462
CHANGE OIL IN SWING MACHINERY CASE…..1462
CHANGE OIL IN FINAL DRIVE CASE…..1463
FAN BELT-INSPECT/REPLACE…..1463
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..1463
CHECK PLAY OF TURBOCHARGER ROTOR…..1463
EVERY 2000 HOURS MAINTENANCE…..1464
CHECK PTO GEAR CASE,ADD OIL…..1464
HYDRAULIC OIL TANK STRAINER-CLEAN…..1465
CLEAN,CHECK TURBOCHARGER…..1465
CHECK ALTERNATOR,STARTING MOTOR…..1465
CHECK ENGINE VALVE CLEARANCE,ADJUST…..1465
EVERY 4000 HOURS MAINTENANCE…..1466
CHECK WATER PUMP…..1466
EVERY 5000 HOURS MAINTENANCE…..1467
CHANGE OIL IN HYDRAULIC TANK…..1467
SPECIFICATIONS…..1468
SPECIFICATIONS…..1469
ATTACHMENTS,OPTIONS…..1472
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…..1473
SAFETY FIRST…..1473
ATTACHMENT INSTALLATION…..1474
BUCKET WITH HOOK…..1475
HOOK CONDITION…..1475
PROHIBITED OPERATIONS…..1475
AIR CONDITIONER…..1476
AIR CONDITIONER CONTROL PANEL…..1476
AIR CONDITIONER CONTROLS…..1481
AIR CONDITIONER MAINTENANCE…..1481
MACHINE READY FOR ATTACHMENT…..1482
LOCATIONS…..1482
HYDRAULIC CIRCUIT…..1485
ATTACHMENT REMOVAL AND INSTALLATION…..1486
ATTACHMENT OPERATIONS…..1490
LONG TERM STORAGE…..1493
SPECIFICATIONS…..1493
ATTACHMENT GUIDE…..1494
OTHER ATTACHMENT…..1494
ATTACHMENT COMBINATIONS…..1495
RECOMMENDED ATTACHMENT OPERATIONS…..1496
HYDRAULIC BREAKER…..1496
INDEX…..1501
SEAM035408T – Hydraulic Excavator GALEO PC128US-2, PC138USLC-2 Operation & Maintenance Manual…..1504
COVER…..1504
FOREWORD…..1505
FOREWORD…..1506
SAFETY INFORMATION…..1509
INTRODUCTION…..1511
DIRECTIONS OF MACHINE…..1511
PRODUCT INFORMATION…..1512
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..1512
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..1512
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…..1513
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..1513
CONTENTS…..1514
SAFETY…..1518
SAFETY INFORMATION…..1519
SAFETY LABELS…..1521
LOCATION OF SAFETY LABELS…..1522
SAFETY LABELS…..1523
SAFETY INFORMATION…..1529
SAFETY RULES…..1529
IF ABNORMALITIES ARE FOUND…..1529
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..1529
FIRE EXTINGUISHER AND FIRST AID KIT…..1529
SAFETY EQUIPMENT…..1529
KEEP MACHINE CLEAN…..1530
KEEP OPERATOR'S COMPARTMENT CLEAN…..1530
LEAVING OPERATOR'S SEAT WITH LOCK…..1530
HANDRAILS AND STEPS…..1531
MOUNTING AND DISMOUNTING…..1531
NO PERSONS ON ATTACHMENTS…..1531
DO NOT GET CAUGHT IN ARTICULATED PORTION…..1531
BURN PREVENTION…..1532
FIRE PREVENTION AND EXPLOSION PREVENTION…..1532
ACTION IF FIRE OCCURS…..1533
WINDSHIELD WASHER FLUID…..1533
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..1533
ATTACHMENT INSTALLATION…..1534
ATTACHMENT COMBINATIONS…..1534
CAB WIDOW GLASSES…..1534
UNAUTHORIZED MODIFICATIONS…..1534
SAFETY AT JOBSITE…..1534
WORKING ON LOOSE GROUND…..1534
DISTANCE TO HIGH VOLTAGE CABLES…..1535
ENSURE GOOD VISIBILITY…..1535
VENTILATION FOR ENCLOSED AREA…..1536
SIGNALMAN'S SIGNAL AND SIGNS…..1536
EMERGENCY EXIT FROM OPERATOR'S CAB…..1536
ASBESTOS DUST HAZARD PREVENTION…..1536
SAFETY MACHINE OPERATION…..1537
STARTING ENGINE…..1537
CHECKS BEFORE STARTING ENGINE…..1537
SAFETY RULES FOR STARTING ENGINE…..1537
STARTING ENGINE IN COLD WEATHER…..1537
OPERATION…..1539
CHECKS BEFORE OPERATION…..1539
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..1539
SAFETY RULES FOR TRAVELING…..1540
TRAVELING ON SLOPES…..1541
OPERATIONS ON SLOPES…..1542
PROHIBITED OPERATIONS…..1542
OPERATIONS ON SNOW…..1543
PARKING MACHINE…..1544
TRANSPORTATION…..1545
LOADING AND UNLOADING…..1545
SHIPPING THE MACHINE…..1545
BATTERY…..1546
BATTERY HAZARD PREVENTION…..1546
STARTING ENGINE WITH BOOSTER CABLES…..1547
TOWING…..1548
SAFETY RULES FOR TOWING…..1548
LIFTING OBJECTS WITH BUCKET…..1549
SAFETY RULES FOR LIFTING OBJECTS…..1549
SAFETY MAINTENANCE INFORMATION…..1550
WARNING TAG…..1550
KEEP WORK PLACE CLEAN AND TIDY…..1550
APPOINT LEADER WHEN WORKING WITH OTHERS…..1550
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..1551
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..1551
PROPER TOOLS…..1552
ACCUMULATOR…..1552
PERSONNEL…..1552
ATTACHMENTS…..1553
WORK UNDER THE MACHINE…..1553
NOISE…..1553
WHEN USING HAMMER…..1553
WELDING WORKS…..1553
REMOVING BATTERY TERMINALS…..1554
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..1554
DO NOT DISASSEMBLE RECOIL SPRINGS…..1554
SAFETY RULES FOR HIGH-PRESSURE OIL…..1554
SAFETY HANDLING HIGH-PRESSURE HOSES…..1555
WASTE MATERIALS…..1555
AIR CONDITIONER MAINTENANCE…..1555
COMPRESSED AIR…..1555
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1555
OPERATION…..1557
MACHINE VIEW ILLUSTRATIONS…..1558
OVERALL MACHINE VIEW…..1558
CONTROLS AND GAUGES…..1559
DETAILED CONTROLS AND GAUGES…..1560
MONITORING SYSTEM…..1560
SWITCHES…..1572
CONTROL LEVERS AND PEDALS…..1577
SUN ROOF…..1580
WINDSHIELD…..1581
SLIDING DOOR…..1586
EMERGENCY ESCAPE HAMMER…..1586
CAP WITH LOCK…..1588
ENGINE HOOD…..1589
CAB REAR COVER…..1590
PUMP ROOM DOOR, BATTERY ROOM DOOR…..1591
DOOR AT FRONT OF TOOL BOX…..1592
FUSE…..1593
FUSIBLELINK…..1594
CONTROLLERS…..1594
AIR CONDITIONER CONTROLS…..1595
RADIO…..1601
ACCUMULATOR…..1606
OPERATION MANUAL STORAGE…..1607
TOOL BOX…..1607
GREASE PUMP HOLDER…..1607
HOT AND COOL BOX…..1607
ASHTRAY…..1608
FIRE EXTINGUISHER…..1608
MACHINE OPERATIONS AND CONTROLS…..1609
BEFORE STARTING ENGINE…..1609
STARTING ENGINE…..1625
AFTER STARTING ENGINE…..1630
STOPPING THE ENGINE…..1633
CHECK AFTER SHUT OFF ENGINE…..1633
MACHINE OPERATION…..1634
STEERING THE MACHINE…..1638
SWINGING…..1640
WORK EQUIPMENT CONTROLS AND OPERATIONS…..1641
WORKING MODE…..1643
PROHIBITED OPERATIONS…..1644
GENERAL OPERATION INFORMATION…..1646
TRAVELING ON SLOPES…..1648
ESCAPE FROM MUD…..1650
RECOMMENDED APPLICATIONS…..1651
BUCKET REPLACEMENT AND INVERSION…..1653
PARKING MACHINE…..1655
MACHINE INSPECTION AFTER DAILY WORK…..1656
LOCKING…..1656
ROAD LINERS…..1657
TRANSPORTATION…..1659
TRANSPORTATION PROCEDURE…..1659
LOADING AND UNLOADING WITH TRAILER…..1660
LIFTING MACHINE…..1666
COLD WEATHER OPERATION…..1668
COLD WEATHER OPERATION INFORMATION…..1668
AFTER DAILY WORK COMPLETION…..1670
AFTER COLD WEATHER SEASON…..1670
LONG TERM STORAGE…..1671
BEFORE STORAGE…..1671
DURING STORAGE…..1671
AFTER STORAGE…..1671
TROUBLESHOOTING…..1672
RUNNING OUT OF FUEL…..1672
PHONOMENA THAT ARE NOT FAILURES…..1672
TOWING THE MACHINE…..1673
LIGHTWEIGHT TOWING HOOK…..1673
SEVERE JOB CONDITION…..1673
DISCHARGED BATTERY…..1674
OTHER TROUBLE…..1678
MAINTENANCE…..1683
MAINTENANCE INFORMATION…..1684
LUBRICANTS, COOLANT AND FILTERS…..1686
HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC…..1686
ELECTRIC SYSTEM MAINTENANCE…..1688
WEAR PARTS …..1689
WEAR PARTS LIST…..1689
LUBRICANTS,FUEL AND COOLANT SPECIFICATIONS…..1690
PROPER SELECTION…..1690
TIGHTENING TORQUE SPECIFICATIONS…..1694
TIGHTENING TORQUE LIST…..1694
SAFETY CRITICAL PARTS…..1695
SAFETY CRITICAL PARTS LIST…..1695
MAINTENANCE SCHEDULE…..1696
MAINTENANCE SCHEDULE CHART…..1696
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..1697
MAINTENANCE PROCEDURE…..1698
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..1698
WHEN REQUIRED…..1699
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..1699
CLEAN INSIDE OF COOLING SYSTEM…..1703
CHECK AND TIGHTEN TRACK SHOE BOLTS…..1706
CHECK AND ADJUST TRACK TENSION…..1707
REPLACE ROAD LINERS…..1709
CHECK ELECTRICAL INTAKE AIR HEATER…..1709
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..1710
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..1713
ADJUST BUCKET CLEARANCE…..1714
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..1715
CHECK AND ADJUST AIR CONDITIONER…..1716
CHECK,CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…..1717
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT…..1718
WASH WASHABLE FLOOR…..1719
BLEEDING AIR FROM HYDRAULIC SYSTEM…..1722
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..1724
CHECK BEFORE STARTING…..1726
EVERY 50 HOURS MAINTENANCE…..1727
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..1727
EVERY 100 HOURS MAINTENANCE…..1728
LUBRICATING…..1728
SWING MACHINERY CASE OIL-CHECK/ADD…..1730
EVERY 250 HOURS MAINTENANCE…..1731
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..1731
CHECK LEVEL OF BATTERY ELECTROLYTE…..1732
ENGINE CRANKCASE OIL AND FILTER CARTRIDGE-CHANGE/REPLACE…..1734
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION,ADJUST…..1735
EVERY 500 HOURS MAINTENANCE…..1736
REPLACE FUEL FILTER CARTRIDGE…..1736
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..1737
LUBRICATE SWING CIRCLE …..1737
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS AND CONDENSER FINS…..1737
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER…..1738
REPLACE HYDRAULIC OIL FILTER ELEMENT…..1740
EVERY 1000 HOURS MAINTENANCE…..1741
CHANGE OIL IN SWING MACHINERY CASE…..1741
CHANGE OIL IN FINAL DRIVE CASE…..1742
FAN BELT-INSPECT/REPLACE…..1742
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..1742
CHECK PLAY TURBOCHARGER ROTOR…..1742
EVERY 2000 HOURS MAINTENANCE…..1743
CHECK PTO GEAR CASE,ADD OIL…..1743
CLEAN HYDRAULIC TANK STRAINER…..1744
CLEAN, CHECK TURBOCHARGER…..1744
CHECK ALTERNATOR, STARTING MOTOR…..1744
CHECK ENGINE VALVE CLEARANCE, ADJUST…..1744
EVERY 4000 HOURS MAINTENENCE…..1745
CHECK WATER PUMP…..1745
EVERY 5000 HOURS MAINTENANCE…..1746
CHANGE OIL IN HYDRAULIC TANK…..1746
SPECIFICATIONS…..1747
SPECIFICATIONS…..1748
ATTACHMENTS,OPTIONS…..1751
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…..1752
SAFETY FIRST…..1752
ATTACHMENT INSTALLATION…..1753
BUCKET WITH HOOK…..1754
HOOK CONDITION…..1754
PROHIBITED OPERATIONS…..1754
AIR CONDITIONER…..1755
AIR CONDITIONER CONTROL PANEL…..1755
AIR CONDITIONER CONTROLS…..1760
AIR CONDITIONER MAINTENANCE…..1760
MACHINES READY FOR ATTACHMENTS…..1761
LOCATIONS…..1761
HYDRAULIC CIRCUIT…..1764
ATTACHMENT REMOVAL AND INSTALLATION…..1765
ATTAMHMENT OPERATIONS…..1769
LONG TERM STORAGE…..1772
SPECIFICATIONS…..1772
ATTACHMENT GUIDE…..1773
OTHER ATTACHMENT…..1773
ATTACHMENT COMBINATIONS…..1774
SELECTION OF TRACK SHOES…..1775
RECOMMENDED ATTACHMENT OPERATIONS…..1776
HYDRAULIC BREAKER…..1776
INDEX…..1781
SEAM035500 – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual…..1784
COVER PAGE…..1784
FOREWORD…..1791
FOREWORD…..1792
SAFETY INFORMATION…..1793
INTRODUCTION…..1795
DIRECTIONS OF MACHINE…..1795
PRODUCT INFORMATION…..1796
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..1796
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..1796
SERVICE METER LOCATION…..1797
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..1797
CONTENTS…..1798
SAFETY…..1802
SAFETY INFORMATION…..1803
POSITION FOR ATTACHING SAFETY LABELS…..1805
POSITION FOR ATTACHING SAFETY LABELS…..1806
SAFETY LABELS…..1807
SAFETY INFORMATION…..1812
SAFETY RULES…..1812
IF ABNORMALITIES ARE FOUND…..1812
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..1812
FIRE EXTINGUISHER AND FIRST AID KIT…..1812
SAFETY EQUIPMENT…..1813
KEEP MACHINE CLEAN…..1813
KEEP OPERATOR'S COMPARTMENT CLEAN…..1813
LEAVING OPERATOR'S SEAT WITH LOCK…..1813
HANDRAILS AND STEPS…..1814
MOUNTING AND DISMOUNTING…..1815
NO PERSONS ON ATTACHMENT…..1815
BURN PREVENTION…..1815
FIRE PREVENTION AND EXPLOSION PREVENTION…..1816
ACTION IF FIRE OCCURS…..1817
WINDSHIELD WASHER FLUID…..1817
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..1817
ATTACHMENT INSTALLATION…..1817
ATTACHMENT COMBINATIONS…..1818
CAB WINDOW GLASSES…..1818
UNAUTHORIZED MODIFICATIONS…..1818
SAFETY AT JOBSITE…..1818
WORKING ON LOOSE GROUND…..1818
DISTANCE AT HIGH VOLTAGE CABLES…..1819
ENSURE GOOD VISIBILITY…..1819
VENTILATION FOR ENCLOSED AREA…..1820
SIGNALMAN'S SIGNAL AND SIGNS…..1820
EMERGENCY EXIT FROM OPERATOR'S CAB…..1820
ASBESTOS DUST HAZARD PREVENTION…..1820
SAFETY MACHINE OPERATION…..1821
BEFORE STARTING ENGINE…..1821
CHECKS BEFORE STARTING ENGINE…..1821
SAFETY RULES FOR STARTING ENGINE…..1822
STARTING ENGINE IN COLD WEATHER…..1822
AFTER STARTING ENGINE…..1823
CHECKS AFTER STARTING ENGINE…..1823
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..1823
SAFETY RULES FOR TRAVELING…..1824
TRAVELING ON SLOPES…..1825
OPERATIONS ON SLOPES…..1826
PROHIBITED OPERATIONS…..1826
OPERATIONS ON SNOW…..1828
PARKING MACHINE…..1828
TRANSPORTATION…..1829
LOADING AND UNLOADING…..1829
SHIPPING THE MACHINE…..1830
BATTERY…..1831
BATTERY HAZARD PREVENTION…..1831
STARTING ENGINE WITH BOOSTER CABLES…..1832
TOWING…..1833
SAFETY RULES FOR TOWING…..1833
LIFTING OBJECTS WITH BUCKET…..1834
SAFETY RULES FOR LIFTING OBJECTS…..1834
SAFETY MAINTENANCE INFORMATION…..1835
WARNING TAG…..1835
KEEP WORK PLACE AND CLEAN AND TIDY…..1835
APPOINT LEADER WHEN WORKING WITH OTHERS…..1835
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..1836
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..1837
PROPER TOOLS…..1837
ACCUMULATOR…..1838
PERSONNEL…..1838
ATTACHMENTS…..1838
WORK UNDER THE MACHINE…..1838
NOISE…..1839
WHEN USING HAMMER…..1839
WELDING WORKS…..1839
REMOVING BATTERY TERMINALS…..1839
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..1840
DO NOT DISASSEMBLE RECOIL SPRINGS…..1840
SAFETY RULES FOR HIGH-PRESSURE OIL…..1840
SAFETY HANDLING HIGH-PRESSURE HOSES…..1841
WASTE MATERIALS…..1841
AIR CONDITIONER MAINTENANCE…..1841
COMPRESSED AIR…..1841
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1842
OPERATION…..1843
GENERAL VIEW…..1844
GENERAL VIEW OF MACHINE…..1844
GENERAL VIEW CONTROLS AND GAUGES…..1845
EXPLANATION OF COMPONENTS…..1846
MACHINE MONITOR…..1846
4-SYSTEM…..1851
SWITCHES…..1854
CONTROL LEVERS, PEDALS…..1859
FRONT WINDOW…..1863
SLIDING DOOR…..1866
REAR WINDOW…..1867
HAMMER FOR EMERGENCY ESCAPE…..1867
STOW-AWAY TYPE STEP…..1868
CAP, COVER WITH LOCK…..1870
ENGINE HOOD…..1871
CAB REAR COVER…..1872
PUMP ROOM DOOR, BATTERY ROOM DOOR…..1873
DOOR AT FRONT OF TOOL BOX…..1874
FUSE…..1875
FUSIBLELINK…..1875
POWER SOURCE FOR OPTION…..1876
CONTROLLER…..1876
HANDLING AIR CONDITIONER…..1877
CAR RADIO…..1880
HANDLING ACCUMULATOR…..1885
OPERATION AND MAINTENANCE MANUAL HOLDER…..1886
TOOL COMPARTMENT…..1886
GREASE GUN HOLDER…..1886
ASHTRAY…..1886
MACHINE OPERATIONS AND CONTROLS…..1887
BEFORE STARTING ENGINE…..1887
STARTING ENGINE…..1900
AFTER STARTING ENGINE…..1903
STOPPING THE ENGINE…..1908
CHECK AFTER SHUT OFF ENGINE…..1908
MACHINE OPERATION…..1909
STEERING THE MACHINE…..1913
SWINGING…..1915
WORK EQUIPMENT CONTROLS AND OPERATIONS…..1916
PROHIBITED OPERATIONS…..1918
GENERAL OPERATION INFORMATION…..1922
TRAVELING ON SLOPES…..1924
ESCAPE FROM MUD…..1926
RECOMMENDED APPLICATIONS…..1927
BUCKET REPLACEMENT…..1929
PARKING MACHINE…..1931
CHECK AFTER FINISHING WORK…..1932
LOCKING…..1933
HANDLING 4-SYSTEM…..1934
HANDLING ROAD LINER…..1948
TRANSPORTATION…..1950
TRANSPORTATION PROCEDURE…..1950
LOADING AND UNLOADING WITH TRAILER…..1951
LIFTING MACHINE…..1957
COLD WEATHER OPERATION…..1959
COLD WEATHER OPERATION INFORMATION…..1959
AFTER DAILY WORK COMPLETION…..1961
AFTER COLD WEATHER SEASON…..1962
LONG TERM STORAGE…..1963
BEFORE STORAGE…..1963
DURING STORAGE…..1963
AFTER STORAGE…..1964
TROUBLESHOOTING…..1965
AFTER RUNNING OUT OF FUEL…..1965
PHENOMENA THAT ARE NOT FAILURES…..1965
TOWING THE MACHINE…..1968
LIGHTWEIGHT TOWING HOOK…..1968
PRECAUTIONS ON PARTICULAR JOBSITES…..1968
DISCHARGED BATTERY…..1969
OTHER TROUBLE…..1974
MAINTENANCE …..1979
MAINTENANCE INFORMATION…..1980
LUBRICANTS, COOLANT AND FILTERS…..1983
OIL…..1983
ELECTRIC SYSTEM MAINTENANCE…..1985
WEAR PARTS LIST…..1986
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..1987
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…..1987
TIGHTENING TORQUE SPECIFICATIONS…..1991
TIGHTENING TORQUE LIST…..1991
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..1992
SAFETY CRITICAL PARTS…..1992
MAINTENANCE SCHEDULE…..1993
MAINTENANCE SCHEDULE CHART…..1993
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..1995
MAINTENANCE PROCEDURE…..1996
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..1996
REPLACE FUEL FILTER CARTRIDGE…..1996
CHECK ENGINE VALVE CLEARANCE, ADJUST…..1996
WHEN REQUIRED…..1997
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..1997
CLEAN INSIDE OF COOLING SYSTEM…..2000
CHECK AND TIGHTEN TRACK SHOE BOLTS…..2003
CHECK AND ADJUST TRACK TENSION…..2005
CHECK ROAD LINER MACHINES EQUIPPED WITH ROAD LINER)…..2007
CHECK ELECTRICAL INTAKE AIR HEATER…..2007
REPLACE BUCKET TEETH (VERTICAL PIN TYPE…..2008
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..2011
ADJUST BUCKET CLEARANCE…..2012
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..2013
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..2014
WASHING WASHABLE FLOOR…..2015
BLEEDING AIR FROM HYDRAULIC SYSTEM…..2017
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..2019
CHECK BEFORE STARTING…..2020
EVERY 50 HOURS MAINTENANCE…..2021
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..2021
EVERY 100 HOURS MAINTENANCE…..2022
LUBRICATING…..2022
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..2024
EVERY 250 HOURS MAINTENANCE…..2025
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2025
CHECK LEVEL OF BATTERY ELECTROLYTE…..2026
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2027
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..2028
EVERY 500 HOURS MAINTENANCE…..2030
REPLACE FUEL FILTER CARTRIDGE…..2030
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..2031
LUBRICATE SWING CIRCLE (2 POINTS)…..2031
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..2032
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..2033
REPLACE HYDRAULIC FILTER ELEMENT…..2034
EVERY 1000 HOURS MAINTENANCE…..2035
CHANGE OIL IN SWING MACHINERY CASE…..2035
CHANGE OIL IN FINAL DRIVE CASE…..2036
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..2036
CHECK PLAY OF TURBOCHARGER ROTOR…..2036
CHECK FAN BELT TENSION AND REPLACE FAN BELT…..2036
EVERY 2000 HOURS MAINTENANCE…..2037
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…..2037
CLEAN HYDRAULIC TANK STRAINER…..2038
CLEAN, CHECK TURBOCHARGER…..2038
CHECK ALTERNATOR, STARTING MOTOR…..2038
CHECK ENGINE VALVE CLEARANCE ADJUST…..2038
EVERY 4000 HOURS MAINTENANCE…..2039
CHECK WATER PUMP…..2039
EVERY 5000 HOURS MAINTENANCE…..2040
CHANGE OIL IN HYDRAULIC TANK…..2040
SPECIFICATIONS…..2042
SPECIFICATIONS…..2043
ATTACHMENTS AND OPTIONS…..2045
GENERAL PRECAUTIONS…..2046
PRECAUTIONS RELATED TO SAFETY…..2046
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..2048
HANDLING BUCKET WITH HOOK…..2049
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..2049
PROHIBITED OPERATIONS…..2049
HANDLING CAR HEATER…..2050
EXPLANATION OF COMPONENTS…..2050
PREPARING CAR HEATER…..2050
LOCATION OF FIRE EXTINGUISHER…..2051
INTRODUCTION OF ATTACHMENTS…..2052
SPECIFICATION, USE…..2052
ATTACHMENT INSTALLATION COMBINATION TABLE…..2053
ATTACHMENT COMBINATIONS…..2053
RECOMMENDED ATTACHMENT OPERATIONS…..2054
HYDRAULIC BREAKER…..2054
INDEX…..2059
SEAM035505T – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual…..2063
COVER…..2063
FOREWORD…..2064
FOREWORD…..2065
SAFETY INFORMATION…..2068
INTRODUCTION…..2070
DIRECTIONS OF MACHINE…..2070
PRODUCT INFORMATION…..2071
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..2071
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..2071
SERVICE METER LOCATION…..2072
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..2072
CONTENTS…..2073
FOREWORD…..2073
SAFETY…..2073
OPERATION…..2073
MAINTENANCE…..2075
SPECIFICATIONS…..2076
ATTACHMENTS AND OPTIONS…..2076
SAFETY…..2078
SAFETY INFORMATION…..2079
POSITION FOR ATTACHING SAFETY LABELS…..2081
POSITION FOR ATTACHING SAFETY LABELS…..2082
SAFETY LABELS…..2083
SAFETY INFORMATION…..2089
SAFETY RULES…..2089
IF ABNORMALITIES ARE FOUND…..2089
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..2089
FIRE EXTINGUISHER AND FIRST AID KIT…..2089
SAFETY EQUIPMENT…..2090
KEEP MACHINE CLEAN…..2090
KEEP OPERATOR'S COMPARTMENT CLEAN…..2090
LEAVING OPERATOR'S SEAT WITH LOCK…..2090
HANDRAILS AND STEPS…..2091
MOUNTING AND DISMOUNTING…..2092
NO PERSONS ON ATTACHMENTS…..2092
BURN PREVENTION…..2092
FIRE PREVENTION AND EXPLOSION PREVENTION…..2093
ACTION IF FIRE OCCURS…..2094
WINDSHIELD WASHER FLUID…..2094
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..2094
ATTACHMENT INSTALLATION…..2094
ATTACHMENT COMBINATIONS…..2095
CAB WIDOW GLASSES…..2095
UNAUTHORIZED MODIFICATIONS…..2095
SAFETY AT JOBSITE…..2095
WORKING ON LOOSE GROUND…..2095
DISTANCE TO HIGH VOLTAGE CABLES…..2096
ENSURE GOOD VISIBILITY…..2096
VENTILATION FOR ENCLOSED AREA…..2097
SIGNALMAN'S SIGNAL AND SIGNS…..2097
EMERGENCY EXIT FROM OPERATOR'S CAB…..2097
ASBESTOS DUST HAZARD PREVENTION…..2097
SAFETY MACHINE OPERATION…..2098
BEFORE STARTING ENGINE…..2098
CHECKS BEFORE STARTING ENGINE…..2098
SAFETY RULES FOR STARTING ENGINE…..2099
STARTING ENGINE IN COLD WEATHER…..2099
AFTER STARTING ENGINE…..2100
CHECKS AFTER STARTING ENGINE…..2100
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..2100
SAFETY RULES FOR TRAVELING…..2101
TRAVELING ON SLOPES…..2102
OPERATIONS ON SLOPES…..2103
PROHIBITED OPERATIONS…..2103
OPERATIONS ON SNOW…..2105
PARKING MACHINE…..2105
TRANSPORTATION…..2106
LOADING AND UNLOADING…..2106
SHIPPING THE MACHINE…..2107
BATTERY…..2108
BATTERY HAZARD PREVENTION…..2108
STARTING ENGINE WITH BOOSTER CABLES…..2109
TOWING…..2110
SAFETY RULES FOR TOWING…..2110
LIFTING OBJECTS WITH BUCKET…..2111
SAFETY RULES FOR LIFTING OBJECTS…..2111
SAFETY MAINTENANCE INFORMATION…..2112
WARNING TAG…..2112
KEEP WORK PLACE CLEAN AND TIDY…..2112
APPOINT LEADER WHEN WORKING WITH OTHERS…..2112
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..2113
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..2114
PROPER TOOLS…..2114
ACCUMULATOR…..2115
PERSONNEL…..2115
ATTACHMENTS…..2115
WORK UNDER THE MACHINE…..2115
NOISE…..2116
WHEN USING HAMMER…..2116
WELDING WORKS…..2116
REMOVING BATTERY TERMINALS…..2116
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..2117
DO NOT DISASSEMBLE RECOIL SPRINGS…..2117
SAFETY RULES FOR HIGH-PRESSURE OIL…..2117
SAFETY HANDLING HIGH-PRESSURE HOSES…..2118
WASTE MATERIALS…..2118
AIR CONDITIONER MAINTENANCE…..2118
COMPRESSED AIR…..2118
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2119
OPERATION…..2120
GENERAL VIEW…..2121
GENERAL VIEW OF MACHINE…..2121
GENERAL VIEW CONTROLS AND GAUGES…..2122
EXPLANATION OF COMPONENTS…..2123
MACHINE MONITOR…..2123
CAUTION ITEMS…..2124
EMERGENCY STOP ITEMS…..2125
METER DISPLAY PORTION…..2126
4-SYSTEM…..2128
SWITCHES…..2131
STARTING SWITCH…..2131
FUEL CONTROL DIAL…..2132
SWIFT DECELERATION SWITCH…..2132
HORN SWITCH…..2133
TRAVEL SPEED SELECTOR SWITCH…..2133
LAMP SWITCH…..2133
WINDSHIELD WIPER SWITCH…..2134
ADDITIONAL LIGHT SWITCH…..2134
EMERGENCY PUMP DRIVE SWITCH…..2134
SWING BRAKE CANCEL SWITCH…..2135
ROOM LAMP SWITCH…..2135
CONTROL LEVERS, PEDALS…..2136
SAFETY LOCK LEVER…..2137
WORK EQUIPMENT CONTROL LEVER…..2137
BLADE CONTROL LEVER…..2138
TRAVEL LEVERS…..2138
PEDAL LOCK (FOR BOOM OFFSET CONTROL PEDAL)…..2139
BOOM OFFSET CONTROL PEDAL…..2139
TRAVELING ACCELERATOR PEDAL…..2139
FRONT WINDOW…..2140
SLIDING DOOR…..2143
REAR WINDOW…..2144
HAMMER FOR EMERGENCY ESCAPE…..2144
STOW-AWAY TYPE STEP…..2145
CAP, COVER WITH LOCK…..2147
METHOD OF OPENING AND CLOSING CAP WITH LOCK…..2147
METHOD OF OPENING AND CLOSING COVER WITH LOCK…..2147
ENGINE HOOD…..2148
CAB REAR COVER…..2149
PUMP ROOM DOOR, BATTERY ROOM DOOR…..2150
DOOR AT FRONT OF TOOL BOX…..2151
FUSE…..2152
FUSE CAPACITIES AND CIRCUIT NAMES…..2152
FUSIBLELINK…..2152
POWER SOURCE FOR OPTION…..2153
CONTROLLER…..2153
HANDLING AIR CONDITIONER…..2154
GENERAL LOCATIONS OF CONTROL PANEL…..2154
PRECAUTIONS WHEN USING AIR CONDITIONER…..2156
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…..2156
CAR RADIO…..2157
EXPLANATION OF COMPONENTS…..2157
METHOD OF OPERATION…..2160
HANDLING ACCUMULATOR…..2162
METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…..2162
OPERATION AND MAINTENANCE MANUAL HOLDER…..2163
TOOL COMPARTMENT…..2163
GREASE GUN HOLDER…..2163
ASHTRAY…..2163
MACHINE OPERATIONS AND CONTROLS…..2164
BEFORE STARTING ENGINE…..2164
WALK-AROUND CHECKS…..2164
CHECKS BEFORE STARTING…..2166
ADJUST BEFORE OPERATION…..2172
SEAT BELT…..2173
OPERATIONS BEFORE STARTING ENGINE…..2175
STARTING ENGINE…..2177
NORMAL STARTING…..2177
STARTING ENGINE IN COLD WEATHER…..2179
AFTER STARTING ENGINE…..2181
BREAKING-IN THE NEW MACHINE…..2181
WARMING-UP OPERATION…..2182
STOPPING THE ENGINE…..2186
CHECK AFTER SHUT OFF ENGINE…..2186
MACHINE OPERATION…..2187
PREPARATIONS FOR MOVING THE MACHINE OFF…..2187
MOVING MACHINE FORWARD…..2188
MOVING MACHINE BACKWARD…..2189
STOPPING MACHINE…..2190
STEERING THE MACHINE…..2191
Steering…..2191
SWINGING…..2193
WORK EQUIPMENT CONTROLS AND OPERATIONS…..2194
PROHIBITED OPERATIONS…..2196
OPERATIONS USING SWING FORCE…..2196
OPERATIONS USING TRAVEL FORCE…..2196
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…..2196
OPERATIONS USING BUCKET DROPPING FORCE…..2197
OPERATIONS USING MACHINE DROPPING FORCE…..2197
DIGGING HARD ROCKY GROUND…..2197
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…..2197
AVOID HITTING BLADE…..2198
FOLDING IN WORK EQUIPMENT…..2198
SUPPORT BLADE ON BOTH SIDES…..2198
BLADE DURING BACKHOE OPERATIONS…..2198
AVOID INTERFERENCE BETWEEN ARM CYLINDER AND OBSTACLES…..2199
GENERAL OPERATION INFORMATION…..2200
TRAVELING…..2200
HIGH SPEED TRAVEL…..2200
PERMISSIBLE WATER DEPTH…..2200
PROTECTION OF SENSORS FROM OBSTACLES…..2201
TRAVELING ON SLOPES…..2202
TRAVELING DOWNHILL…..2203
IF SHOES SLIP…..2203
ENGINE STOPPED ON SLOPE…..2203
CAB DOORS ON SLOPE…..2203
ESCAPE FROM MUD…..2204
STUCK ONE SIDE OF TRACK…..2204
STUCK BOTH SIDES OF TRACKS…..2204
RECOMMENDED APPLICATIONS…..2205
BACKHOE WORK…..2205
DITCHING WORK…..2205
LOADING WORK…..2205
SMOOTHING WORK…..2206
SIDE DITCHING WORK…..2206
OPERATIONS IN CONFINED SPACES…..2206
BUCKET REPLACEMENT…..2207
REPLACEMENT…..2207
PARKING MACHINE…..2209
CHECK AFTER FINISHING WORK…..2210
LOCKING…..2211
HANDLING 4-SYSTEM…..2212
INTERFERENCE PREVENTION DEVICE (BETWEEN BUCKET AND CAB)…..2214
INTERFERENCE PREVENTION DEVICE (BETWEEN BUCKET AND FRONT RIGHT OUTSIDE, HANDRAIL)…..2216
HANDLING AUTOMATIC CONTROL DEVICE…..2219
HANDLING ROAD LINER…..2226
ROAD LINERS INFORMATION…..2226
WARRANTY FOR ROAD LINERS…..2226
USING ROAD LINERS…..2227
LONG LIFE OPERATIONS…..2227
TRANSPORTATION…..2228
TRANSPORTATION PROCEDURE…..2228
LOADING AND UNLOADING WITH TRAILER…..2229
LOADING…..2230
SECURING MACHINE…..2232
UNLOADING…..2233
LIFTING MACHINE…..2235
STANDARD SPECIFICATION MACHINE…..2235
COLD WEATHER OPERATION…..2237
COLD WEATHER OPERATION INFORMATION…..2237
FUEL AND LUBRICANTS…..2237
COOLING SYSTEM COOLANT…..2237
BATTERY…..2238
AFTER DAILY WORK COMPLETION…..2239
AFTER COLD WEATHER SEASON…..2240
LONG TERM STORAGE…..2241
BEFORE STORAGE…..2241
DURING STORAGE…..2241
AFTER STORAGE…..2242
TROUBLESHOOTING…..2243
AFTER RUNNING OUT OF FUEL…..2243
PHENOMENA THAT ARE NOT FAILURES…..2243
TOWING THE MACHINE…..2246
LIGHTWEIGHT TOWING HOOK…..2246
PRECAUTIONS ON PARTICULAR JOBSITES…..2246
DISCHARGED BATTERY…..2247
REMOVAL AND INSTALLATION OF BATTERY…..2248
BATTERY CHARGES…..2249
STARTING ENGINE WITH BOOSTER CABLES…..2250
OTHER TROUBLE…..2252
ELECTRICAL SYSTEM…..2252
CHASSIS…..2253
ENGINE…..2254
4-SYSTEM RELATED PARTS…..2256
MAINTENANCE…..2258
MAINTENANCE INFORMATION…..2259
SERVICE METER READING…..2259
KOMATSU GENUINE REPLACEMENT PARTS…..2259
KOMATSU GENUINE LUBRICANTS…..2259
WINDSHIELD WASHER FLUID…..2259
FRESH AND CLEAN LUBRICANTS…..2259
CHECK DRAINED OIL AND USED FILTER…..2259
FUEL STRAINER…..2259
WELDING INSTRUCTIONS…..2259
DO NOT DROP THINGS INSIDE MACHINE…..2260
DUSTY JOBSITE…..2260
AVOID MIXING LUBRICANTS…..2260
LOCKING THE INSPECTION COVERS…..2260
HYDRAULIC SYSTEM – AIR BLEEDING…..2260
HYDRAULIC HOSE INSTALLATION…..2260
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…..2261
OUTLINE OF SERVICE…..2262
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2262
OIL…..2262
FUEL…..2263
COOLANT AND WATER FOR DILUTION…..2263
GREASE…..2264
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…..2264
OIL AND FUEL STORAGE…..2265
FILTERS…..2265
ELECTRIC SYSTEM MAINTENANCE…..2266
WEAR PARTS LIST…..2267
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..2268
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..2269
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..2270
TIGHTENING TORQUE SPECIFICATIONS…..2271
TIGHTENING TORQUE LIST…..2271
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2272
SAFETY CRITICAL PARTS…..2272
MAINTENANCE SCHEDULE…..2273
MAINTENANCE SCHEDULE CHART…..2273
Initial 250 Hours Maintenance (Only after the first 250 hours)…..2273
When Required…..2273
Checks Before Starting…..2273
Every 50 Hours Maintenance…..2273
Every 100 Hours Maintenance…..2273
Every 250 Hours Maintenance…..2274
Every 500 Hours Maintenance…..2274
Every 1000 Hours Maintenance…..2274
Every 2000 Hours Maintenance…..2274
Every 4000 Hours Maintenance…..2274
Every 5000 Hours Maintenance…..2274
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..2275
REPLACING HYDRAULIC ELEMENT…..2275
CHANGING OIL IN HYDRAULIC TANK…..2275
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER…..2275
MAINTENANCE PROCEDURE…..2276
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..2276
WHEN REQUIRED…..2277
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..2277
CLEAN INSIDE OF COOLING SYSTEM…..2280
CHECK AND TIGHTEN TRACK SHOE BOLTS…..2283
CHECK AND ADJUST TRACK TENSION…..2285
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)…..2286
CHECK ELECTRICAL INTAKE AIR HEATER…..2287
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..2288
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..2291
ADJUST BUCKET CLEARANCE…..2292
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..2293
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..2294
WASHING WASHABLE FLOOR…..2295
BLEEDING AIR FROM HYDRAULIC SYSTEM…..2297
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..2299
CHECK BEFORE STARTING…..2300
EVERY 50 HOURS MAINTENANCE…..2301
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..2301
EVERY 100 HOURS MAINTENANCE…..2302
LUBRICATING…..2302
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..2304
EVERY 250 HOURS MAINTENANCE…..2305
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2305
CHECK LEVEL OF BATTERY ELECTROLYTE…..2306
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2308
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..2309
EVERY 500 HOURS MAINTENANCE…..2311
REPLACE FUEL FILTER CARTRIDGE…..2311
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..2312
LUBRICATE SWING CIRCLE (2 POINTS)…..2312
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W…..2313
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WIT…..2314
REPLACE HYDRAULIC FILTER ELEMENT…..2315
EVERY 1000 HOURS MAINTENANCE…..2316
CHANGE OIL IN SWING MACHINERY CASE…..2316
CHANGE OIL IN FINAL DRIVE CASE…..2317
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..2317
CHECK PLAY OF TURBOCHARGER ROTOR…..2317
CHECK FAN BELT TENSION AND REPLACE FAN BELT…..2317
EVERY 2000 HOURS MAINTENANCE…..2318
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…..2318
CLEAN HYDRAULIC TANK STRAINER…..2319
CLEAN, CHECK TURBOCHARGER…..2319
CHECK ALTERNATOR, STARTING MOTOR…..2319
CHECK ENGINE VALVE CLEARANCE, ADJUST…..2319
EVERY 4000 HOURS MAINTENENCE…..2320
CHECK WATER PUMP…..2320
EVERY 5000 HOURS MAINTENANCE…..2321
CHANGE OIL IN HYDRAULIC TANK…..2321
SPECIFICATIONS…..2324
SPECIFICATIONS…..2325
ATTACHMENTS AND OPTIONS…..2328
GENERAL PRECAUTIONS…..2329
PRECAUTIONS RELATED TO SAFETY…..2329
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..2331
HANDLING BUCKET WITH HOOK…..2332
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..2332
PROHIBITED OPERATIONS…..2332
PRECAUTIONS DURING OPERATIONS…..2332
HANDLING CAR HEATER…..2333
EXPLANATION OF COMPONENTS…..2333
PREPARING CAR HEATER…..2333
LOCATION OF FIRE EXTINGUISHER…..2334
INTRODUCTION OF ATTACHMENTS…..2335
SPECIFICATION, USE…..2335
ATTACHMENT INSTALLATION COMBINATION TABLE…..2336
ATTACHMENT COMBINATIONS…..2336
SELECTION OF TRACK SHOES…..2337
METHOD OF SELECTING SHOES…..2337
RECOMMENDED ATTACHMENT OPERATIONS…..2338
HYDRAULIC BREAKER…..2338
MAIN APPLICATIONS…..2338
PROHIBITED WORKS…..2340
GREASING POSITION FOR HYDRAULIC BREAKER…..2342
INDEX…..2344
Numerics…..2344
A…..2344
B…..2344
C…..2344
D…..2344
E…..2344
F…..2344
G…..2344
H…..2344
I…..2344
L…..2345
M…..2345
O…..2345
P…..2345
R…..2345
S…..2345
T…..2345
W…..2345
Y…..2345
SEAM045102T – Hydraulic Excavator PC158US-2, PC158USLC-2 Operation & Maintenance Manual…..2348
COVER…..2348
FOREWORD…..2349
FOREWORD…..2350
SAFETY INFORMATION…..2353
INTRODUCTION…..2355
DIRECTIONS OF MACHINE…..2355
PRODUCT INFORMATION…..2356
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..2356
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..2356
EMISSION CONTROL INFORMATION LABEL…..2357
SERVICE METER LOCATION…..2357
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..2357
CONTENTS…..2358
SAFETY…..2362
SAFETY INFORMATION…..2363
POSITION FOR ATTACHING SAFETY LABELS…..2365
POSITION FOR ATTACHING SAFETY LABELS…..2366
SAFETY LABELS…..2367
SAFETY INFORMATION…..2371
SAFETY RULES…..2371
IF ABNORMALITIES ARE FOUND…..2371
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..2371
FIRE EXTINGUISHER AND FIRST AID KIT…..2371
SAFETY EQUIPMENT…..2372
KEEP MACHINE CLEAN…..2372
KEEP OPERATOR'S COMPARTMENT CLEAN…..2372
LEAVING OPERATOR'S SEAT WITH LOCK…..2372
HANDRAILS AND STEPS…..2373
CRUSHING OR CUTTING PREVENTION…..2374
MOUNTING AND DISMOUNTING…..2374
NO PERSONS ON ATTACHMENTS…..2374
BURN PREVENTION…..2374
FIRE PREVENTION AND EXPLOSION PREVENTION…..2375
ACTION IF FIRE OCCURS…..2376
WINDSHIELD WASHER FLUID…..2376
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..2376
ATTACHMENT INSTALLATION…..2376
ATTACHMENT COMBINATIONS…..2377
CAB WINDOW GLASSES…..2377
UNAUTHORIZED MODIFICATIONS…..2377
SAFETY AT JOBSITE…..2377
WORKING ON LOOSE GROUND…..2377
DISTANCE TO HIGH VOLTAGE CABLES…..2378
ENSURE GOOD VISIBILITY…..2378
VENTILATION FOR ENCLOSED AREA…..2379
SIGNALMAN'S SIGNAL AND SIGNS…..2379
EMERGENCY EXIT FROM OPERATOR'S CAB…..2379
ASBESTOS DUST HAZARD PREVENTION…..2379
SAFETY MACHINE OPERATION…..2380
STARTING ENGINE…..2380
CHECKS BEFORE STARTING ENGINE…..2380
SAFETY RULES FOR STARTING ENGINE…..2381
STARTING ENGINE IN COLD WEATHER…..2381
OPERATION…..2382
CHECKS AFTER STARTING ENGINE…..2382
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..2382
SAFETY RULES FOR TRAVELING…..2383
TRAVELING ON SLOPES…..2384
OPERATIONS ON SLOPES…..2385
PROHIBITED OPERATIONS…..2385
OPERATIONS ON SNOW…..2387
PARKING MACHINE…..2387
TRANSPORTATION…..2388
LOADING AND UNLOADING…..2388
SHIPPING THE MACHINE…..2389
BATTERY…..2390
BATTERY HAZARD PREVENTION…..2390
STARTING ENGINE WITH BOOSTER CABLES…..2391
TOWING…..2392
SAFETY RULES FOR TOWING…..2392
LIFTING OBJECTS WITH BUCKET…..2393
SAFETY RULES FOR LIFTING OBJECTS…..2393
SAFETY MAINTENANCE INFORMATION…..2394
WARNING TAG…..2394
KEEP WORK PLACE CLEAN AND TIDY…..2394
APPOINT LEADER WHEN WORKING WITH OTHERS…..2394
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..2395
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..2396
PROPER TOOLS…..2396
ACCUMULATOR…..2397
PERSONNEL…..2397
ATTACHMENTS…..2397
WORK UNDER THE MACHINE…..2397
NOISE…..2398
WHEN USING HAMMER…..2398
WELDING WORKS…..2398
REMOVING BATTERY TERMINALS…..2398
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..2399
DO NOT DISASSEMBLE RECOIL SPRINGS…..2399
SAFETY RULES FOR HIGH-PRESSURE OIL…..2399
SAFETY HANDLING HIGH-PRESSURE HOSES…..2400
WASTE MATERIALS…..2400
AIR CONDITIONER MAINTENANCE…..2400
COMPRESSED AIR…..2400
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2401
OPERATION…..2402
GENERAL VIEW…..2403
GENERAL VIEW OF MACHINE…..2403
GENERAL VIEW CONTROLS AND GAUGES…..2404
EXPLANATION OF COMPONENTS…..2405
MACHINE MONITOR…..2405
SWITCHES…..2411
CONTROL LEVERS, PEDALS…..2417
CEILING WINDOW…..2419
FRONT WINDOW…..2420
SLIDING DOOR…..2423
REAR WINDOW…..2424
HAMMER FOR EMERGENCY ESCAPE…..2424
CAP, COVER WITH LOCK…..2425
ENGINE HOOD…..2426
CAB REAR COVER…..2427
PUMP ROOM DOOR, BATTERY ROOM DOOR…..2428
DOOR AT FRONT OF TOOL BOX…..2429
FUSE…..2430
FUSIBLELINK…..2430
POWER SOURCE FOR OPTION…..2431
CONTROLLER…..2431
HANDLING AIR CONDITIONER…..2432
CAR RADIO…..2435
HANDLING ACCUMULATOR…..2440
OPERATION AND MAINTENANCE MANUAL HOLDER…..2441
TOOL COMPARTMENT…..2441
GREASE GUN HOLDER…..2441
ASHTRAY…..2441
CUP HOLDER…..2442
MACHINE OPERATIONS AND CONTROLS…..2443
BEFORE STARTING ENGINE…..2443
STARTING ENGINE…..2457
AFTER STARTING ENGINE…..2460
STOPPING THE ENGINE…..2463
CHECK AFTER SHUT OFF ENGINE…..2463
MACHINE OPERATION…..2464
STEERING THE MACHINE…..2468
SWINGING…..2470
WORK EQUIPMENT CONTROLS AND OPERATIONS…..2471
PROHIBITED OPERATIONS…..2473
GENERAL OPERATION INFORMATION…..2475
TRAVELING ON SLOPES…..2476
ESCAPE FROM MUD…..2478
RECOMMENDED APPLICATIONS…..2479
REPLACEMENT AND INVERSION OF BUCKET…..2481
PARKING MACHINE…..2485
CHECK AFTER FINISHING WORK…..2486
LOCKING…..2487
TRANSPORTATION…..2488
TRANSPORTATION PROCEDURE…..2488
LOADING AND UNLOADING WITH TRAILER…..2489
LIFTING MACHINE…..2495
COLD WEATHER OPERATION…..2497
COLD WEATHER OPERATION INFORMATION…..2497
AFTER DAILY WORK COMPLETION…..2499
AFTER COLD WEATHER SEASON…..2500
LONG TERM STORAGE…..2501
BEFORE STORAGE…..2501
DURING STORAGE…..2501
AFTER STORAGE…..2502
TROUBLESHOOTING…..2503
AFTER RUNNING OUT OF FUEL…..2503
PHENOMENA THAT ARE NOT FAILURES…..2503
TOWING THE MACHINE…..2504
LIGHTWEIGHT TOWING HOOK…..2504
PRECAUTIONS ON PARTICULAR JOBSITES…..2504
DISCHARGED BATTERY…..2505
OTHER TROUBLE…..2510
MAINTENANCE…..2514
MAINTENANCE INFORMATION…..2515
OUTLINE OF SERVICE…..2518
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2518
ELECTRIC SYSTEM MAINTENANCE…..2522
HANDLING HYDRAULIC SYSTEM…..2522
WEAR PARTS LIST…..2523
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..2524
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..2525
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..2526
TIGHTENING TORQUE SPECIFICATIONS…..2527
TIGHTENING TORQUE LIST…..2527
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2528
SAFETY CRITICAL PARTS…..2528
MAINTENANCE SCHEDULE…..2529
MAINTENANCE SCHEDULE CHART…..2529
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..2531
MAINTENANCE PROCEDURE…..2532
INITIAL 250 HOURS MAINTENANCE(ONLY AFTER THE FIRST 250 HOURS)…..2532
WHEN REQUIRED…..2533
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..2533
CLEAN INSIDE OF COOLING SYSTEM…..2536
CHECK AND TIGHTEN TRACK SHOE BOLTS…..2539
CHECK AND ADJUST TRACK TENSION…..2540
CHECK ELECTRICAL INTAKE AIR HEATER…..2541
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..2542
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..2545
ADJUST BUCKET CLEARANCE…..2546
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..2547
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..2548
REPLACE ADDITIONAL BREAKER FILTER ELEMENT(IF EQUIPPED)…..2549
WASHING WASHABLE FLOOR…..2550
BLEEDING AIR FROM HYDRAULIC SYSTEM…..2552
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..2554
CHECK BEFORE STARTING…..2555
EVERY 50 HOURS MAINTENANCE…..2556
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..2556
EVERY 100 HOURS MAINTENANCE…..2557
LUBRICATING…..2557
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..2559
EVERY 250 HOURS MAINTENANCE…..2560
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..2560
CHECK LEVEL OF BATTERY ELECTROLYTE…..2561
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..2563
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..2564
EVERY 500 HOURS MAINTENANCE…..2566
REPLACE FUEL FILTER CARTRIDGE…..2566
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..2567
LUBRICATE SWING CIRCLE (2 POINTS)…..2567
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..2568
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..2569
REPLACE HYDRAULIC FILTER ELEMENT…..2570
EVERY 1000 HOURS MAINTENANCE…..2571
CHANGE OIL IN SWING MACHINERY CASE…..2571
CHANGE OIL IN FINAL DRIVE CASE…..2572
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..2572
CHECK PLAY OF TURBOCHARGER ROTOR…..2572
CHECK FAN BELT TENSION AND REPLACE FAN BELT…..2572
EVERY 2000 HOURS MAINTENANCE…..2573
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…..2573
CLEAN HYDRAULIC TANK STRAINER…..2574
CLEAN, CHECK TURBOCHARGER…..2574
CHECK ALTERNATOR, STARTING MOTOR…..2574
CHECK ENGINE VALVE CLEARANCE, ADJUST…..2574
EVERY 4000 HOURS MAINTENENCE…..2575
CHECK WATER PUMP…..2575
EVERY 5000 HOURS MAINTENANCE…..2576
CHANGE OIL IN HYDRAULIC TANK…..2576
SPECIFICATIONS…..2578
SPECIFICATIONS…..2579
ATTACHMENTS AND OPTIONS…..2581
GENERAL PRECAUTIONS…..2582
PRECAUTIONS RELATED TO SAFETY…..2582
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..2584
HANDLING CAR HEATER…..2585
EXPLANATION OF COMPONENTS…..2585
PREPARING CAR HEATER…..2585
MACHINES READY FOR ATTACHMENTS…..2586
EXPLANATION OF COMPONENTS…..2586
HYDRAULIC CIRCUIT…..2589
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…..2590
OPERATION…..2592
LONG TERM STORAGE…..2594
SPECIFICATIONS…..2594
INTRODUCTION OF ATTACHMENTS…..2595
SPECIFICATION, USE…..2595
ATTACHMENT INSTALLATION COMBINATION TABLE…..2596
ATTACHMENT COMBINATIONS…..2596
RECOMMENDED ATTACHMENT OPERATIONS…..2597
HYDRAULIC BREAKER…..2597
INDEX…..2602
SEAM049000T – Hydraulic Excavator GALEO PC128US-2, PC138US-2 Operation & Maintenance Manual…..2605
COVER…..2605
FOREWORD…..2606
FOREWORD…..2607
SAFETY INFORMATION…..2610
INTRODUCTION…..2612
DIRECTIONS OF MACHINE…..2612
PRODUCT INFORMATION…..2613
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…..2613
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..2613
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION…..2614
SERVICE METER LOCATION…..2614
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..2614
CONTENTS…..2615
SAFETY…..2618
SAFETY INFORMATION…..2619
WARNING LABELS AND PICTOGRAMS…..2621
WARNING LABELS AND PICTOGRAMS-LOCATION…..2622
WARNING LABELS AND PICTOGRAMS-ACTUAL…..2623
SAFETY INFORMATION…..2628
SAFETY RULES…..2628
IF ABNORMALITIES ARE FOUND…..2628
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..2628
FIRE EXTINGUISHER AND FIRST AID KIT…..2628
SAFETY EQUIPMENT…..2628
KEEP MACHINE CLEAN…..2629
KEEP OPERATOR'S COMPARTMENT CLEAN…..2629
LEAVING OPERATOR'S SEAT WITH LOCK…..2629
HANDRAILS AND STEPS…..2630
MOUNTING AND DISMOUNTING…..2630
NO PERSONS ON ATTACHMENTS…..2630
DO NOT GET CAUGHT IN ARTICULATED PORTION…..2630
BURN PREVENTION…..2631
FIRE PREVENTION AND EXPLOSION PREVENTION…..2631
ACTION IF FIRE OCCURS…..2632
WINDSHIELD WASHER FLUID…..2632
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..2632
ATTACHMENT INSTALLATION…..2633
ATTACHMENT COMBINATIONS…..2633
CAB WINDOW GLASSES…..2633
UNAUTHORIZED MODIFICATIONS…..2633
SAFETY AT JOBSITE…..2633
WORKING ON LOOSE GROUND…..2634
DISTANCE TO HIGH VOLTAGE CABLES…..2634
ENSURE GOOD VISIBILITY…..2634
VENTILATION FOR ENCLOSED AREA…..2635
SIGNALMAN'S SIGNAL AND SIGNS…..2635
EMERGENCY EXIT FROM OPERATOR'S CAB…..2635
ASBESTOS DUST HAZARD PREVENTION…..2635
SAFETY MACHINE OPERATION…..2636
STARTING ENGINE…..2636
CHECKS BEFORE STARTING ENGINE…..2636
SAFETY RULES FOR STARTING ENGINE…..2636
STARTING ENGINE IN COLD WEATHER…..2637
OPERATION…..2638
CHECKS BEFORE OPERATION…..2638
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..2638
SAFETY RULES FOR TRAVELING…..2639
TRAVELING ON SLOPES…..2640
OPERATIONS ON SLOPES…..2641
PROHIBITED OPERATIONS…..2641
OPERATIONS ON SNOW…..2642
PARKING MACHINE…..2643
TRANSPORTATION…..2644
LOADING AND UNLOADING…..2644
SHIPPING THE MACHINE…..2644
BATTERY…..2645
BATTERY HAZARD PREVENTION…..2645
STARTING ENGINE WITH BOOSTER CABLES…..2646
TOWING…..2647
SAFETY RULES FOR TOWING…..2647
LIFTING OBJECTS WITH BUCKET…..2648
SAFETY RULES FOR LIFTING OBJECTS…..2648
SAFETY MAINTENANCE INFORMATION…..2649
WARNING TAG…..2649
KEEP WORK PLACE CLEAN AND TIDY…..2649
APPOINT LEADER WHEN WORKING WITH OTHERS…..2649
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..2650
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..2650
PROPER TOOLS…..2651
ACCUMULATOR…..2651
PERSONNEL…..2651
ATTACHMENTS…..2652
WORK UNDER THE MACHINE…..2652
NOISE…..2652
WHEN USING HAMMER…..2652
WELDING WORKS…..2652
REMOVING BATTERY TERMINALS…..2653
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..2653
DO NOT DISASSEMBLE RECOIL SPRINGS…..2653
SAFETY RULES FOR HIGH-PRESSURE OIL…..2653
SAFETY HANDLING HIGH-PRESSURE HOSES…..2654
WASTE MATERIALS…..2654
AIR CONDITIONER MAINTENANCE…..2654
COMPRESSED AIR…..2654
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..2654
OPERATION…..2655
MACHINE VIEW ILLUSTRATIONS…..2656
OVERALL MACHINE VIEW…..2656
CONTROLS AND GAUGES…..2657
DETAILED CONTROLS AND GAUGES…..2658
MONITORING SYSTEM…..2658
SWITCHES…..2670
CONTROL LEVERS AND PEDALS…..2675
SUN ROOF…..2678
WINDSHIELD…..2679
SLIDING DOOR…..2684
EMERGENCY ESCAPE HAMMER…..2684
CAP WITH LOCK…..2686
ENGINE HOOD…..2687
CAB REAR COVER…..2688
PUMP ROOM DOOR,BATTERY ROOM DOOR…..2689
DOOR AT FRONT OF TOOL BOX…..2690
FUSE…..2691
FUSIBLELINK…..2692
CONTROLLERS…..2692
AIR CONDITIONER CONTROLS…..2693
RADIO…..2699
ACCUMULATOR…..2704
OPERATION MANUAL STORAGE…..2705
TOOL BOX…..2705
GREASE PUMP HOLDER…..2705
HOT AND COOL BOX…..2705
ASHTRAY…..2706
FIRE EXTINGUISHER…..2706
MACHINE OPERATIONS AND CONTROLS…..2707
BEFORE STARTING ENGINE…..2707
STARTING ENGINE…..2723
AFTER STARTING ENGINE…..2727
STOPPING THE ENGINE…..2730
CHECK AFTER SHUT OFF ENGINE…..2730
MACHINE OPERATION…..2731
STEERING THE MACHINE…..2735
SWINGING…..2737
WORK EQUIPMENT CONTROLS AND OPERATIONS…..2738
WORK MODE…..2740
PROHIBITED OPERATIONS…..2741
GENERAL OPERATION INFORMATION…..2743
TRAVELING ON SLOPES…..2745
ESCAPE FROM MUD…..2747
RECOMMENDED APPLICATIONS…..2748
BUCKET REPLACEMENT AND INVERSION…..2750
PARKING MACHINE…..2752
MACHINE INSPECTION AFTER DAILY WORK…..2753
LOCKING…..2753
ROAD LINERS…..2754
TRANSPORTATION…..2756
TRANSPORTATION PROCEDURE…..2756
LOADING AND UNLOADING WITH TRAILER…..2757
LIFTING MACHINE…..2763
COLD WEATHER OPERATION…..2765
COLD WEATHER OPERATION INFORMATION…..2765
AFTER DAILY WORK COMPLETION…..2767
AFTER COLD WEATHER SEASON…..2767
LONG TERM STORAGE…..2768
BEFORE STORAGE…..2768
DURING STORAGE…..2768
AFTER STORAGE…..2768
TROUBLES AND ACTIONS…..2769
RUNNING OUT OF FUEL…..2769
PHENOMENA THAT ARE NOT FAILURES…..2769
TOWING THE MACHINE…..2770
LIGHTWEIGHT TOWING HOOK…..2770
SEVERE JOB CONDITION…..2770
DISCHARGED BATTERY…..2771
OTHER TROUBLE…..2775
MAINTENANCE…..2780
MAINTENANCE INFORMATION…..2781
LUBRICANTS, COOLANT AND FILTERS…..2783
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..2783
ELECTRIC SYSTEM MAINTENANCE…..2785
WEAR PARTS…..2786
WEAR PARTS LIST…..2786
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS…..2787
PROPER SELECTION…..2787
TIGHTENING TORQUE SPECIFICATIONS…..2791
TIGHTENING TORQUE LIST…..2791
SAFETY CRITICAL PARTS…..2792
SAFETY CRITICAL PARTS LIST…..2792
MAINTENANCE SCHEDULE…..2793
MAINTENANCE SCHEDULE CHART…..2793
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..2794
MAINTENANCE PROCEDURE…..2795
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..2795
WHEN REQUIRED…..2796
AIR CLEANER ELEMENT-CHECK/CLEAN/REPLACE…..2796
COOLING SYSTEM COOLANT-CLEAN/CHANGE…..2800
TRACK SHOE BOLTS-CHECK/TIGHTEN…..2803
TRACK TENSION-CHECK/ADJUST…..2804
ROAD LINERS-CHECK…..2806
ROAD LINERS-REPLACE…..2806
ELECTRICAL INTAKE AIR HEATER-CHECK…..2806
BUCKET TEETH(VERTICAL PIN TYPE)-REPLACE…..2807
BUCKET TEETH(HORIZONTAL PIN TYPE)-REPLACE…..2810
BUCKET CLEARANCE-ADJUST…..2811
WINDSHIELD WASHER FLUID LEVEL-CHECK/ADD…..2812
AIR CONDITIONER-CHECK/MAINTENANCE…..2813
CAB SLIDE DOOR RAIL AND ROLLER-CHECK/CLEAN/LUBRICATE…..2814
BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT(IF EQUIPPED)-REPLACE…..2815
WASH WASHABLE FLOOR…..2816
HYDRAULIC SYSTEM-BLEED AIR…..2819
HYDRAULIC SYSTEM-PRESSURE RELEASE…..2821
CHECK BEFORE STARTING…..2823
EVERY 50 HOURS MAINTENANCE…..2824
FUEL TANK-DRAIN…..2824
EVERY 100 HOURS MAINTENANCE…..2825
LUBRICATING…..2825
SWING MACHINERY CASE OIL-CHECK/ADD…..2827
EVERY 250 HOURS MAINTENANCE…..2828
FINAL DRIVE CASE OIL LEVEL-CHECK/ADD…..2828
BATTERY ELECTROLYTE LEVEL-CHECK…..2829
ENGINE CRANKCASE OIL AND FILTER CARTRIDGE- CHANGE/REPLACE…..2831
AIR CONDITIONER COMPRESSOR BELT TENSION-INSPECT/ADJUST…..2832
EVERY 500 HOURS MAINTENANCE…..2833
FUEL FILTER CARTRIDGE-REPLACE…..2833
SWING PINION GEAR OIL LEVEL-CHECK/ADD…..2834
SWING CIRCLE-LUBRICATE…..2834
RADIATOR FINS,OIL COOLER FINS AND CONDENSOR FINS-CHECK/CLEAN…..2834
AIR CONDITIONER AIR FILTER-CLEAN…..2835
HYDRAULIC OIL FILTER ELEMENT-REPLACE…..2837
EVERY 1000 HOURS MAINTENANCE…..2838
SWING MACHINERY CASE OIL-CHANGE…..2838
FINAL DRIVE CASE OIL-CHANGE…..2839
FAN BELT-INSPECT/REPLACE…..2839
TURBOCHARGER FASTENING PARTS-INSPECT/TIGHTEN…..2839
TURBOCHARGER ROTOR PLAY-INSPECT…..2839
EVERY 2000 HOURS MAINTENANCE…..2840
PTO GEAR CASE OIL LEVEL-CHECK/ADD…..2840
HYDRAULIC OIL TANK STRAINER-CLEAN…..2841
TURBOCHARGER-INSPECT…..2841
ALTERNATOR AND STARTING MOTOR-INSPECT…..2841
ENGINE VALVE CLEARANCES-INSPECT…..2841
EVERY 4000 HOURS MAINTENANCE…..2842
WATER PUMP-INSPECT…..2842
EVERY 5000 HOURS MAINTENANCE…..2843
HYDRAULIC OIL-CHANGE…..2843
SPECIFICATIONS…..2844
SPECIFICATIONS…..2845
ATTACHMENTS, OPTIONS…..2848
ATTACHMENTS AND OPTIONS-GENERAL INFORMATION…..2849
SAFETY FIRST…..2849
ATTACHMENT INSTALLATION…..2850
BUCKET WITH HOOK…..2851
HOOK CONDITION…..2851
PROHIBITED OPERATIONS…..2851
AIR CONDITIONER…..2852
AIR CONDITIONER CONTROL PANEL…..2852
AIR CONDITIONER CONTROLS…..2857
AIR CONDITIONER MAINTENANCE…..2857
MACHINE READY FOR ATTACHMENT…..2858
LOCATIONS…..2858
HYDRAULIC CIRCUIT…..2861
ATTACHMENT REMOVAL AND INSTALLATION…..2862
ATTACHMENT OPERATIONS…..2866
LONG TERM STORAGE…..2869
SPECIFICATIONS…..2869
ATTACHMENT GUIDE…..2870
OTHER ATTACHMENTS…..2870
ATTACHMENT COMBINATIONS…..2871
RECOMMENDED ATTACHMENT OPERATIONS…..2872
HYDRAULIC BREAKER…..2872
INDEX…..2877
SEBM009805 – Hydraulic Excavator PC128UU-2, PC128US-2 Shop Manual…..2880
COVER…..2880
CONTENTS…..2881
01 GENERAL…..2906
GENERAL ASSEMBLY DRAWING…..2907
SPECIFICATIONS…..2909
WEIGHT TABLE…..2913
LIST OF LUBRICANTS AND WATER…..2915
10 STRUCTURE AND FUNCTION …..2917
RADIATOR AND OIL COOLER…..2918
PTO (COUPLING)…..2919
ENGINE CONTROL…..2920
POWER TRAIN SYSTEM…..2921
SWING CIRCLE…..2922
SWING MACHINERY…..2923
TRACK FRAME …..2924
IDLER CUSHION…..2925
TRACK SHOE…..2926
HYDRAULIC PIPING DRAWING…..2929
HYDRAULIC CIRCUIT DIAGRAM…..2933
HYDRAULIC TANK…..2936
HYDRAULIC PUMP…..2937
CONTROL VALVE…..2954
CLSS…..2969
SWING MOTOR…..3001
TRAVEL MOTOR…..3013
CENTER SWIVEL JOINT…..3024
VALVE CONTROL…..3026
PPC VALVE…..3029
PPC SHUTTLE AND TRAVEL JUNCTION VALVE…..3041
EPC SOLENOID VALVE…..3045
BOOM HOLDING VALVE…..3061
WORK EQUIPMENT…..3064
AIR CONDITIONER …..3066
ACTUAL ELECTRICAL WIRING DIAGRAM…..3067
ELECTRONIC CIRCUIT DIAGRAM…..3074
ELECTRONIC CONTROL SYSTEM…..3078
MACHINE MONITORING SYSTEM…..3125
20 TESTING AND ADJUSTING…..3134
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..3135
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..3137
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS (EXCEPT AUTOMATIC HORIZONTAL DIGGING MACHINE)…..3153
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS…..3161
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…..3167
MEASURING ENGINE SPEED…..3168
MEASURING EXHAUST COLOR…..3169
ADJUSTMENT VALVE CLEARANCE…..3170
MEASUREMENT BLOW-BY PRESSURE…..3171
MEASUREMENT ENGINE OIL PRESSURE…..3171
TESTING AND ADJUSTMENT OF FUEL INJECTION TIMING…..3172
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..3173
ADJUSTING ENGINE SPEED SENSOR…..3173
ADJUSTING FUEL CONTROL CABLE…..3174
ADJUSTING FUEL CONTROL CABLE…..3175
ADJUSTING ENGINE STOP SOLENOID LINKAGE…..3176
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…..3177
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)…..3179
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…..3181
TESTING AND ADJUSTING CONTROL PUNP CIRCUIT OIL PRESSURE…..3184
TESTING SOLENOID VALVE OUTPUT PRESSURE…..3186
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…..3188
ADJUSTING WORK EQUIPMENT, SEING PPC VALVE…..3190
TESTING AND ADJUSTING TRAVEL DEVIATION …..3191
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT…..3192
MEASUREMENT OIL LEAKAGE OF SWING, TRAVEL MOTOR…..3194
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…..3194
TESTING CLEARANCE OF SWING CIRCLE BEARING…..3195
TESTING AND ADJUSTING TRACK SHOE TENSION…..3196
BLEEDING AIR…..3197
PROCEDURE FOR RESETTING ELECTRICAL SYSTEM AND CHECKING OPERATION…..3199
PROCEDURE FOR REPLACING POTENTIOMETER…..3211
PREOCEDURE FOR CHECKING DIODE…..3212
TROUBLESHOOTING…..3213
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..3214
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..3215
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..3216
CHECKS BEFORE TROUBLESHOOTING…..3224
CONNECTOR TYPES AND MOUNTING LOCATIONS…..3225
CONNECTOR ARRANGEMENT DIAGRAM…..3227
CONNECTOR TYPES AND MOUNTING LOCATIONS…..3229
CONNECTOR ARRANGEMENT DIAGRAM…..3231
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..3234
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…..3244
DISPLAY METHOD FOR MOMITOR PANEL, CONTROLLER…..3249
METHOD OF USING JUDGEMENT TABLE…..3255
METHOD OF USING TROUBLESHOOTING CHARTS…..3256
TROUBLESHOOTING OF CONTROLLER ELECTRICAL SYSTEM (E MODE)…..3258
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE…..3260
JUDGEMENT TABLE FOR 4 SYSTEM…..3264
JUDGEMENT TABLE FOR CHASSIS RELATED PARTS…..3266
ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM…..3268
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM…..3272
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS…..3275
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED…..3276
a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM…..3276
b) ABNORMALITY IN COMMUNICATIONS SYSTEM…..3277
E-2 ERROR CODE [31](ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED…..3278
E-3 ERROR CODE [32](ABNORMALITY IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED…..3279
E-4 ERROR CODE [34](ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED…..3280
E-5 ERROR CODE [41](ABNORMALITY IN ROTATION SENSOR SYSTEM)IS DISPLAYED…..3281
E-6 ERROR CODE [51](ABNORMALITY IN PPC HYDRAULIC LOCK SOLENOID SYSTEM) IS DISPLAYED…..3282
E-7 ERROR CODE [52](ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED…..3283
E-8 ERROR CODE [54](ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED…..3284
E-9 ERROR CODE [61](ABNORMALITY IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED…..3285
E-10 ERROR CODE [62](ABNORMALITY IN LS BYPASS SOLENOID SYSTEM) IS DISPLAYED…..3287
E-11 ERROR CODE [71](ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM) IS DISPLAYED…..3288
E-12 ERROR CODE [72](ABNORMALITY IN BOOM LOWER STOP SOLENOID SYSTEM) IS DISPLAYED…..3289
E-13 ERROR CODE [74](ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED…..3290
E-14 ERROR CODE [78](ABNORMALITY IN SWING RIGHT BRAKE SOLENOID SYSTEM) IS DISPLAYED…..3291
E-15 ERROR CDOE [81](ABNORMALITY IN ARM IN STOP EPC SOLENOID SYSTEM) IS DISPLAYED…..3292
E-16 ERROR CODE [C1](BOOM LOWER, BOOM RAISE PRESSURE SWITCHES INPUT AT SAME TIME FOR MORE THAN 3 SECONDS) IS DISPLAYED…..3292
E-17 ABNORMALITY IN PC-EPC SOLENOID SYSTEM (POWER MODE DOES NOT SWITCH)…..3293
a) DOES NOT SWITCH TO POWER MODE…..3293
b) DOES NOT SWITCH TO ECONOMY MODE (STALLS IN LOW SPEED RANGE)…..3294
E-18 ABNORMALITY IN TRAVEL SPEED BOOST SOLENOID SYSTEM (SPEED DOES NOT INCRESE OR DOES NOT DECREASE…..3295
a)SPEED DOES NOT INCREASE (STAYS AT LOW SPEED)…..3295
b)SPEED DOES NOT DECREASE (STAYS AT HIGH SPEED)…..3296
E-19 WORK EQUIPMENT DOES NOT WORK EVEN WHEN WORK EQUIPMENT LOCK LEVER IS RELESSED…..3297
E-20 WORK EQUIPMENT LOCK LEVER IS AT LOCK POSITION BUT WORK EQUIPMENT MOVES…..3298
E-21 DEPTH MODE, HEIGHT MODE, OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE RESCHING SET POSITION)…..3299
E-22 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE, DEPTH MODE,HEIGHT MODE, OFFSET MODE…..3300
E-23 CANCEL SWITCH IS NOT TURNED ON, BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES…..3301
E-24 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE, ARM IN, LEFT OFFSET (WHEN ERROR CODE [91] IS NOT DISPLAYED)…..3302
E-25 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN)…..3303
E-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…..3304
E-27 OFFSET DOES NOT WORK (PARTICULARLY LEFT OFFSET)…..3305
E-28 ENGINE DOES NOT START…..3306
a) STARTING MOTOR DOES NOT TURN…..3306
b) ENGINE STOP SOLENOID DOES NOT WORK…..3308
E-29 ENGINE DOES NOT STOP …..3309
E-30 WIPER DOES NOT WORK…..3310
E-31 ERROR CODE [64](ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED…..3311
E-32 ERROR CODE [68](SHORT CIRCUIT WITH GROUND IN SWIFT SLOW-DOWN CONTROL SIGNAL SYSTEM) IS DISPLAYED…..3312
E-33 AUTO-DECELERATION DOES NOT WORK WHEN AUTO-DECELERATION IS SWITCHED ON (AUTO-DECELERATION CANCEL SWITCH OFF)…..3313
E-34 ENGINE SPEED DOES NOT RISE WHEN AUTO-DECELERATION CANCEL SWITCH IS OFF (AUTO-DECELERATION REMAINS IN EFFECT)…..3314
E-35 AUTO-DECELERATION IS ACTUATED WHEN AUTO-DECELERATION CANCEL SWITCH IS OFF…..3314
E-36 DEFECTIVE ENGINE CONTROL…..3315
a) DOES NOT WORK, OR WORKS FOR A MOMENT AND THEN STOPS WORKING…..3315
b) SWIFT SLOW-DOWN DOES NOT WORK…..3318
c) WORKS AT NESR IDLING SPEED, BUT DOES NOT WORK UP TO FULL THROTTLE (LOAD BECOMES HIGH)…..3319
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…..3320
METHOD OF USING TROUBLESHOOTING CHARTS…..3321
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..3325
S-2 ENGINE DOES NOT START…..3327
(1) ENGINE DOES NOT TURN…..3327
(2) ENGINE TURNS BUT NO EXHAUST SMOKES COMES OUT (FUEL IS NOT BEING INJECTED)…..3328
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..3329
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)…..3330
S-4 ENGINE STOPS DURING OPERATIONS…..3331
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)…..3332
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..3333
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)…..3334
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..3335
S-9 OIL BECOMES CONTAMINATED QUICKLY…..3336
S-10 FUEL CONSUMPTION IS EXCESSIVE…..3337
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..3338
S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)…..3339
S-13 OIL LEVEL RISES(WATER, FUEL IN OIL)…..3340
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..3341
S-15 ABNORMAL NOISE IS MADE…..3342
S-16 VIBRATION IS EXCESSIVE…..3343
TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)…..3344
F-1 MONITOR DISPLAY DOES NOT SHOW [P1](BOOM RAISE PRESSURE SWITCH)…..3345
F-2 MONITOR DISPLAY DOES NOT SHOW [P2](BOOM LOWER PRESSURE SWITCH)…..3346
F-3 MONITOR DISPLAY DOES NOT SHOW [P3](SWING PRESSURE SWITCH)…..3347
F-4 MONITOR DISPLAY DOES NOT SHOW [P4](SWING PRESSURE SWITCH)…..3348
F-5 MONITOR DISPLAY DOES NOT SHOW [P5](ARM IN PRESSURE SWITCH)…..3349
F-6 MONITOR DISPLAY DOES NOT SHOW [P7](TRAVEL PRESSURE SWITCH)…..3350
F-7 MONITOR DISPLAY DOES NOT SHOW [P8](BRAKE PRESSURE SWITCH)…..3351
F-8 MONITOR DISPLAY DOES NOT SHOW [P9] (BUCKET, OFFSET PRESSURE SWITCH)…..3352
F-9 CONTROLLER DISPLAY DOES NOT SHOW [UP](KNOB SWITCH)…..3353
F-10 CONTROLLER DISPLAY DOES NOT SHOW [HI](TRAVEL SPEED BOOST SWITCH)…..3354
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE)…..3355
TABLE OF FAILURE MODES AND CAUSES…..3357
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWIJNG, TRAVEL ARE SLOW OR LACK POWER…..3360
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE ATALLS…..3362
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…..3363
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…..3363
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…..3364
H-7 BOOM IS SLOW OR LACKS POWER…..3365
H-8 ARM IS SLOW OR LACKS POWER…..3367
H-9 BUCKET IS SLOW OR LOCKS POWER…..3369
H-10 OFFSET IS SLOW OR LACKS POWER…..3370
H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…..3371
H-12 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)…..3371
H-13 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…..3372
H-14 LACK OF POWER WHEN PRESSURE RISES (EXCEPT AUTOMATIC HORIZONTAL DIGGING MACHINE)…..3372
H-15 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…..3373
H-16 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…..3374
H-17 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCEESSIVELY…..3374
H-18 IN WORK EQUIPMENT (BOOM RAISE) +TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…..3374
H-19 TRAVEL DEVIATION …..3375
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL…..3375
b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING…..3375
H-20 TRAVEL SPEED IS SLOW…..3376
H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER…..3378
H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…..3380
H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…..3380
H-24 DOES NOT SWING…..3381
a) DOES NOT SWING TO EITHER LEFT OR RIGHT…..3381
b) DOES NOT SWING IN ONE DIRECTION…..3381
H-25 SWING ACCELERATION IS POOR LOR SWING SPEED IS SLOW…..3382
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING…..3384
a) ONE DIRECTION ONLY…..3384
b) BOTH DIRECTIONS…..3384
H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…..3385
H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…..3386
H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING…..3387
a) WHEN SWING HOLDING BRAKE IS RELESASED…..3387
b) WHEN SWING HOLDING BRAKE IS APPLIED…..3387
H-30 BLADE IS SLOW OR LACKS POWER…..3388
H-31 EXCESSIVE HYDRAULIC DRIFT OF BLADE…..3388
H-32 ERROR CODE [91] IS DISPLAYED ON MONITOR PANEL,ANG BOOM RAISE,BOOM LOWER,AND LEFT OFFSET ALL STOP JUST BEFORE THERE IS INTERFERENCE…..3389
H-33 AUTOMATIC STOP IS NOT CARRIED OUT,AND THERE IS INTERFERENCE OF BOOM RAISE,ARM IN,AND LEFT OFFSET…..3389
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)…..3390
CHASSIS MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM…..3391
M-1 WHEN STARTING SWITCH IS TURNED ON, NOTHING IS DISPLAYED (NOTHING LIGHTS UP FOR 3 SEC.)…..3392
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS LIGHT UP,BUT THEY DO NOT GO OUT AFTER 3 SEC…..3392
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SEC…..3393
a) NO GAUGES LIGHT UP…..3393
b) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP…..3393
c) CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP…..3393
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…..3393
M-4 WHEN STRATING SWITCH IS AT ON (ENGINE STOPPED),CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP…..3394
M-5 WHEN STARTING SWITCH IS AT ON (ENGINE STOPPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP …..3394
M-6 PREHESTING PILOT LAMP DOES NOT LIGHT UP DURING PREHEATING…..3395
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)…..3395
M-8 CHARGE LEVEL CAUTION LIGHTS UP WHEN ENGINE IS RUNNING…..3396
M-9 ABNORMALITY IN COOLANT TEMPERATURE SYSTEM IS DISPLAYED…..3396
a) AFTER ENGINE ATARTS, LEVEL STAYS AT BOTTOM AND DOES NOT GO UP…..3396
b) AFTER ENGINE ATARTS, LEVEL GOES UP IMMEDIATELY(ENTERS RED RANGE EVEN THOUGH THERE IS NO OVERHEATING)…..3397
M-10 ABNORMAL DISPLAY IS GIVEN FOR FUEL GAUGE SYSTEM…..3397
a) ALL FUEL LEVEL GAUGE SEGMENTS GO OUT…..3397
b) FUEL HAS GONE DOWN, BUT FUEL GAUGE CONTINUES TO DISPALY FULL…..3398
c) EVEN WHEN FUEL TANK IS FILLED,FUEL LEVEL GAUGE DOES NOT SHOW FULL…..3398
M-11 DEFECTIVE OPERATION OF ALARM BUZZER…..3399
a) BUZZER DOES NOT SOUND…..3399
b) BUZZER DOES NOT STOP SOUNDING…..3399
M-12 SERVICE MEMTER DOES NOT MOVE WHEN ENGINE IS RUNNING…..3400
a) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP…..3400
b) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UO…..3400
M-13 NIGHT LIGHTING DOES NOT LIGHT UP…..3401
a) COOLANT TEMPERATURE GAUGE,FULE GAUGE,DEPTH DISPLAY DO NOT LIGHT UP…..3401
b) SERVICE METER DOES NOT LIGHT UP…..3401
M-14 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP (THERE IS NO ABNORMALITY DISPLAY ON CONTROLLER,OPERATION IS NORMAL)…..3402
a) STD MACHINE…..3402
b) MACHINE EQUIPPED WITH AUTIMATIC HORIZONTAL DIGGING SYSTEM…..3402
30 DISASSEMBLY AND ASSEMBLY…..3403
METHOD OF USING MANUAL…..3405
PRECAUTIONS WHEN CARRYING OUT OPERATION…..3406
SPECIAL TOOL LIST…..3408
SKECHES OF SPECIAL TOOLS…..3412
STARTING MOTOR…..3416
REMOVEL AND INSTALLATION…..3416
ALTERNATOR…..3417
REMOVAL AND INSTALLATION…..3417
ENGINE OIL COOLER…..3418
REMOVEL AND INSTALLATION…..3418
FUEL INJECTION PUMP…..3419
REMOVAL…..3419
INSTALLATION…..3423
WATER PUMP…..3426
REMOVAL AND INSTALLATION…..3426
NOZZLE HOLDER…..3427
REMOVAL AND INATALLATION…..3427
TURBOCHARGER…..3428
REMOVAL…..3428
INSTALLATION…..3429
THERMOSTAT…..3430
REMOVAL AND INSTALLATION…..3430
CYLINDER HEAD…..3431
REMOVAL…..3431
INSTALLATION…..3437
ENGINE, MAIN PUMP…..3440
REMOVAL…..3440
INTALLATION…..3446
RADIATOR, HYDRAULIC COOLER…..3447
REMOVAL …..3447
INSTALLATION…..3450
FUEL TANK…..3451
REMOVAL …..3451
INSTALLATION…..3452
CENTER SWIVEL JOINT…..3453
REMOVAL AND INATALLATION…..3453
DISASSEMBLY AND ASSEMBLY…..3454
SPROCKET …..3455
REMOVAL AND INSTALLATION…..3455
TRAVEL MOTOR…..3456
REMOVAL AND INSTALLATION…..3456
SWING MOTOR, SWINMG MACHINERY…..3457
REMOVAL …..3457
INSTALLATION…..3458
SWING MACHINERY…..3459
DISASSEMBLY…..3459
ASSEMBLY…..3462
SWING MOROR …..3466
REMOVAL AND INSTALLATION…..3466
DISASSEMBLY…..3467
ASSEMBLY…..3470
REVOLVING FRAME…..3477
REMOVAL…..3477
INSTALLATION…..3478
SWING CIRCLE…..3479
REMOVAL AND INSTALLATION…..3479
IDLER, RECOIL SPRING…..3480
REMOVAL AND INSTALLATION…..3480
RECOIL SPRING…..3481
DISASSEMBLY…..3481
ASSEMBLY…..3482
IDLER …..3483
DISASSEMBLY…..3483
ASSEMBLY…..3484
TRACK ROLLER…..3486
REMOVAL AND INSTALLATION…..3486
DISASEMBLY…..3487
ASSEMBLY…..3489
CARRIER ROLLER…..3491
REMOVAL AND INSTALLATION…..3491
SEEEL SHOE RUBBER PAD SHOE, LOAD LINER…..3492
REMOVAL AND INSTALLATION…..3492
INTEGRATED RUBBER SHOE…..3493
REMOVAL AND INSTALLATION…..3493
HYDRAULIC TANK …..3494
REMOVAL …..3494
INSTALLATION…..3495
MAIN PUMP…..3496
REMOVAL…..3496
INSTALLATION…..3498
DISASSEMBLY…..3499
ASSEMBLY…..3509
CONTROL PUMP…..3521
REMOVAL AND INSTALLATION…..3521
PC-EPC, LS-EPC VALVE…..3522
REMOVAL AND INSTALLATION…..3522
PC VALVE…..3523
REMOVAL AND INSTALLATION…..3523
LS VALVE…..3524
REMOVAL AND INSTALLATION …..3524
CONTROL VALVE…..3525
REMOVAL …..3525
INSTALLATION…..3527
DISASSEMBLY…..3528
ASSEMBLY…..3530
LS SELSECT VALVE…..3533
DISASSEMBLY AND ASSEMBLY…..3533
LS SHUTTLE VALVE…..3534
DISASSEMBLY AND ASSEMBLY…..3534
PRESSURE COMPENSATION VALVE…..3535
DISASSEMBLY AND ASSEMBLY…..3535
MAIN RELIEF VALVE…..3537
REMOVAL AND INSTALLATION…..3537
DISASSEMBLY AND ASSEMBLY…..3538
SOLENOID VALVE…..3540
(LS BYPASS, SWING HOLDING BRAKE, TRAVEL SPEED BOOST)…..3540
REMOVAL AND INSTALLATION…..3540
(EPC, LEFT OFFSET)…..3541
REMOVAL AND INSTALLATION…..3541
WORK EQUIPMENT LH.PPC VALVE (ARM, SWING)…..3542
REMOVAL AND INSTALLATION…..3542
WORK EAUIPMENT R.H. PPC VALVE (BOOM, BUCKET)…..3543
REMOVAL AND INSTALLATION…..3543
WORK EQUIPMENT PPC VALVE (BOOM, BUCKET, ARM, SWING)…..3544
DISASSEMBLY…..3544
ASSEMBLY…..3545
TRAVEL PPC VALVE…..3546
REMOVAL AND INSTALLATION…..3546
DISASSEMBLY AND ASSEMBLY…..3547
PPC VALVE FPR OFFSET CONTROL…..3548
REMOVAL AND INSTALLATION…..3548
BLADE PPC VALVE…..3549
REMOVAL AND INSTALLATION…..3549
BOOM LOCK VALVE…..3550
REMOVAL AND INSTALLATION…..3550
BOOM CYLINDER…..3551
REMOVAL …..3551
INSTALLATION …..3552
ARM CYLINDER…..3553
REMOVAL …..3553
INSTALLATION…..3554
BUCKET CYLINDER…..3555
REMOVAL …..3555
INSATLLATION…..3556
OFFSET CYLINDER…..3557
REMOVAL …..3557
INSTALLATION…..3558
BLADE CYLINDER…..3559
REMOVAL …..3559
INSTALLATION…..3560
HYDRAULIC CYLINDER…..3561
DISASSEMBLY…..3561
ASSEMBLY…..3564
WORK EQUIPMENT…..3567
REMOVAL …..3567
INSTALLATION…..3569
BUCKET…..3570
REMOVAL …..3570
INSTALLATION…..3571
ARM…..3572
REMOVAL …..3572
INSTALLATION…..3573
BUCKET, ARM…..3574
REMOVAL …..3574
INSTALLATION…..3575
SECOND BOOM…..3576
REMOVAL …..3576
INSTALLATION …..3579
1ST BOOM…..3581
REMOVAL …..3581
INSTALLATION…..3583
BLADE…..3584
REMOVAL AND INSTALLATION…..3584
OPERATOR'S CAB…..3585
REMOVAL …..3585
INSTALLATION…..3586
FLOOR FRAME…..3587
REMOVAL…..3587
INSTALLATION…..3588
AIR CONDITIONER COMPRESSOR…..3589
REMOVAL …..3589
INSTALLATION…..3590
AIR CONDENSER…..3591
REMOVAL …..3591
INSTALLATION…..3592
COUNTERWEIGHT…..3593
REMOVAL AND INSTALLATION…..3593
CONTROLLER…..3594
REMOVAL AND INSTALLATION…..3594
MONITOR…..3595
REMOVAL AND INSTALLATION…..3595
CAR COOLER UNIT…..3596
REMOVAL AND INSTALLATION…..3596
40 MAINTENANCE STANDARD…..3597
SWING MACHINERY…..3598
SWING CIRCLE …..3600
TRACK FRAME…..3601
IDLER…..3602
CARRIER ROLLER…..3603
TRACK ROLLER…..3604
SPROCKET…..3605
TRACK SHOE…..3606
HYDRAULIC PUMP…..3613
CONTROL VALVE…..3615
SWING MOTOR…..3625
TRAVEL MOTOR…..3627
CENTER SWIVEL JOINT…..3628
PPC VALVE…..3630
PPC SHUTTLE・TRAVEL JUNCTION VALVE…..3634
EPC SOLENOID VALVE…..3635
BOOM HOLDING VALVE…..3640
HYDRAULIC CYLINDER…..3641
WORK EQUIPMENT…..3645
DIMENSION OF WORK EQUIPMENT…..3649
90 OTHERS…..3655
HYDRAULIC PIPING DRAWING…..3656
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)…..3657
HYDRAUIC CIRCUIT DIAGRAM (PC128UU-1)…..3658
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)…..3659
CLSS…..3660
OPERATION OF CLSS SYSTEM AS A WHOLE…..3660
1) WHEN ALL CONTROL VALVES ARE AT NEUTRAL…..3660
2) WHEN BOOM RAISE IS OPERATED INDEPENDENTLY…..3661
3) WHEN SWING IS OPERATED INDEPENDENTLY…..3662
4) WHEN BOOM AND ARM ARE OPERATED SIMULTANEOUSLY…..3663
ACTUAL ELECTRICAL WIRING DIAGRAM (PC128UU-1)…..3664
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (PC128UU-1)…..3665
ELECTRICAL CIRCUIT DIAGRAM (PC128UU-1)…..3666
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (1/2) (PC128UU-1)…..3667
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL (2/2) (PC128UU-1)…..3668
ELECTRONIC CONTRAL SYSTEM…..3669
OVERALL SYSTEM DRAWING…..3669
MACHINE EQUIPMENT WITH AUTOMATIC HORIZONTAL EXCAVATION CONTROL …..3670
HYDRAUIC CIRCUIT DIAGRAM (PC128US-1)…..3671
ELECTRICAL CIRCUIT DIAGRAM (PC128US-1)…..3672
CONNECTOR ARRANGEMENT DIAGRAM…..3673
SEBM018419 – Hydraulic Excavator PC128US-2, PC138US-2, PC138USLC-2E0 Shop Manual…..3674
COVER…..3674
CONTENTS…..3675
FOREWORD…..3683
GENERAL…..3683
HOW TO READ THE SHOP MANUAL…..3684
HOISTING INSTRUCTIONS…..3685
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…..3686
COATING MATERIALS…..3688
STANDARD TIGHTENING TORQUE…..3690
ELECTRIC WIRE CODE…..3693
CONVERSION TABLE…..3694
UNITS…..3700
01 GENERAL…..3701
GENERAL ASSEMBLY DRAWING…..3702
SPECIFICATIONS…..3713
WEIGHT TABLE…..3735
LIST OF LUBRICANTS AND WATER…..3749
10 STRUCTURE AND FUNCTION…..3751
PTO…..3752
RADIATOR AND OIL COOLER…..3753
POWER TRAIN…..3757
SWING CIRCLE…..3758
SWING MACHINERY…..3759
TRACK FRAME…..3761
IDLER CUSHION…..3763
HYDRAULIC COMPONENT LAYOUT…..3764
VALVE CONTROL…..3766
HYDRAULIC TANK AND FILTER…..3770
HYDRAULIC PUMP (PISTON PUMP)…..3772
CONTROL VALVE…..3800
SUCTION SAFETY VALVE…..3822
CLSS…..3823
SELF PRESSURE REDUCING VALVE…..3860
CENTER SWIVEL JOINT…..3867
TRAVEL MOTOR (FINAL DRIVE)…..3869
SWING MOTOR…..3878
SOLENOID VALVE…..3884
PPC ACCUMULATOR…..3886
ACCUMULATOR FOR BREAKER (OPT)…..3887
PPC VALVE…..3888
HYDRAULIC DRIFT PREVENTION VALVE…..3901
ARM HYDRAULIC DRIFT PREVENTION VALVE…..3906
AIR-CONDITIONER PIPING…..3910
ELECTRIC COMPONENT LAYOUT…..3913
ENGINE CONTROL…..3917
ELECTRIC CONTROL SYSTEM…..3938
MONITOR SYSTEM…..3986
20 TESTING AND ADJUSTING…..3995
STANDARD VALUE TABLE…..3996
STANDARD VALUE TABLE FOR ENGINE…..3996
STANDARD VALUE TABLE FOR CHASSIS…..3998
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..4019
TESTING AND ADJUSTING…..4030
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…..4031
MEASURING ENGINE SPEED…..4032
MEASURING EXHAUST COLOR…..4034
ADJUSTING VALVE CLEARANCE…..4035
MEASURING BLOW-BY PRESSURE…..4037
MEASURING ENGINE OIL PRESSURE…..4038
TESTING AND ADJUSTING FUEL INJECTION TIMING…..4039
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…..4044
TESTING AND ADJUSTING FAN BELT TENSION…..4045
ADJUSTING ENGINE SPEED SENSOR…..4046
ADJUSTING FUEL CONTROL CABLE…..4047
ADJUSTING ENGINE STOP SOLENOID LINKAGE…..4048
TESTING CLEARANCE OF SWING CIRCLE BEARING…..4049
CHECKING WEAR OF SPROCKET…..4050
TESTING AND ADJUSTING TRACK SHOE TENSION…..4051
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…..4052
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)…..4055
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…..4057
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE…..4060
MEASURING SOLENOID VALVE OUTPUT PRESSURE…..4061
MEASURING PPC VALVE OUTPUT PRESSURE…..4062
ADJUSTING PPC VALVE…..4063
TESTING AND ADJUSTING TRAVEL DEVIATION…..4064
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT…..4065
MEASURING OIL LEAKAGE IN SWING MOTOR…..4066
MEASURING OIL LEAKAGE IN TRAVEL MOTOR…..4066
BLEEDING AIR…..4067
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…..4069
RELEASING REMAINING PRESSURE IN HYDRAULIC TANK…..4069
PROCEDURE FOR CHECKING DIODE…..4070
PM CLINIC INSPECTION TABLE…..4071
TROUBLESHOOTING…..4077
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..4078
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..4079
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..4080
CHECKS BEFORE TROUBLESHOOTING…..4088
CONNECTOR TYPES AND MOUNTING LOCATIONS…..4089
CONNECTOR ARRANGEMENT DIAGRAM…..4091
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..4104
T-ADAPTER TABLE…..4125
FUNCTIONAL DESCRIPTION OF ELECTRICAL SYSTEM MECHANISM (SERIAL NO.: 7731 AND UP)…..4129
MONITOR PANEL DISPLAY SPECIAL FUNCTIONS (SERIAL NO.: 7731 AND UP)…..4131
METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 5001 -7730)…..4150
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM (SERIAL NO.: 5001 -7730)…..4152
HOW TO READ DECISION LIST (SERIAL NO.: 7731 AND UP)…..4154
METHOD OF USING TROUBLESHOOTING CHARTS (SERIAL NO.: 7731 AND UP)…..4156
DIAGNOSTIC CONTENTS AND DIAGNOSTIC PROCEDURE AT TROUBLESHOOTING (SERIAL NO.:7731 AND UP)…..4158
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) (SERIAL NO.: 5001-7730)…..4163
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM…..4164
RELATED ELECTRICAL CIRCUIT DIAGRAMS FOR ELECTRICAL SYSTEM…..4166
E-1 ABNORMALITY IN PC-EPC SYSTEM…..4174
A) SPEEDS OF ALL WORK EQUIPMENT , TRAVEL, SWING ARE SLOW OR LACK POWER…..4175
B) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…..4176
E-2 ABNOMALITY IN PPC LOCK SOLENOID SYSTEM…..4182
A) EVEN WHEN SAFETY LOCK LEVER IS SET TO FREE, NO WORK EQUIPMENT, TRAVEL, SWING MOVE…..4182
B) EVEN WHEN SAFETY LOCK LEVER IS SET TO LOCK, WORK EQUIPMENT, TRAVEL, SWING MOVE…..4182
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM…..4186
A) EVEN WHEN SWING LOCK SWITCH IS TURNED OFF, UPPER STRUCTURE DOES NOT SWING…..4186
B) EVEN WHEN SWING LOCK SWITCH IS TURNED TO LOCK, UPPER STRUCTURE SWINGS…..4187
E-4 ABNOMALITY IN TRAVEL SPEED SOLENOID SYSTEM…..4190
A) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO HI, TRAVEL SPEED DOES NOT CHANGE TO HIGH SPEED…..4190
B) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO LO, TRAVEL SPEED DOES NOT CHANGE TO LOW SPEED…..4190
E-5 TROUBLE IN AUTOMATIC TRAVEL SPEED CONTROL SYSTEM…..4193
A) MAIN PUMP PRESSURE SENSOR SYSTEM…..4193
B) ENGINE SPEED SENSOR SYSTEM…..4193
E-6 ABNORMALITY IN ENGINE STARTING SYSTEM…..4198
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEMS (H MODE)…..4206
TABLE OF FAILURE MODES AND CAUSES…..4207
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER…..4211
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…..4212
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…..4213
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…..4214
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…..4214
H-6 BOOM IS SLOW OR LACKS POWER…..4215
ARM IS SLOW OR LACKS POWER…..4216
BUCKET IS SLOW OR LACKS POWER…..4216
H-7 WORK EQUIOPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE…..4217
H-8 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)…..4217
H-9 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…..4217
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…..4218
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…..4218
H-12 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDENTLY, OTHER WORK EQUIPMENT MOVES…..4219
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…..4219
H-14 IN SWING+BOOM RAISE, BOOM IS SLOW…..4220
A) DEVIATION IS EXCESSIVE DURING NORMAL TRAVEL…..4220
B) DEVIATION IS EXCESSIVE WHEN STARTING…..4220
H-15 TRAVEL SPEED IS SLOW…..4221
H-16 STEERING IS DIFFICULT TO TURN OR LACKS POWER…..4222
H-17 TRAVEL SPPED DOES NOT SWITCH…..4224
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…..4224
H-19 UPPER STRUCTURE DOES NOT SWING…..4225
A) DOES NOT SWING IN EITHER DIRECTION (LEFT AND RIGHT)…..4225
B) DOES NOT SWING IN ONE DIRECTION ONLY (LEFT AND RIGHT)…..4225
H-20 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…..4226
A) ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT)…..4226
B) ACCELERATION IS POOR OR SWING SPEED IS SLOW (ONE DIRECTION ONLY)…..4226
H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING…..4227
A) EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT) (WHEN OPERATION OF CONTROL VALVE SPOOL AND PPC CIRCUIT THROTTL…..4227
B) EXCESSIVE OVERRUN WHEN STOPPING SWING (ONE DIRECTION ONLY)…..4227
H-22 EXCESIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…..4228
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…..4228
H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING…..4229
A) WHEN SWING HOLDING BRAKE IS ACTUATED…..4229
B) WHEN SWING HOLDING BRAKE IS RELEASED…..4229
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: 5001-7730)…..4230
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM…..4231
M-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON…..4232
M-2 DISPLAY DOES NOT GO OUT AFTER COMPLETION OF SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED…..4233
M-3 SOME ITEMS DO NOT LIGHT UP DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON…..4233
A) NO GAUGES (FUEL LEVEL, ENGINE WATER TEMPERATURE) LIGHT UP. PREHEATING PILOT LAMP DOES NOT LIGHT UP…..4233
B) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE) DO NOT LIGHT UP…..4233
M-4 CHARGE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)…..4234
M-5 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)…..4235
M-6 PREHEATING PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT HEAT…..4236
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING…..4237
M-8 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING…..4238
M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE…..4239
A) AFTER ENGINE IS STARTED, TEMPERATURE REMAINS AT BOTTOM LEVEL AND DOES NOT MOVE…..4239
B) AFTER ENGINE IS STARTED, TEMPERATURE IMMEDIATELY GOES UP (THERE IS NO OVERHEATING BUT GAUGE ENTERS RED RANGE)…..4239
M-10 ABNORMALITY IN FUEL GUAGE…..4240
A) NO SEGMENTS ON FUEL GAUGE LIGHT UP…..4240
B) FUEL LEVEL HAS GONE DOWN BUT FUEL GAUGE REMAINS AT FULL TANK DISPLAY…..4240
C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT GIVE FULL TANK DISPLAY…..4241
M-11 DEFECTIVE OPERATION OF ALARM BUZZER…..4242
A) BUZZER DOES NOT SOUND…..4242
B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…..4242
M-12 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING…..4243
A) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP…..4243
B) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP…..4243
M-13 NIGHT LIGHTING DOES NOT LIGHT UP…..4244
A) GAUGE LIGHTING DOES NOT LIGHT UP…..4244
B) SERVICE METER LIGHTING DOES NOT LIGHT UP…..4244
M-14 HEATER DOES NOT WORK…..4245
A) NEITHER HI NOR LO WORK…..4245
B) ONLY LO DOES NOT WORK…..4245
C) ONLY HI DOES NOT WORK…..4245
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) (SERIAL NO.: PC128US-2; 7731 & UP AND PC138USLC-2; 1001 & UP)…..4247
ACTIONS TO BE TAKEN ON MONITOR AND PHENOMENA ON MACHINE BODY AT THE TIME OF ABNORMALITY OCCURRENCE…..4250
ELECTRICAL CIRCUIT DIAGRAM OF MODE M SYSTEM…..4252
M-1 [E101] (AN ERROR HISTORY DATA ABNORMALITY) IS DISPLAYED…..4256
M-2 [E108] (DETECTION OF ENGINE WATER TEMPERATURE 105°) IS DISPLAYED…..4258
M-3 [E112] (SHORT CIRCUITOF WIPER NORMAL ROTATION OUTPUT) IS DISPLAYED)…..4258
M-4 [E113] (SHORT CIRCUIT OF WIPER REVERSE ROTATION OUTPUT) IS DISPLAYED…..4258
M-5 [E114] (CONTACT OF WASHER OUTPUT WITH 24V) IS DISPLAYED…..4258
M-6 [E115] (IMPOSSIBILITY IN 10 SEC. AT THE TIME OF WIPING AWAY) IS DISPLAYED…..4258
M-7 [E116] (IMPOSSIBILITY IN 10 SEC. OF STORAGE) IS DISPLAYED…..4258
M-8 WHEN THE STARTING SWITCH IS SET TO ON, THE WHOLE MONITOR PANEL DOES NOT COME ON FOR 3 SEC…..4259
A) WHEN THE WHOLE MONITOR PANEL DOES NOT COME ON…..4259
B) WHEN PART OF THE MONITOR PANEL DOES NOT COME ON…..4259
M-9 THE STARTING SWITCH IS SET TO ON, AND THE WHOLE MONITOR PANEL REMAINS LIGHTED…..4262
M-10 (THE ENGINE PRE-HEATING MONITOR) COMES ON EVEN WITHOUT PREHEATING ARRANGEMENT…..4263
M-11 WHEN THE STARTING SWITCH IS SET TO ON, THE ENGINE IS STARTED, THE BASIC CHECK ITEMS FLASH …..4265
A) ALTERNATOR SYSTEM…..4265
B) ENGINE OIL PRESSURE SYSTEM…..4266
M-12 WHEN THE STARTING SWITCH IS SET TO ON (THE ENGINE STOPPED), PRECAUTIONS AND EMERGENCY STOP ITEMS FLASH. (BUT "BATTERY" AND "ENGINE OIL PRESSURE" DO NOT COME ON.)…..4267
A) ALTERNATOR SYSTEM…..4267
B) OIL PRESSURE SENSOR SYSTEM…..4268
M-13 WHEN THE STARTING SWITCH IS SET TO ON (THE ENGINE STOPPED), PRECAUTIONS AND EMERGENCY STOP ITEMS FLASH. (BUT WHEN INSPEC…..4269
A) (ENGINE OIL PRESSURE) FLASHES…..4269
B) (BATTERY CHARGE LEVEL) FLASHES…..4269
C) (COOLANT TEMPERATURE) FLASHES…..4270
D) (FUEL LEVEL) FLASHES…..4271
M-14 WHEN THE STARTING SWITCH IS SET TO ON (THE ENGINE STOPS), THE BUZZER DOES NOT SOUND FOR 1 SEC THOUGH CAUTION ITEMS FLASH…..4272
M-15 MONITOR PANEL NIGHT LIGHTING DOES NOT COME ON. (THE LIQUID CRYSTAL DISPLAY IS NORMAL)…..4273
M-16 THE COOLANT TEMPERATURE GAUGE DOES NOT RISE…..4274
M-17 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE (DURING OPERATION, THE GAUGE DOES NOT INDICATE ANY STAGE)…..4274
M-18 THE FUEL LEVEL GAUGE INDICATES FULL ALL THE TIME…..4276
M-19 THE FUEL LEVEL GAUGE INDICATES NOTHING…..4276
M-20 THOUGH THE SWING LOCK SWITCH IS SET TO ON (LOCK), (THE SWING LOCK MONITOR) DOES NOT COME ON…..4278
M-21 WHILE THE ENGINE IS ROTATING, THE SERVICE METER DOES NOT ADVANCE…..4278
M-22 THE FUEL LEVEL SENSOR SYSTEM IS DEFECTIVE…..4279
M-23 THE COOLANT TEMPERATURE SENSOR SYSTEM IS DEFECTIVE…..4280
M-24 THE WINDSHEILD WIPER DOES NOT WORK, OR WORKS THOUGH THE WIPER IS NOT SWITCHED ON…..4281
A) THE WINDSHEILD WIPER DOES NOT WORK…..4281
B) THE WINDSHEILD WIPER WORKS THOUGH IT IS NOT SWITCHED ON…..4281
M-25 THE WASHER MOTOR DOES NOT WORK, OR WORKS THOUGH THE WASHER IS NOT SWITCHED ON …..4284
A) THE WASHER MOTOR DOES NOT WORK…..4284
B) THE WASHER MOTOR WORKS THOUGH THE WASHER IS NOT SWITCHED ON…..4284
TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE) SERIAL NO.: 7731 AND UP…..4287
N-1 [E218] COMMUNICATION ABNORMALITY…..4288
TROUBLESHOOTING OF CONTROLLER CR700 [DELEERATION CONTROL SYSTEM] (E MODE) SERIAL.: 7731 AND UP…..4290
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [DELERATION CONTROL SYSTEM]…..4291
RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURRED…..4293
TABLE FOR DETERMINING CONTROLLER (ENGINE THROTTLE CONTROL SYSTEM) OR ENGINE RELATED…..4295
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM…..4297
E-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER CR700 (LED ON CONTROLLER IS OFF)…..4301
E-2 [E321] [E322] "SHORT CIRCUIT/DISCONNECTION IN MOTOR DRIVE RELAY SYSTEM" IS DISPLAYED…..4303
E-3 [E323] [E324] "SHORT CIRCUIT/DISCONNECTION IN ACCELERATOR RELAY SYSTEM" IS DISPLAYED…..4304
E-4 [E325] [E326] "SHORT CIRCUIT/DISCONNECTION IN DECELERATOR RELAY SYSTEM" IS DISPLAYED…..4306
E-5 [E328] "ABNORMALITY IN MOTOR STALL SYSTEM" IS DISPLAYED…..4308
E-6 [E308] "ABNORMALITY IN FUEL DIAL INPUT VALUE" IS DISPLAYED…..4310
E-7 [E227] "ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED…..4311
E-8 [E306] "ABNORMALITY IN MOTOR FEEDBACK POTENTIOMETER INPUT VALUE" IS DISPLAYED…..4312
E-9 [E258] "SHORT CIRCUIT IN POTENTIOMETER POWER SUPPLY" IS DISPLAYED…..4314
E-10 [E304] [E314] "SHORT CIRCUIT/DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM" IS DISPLAYED…..4316
E-11 AUTO-DECELERATOR DOES NOT OPERATE…..4317
TROUBLESHOOTING OF CONTROLLER CR700 [PUMP CONTROL SYSTEM] (C MODE) SERIAL.: 7731 AND UP…..4319
CAUTIONS WHEN TROUBLESHOOTING CONTROLLER CR700 [PUMP CONTROL SYSTEM…..4320
RESPONSE OF CONTROLLER AND PHENOMENA ON MACHINE BODY WHEN ABNORMALITY HAS OCCURED…..4322
TABLE FOR DETERMINING CONTROLLER CR700 [PUMP CONTROL SYSTEM] OR OIL PRESSURE IN RELATED…..4326
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM…..4330
TROUBLESHOOTING FLOW CHART FOR EACH FAILURE MODE…..4334
C-1 ABNORMALITY IN POWER SUPPLY OF CONTROLLER (LED ON CONTROLLER IS OFF)…..4334
C-2 [E232] "SHORT CIRCUIT IN PC-EPC SOLENOID SYSTEM" IS DISPLAYED…..4336
C-3 [E233] "DISCONNECTION IN PC-EPC SOLENOID SYSTEM" IS DISPLAYED…..4338
C-4 [E203] "SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM" IS DISPLAYED…..4340
C-5 [E213] "DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM" IS DISPLAYED…..4344
C-6 [E206] "SHORT CIRCUIT IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM" IS DISPLAYED…..4348
C-7 [E216] "DISCONNECTION IN TRAVEL HI/LO SELECTION SOLENOID SYSTEM" IS DISPLAYED…..4350
C-8 [E205] "SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM" IS DISPLAYED…..4352
C-9 [E215] "DISCONNECTION IN 2-STAGE RELIEIF SOLENOID SYSTEM" IS DISPLAYED…..4354
C-10 [E222] "SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM" IS DISPLAYED…..4356
C-11 [E223] "DISCONNECTION IN LS-EPC SOLENOID SYSTEM" IS DISPLAYED…..4357
C-12 [E224] "ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM" IS DISPLAYED…..4358
C-13 [E227] "ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM" IS DISPLAYED…..4359
TROUBLESHOOTING OF CONTROLLER CR700 [INPUT SIGNAL SYSTEM] (F MODE) SERIAL.: 7731 AND UP…..4360
ELECTRICAL CIRCUIT DIAGRAM OF MODE F SYSTEM PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4361
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4362
F-1 BIT-PATTERN 1023-(4) SWING PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4363
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4364
F-2 BIT-PATTERN 1023-(3) TRAVEL PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4365
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4366
F-3 BIT-PATTERN 1023-(2) BOOM LOWER PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4367
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4368
F-4 BIT-PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4369
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4370
F-5 BIT-PATTERN 1023-(5) ARM IN PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4371
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4372
F-6 BIT-PATTERN 1023-(2) ARM OUT PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4373
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4374
F-7 BIT-PATTERN 1023-(2) BUCKET CURL PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4375
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4376
F-8 BIT-PATTERN 1023-(2) BUCKET DUMP PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4377
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4378
F-9 BIT-PATTERN 1023-(2) SERVICE PRESSURE SWITCH IS NOT TURNED ON PC128US-2 Serial No.: 7731 and up PC138USLC-2 Serial No.: 1001 – 1500…..4379
PC138US-2 Serial No.: 4501 and up PC138USLC-2 Serial No.: 1501 and up…..4380
F-10 BIT-PATTERN 1021-(6) KEROSENE IS NOT TURNED ON…..4381
TROUBLESHOOTING OF ENGINE (S MODE)…..4382
METHOD OF USING TROUBLESHOOTING CHARTS…..4383
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..4387
S-2 ENGINE DOES NOT START…..4389
1) ENGINE DOES NOT TURN…..4389
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…..4390
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..4391
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)…..4392
S-4 ENGINE STOPS DURING OPERATIONS…..4393
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..4394
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..4395
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..4396
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..4397
S-9 OIL BECOMES CONTAMINATED QUICKLY…..4398
S-10 FUEL CONSUMPTION IS EXCESSIVE…..4399
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..4400
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..4401
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..4402
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..4403
S-15 ABNORMAL NOISE IS MADE…..4404
S-16 VIBRATION IS EXCESSIVE…..4405
30 DISASSEMBLY AND ASSEMBLY…..4406
METHOD OF USING MANUAL…..4407
PRECAUTIONS WHEN CARRYING OUT OPERATION…..4408
SPECIAL TOOL LIST…..4410
SKETCH OF SPECIAL TOOL…..4414
CYLINDER HEAD ASSEMBLY…..4416
REMOVAL…..4416
INSTALLATION…..4419
INJECTION PUMP ASSEMBLY…..4421
REMOVAL…..4421
INSTALLATION…..4423
ENGINE AND MAIN PUMP ASSEMBLY…..4424
REMOVAL …..4424
INSTALLATION…..4425
RADIATOR, HYDRAULIC OIL COOLER…..4436
REMOVAL…..4436
INSTALLATION…..4437
RADIATOR ASSEMBLY…..4438
REMOVAL AND INSTALLATION…..4438
HYDRAULIC OIL COOLER ASSEMBLY…..4439
REMOVAL…..4439
INSTALLATION…..4440
AFTER COOLER ASSEMBLY…..4441
REMOVAL AND INSTALLATION…..4441
FUEL TANK…..4443
REMOVAL AND INSTALLATION…..4443
CENTER SWIVEL JOINT…..4444
REMOVAL AND INSTALLATION…..4444
DISASSEMBLY AND ASSEMBLY…..4445
SWING MOTOR, SWING MACHINERY…..4446
REMOVAL AND INSTALLATION…..4446
SWING MACHINERY…..4447
DISASSEMBLY…..4447
ASSEMBLY…..4450
REVOLVING FRAME…..4460
REMOVAL…..4460
INSTALLATION…..4461
SWING CIRCLE…..4462
REMOVAL AND INSTALLATION…..4462
TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…..4463
REMOVAL AND INSTALLATION…..4463
RECOIL SPRING…..4464
DISASSEMBLY…..4464
ASSEMBLY…..4465
IDLER …..4468
DISASSEMBLY…..4468
ASSEMBLY…..4469
TRACK ROLLER…..4472
DISASSEMBLY…..4472
ASSEMBLY…..4473
TRACK SHOE…..4475
REMOVAL AND INSTALLATION…..4475
HYDRAULIC TANK…..4476
REMOVAL…..4476
INSTALLATION…..4477
MAIN PUMP…..4478
REMOVAL…..4478
INSTALLATION…..4480
CONTROL VALVE…..4481
REMOVAL …..4481
INSTALLATION…..4482
DISASSEMBLY…..4483
ASSEMBLY…..4488
LS SELECTION VALVE…..4497
DISASSEMBLY AND ASSEMBLY…..4497
PRESSURE COMPENSATION VALVE…..4498
DISASSEMBLY…..4498
ASSEMBLY…..4500
MAIN RELIEF VALVE…..4502
DISASSEMBLY…..4502
ASSEMBLY…..4503
WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET, ARM, SWING CONTROL)…..4504
DISASSEMBLY…..4504
ASSEMBLY…..4505
TRAVEL PPC VALVE…..4508
DISASSEMBLY…..4508
ASSEMBLY…..4509
HYDRAULIC CYLINDER…..4511
DISASSEMBLY…..4511
ASSEMBLY…..4514
WORK EQUIPMENT…..4518
REMOVAL …..4518
INSTALLATION…..4519
OPERATOR'S CAB…..4520
REMOVAL…..4520
INSTALLATION…..4521
OPERATOR’S CAB GLASS (STUCK GLASS)…..4527
REMOVAL…..4528
INSTALLATION…..4529
FRONT WINDOW ASSEMBLY…..4539
REMOVAL AND INSTALLATION…..4539
FLOOR FRAME…..4540
REMOVAL…..4540
INSTALLATION…..4541
AIR CONDITIONER COMPRESSOR…..4547
REMOVAL AND INSTALLATION…..4547
AIR CONDITIONER CONDENSOR…..4549
REMOVAL AND INSTALLATION…..4549
AIR CONDITIONER UNIT…..4551
REMOVAL…..4551
INSTALLATION…..4552
COUNTERWEIGHT…..4559
REMOVAL AND INSTALLATION…..4559
MONITOR PANEL ASSEMBLY…..4560
REMOVAL AND INSTALLATION…..4560
CONTROLLER ASSEMBLY…..4561
REMOVAL AND INSTALLATION…..4561
40 MAINTENANCE STANDARD…..4562
SWING MACHINERY…..4563
SWING CIRCLE…..4567
TRACK FRAME, IDLER CUSHION…..4568
IDLER…..4570
CARRIER ROLLER…..4574
TRACK ROLLER…..4575
SPROCKET…..4578
TRACK SHOE…..4579
HYDRAULIC PUMP (PISTON PUMP)…..4587
CONTROL VALVE…..4590
SUCTION SAFETY VALVE…..4610
SELF PRESSURE REDUCTION VALVE…..4611
TRAVEL MOTOR…..4612
SWING MOTOR…..4613
SOLENOID VALVE…..4614
CENTER SWIVEL JOINT…..4615
PPC VALVE…..4617
BOOM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC)…..4622
ARM HYDRAULIC DRIFT PREVENTION VALVE (FOR KUK SPEC) (IF EQUIPPED)…..4624
HYDRAULIC CYLINDER…..4625
WORK EQUIPMENT…..4628
DIMENSION OF WORK EQUIPMENT…..4631
90 OTHERS…..4645
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(BREAKER: 1 SERVICE VALVE: 50: AMOUNT)…..4647
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT)(CRASHER: 1 SERVICE VALVE: 100% AMOUNT)…..4648
HYDRAULIC CIRCUIT DIAGRAM (ATTACHMENT) (CRASHER: 2 SERVICE VALVE: 100% AMOUNT)…..4649
ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 5001-7730)…..4650
ELECTRIC CIRCUIT DIAGRAM (AIR CONDITIONER) PC128US-2 (SERIAL NO.: 7731 AND UP) AND PC138USLC-2 (SERIAL NO.: 1001 AND UP)…..4651
HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 5001-7730)…..4652
HYDRAULIC CIRCUIT DIAGRAM PC128US-2 (SERIAL NO.: 7731 AND UP) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP)…..4654
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACUTUATOR ATTACHEMENT PC128US-2 (SERIAL NO.: 5001-7730)…..4656
HYDRAULIC CIRCUIT DIAGRAM (WITH 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 7731 AND UP), PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP)…..4658
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 5001-7730)…..4660
HYDRAULIC CIRCUIT DIAGRAM (WITH BLADE + 1 ACTUATOR ATTACHMENT) PC128US-2 (SERIAL NO.: 7731 AND UP), PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1001 AND UP)…..4662
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)…..4664
HYDRAULIC CIRCUIT DIAGRAM (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP)…..4666
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIAL NO.: 5001-7730)…..4668
HYDRAULIC CIRCUIT DIAGRAM (WITH 2 ACTUATOR ATTACHMENT) (FOR KUK SPEC.) PC128US-2 (SERIALNO.: 7731 AND UP) & PC138US-2 (SERIAL NO.: 4501 AND UP)…..4670
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)…..4672
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 5001-6300)…..4672
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 5001-6300)…..4674
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 SERIAL NO.: 6301-7730)…..4676
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 SERIAL NO.: 6301-7730)…..4678
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7731-7874)…..4680
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7731-7874)…..4682
ELECTRIC CIRCUIT DIAGRAM (1/2) PC128US-2 (SERIAL NO.: 7875 AND UP) & PC138USLC-2 (SERIAL NO.: 1001-1500)…..4683
ELECTRIC CIRCUIT DIAGRAM (2/2) PC128US-2 (SERIAL NO.: 7875 AND UP) PC138USLC-2 (SERIAL NO.: 1001-1500)…..4684
ELECTRIC CIRCUIT DIAGRAM (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)…..4685
ELECTRIC CIRCUIT DIAGRAM (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)…..4686
ELECTRIC CIRCUIT DIAGRAM (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP) & PC138USLC-2 (SERIAL NO.: 1501 AND UP)…..4687
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 5001-6300)…..4689
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 5001-6300)…..4691
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/2) PC128US-2 (SERIAL NO.: 6301-7730)…..4693
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 6301-7730)…..4695
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.)(1/2) PC128US-2 (SERIAL NO.: 7731 AND UP)…..4697
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/2) PC128US-2 (SERIAL NO.: 7731 AND UP)…..4698
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (1/3) PC138US-2 (SERIAL NO.: 4501 AND UP)…..4699
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (2/3) PC138US-2 (SERIAL NO.: 4501 AND UP)…..4700
ELECTRIC CIRCUIT DIAGRAM (FOR KUK SPEC.) (3/3) PC138US-2 (SERIAL NO.: 4501 AND UP)…..4701
SEBM018506 – Hydraulic Excavator PC128UU-2 Shop Manual…..4703
COVER…..4703
CONTENTS…..4704
01 GENERAL…..4728
GENERAL ASSEMBLY DRAWING…..4729
SPECIFICATIONS…..4731
WEIGHT TABLE…..4734
LIST OF LUBRICANTS AND COOLANT…..4736
10 STRUCTURE AND FUNCTION…..4738
PTO…..4739
RADIATOR AND OIL COOLER…..4740
POWER TRAIN…..4742
SWING CIRCLE…..4743
SWING MACHINERY…..4744
TRACK FRAME…..4745
IDLER CUSHION…..4746
HYDRAULIC EQUIPMENT LAYOUT DRAWING…..4747
VALVE CONTROL…..4749
HYDRAULIC TANK AND FILTER…..4750
HYDRAULIC PUMP (PISTON PUMP)…..4751
CONTROL VALVE…..4772
SUCTION SAFETY VALVE…..4783
CLSS…..4784
SELF PRESSURE REDUCING VALVE…..4821
CENTER SWIVEL JOINT…..4827
TRAVEL MOTOR …..4828
SWING MOTOR…..4837
SOLENOID VALVE…..4845
EPC SOLENOID VALVE…..4847
PPC ACCUMULATOR…..4852
PPC VALVE…..4853
AIR CONDITIONER PIPING…..4864
ELECTRIC EQUIPMENT LAYOUT DRAWING…..4865
ENGINE CONTROL…..4869
ELECTRIC CONTROL SYSTEM…..4877
4-SYSTEM…..4888
MONITOR SYSTEM…..4911
20 TESTING AND ADJUSTING…..4917
STANDARD VALUE TABLE FOR ENGINE…..4918
STANDARD VALUE TABLE FOR CHASSIS…..4919
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..4929
TESTING AND ADJUSTING…..4937
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…..4938
MEASURING ENGINE SPEED…..4939
MEASURING EXHAUST COLOR…..4940
ADJUSTING VALVE CLEARANCE…..4941
MEASURING BLOW-BY PRESSURE…..4942
MEASURING ENGINE OIL PRESSURE…..4942
TESTING AND ADJUSTING FUEL INJECTION TIMING…..4943
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..4944
ADJUSTING ENGINE SPEED SENSOR…..4944
ADJUSTING FUEL CONTROL CABLE…..4945
ADJUSTING ENGINE STOP SOLENOID LINKAGE…..4946
TESTING CLEARANCE OF SWING CIRCLE BEARING…..4947
MEASURING WEAR OF SPROCKET…..4948
TESTING AND ADJUSTING TRACK SHOE…..4949
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…..4950
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…..4953
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…..4955
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE…..4958
TESTING SOLENOID VALVE OUTPUT PRESSURE…..4959
MEASURING PPC VALVE OUTPUT PRESSURE…..4962
ADJUSTING PPC VALVE…..4963
TESTING AND ADJUSTING TRAVEL DEVIATION…..4964
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT…..4965
MEASURING OIL LEAKAGE FROM SWING MOTOR…..4966
MEASURING OIL LEAKAGE FROM TRAVEL MOTOR…..4966
BLEEDING FROM EACH PART…..4967
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…..4969
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK…..4969
PROCEDURE OF TESTING DIODE…..4970
RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION…..4971
REPLACEMENT PROCEDURE OF POTENTIOMETERS…..4985
PM CLINIC INSPECTION TABLE…..4986
TROUBLESHOOTING…..4988
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..4989
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..4990
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..4991
CHECK BEFORE TROUBLESHOOTING…..4999
TYPES AND LOCATIONS OF CONNECTORS…..5000
CONNECTOR ARRANGEMENT DIAGRAM…..5003
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..5007
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…..5019
DISPLAY METHOD FOR MONITOR PANEL, CONTROLLER…..5025
METHOD OF USING TROUBLESHOOTING CHARTS…..5031
TROUBLESHOOTING OF CONTROLLER, ELECTRICAL SYSTEM (E MODE)…..5033
ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE…..5035
JUDGEMENT TABLE FOR 4 SYSTEM…..5039
JUDGEMENT TABLE FOR CHASSIS RELATED PARTS…..5041
ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM…..5043
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM…..5045
PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS…..5048
E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM) IS DISPLAYED…..5049
A) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM…..5049
B) ABNORMALITY IN COMMUNICATIONS SYSTEMS…..5050
E-2 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTIOMETER SYSTEM) IS DISPLAYED…..5051
E-3 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED…..5052
E-4 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED…..5053
E-5 ERROR CODE [41](ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED…..5054
E-6 ERROR CODE [51] (ABNORMALITY IN PPC HYDRAULIC LOCK SOLENOID SYSTEM) IS DISPLAYED…..5055
E-7 ERROR CODE [52] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED…..5056
E-8 ERROR CODE [54] (ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED…..5057
E-9 ERROR CODE [62] (ABNORMALITY IN OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED…..5058
E-10 ERROR CODE [64] (ABNORMALITY IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED…..5059
E-11 ERROR CODE [71] (ABNORMALITY IN BOOM RAISE STOP EPC SOLENOID SYSTEM) IS DISPLAYED…..5060
E-12 ERROR CODE [72] (ABNORMALITY IN BOOM LOWER STOP EPC SOLENOID SYSTEM) IS DISPLAYED…..5061
E-13 ERROR CODE [74] (ABNORMALITY IN PC-EPC SOLENOID SYSTEM) IS DISPLAYED…..5062
E-14 ERROR CODE [81] (ABNORMALITY IN ARM IN STOP SOLENOID SYSTEM) IS DISPLAYED…..5063
E-15 ERROR CODE [C1] (3 SECONDS PASSED AFTER BOOM LOWER AND RAISE PRESSURE SWITCHES WERE INPUT SIMULTANEOUSLY) IS DISPLAYED…..5063
E-16 ABNORMALITY IN TRAVEL SPEED SELECTION SOLENOID SYSTEM (TRAVEL SPEED DOES NOT RISE OR DOES NOT DECREASE)…..5064
A) TRAVEL SPEED DOES NOT RISE (BUT KEEPS LOW)…..5064
B) TRAVEL SPEED DOES NOT LOWER (BUT KEEPS HIGH)…..5065
E-17 WORK EQUIPMENT DOES NOT MOVE AFTER WORK EQUIPMENT LOCK LEVER IS RELEASED…..5066
E-18 WORK EQUIPMENT MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET IN LOCK POSITION…..5067
E-19 DEPTH MODE, HEIGHT MODE, OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHIN…..5068
E-20 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE, DEPTH MODE, HEIGHT MODE, OFFSET MODE…..5069
E-21 CANCEL SWITCH IS NOT TURNED ON, BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRICAL SYSTEM CAUTION LAMP FLASHES…..5070
E-22 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE, LOWER, ARM IN, LEFT OFFSET, RIGHT OFFSET (WHEN ERROR CODE [91] IS NOT …..5071
A) ALL OPERATIONS STOP IMMEDIATELY BEFORE INTERFERENCE…..5071
B) THERE IS INTERFERENCE…..5071
E-23 SWING DOES NOT WORK (WHEN NO ERROR DISPLAY IS GIVEN)…..5072
E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING…..5073
E-25 OFFSET DOES NOT WORK (PARTICULARLY LEFT OFFSET)…..5074
E-26 OFFSET DOES NOT WORK (PARTICULARLY RIGHT OFFSET)…..5075
E-27 ENGINE DOES NOT START…..5076
A) WHEN STARTING MOTOR DOES NOT ROTATE…..5076
B) ENGINE STOP SOLENOID DOES NOT WORK…..5080
E-28 ENGINE DOES NOT STOP…..5081
E-29 WIPER DOES NOT OPERATE…..5082
E-30 ENGINE CONTROL IS ABNORMAL…..5083
A) WHEN ENGINE DOES NOT START OR IT STARTS BUT STOPS SOON…..5083
B) SWIFT SLOW-DOWN DOES NOT WORK…..5085
C) WORKS AT NEAR IDLING SPEED, BUT DOES NOT WORK UP TO FULL THROTTLE (LOAD BECOMES HIGH)…..5085
TROUBLESHOOTING OF CONTROLLER INPUT SIGNAL SYSTEM (F MODE)…..5087
F-1 MONITOR DOES NOT DISPLAY [P1] (BOOM RAISE PRESSURE SWITCH)…..5088
F-2 MONITOR DOES NOT DISPLAY [P2] (BOOM LOWER PRESSURE SWITCH)…..5089
F-3 MONITOR DOES NOT DISPLAY [P3] (SWING PRESSURE SWITCH)…..5090
F-4 MONITOR DOES NOT DISPLAY [P5] (ARM IN PRESSURE SWITCH)…..5091
F-5 MONITOR DOES NOT DISPLAY [P7] (TRAVEL PRESSURE SWITCH)…..5092
F-6 MONITOR DOES NOT DISPLAY [HI] (TRAVEL SPEED SELECTOR SWITCH)…..5093
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…..5094
TABLE OF FAILURE MODES AND CAUSES…..5095
H-1 ALL WORK EQUIPMENT, TRAVEL, AND SWING SPEED OR POWER IS LOW…..5097
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS…..5098
H-3 WORK EQUIPMENT DOES NOT MOVE AT ALL AND MACHINE DOES NOT TRAVEL OR SWING…..5099
H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP)…..5100
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW…..5100
H-6 BOOM SPEED OR POWER IS LOW…..5101
H-7 ARM SPEED OR POWER IS LOW…..5102
H-8 BUCKET SPEED OR POWER IS LOW…..5102
H-9 BLADE SPEED OR POWER IS LOW…..5102
H-10 OFFSET SPEED OR POWER IS LOW…..5103
H-11 WORK EQUIPMENT (BOOM, ARM, BUCKET, OFFSET MECHANISM, OR BLADE) DOES NOT MOVE…..5104
H-12 HYDRAULIC DRIFT (BOOM, ARM, BUCKET, OR BLADE) IS LARGE…..5104
H-13 TIME LAG IS LONG (ENGINE SPEED IS LOW)…..5105
H-14 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDANTLY, OTHER WORK EQUIPMENT MOVE…..5105
H-15 SPEED IS HEAVIER OPERATION IS SLOWER DURING COMPOUND OPERATION…..5105
H-16 BOOM RAISE SPEED IS LOW DURING COMPOUND OPERATION OF BOOM SWING AND RAISE OPERATIONS…..5106
H-17 TRAVEL SPEED LOWERS DURING COMPOUND OPERATION OF WORK EQUIPMENT OR SWINGING AND TRAVEL…..5106
H-18 MACHINE DEVIATES…..5107
H-19 TRAVEL SPEED IS LOW…..5108
H-20 STEERING CONDITION IS BAD OR STEERING FORCE IS LOW…..5109
H-21 TRAVEL SPEED DOES NOT CHANGE…..5111
H-22 MACHINE DOES NOT TRAVEL (ONLY ONE SIDE)…..5111
H-23 MACHINE DOES NOT SWING…..5112
A) WHEN MACHINE DOES NOT SWING IN EITHER DIRECTION…..5112
B) WHEN MACHINE DOES NOT SWING IN ONLY ONE DIRECTION…..5112
H-24 SWING ACCELERATION OR SWING SPEED IS LOW…..5113
A) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN EITHER DIRECTION…..5113
B) WHEN SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION…..5113
H-25 WORK EQUIPMENT OVERRUNS…..5114
A) WHEN WORK EQUIPMENT OVERRUNS IN EITHER DIRECTION…..5114
B) WHEN WORK EQUIPMENT OVERRUNS IN ONLY ONE DIRECTION…..5114
H-26 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING (IN ONLY ONE DIRECTION)…..5115
H-27 LARGE NOISE IS MADE WHEN MACHINE STOPS SWINGING…..5115
H-28 HYDRAULIC DRIFT OF SWING IS LARGE…..5116
A) WHEN SWING HOLDING BRAKE IS APPLIED…..5116
B) WHEN SWING HOLDING BRAKE IS RELEASED…..5116
H-29 ERROR CODE[91] IS DISPLAYED ON MONITOR PANEL AND ALL OF BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS STOP JUST BEFORE…..5117
H-30 BOOM RAISE, ARM IN, AND OFFSET LEFT OPERATIONS DO NOT STOP AUTOMATICALLY AND MACHINE INTERFERES…..5117
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)…..5118
ELECTRIC CIRCUIT DIAGRAM OF MONITOR SYSTEM…..5119
M-1 AFTER STARTING SWITCH IS TURNED TO ON POSITION, NOTHING IS DISPLAYED…..5120
M-2 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SECS) ARE TURNED ON BUT NOT…..5120
M-3 AFTER STARTING SWITCH IS TURNED TO ON POSITION, SOME OF SELF-CHECK ITEMS (WHICH SHOULD LIGHT UP FOR 3 SEC) ARE NOT TURNED…..5121
A) NO GAUGES (FUEL, ENGINE COOLANT TEMPERATURE) ARE TURNED ON PRE-HEATING PILOT LAMP DOES NOT LIGHT UP…..5121
B) CAUTION LAMPS (ENGINE OIL PRESSURE, CHARGE) DO NO LIGHT UP…..5121
C) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP…..5121
M-4 AFTER STARTING SWITCH IS TURNED TO ON POSITION (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP…..5122
M-5 AFTER STARTING SWITCH IS TURNED TO ON POSTION (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT…..5123
M-6 AFTER STARTING SWITCH IS TURNED TO HEAT POSITION, PRE-HEATING PILOT LAMP DOES NOT LIGHT UP…..5124
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…..5125
M-8 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING…..5126
M-9 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE…..5127
A) EVEN IF ENGINE IS OPERATED FOR LONG TIME, COOLANT TEMPERATURE LEVEL DOES NOT RISE AT ALL…..5127
B) LEVEL RISES SOON AFTER ENGINE IS STARTED (TO RED RANGE WHILE ENGINE IS NOT OVERHEATED)…..5127
C) RELATED ELECTRIC CIRCUIT DIAGRAM…..5127
M-10 ABNORMALITY IN FUEL GAUGE…..5128
A) ALL SEGMENTS OF FUEL GAUGE GO OFF…..5128
B) FUEL GAUGE INDICATES FULL WHILE FUEL LEVEL IS LOWERED…..5128
C) FUEL GAUGE DOES NOT INDICATE FULL EVEN IF FUEL TANK IS FULL…..5129
M-11 MALFUNCTION OF ALARM BUZZER…..5130
A) BUZZER DOES NOT SOUND…..5130
B) BUZZER DOES NOT STOP SOUNDING…..5130
M-12 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING…..5131
A) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP…..5131
B) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UP…..5131
M-13 LAMPS DO NOT LIGHT UP AT NIGHT…..5132
A) LAMP FOR GAUGES DOES NOT LIGHT UP…..5132
B) LAMP FOR SERVICE METER DOES NOT LIGHT UP…..5132
M-14 ELECTRICAL SYSTEM CAUTION LAMPS KEEPS LIGHTING UP…..5133
M-15 HEATER DOES NOT WORK…..5134
TROUBLESHOOTING OF ENGINE (S MODE)…..5136
METHOD OF USING TROUBLESHOOTING CHARTS…..5137
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..5141
S-2 ENGINE DOES NOT START…..5143
1) ENGINE DOES NOT TURN…..5143
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…..5144
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..5145
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW UP IS POOR)…..5146
S-4 ENGINE STOPS DURING OPERATIONS…..5147
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..5148
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..5149
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..5150
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..5151
S-9 OIL BECOMES CONTAMINATED QUICKLY…..5152
S-10 FUEL CONSUMPTION IS EXCESSIVE…..5153
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..5154
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..5155
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..5156
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..5157
S-15 ABNORMAL NOISE IS MADE…..5158
S-16 VIBRATION IS EXCESSIVE…..5159
30 DISASSEMBLY AND ASSEMBLY…..5160
METHOD OF USING MANUAL…..5162
PRECAUTIONS WHEN CARRYING OUT OPERATION…..5163
SPECIAL TOOL LIST…..5165
SKETCHES OF SPECIAL TOOLS…..5169
ENGINE, MAIN PUMP…..5172
REMOVAL…..5172
INSTALLATION…..5173
RADIATOR, HYDRAULIC OIL COOLER…..5174
REMOVAL…..5174
INSTALLATION…..5175
FUEL TANK…..5176
REMOVAL AND INSTALLATION…..5176
CENTER SWIVEL JOINT…..5177
REMOVAL AND INSTALLATION…..5177
DISASSEMBLY AND ASSEMBLY…..5178
SWING MOTOR, SWING MACHINERY…..5179
REMOVAL AND INSTALLATION…..5179
SWING MACHINERY…..5180
DISASSEMBLY…..5180
ASSEMBLY…..5183
REVOLVING FRAME…..5187
REMOVAL…..5187
INSTALLATION…..5188
SWING CIRCLE…..5189
REMOVAL AND INSTALLATION…..5189
RECOIL SPRING…..5190
DISASSEMBLY…..5190
ASSEMBLY…..5191
IDLER…..5192
DISASSEMBLY…..5192
ASSEMBLY…..5193
TRACK ROLLER…..5195
DISASSEMBLY…..5195
ASSEMBLY…..5197
TRACK SHOE…..5199
REMOVAL AND INSTALLATION…..5199
HYDRAULIC TANK…..5200
REMOVAL…..5200
INSTALLATION…..5201
MAIN PUMP…..5202
REMOVAL…..5202
INSTALLATION…..5203
MAIN CONTROL VALVE…..5204
REMOVAL AND INSTALLATION…..5204
CONTROL VALVE…..5205
DISASSEMBLY…..5205
ASSEMBLY…..5210
LS SELECT VALVE…..5216
DISASSEMBLY AND ASSEMBLY…..5216
MAIN RELIEF VALVE…..5217
DISASSEMBLY…..5217
ASSEMBLY…..5218
WORK EQUIPMENT PPC VALVE (BOOM, BUCKET, ARM, SWING)…..5219
DISASSEMBLY…..5219
ASSEMBLY…..5220
TRAVEL PPC…..5221
DISASSEMBLY…..5221
ASSEMBLY…..5222
ARM CYLINDER…..5223
REMOVAL…..5223
INSTALLATION…..5224
OFFSET CYLINDER…..5225
REMOVAL…..5225
INSTALLATION…..5226
HYDRAULIC CYLINDER…..5227
DISASSEMBLY…..5227
ASSEMBLY…..5230
OFFSET CYLINDER…..5234
DISASSEMBLY…..5234
ASSEMBLY…..5236
WORK EQUIPMENT…..5238
REMOVAL…..5238
INSTALLATION…..5240
ARM…..5241
REMOVAL…..5241
INSTALLATION…..5244
SECOND BOOM…..5245
REMOVAL…..5245
INSTALLATION…..5248
OPERATOR CAB…..5250
REMOVAL…..5250
INSTALLATION…..5251
FLOOR FRAME…..5252
REMOVAL…..5252
INSTALLATION…..5254
AIR CONDITIONER COMPRESSOR…..5255
REMOVAL AND INSTALLATION…..5255
AIR CONDITIONER CAPACITOR…..5256
REMOVAL AND INSTALLATION…..5256
AIR CONDITIONER UNIT…..5257
REMOVAL …..5257
INSTALLATION…..5258
COUNTERWEIGHT…..5259
REMOVAL AND INSTALLATION…..5259
40 MAINTENANCE STANDARD…..5260
SWING MACHINERY…..5261
SWING CIRCLE…..5263
TRACK FRAME, IDLER CUSHION…..5264
IDLER…..5265
CARRIER ROLLER…..5267
TRACK ROLLER…..5269
SPROCKET…..5271
TRACK SHOE…..5272
HYDRAULIC PUMP…..5277
CONTROL VALVE…..5278
SUCTION SAFETY VALVE…..5288
SELF PRESSURE REDUCTION VALVE…..5289
TRAVEL MOTOR…..5290
SWING MOTOR…..5291
SOLENOID VALVE…..5292
EPC SOLENOID VALVE…..5293
CENTER SWIVEL JOINT…..5294
PPC VALVE…..5295
HYDRAULIC CYLINDER…..5298
WORK EQUIPMENT…..5301
DIMENSION OF WORK EQUIPMENT…..5304
90 OTHERS…..5308
HYDRAULIC CIRCUIT DIAGRAM…..5309
ELECTRONIC CIRCUIT DIAGRAM (1/2)…..5314
ELECTRONIC CIRCUIT DIAGRAM (2/2)…..5319
AIR CONDITIONER CIRCUIT DIAGRAM…..5324
SEBM026504 – Hydraulic Excavator PC158US-2 Shop Manual…..5326
COVER…..5326
CONTENTS…..5327
01 GENERAL…..5351
SPECIFICATION DIMENSION DRAWINGS…..5352
SPECIFICATIONS…..5354
WEIGHT TABLE…..5357
LIST OF LUBRICANTS AND WATER…..5359
10 STRUCTURE AND FUNCTION…..5361
PTO…..5362
RADIATOR AND OIL COOLER…..5363
POWER TRAIN…..5365
SWING CIRCLE…..5366
SWING MACHINERY…..5367
FINAL DRIVE…..5368
TRACK FRAME・RECOIL SPRING…..5369
HYDRAULIC COMPONENT LAYOUT…..5370
VALVE CONTROL…..5372
HYDRAULIC TANK AND FILTER…..5374
HYDRAULIC PUMP (PISTON PUMP)…..5375
PC-EPC VALVE…..5396
CONTROL VALVE…..5399
CLSS…..5409
SELF PRESSURE REDUCING VALVE…..5446
CENTER SWIVEL JOINT…..5453
TRAVEL MOTOR…..5454
SWING MOTOR…..5462
SOLENOIL VALVE…..5469
PPC ACCUMULATOR…..5471
ACCUMULATOR FOR BREAKER…..5472
PPC VALVE…..5473
WORK EQUIPMENT…..5484
AIR CONDITIONER PIPING…..5485
ELECTRIC COMPONENT LAYOUT…..5486
ENEGINE CONTROL…..5490
ELECTRIC CONTROL SYSTEM…..5498
MONITOR SYSTEM…..5514
20 TESTING ANS ADJUSTING…..5519
STANDARD VALUE TABLE…..5520
STANDARD VALUE TABLE FOR ENGINE…..5520
STANDARD VALUE TABLE FOR CHASSIS…..5521
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…..5529
TESTING AND ADJUSTING…..5533
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…..5534
MEASURING ENGINE SPEED…..5535
MEASURING EXHAUST COLOR…..5536
ADJUSTING VALVE CLEARANCE…..5537
MEASURING BLOW-BY PRESSURE…..5538
MEASURING ENGINE OIL PRESSURE…..5539
TESTING AND ADJUSTING FUEL INJECTION TIMEING…..5539
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…..5540
ADJUSTING ENGINE SPEED SENSOR…..5540
ADJUSTING FUEL CONTROL CABLE…..5541
ADJUSTING ENGINE STOP SOLENOLD LINKAGE INSPECTION…..5542
TESTING CLEARANCE OF SWING CIRCLE BEARING…..5543
CHECKING WEAR OF SPROCKET…..5544
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION…..5545
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING,TRAVEL CIRCUIT…..5546
TESTING AND ADJUSTING OUTPUT PRESSURE OF PC VALVE (SERVO PISTON INPUT PRESSURE)…..5549
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…..5551
TESTING AND ADJUSTING CONTROL CICUIT OIL PRESSURE…..5554
TESTING SOLENIOD VALVE OUTPOUT PRESSURE…..5555
MEASURING PPC VALVE OUTPUT PRESSURE…..5556
ADJUSTING PPC VALVE…..5557
TESTING AND ADJUSTING TRAVEL DEVIATION…..5558
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF WORK EQUIPMENT…..5559
MEASURING OIL LEAKAGE OF SWING MOTOR…..5560
MEASURING OIL LEAKAGE OF TRAVEL MOTOR…..5560
BLEEDING AIR…..5561
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…..5563
RELEASING REMAINING PRESSURE IN HYDRAULIC TANK…..5563
PROCEDURE FOR CHECKIG DIODE…..5564
PM CLINIC INSPECTION TABLE…..5565
TROUBLESHOOTING…..5567
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..5568
SEQUENCE OF EVENTS IN TROUBLESHOOING…..5569
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..5570
CHECEKS BEFORE TROUBLESHOOTING…..5578
CONNECTOR TYPES AND MOUNTING LOCATIONS…..5579
CONNECTOR ARRANGEMENT DIAGRAM…..5581
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..5584
T-BRANCH BOX AND T-BRANCH TABLE…..5606
METHOD OF USING TROUBLESHOOTING CHARTS…..5608
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM…..5610
TROUBLESHOTING OF CONTROLLER, ELECTRICAL SYSTEM…..5613
RELATED ELECTRICAL CIRCUIT DIAGRMS FOR ELECTRICAL SYSTEM…..5614
E-1 ABNORMALITY IN PC-EPC SYSTEM…..5617
a) SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER…..5618
b) TEERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…..5619
E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM…..5621
a) EVEN WHEN SAFETY LOCK LEVER IS SET TO FREE, NO WORK EQUIPMENT, TRAVEL, SWING MOVE…..5621
b) EVEN WHEN SAFETY LOCK LEVER IS SET TO LOCK, WORK EQUIPMENT, TRAVEL, SWING MOVE…..5621
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM…..5623
a) EVEN WHEN SWING LOCK SWITCH IS TURNED OFF, UPPWE STRUCTURE DOSE NOT SWING…..5623
b) EVEN WHEN SWING LOCK SWITCH IS TURNED TO LOCK, UPPER STRUCTURE SWINGS…..5624
E-4 ABNORMALTY TRAVEL SPEED SOLENOID SYSTEM…..5625
a) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO HI, TRAVEL SPEED DOES NOT CHANGE TO HIGH SPEED…..5625
b) EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS TURNED TO LO, TRACEL SPEED DOES NOT CHANGE TO LOW SPEED…..5626
E-5 DEFECTIVE RUNNING SPEED AUTO SPEED CHANGE SYSTEM…..5627
a) MAIN PUMP PRESSURE SENSOR SYSTEM…..5627
b) ENGINE ROTATION SENSOR SYSTEM…..5627
E-6 DEFECTIVE ENGINE STARTING SYSTEM TROUBLESHOOTING MODE…..5629
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM…..5633
TABLE OF FAILURE MODES AND CAUSES…..5634
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER…..5636
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…..5637
H-3 NO WORK EQUIPMENT, TRAVEK, SWING MIVE…..5638
H-4 ABNORMAIL NOISE GENERATED (AROND PUMP)…..5639
H-5 FAIN CONTROL ABILITY IS POOR OR RESPONSE IS POOR…..5639
H-6 BOOM IS SLOW OR LACKS POWER…..5640
H-7 ARM IS SLOW OR LACKS POWER …..5641
H-8 BUCKET IS SLOW OR LACKS POWER…..5641
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE…..5642
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM,ARM, OR BUCKET)…..5642
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…..5642
H-12 WHEN WORK EQUIPMENT IS RELIEVED INDEPENDENTLY, OTHER WORK EQUIPMENT MOVES…..5643
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITN LARGER LOAD IS SLOW…..5643
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…..5644
H-15 IN SWING OR WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…..5644
H-16 TRAVEL DEVIATION…..5645
a) DEVIATION IS EXCESSIVE DURING NORMAL TRAVEL…..5645
b) DEVIATION IS EXCESSIVE WHEN STARTING…..5645
H-17 TRAVEL SPEED IS SLOW…..5646
H-18 STEERING IS DIFFICULT TO TUEN OR LACKS POWER…..5647
H-19 TRAVEL SPEED DOES NOT SWITCH…..5649
H-20 TRAVEL DOES DOES NOT MOVE (ONE SIDE ONLY)…..5649
H-21 UPPER STRUVTURE DOES NOT SWING…..5650
a) DOES NOT SWING IN EITHER DIRECTION (LIFT AND RIGHT)…..5650
b) DOES NOT SEING IN ONE DIRECTION ONLY (LEFT AND RIGHT)…..5650
H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…..5651
a) ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT)…..5651
b) ACCELERATION IS POOR OR SWING SPEED IS SLOW (ONE DIRECTION ONLY)…..5651
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…..5652
a) EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT) (WHEN OPERATION OF CONTROL VALVE SPOOL, PPC CIRCUIT THROTTLE IS NORMAL)…..5652
b) EXCESSIVE OVERRUN WHEN STOPPING SWING (ONE DIRECTION ONLY)…..5652
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…..5653
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING …..5653
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…..5654
a) WHEN SWING HOLDING BRAKE IS ACTUATED…..5654
b) WHEN SWING HOLDING BRAKE IS RELEASED…..5654
TROUBLESHOOTING OF MACHINE MONOTOR SYSTEM…..5655
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM…..5656
M-1 NO DISPLAY APPEARS WHEN STARTING SWITCH IS TURNED ON…..5657
M-2 DISPLAY DOES NOT GO OUT AFTER COMPLETION OF SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON…..5658
M-3 SOME ITEMS DO NOT LIGHT UP DURING DELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS) WHEN STARTING SWITCH IS TURNED ON…..5658
a) NO GAUGES (FUEL LEVEL, ENGINE WATER TEMPERATURE) LIGTH UP PREHEATING PILOT LAMP DOES NOT LIGHT UP…..5658
b) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERLY CHARGE) DO NOT LIGTH UP…..5658
M-4 CHARGE CAUTION LAMP DOES NOT LIGHT UP WHENSTARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)…..5659
M-5 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON (BEFORE STARTING ENGINE)…..5660
M-6 PRSHEATING PILOT LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS AT HEAT…..5661
M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN WNGINE IS RUNNING…..5662
M-8 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING…..5663
M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE…..5664
a) AFTER ENGINE IS STARTED, TEMPERATURE REMAINS AT BLTTOM LEVEL AND DOES NOT MOVE…..5664
b) AFTER ENGINE IS STARTED, TEMPERATURE IMMEDIATELY GOES UP (THERE IS NO OVERHEATING BUT GAUGE ENTERS RED RANGE)…..5664
M-10 ABNORMALITY IN FUEL GAUGE…..5665
a) NO SEGMENTS ON FUEL GAUGE LIGHT UP…..5665
b) FUEL LEVEL HAS GONE BUT FUEL GAUGE REMAINS AT FULL TANK DISPLAY…..5665
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT GIVE FULL TANK DISPLAY…..5666
M-11 DEFECTIVE OPERATION OF ALARM BUZZER…..5667
a) BUZZER DOES NOT SOUND…..5667
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…..5667
M-12 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING…..5668
a) WHEN BATTERY CHARGE CAUTION LAMP DOES LIGHT UP…..5668
b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP…..5668
M-13 NIGHT LIGHTING DOES NOT LIGHT UP…..5669
a) GAUGE LIGHTING DOES NOT LIGHT UP…..5669
b) SERVICE METER LIGHTING DOES NOT LIGHT UP…..5669
M-14 HEATER DOES NOT WORK…..5670
a) NEITHER HI NOR LO WORK…..5670
b) ONLY LO DOES NOT WORK…..5670
c) ONLY HI DOES NOT WORK…..5670
TROUBLESHOOTING OF ENGINE (S MODE)…..5672
MERHOD OF USING TROUBLESHOOTING CHARTS…..5673
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…..5677
S-2 ENGINE DOES NOT START…..5679
(1) ENGINE DOES NOT TURN…..5679
(2) ENGINE TURN BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…..5680
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…..5681
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…..5682
S-4 ENGINE STOPS DURING OPERATIONS…..5683
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…..5684
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) …..5685
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..5686
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..5687
S-9 OIL BECOMES CONTAMINATED QUICKLY…..5688
S-10 FUEL CONSUMPTION IS EXCESSIVE…..5689
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…..5690
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…..5691
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…..5692
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..5693
S-15 ABNORMAL NOISE IS MADE…..5694
S-16 VIBRATION IS EXCESSIVE…..5695
30 DISASSEMBLY AND ASSEMBLY…..5696
METHOD OF USING MANUAL…..5698
PRECAUTIONS WHEN CARRYING OUT OPERATION…..5699
SPECIAL TOOL LIST…..5701
SKETCHES OF SPECIAL TOOL…..5704
ENGINE, MAIN PUMP…..5705
REMOVAL…..5705
INSTALLATION…..5706
REDIATOR, HYDRAULIC OIL COOLER…..5707
REMOVAL…..5707
INSTALLATION…..5708
FUEL TANK…..5709
REMOVAL AND INSTALLATION…..5709
CENTER SWIVEL JOINT…..5710
REMOVAL AND INSTALLATION…..5710
DISASSEMBLY AND ASSEMBLY…..5711
FINAL DRIVE, TRAVEL MOTOR…..5712
REMOVAL AND INSTALLATION…..5712
FINAL DRIVE…..5713
DISASSEMBLY…..5713
ASSEMBLY…..5716
SWING MOTOR, SWING MACHINERY…..5722
REMOVAL AND INSTALLATION…..5722
SWING MACHINERY…..5723
DISASSEMBLY…..5723
ASSEMBLY…..5726
REVOLVIND FRAME…..5730
REMVOAL…..5730
INSTALLATION…..5731
SWING CIRCLE…..5732
REMOVAL AND INSTALATION…..5732
RECOIL SPRING…..5733
DISASSEMBLY…..5733
ASSEMBLY…..5734
IDLER…..5735
ASSEMBLY…..5735
TRACK ROLLER…..5737
ASSEMBLY…..5737
TRACK SHOE…..5739
REMOVAL AND INSTALLATION…..5739
HYDRAULIC TANK…..5740
REMOVAL…..5740
INSTALLATION…..5741
MAIN PUMP…..5742
REMOVAL…..5742
INSTALLATION…..5743
CONTROL VALVE…..5744
REMOVAL…..5744
INSTALLATION…..5745
DISASSEMBLY…..5746
ASSEMBLY…..5751
LS SELECTION VALVE…..5756
DISASSEMBLY AND ASSEMBLY…..5756
PRESSURE COMPENSATION VALVE…..5757
DISASSEMBLY…..5757
ASSEMBLY…..5759
MIAN RELIEF VALVE…..5761
DISASSEMBLY…..5761
ASSEMBLY…..5762
WORK EQUIPMENT PPC VALVE (FOE BOOM, BUCKET, ARM, SWING CONTROL)…..5763
DISADDEMBLY…..5763
ASSEMBLY…..5764
TRAVEL PPC VALVE…..5765
DISASSEMBLY…..5765
ASSEMBLY…..5766
HYDRAULIC CYLINDER…..5767
DISASSEMBLY…..5767
ASSEMBLY…..5770
WORK EQUIPMENT…..5774
REMOVAL…..5774
INSTALLATION…..5775
OPERATOR CAB…..5776
REMOVAL…..5776
INSTALLATION…..5777
OPERATOR'S CAB GLASS (STUCK GLASS)…..5778
REMOVAL…..5779
INSTALLATION…..5780
FRONT WINDOW…..5790
REMVOAL AND INSTALLATION…..5790
FLOOR FRAME…..5791
REMOVAL…..5791
INSTALLATION…..5792
AIRCONDITIONER COMPRESSOR…..5793
REMOVAL AND INSTALLATION…..5793
AIRCONDITIONER CONDENSER…..5794
REMOVAL AND INSTALLATION…..5794
AIRCONDITIONER UNIT…..5795
REMOVAL…..5795
INSTALLATION…..5796
COUNTERWEIGHT…..5797
REMOVAL AND INSTALLATION…..5797
40 MAINTENANCE STANDARD…..5798
SWING MACHINERY…..5799
FINAL DRIVE…..5801
SWING CIRCLE…..5803
TRACK FRAME, RECOIL SPRING…..5804
IDLER…..5805
CARRIER ROLLER …..5807
TRACK ROLLER…..5809
SPRICKET…..5811
TRACK SHOE…..5812
HYDRAULIC PUMP…..5816
PC-EPC VALVE…..5817
CONTROL VALVE…..5818
SELF PRESSURE REDUCTUIN VALVE…..5827
TRAVEL MOTOR…..5828
SWING MOTOR…..5829
SOLENOID VALVE…..5830
CENTER SWIVEL JOINT…..5831
PPC VALVE…..5832
HYDRAULIC CYLINDER…..5835
WORK EQUIPMENT…..5837
DIMENSION OF WORK EQUIPMENT…..5839
90 OTHERS…..5843
HYDRAULIC CIRCUIT DIAGRAM…..5844
ELECTRIC CIRCUIT DIAGRAM (1/2)…..5845
ELECTRIC CIRCUIT DIAGRAM (2/2)…..5846
SEN01968-12 – Hydraulic Excavator PC138US-8, PC138USLC-8 Shop Manual…..5847
COVER…..5847
00 INDEX AND FOREWORD…..0
Index…..5849
Composition of shop manual…..5850
Table of contents…..5852
Foreword and general information…..5861
Safety notice…..5862
How to read the shop manual…..5867
Explanation of terms for maintenance standard…..5869
Handling of electric equipment and hydraulic component…..5871
Handling of connectors newly used for engines…..5880
How to read electric wire code…..5883
Precautions when carrying out operation…..5886
Method of disassembling and connecting push-pull type coupler…..5889
Standard tightening torque table…..5892
Conversion table…..5896
01 SPECIFICATION…..0
SPECIFICATION AND TECHNICAL DATA…..5903
Specification dimension drawing…..5904
WORKING RANGE DIAGRAM…..5905
SPECIFICATIONS…..5906
Weight table…..5912
TABLE OF FUEL, COOLANT AND LUBRICANTS…..5916
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…..0
ENGINE AND COOLING SYSTEM…..5919
ENGINE MOUNT…..5920
PTO…..5921
COOLING SYSTEM…..5922
POWER TRAIN…..5925
POWER TRAIN…..5926
SWING CIRCLE…..5927
SWING MACHINERY…..5928
UNDERCARRIAGE AND FRAME…..5931
TRACK FRAME…..5932
IDLER CUSHION…..5934
IDLER…..5936
TRACK ROLLER…..5937
CARRIER ROLLER…..5938
SPROCKET…..5939
TRACK SHOE…..5940
HYDRAULIC SYSTEM, PART 1…..5947
HYDRAULIC EQUIPMENT LAYOUT DRAWING…..5948
VALVE CONTROL…..5950
HYDRAULIC TANK AND FILTER…..5952
HYDRAULIC PUMP…..5954
HYDRAULIC SYSTEM, PART 2…..5981
CONTROL VALVE…..5982
CLSS…..5994
FUNCTIONS AND OPERATION BY VALVE…..5998
HYDRAULIC SYSTEM, PART 3…..6029
PPC VALVE…..6030
SWING MOTOR…..6047
TRAVEL MOTOR…..6055
CENTER SWIVEL JOINT…..6064
SOLENOID VALVE…..6068
PPC ACCUMULATOR…..6072
HOLDING VALVE…..6074
MULTI-CONTROL VALVE…..6079
WORK EQUIPMENT…..6081
WORK EQUIPMENT…..6082
DIMENSIONS OF COMPONENTS…..6084
HYDRAULIC CYLINDER…..6088
CAB AND ITS ATTACHMENTS…..6091
AIR CONDITIONER…..6092
ELECTRICAL SYSTEM…..6105
ELECTRONIC CONTROL SYSTEM…..6106
MONITOR SYSTEM…..6139
KOMTRAX SYSTEM…..6153
SENSOR…..6155
20 STANDARD VALUE TABLE…..0
STANDARD SERVICE VALUE TABLE…..6163
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..6164
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..6165
30 TESTING AND ADJUSTING…..0
TESTING AND ADJUSTING, PART 1…..6175
Tools for testing, adjusting, and troubleshooting…..6177
Sketches of special tools…..6181
Testing engine speed…..6182
Testing exhaust temperature…..6183
Checking exhaust gas color…..6184
Adjusting valve clearance…..6185
Testing compression pressure…..6187
Testing blow-by pressure…..6189
Testing engine oil pressure…..6190
Handling fuel system parts…..6191
Releasing residual pressure from fuel system…..6191
Testing fuel pressure…..6192
Testing fuel return rate and fuel leakage…..6193
Bleeding air from fuel circuit…..6195
Checking fuel circuit for leakage…..6197
Testing and adjusting alternator belt tension…..6198
Checking and adjusting air conditioner compressor belt tension…..6199
Testing swing circle bearing clearance…..6200
Checking and adjusting track shoe tension…..6201
Testing and adjusting oil pressure in work equipment, swing, and travel circuits…..6203
Testing control circuit basic pressure…..6206
Testing and adjusting oil pressure in pump PC control circuit…..6207
Testing and adjusting oil pressure in pump LS control circuit…..6210
Testing solenoid valve output pressure…..6214
Testing PPC valve output pressure…..6215
Adjusting play of work equipment and swing PPC valves…..6217
Checking parts which cause hydraulic drift of work equipment…..6218
Testing and adjusting travel deviation…..6220
Releasing residual pressure from hydraulic circuit…..6222
Testing oil leakage…..6223
Bleeding air from each part…..6226
Checking cab tipping stopper…..6228
Adjusting mirrors…..6228
TESTING AND ADJUSTING, PART 2 …..6231
SPECIAL FUNCTIONS OF MACHINE MONITOR…..6232
TESTING AND ADJUSTING, PART 3…..6285
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..6286
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…..6287
PROCEDURE FOR TESTING DIODES…..6292
PM CLINIC SERVICE…..6293
40 TROUBLESHOOTING…..0
FAILURE CODE TABLE AND FUSE LOCATIONS…..6299
FAILURE CODE TABLE…..6300
FUSE LOCATIONS…..6304
General information on troubleshooting…..6307
Points to remember when troubleshooting…..6308
Sequence of events in troubleshooting…..6309
Checks before troubleshooting…..6310
Classification and procedures for troubleshooting…..6311
Information in troubleshooting table…..6312
Phenomena looking like troubles and troubleshooting Nos…..6314
Connection table for connector pin numbers…..6317
T- branch box and T- branch adapter table…..6353
TROUBLESHOOTING BY FAILURE CODE, PART 1…..6357
Failure code [989L00] Engine controller lock caution 1…..6359
Failure code [989M00] Engine controller lock caution 2…..6359
Failure code [989N00] Engine controller lock caution 3…..6360
Failure code [AB00KE] Charge voltage low…..6362
Failure code [B@BAZG] Eng oil press. low…..6364
Failure code [B@BAZK] Eng oil level low…..6364
Failure code [B@BCNS] Eng coolant overheat…..6365
Failure code [B@HANS] Hydr oil overheat…..6365
Failure code [CA111] ECM critical internal failure…..6366
Failure code [CA115] Eng. Ne and Bkup speed sensor error…..6369
Failure code [CA122] Charge air press sensor high error…..6370
Failure code [CA123] Charge air press sensor low error…..6372
Failure code [CA131] Throttle sensor high error…..6374
Failure code [CA132] Throttle sensor low error…..6376
Failure code [CA144] Coolant temp. sensor high error…..6377
Failure code [CA145] Coolant temp. sensor low error…..6378
Failure code [CA153] Charge air temp. sensor high error…..6379
Failure code [CA154] Charge air temp. sensor low error…..6380
Failure code [CA187] Sensor sup. 2 volt. low error…..6380
Failure code [CA221] Ambient air press. sensor high error…..6382
Failure code [CA222] Ambient air press. sensor low error…..6384
Failure code [CA227] Sensor sup. 2 volt. high error…..6386
Failure code [CA234] Eng. overspeed…..6387
Failure code [CA238] Ne speed sensor sup. volt. error…..6388
Failure code [CA271] IMV/PCV1 short error…..6390
Failure code [CA272] IMV/PCV1 open error…..6391
Failure code [CA322] Injector #1 (L #1) system open/short error…..6392
Failure code [CA324] Injector #3 (L #3) system open/short error…..6394
Failure code [CA331] Injector #2 (L #2) system open/short error…..6396
Failure code [CA332] Injector #4 (L #4) system open/short error…..6398
TROUBLESHOOTING BY FAILURE CODE, PART 2…..6401
FAILURE CODE [CA351] INJ. DRIVE CIRCUIT ERROR…..6403
FAILURE CODE [CA352] SENSOR SUP. 1 VOLT. LOW ERROR…..6406
FAILURE CODE [CA386] SENSOR SUP. 1 VOLT. HIGH ERROR…..6408
FAILURE CODE [CA435] ABNORMALITY IN ENGINE OIL PRESSURE SWITCH…..6410
FAILURE CODE [CA441] BATTERY VOLTAGE LOW ERROR…..6411
FAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERROR…..6411
FAILURE CODE [CA449] RAIL PRESS. VERY HIGH ERROR…..6412
FAILURE CODE [CA451] RAIL PRESS. SENSOR HIGH ERROR…..6414
FAILURE CODE [CA452] RAIL PRESS. SENSOR LOW ERROR…..6416
FAILURE CODE [CA553] RAIL PRESS. HIGH ERROR…..6416
FAILURE CODE [CA559] RAIL PRESS. LOW ERROR…..6417
FAILURE CODE [CA689] ENG. NE SPEED SENSOR ERROR…..6420
FAILURE CODE [CA731] ENG. BKUP SPEED SENSOR PHASE ERROR…..6422
FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERROR…..6422
FAILURE CODE [CA778] ENG. BKUP SPEED SENSOR ERROR…..6424
FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERROR…..6426
FAILURE CODE [CA2185] THROTTLE SENS. SUP. VOLT. HIGH ERROR…..6428
FAILURE CODE [CA2186] THROTTLE SENS. SUP. VOLT. LOW ERROR…..6430
FAILURE CODE [CA2249] RAIL PRESS. VERY LOW ERROR…..6430
FAILURE CODE [CA2311] ABNORMALITY IN IMV SOLENOID…..6431
FAILURE CODE [D110KB] BATTERY RELAY DRIVE SHORT…..6432
FAILURE CODE [D19JKZ] PERSONAL CODE RELAY ABNORMALITY…..6434
FAILURE CODE [D862KA] GPS ANTENNA DISCON…..6436
FAILURE CODE [DA22KK] PUMP SOLENOID POWER LOW ERROR…..6438
FAILURE CODE [DA25KP] 5V SENSOR 1 POWER ABNORMALITY…..6440
FAILURE CODE [DA26KP] 5V SENSOR 2 POWER ABNORMALITY…..6443
TROUBLESHOOTING BY FAILURE CODE, PART 3…..6445
FAILURE CODE [DA2RMC] CAN DISCON (PUMP CONTROLLER DETECTED)…..6448
FAILURE CODE [DAF8KB] SHORT CIRCUIT IN CAMERA POWER SUPPLY…..6450
FAILURE CODE [DAFGMC] GPS MODULE ERROR…..6452
FAILURE CODE [DAFRMC] CAN DISCON (MONITOR DETECTED)…..6454
FAILURE CODE [DGH2KB] HYDR OIL SENSOR SHORT…..6456
FAILURE CODE [DHPAMA] PUMP PRESS SENSOR ABNORMALITY…..6458
FAILURE CODE [DHSFMA] TRAVEL LEFT FORWARD PPC PRESS SENSOR ABNORMALITY…..6460
FAILURE CODE [DHSGMA] TRAVEL RIGHT FORWARD PPC PRESS SENSOR ABNORMALITY…..6462
FAILURE CODE [DHSHMA] TRAVEL LEFT REVERSE PPC PRESS SENSOR ABNORMALITY…..6464
FAILURE CODE [DHSJMA] TRAVEL RIGHT REVERSE PPC PRESS SENSOR ABNORMALITY…..6466
FAILURE CODE [DHSKMA] BLADE RAISE PPC PRESS SENSOR ABNORMALITY…..6468
FAILURE CODE [DHSLMA] BLADE LOWER PPC PRESS SENSOR ABNORMALITY…..6470
FAILURE CODE [DHX1MA] OVERLOAD SENSOR ABNORMALITY (ANALOG)…..6472
FAILURE CODE [DV20KB] TRAVEL ALARM S/C…..6473
FAILURE CODE [DW43KA] TRAVEL SPEED SOL DISCON…..6474
FAILURE CODE [DW43KB] TRAVEL SPEED SOL SHORT…..6475
FAILURE CODE [DW45KA] SWING BRAKE SOL DISCON…..6476
FAILURE CODE [DW45KB] SWING BRAKE SOL SHORT…..6478
FAILURE CODE [DW91KA] TRAVEL JUNCTION SOL DISCON…..6480
FAILURE CODE [DW91KB] TRAVEL JUNCTION SOL SHORT…..6481
FAILURE CODE [DWJ0KA] MERGE-DIVIDER SOL DISCON…..6482
FAILURE CODE [DWJ0KB] MERGE-DIVIDER SOL SHORT…..6483
TROUBLESHOOTING BY FAILURE CODE, PART 4 …..6485
FAILURE CODE [DXA8KA] PC-EPC SOL DISCON…..6486
FAILURE CODE [DXA8KB] PC-EPC SOL SHORT…..6488
FAILURE CODE [DXE4KA] SERVICE CURRENT EPC DISCON…..6490
FAILURE CODE [DXE4KB] SERVICE CURRENT EPC SHORT…..6491
FAILURE CODE [DY20KA] WIPER WORKING ABNORMALITY…..6492
FAILURE CODE [DY20MA] WIPER PARKING ABNORMALITY…..6494
FAILURE CODE [DY2CKA] WASHER DRIVE DISCON…..6496
FAILURE CODE [DY2CKB] WASHER DRIVE SHORT…..6498
FAILURE CODE [DY2DKB] WIPER DRIVE (FOR) SHORT…..6500
FAILURE CODE [DY2EKB] WIPER DRIVE (REV) SHORT…..6502
Troubleshooting of electrical system (E-mode)…..6505
Before carrying out troubleshooting of electrical system…..6507
Information in troubleshooting table…..6509
E-1 When starting switch turned ON, machine monitor displays nothing…..6510
E-2 When starting switch turned ON (before starting engine), basic check item lights up…..6512
E-3 Engine does not start (Engine does not turn)…..6513
E-4 Preheater does not operate…..6516
E-5 Automatic warm-up system does not operate (in cold season)…..6518
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked…..6520
E-7 Precaution lights up while engine is running…..6522
E-8 Emergency stop item lights up while engine is running…..6525
E-9 Engine coolant temperature gauge does not indicate normally…..6526
E-10 Hydraulic oil temperature gauge does not indicate normally…..6527
E-11 Fuel level gauge does not indicate normally…..6529
E-12 Contents of display by machine monitor are different from applicable machine…..6531
E-13 Machine monitor does not display some items…..6531
E-14 Function switch does not work…..6531
E-15 Auto-decelerator does not operate normally…..6532
E-16 Working mode does not change…..6533
E-17 Travel speed does not change…..6534
E-18 Alarm buzzer cannot be stopped…..6535
E-19 Windshield wiper and window washer do not operate…..6536
E-20 Swing holding brake does not operate normally…..6540
E-21 Travel alarm does not sound or does not stop sounding…..6542
E-22 Air conditioner does not operate normally (including air conditioner abnormality record)…..6543
E-23 While starting switch is in OFF position, service meter is not displayed…..6555
E-24 Machine monitor cannot be set in service mode…..6555
E-25 Monitoring function does not display lever control signal normally…..6556
E-26 KOMTRAX system does not operate normally…..6572
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…..6575
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..6577
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS…..6578
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, SWING, AND TRAVEL ARE LOW…..6580
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS…..6581
H-3 NO WORK EQUIPMENT, TRAVEL AND SWING MOVE…..6582
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP…..6582
H-5 FINE CONTROL MODE DOES NOT FUNCTION…..6583
H-6 SPEED OR POWER OF BOOM IS LOW…..6584
H-7 SPEED OR POWER OF ARM IS LOW…..6585
H-8 SPEED OR POWER OF BUCKET IS LOW…..6586
H-9 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION…..6587
H-10 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE…..6588
H-11 TIME LAG OF WORK EQUIPMENT IS LARGE…..6589
H-12 WORK EQUIPMENT LOADED MORE IS SLOWER DURING COMPOUND OPERATION…..6589
H-13 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING + BOOM RAISE…..6589
H-14 TRAVEL SPEED LOWERS LARGELY DURING COMPOUND OPERATION OF WORK EQUIPMENT/SWING + TRAVEL…..6590
H-15 MACHINE DEVIATES DURING TRAVEL…..6591
H-16 TRAVEL SPEED IS LOW…..6592
H-17 MACHINE CANNOT BE STEERED EASILY OR STEERING POWER IS LOW…..6593
H-18 TRAVEL SPEED DOES NOT CHANGE OR IT IS KEPT LOW OR HIGH…..6594
H-19 TRACK DOES NOT MOVE (ONLY EITHER SIDE)…..6594
H-20 MACHINE DOES NOT SWING…..6595
H-21 SWING ACCELERATION OR SWING SPEED IS LOW…..6596
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING…..6597
H-23 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SHOCK…..6598
H-24 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND…..6598
H-25 HYDRAULIC DRIFT OF SWING IS LARGE…..6599
H-26 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED…..6600
TROUBLESHOOTING OF ENGINE (S-MODE)…..6603
METHOD OF USING TROUBLESHOOTING CHART…..6606
S-1 STARTING PERFORMANCE IS POOR…..6610
S-2 ENGINE DOES NOT START…..6611
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…..6614
S-4 ENGINE STOPS DURING OPERATIONS…..6615
S-5 ENGINE DOES NOT ROTATE SMOOTHLY…..6616
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…..6617
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…..6618
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…..6619
S-9 OIL BECOMES CONTAMINATED QUICKLY…..6620
S-10 FUEL CONSUMPTION IS EXCESSIVE…..6621
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…..6622
S-12 OIL PRESSURE DROPS…..6623
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)…..6624
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…..6625
S-15 ABNORMAL NOISE IS MADE…..6626
S-16 VIBRATION IS EXCESSIVE…..6627
50 DISASSEMBLY AND ASSEMBLY…..0
General information on disassembly and assembly…..6629
How to read this manual…..6630
Coating materials list…..6632
Special tool list…..6635
Sketch of special tool…..6639
Engine and cooling system…..6643
Removal and installation of fuel supply pump assembly…..6644
Removal and installation of fuel injector assembly…..6646
Removal and installation of front oil seal…..6649
Removal and installation of rear oil seal…..6651
Removal and installation of work equipment oil cooler assembly…..6665
Removal and installation of cylinder head assembly…..6654
Removal and installation of radiator assembly…..6661
Removal and installation of aftercooler assembly…..6663
Removal and installation of engine and work equipment pump assembly…..6668
Removal and installation of fuel tank assembly…..6673
Power train…..6677
Removal and installation of travel motor and final drive assembly…..6678
Disassembly and assembly of travel motor and final drive assembly…..6680
Removal and installation of swing motor and swing machinery assembly…..6717
Disassembly and assembly of swing machinery assembly…..6719
Removal and installation of swing circle assembly…..6725
UNDERCARRIAGE AND FRAME…..6727
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER…..6728
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY…..6731
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING…..6734
REMOVAL AND INSTALLATION OF OF TRACK SHOE ASSEMBLY…..6737
REMOVAL AND INSTALLATION OF SPROCKET…..6739
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY…..6740
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY (MACHINE WITHOUT ADD-ON WEIGHT)…..6742
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY (MACHINE WITH ADD-ON WEIGHT)…..6744
HYDRAULIC SYSTEM…..6747
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY…..6748
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY…..6750
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY…..6751
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY…..6754
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY…..6758
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY…..6763
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY…..6773
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY…..6776
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY…..6778
WORK EQUIPMENT BODY…..6785
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY…..6786
Cab and its attachments…..6791
Removal and installation of operator cab assembly…..6792
Removal and Installation of operator’s cab door…..6794
Removal and installation of operator’s cab glass (stuck glass)…..6797
Removal and installation of front window assembly…..6806
Removal and installation of floor frame assembly…..6807
ELECTRICAL SYSTEM…..6815
REMOVAL AND INSTALLATION OF AIR COMPRESSOR ASSEMBLY…..6816
REMOVAL AND INSTALLATION OF AIR CONDITIONER CONDENSER…..6817
REMOVAL AND INSTALLATION OF AIR COMPRESSOR UNIT ASSEMBLY…..6818
REMOVAL AND INSTALLATION OF MACHINE MONITOR ASSEMBLY…..6821
REMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLY…..6822
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY…..6823
REMOVAL AND INSTALLATION OF KOMTRAX COMMUNICATIONS MODULE…..6824
90 DIAGRAMS AND DRAWINGS…..0
HYDRAULIC CIRCUIT DIAGRAM…..6827
HYDRAULIC CIRCUIT DIAGRAM…..6828
Electrical diagrams and drawings…..6833
Electrical circuit diagram…..6835
Connectors table and arrangement drawing…..6841
SEN06062-01 – Hydraulic Excavator PC138USLC-10 Shop Manual…..6844
Cover…..6844
00 Index and foreword …..6846
Index …..6847
Foreword, safety and general information …..6858
Important safety notice …..6858
How to read the shop manual …..6865
Explanation of terms for maintenance standard …..6867
Handling equipment of fuel system devices …..6869
Handling of intake system parts …..6870
Handling of hydraulic equipment …..6871
Method of disconnecting and connecting of push-pull type coupler …..6873
Handling of electrical equipment …..6876
How to read electric wire code …..6884
Precautions when performing operation …..6887
Practical use of KOMTRAX …..6892
Standard tightening torque table …..6893
List of abbreviation …..6899
Conversion table …..6904
01 Specification …..6910
Table of contents …..6911
Specifications …..6912
Specification drawing …..6912
Working range drawings …..6913
Specifications …..6914
Weight table …..6918
Table of fuel, coolant, and lubricants …..6920
10 Structure and function …..6922
Table of contents …..6923
Engine and cooling system …..6924
Engine related parts …..6924
PTO …..6926
VFT …..6927
EGR system piping drawing …..6931
EGR system circuit diagram …..6933
EGR valve …..6934
EGR cooler …..6936
KCCV layout drawing …..6938
KCCV ventilator …..6940
KDOC muffler …..6942
Cooling system …..6944
Power train …..6946
Power train system …..6946
Swing circle …..6948
Swing machinery …..6949
Undercarriage and frame …..6951
Track frame …..6951
Idler cushion …..6952
Hydraulic system …..6953
Hydraulic component layout …..6953
Valve control …..6955
Hydraulic tank …..6956
CLSS …..6958
Main pump …..6962
Control valve …..6989
Swing motor …..7034
Travel motor …..7046
Work equipment and swing PPC valve …..7057
Travel PPC valve …..7064
Blade PPC valve …..7070
1st-line attachment PPC valve (with EPC valve) …..7072
Solenoid valve …..7080
Attachment circuit selector valve (for low pressure circuit) …..7086
Attachment circuit selector valve (for high pressure circuit) …..7089
Multi-control valve …..7091
Center swivel joint …..7092
PPC circuit accumulator …..7094
Attachment circuit accumulator (for low pressure circuit) …..7095
Attachment circuit accumulator (for high pressure circuit) …..7096
Work equipment …..7097
Work equipment …..7097
Work equipment shim …..7098
Bucket play adjustment shim …..7099
Cab and its attachments …..7100
Cab mount and cab tipping stopper …..7100
ROPS cab …..7101
Electrical system …..7103
Electrical control system …..7103
Machine monitor system …..7135
KOMTRAX system …..7156
Sensor …..7173
20 Standard value tables …..7186
Table of contents …..7187
Standard service value table …..7188
Standard value table for engine …..7188
Standard value table for machine …..7189
Standard value table for electrical system …..7202
30 Testing and adjusting …..7208
Table of contents …..7209
General information on testing and adjusting …..7210
Tools for testing and adjusting …..7210
Sketch of tools for testing and adjusting …..7213
Engine and cooling system …..7215
Testing engine speed …..7215
Testing exhaust gas color …..7216
Testing and adjusting valve clearance …..7217
Testing compression pressure …..7219
Testing blowby pressure …..7222
Testing engine oil pressure …..7223
Testing fuel pressure …..7224
Testing fuel return rate and leakage …..7225
Bleeding air from fuel system …..7228
Testing fuel circuit for leakage …..7230
Handling cylinder cutout mode operation …..7231
Handling no-injection cranking operation …..7232
Checking and adjusting air conditioner compressor belt tension …..7233
Replacing fan belt …..7234
Writing compensation values at replacement of injector and engine controller …..7235
Power train …..7239
Testing swing circle bearing clearance …..7239
Undercarriage and frame …..7240
Testing and adjusting track shoe tension …..7240
Hydraulic system …..7241
Releasing remaining pressure from hydraulic circuit …..7241
Testing and adjusting oil pressure in work equipment, swing, and travel circuits …..7242
Testing oil pressure of control circuit …..7245
Testing and adjusting oil pressure in pump PC control circuit …..7246
Testing and adjusting oil pressure in pump LS control circuit …..7249
Testing outlet pressure of solenoid valve …..7254
Testing PPC valve output pressure …..7255
Adjusting play of work equipment and swing PPC valves …..7257
Isolating the parts causing hydraulic drift in work equipment …..7258
Testing and adjusting travel deviation …..7259
Testing oil leakage …..7261
Bleeding air from hydraulic circuit …..7263
Cab and its attachments …..7266
Checking cab tipping stopper …..7266
Testing, cleaning and lubricating slide door rail and roller …..7267
Adjusting mirrors …..7268
Electrical system …..7270
Special functions of machine monitor …..7270
Adjusting rearview camera angle …..7322
Handling voltage circuit of engine controller …..7324
Handling battery disconnect switch …..7325
Testing diodes …..7326
Pm clinic …..7327
Pm Clinic service …..7327
40 Troubleshooting …..7334
Table of contents …..7335
General information on troubleshooting …..7340
Troubleshooting points …..7340
Sequence of events in troubleshooting …..7342
Checks before troubleshooting …..7344
Inspection procedure before troubleshooting …..7346
Preparation for troubleshooting of electrical system …..7363
Classification and procedure for troubleshooting …..7367
Symptom and troubleshooting numbers …..7370
Information in troubleshooting table …..7373
Troubleshooting method for open circuit in wiring harness of pressure sensor system …..7375
Connector list and layout …..7377
Connector contact identification …..7387
T-branch box and T-branch adapter table …..7425
Fuse location table …..7430
Failure codes table …..7432
Troubleshooting by failure code (Display of code) …..7438
Failure code [879AKA] A/C Inner Sensor Open Circuit …..7438
Failure code [879AKB] A/C Inner Sensor Short Circuit …..7439
Failure code [879BKA] A/C Outer Sensor Open Circuit …..7440
Failure code [879BKB] A/C Outer Sensor Short Circuit …..7441
Failure code [879CKA] Ventilating Sensor Open Circuit …..7442
Failure code [879CKB] Ventilating Sensor Short Circuit …..7443
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit …..7444
Failure code [879EMC] Ventilation Damper Abnormality …..7445
Failure code [879FMC] Air Mix Damper Abnormality …..7446
Failure code [879GKX] Refrigerant Abnormality …..7447
Failure code [989L00] Engine Controller Lock Caution 1 …..7448
Failure code [989M00] Engine Controller Lock Caution 2 …..7449
Failure code [989N00] Engine Controller Lock Caution 3 …..7450
Failure code [AB00KE] Charge Voltage Low …..7451
Failure code [B@BAZG] Eng Oil Press Low …..7453
Failure code [B@BAZK] Eng Oil Level Low …..7454
Failure code [B@BCNS] Eng Water Overheat …..7455
Failure code [CA115] Eng Ne and Bkup Speed Sens Error …..7456
Failure code [CA122] Chg Air Press Sensor High Error …..7457
Failure code [CA123] Chg Air Press Sensor Low Error …..7459
Failure code [CA131] Throttle Sensor High Error …..7461
Failure code [CA132] Throttle Sensor Low Error …..7463
Failure code [CA144] Coolant Temp Sens High Error …..7465
Failure code [CA145] Coolant Temp Sens Low Error …..7467
Failure code [CA153] Chg Air Temp Sensor High Error …..7469
Failure code [CA154] Chg Air Temp Sensor Low Error …..7471
Failure code [CA187] Sensor 2 Supply Volt Low Error …..7473
Failure code [CA221] Ambient Press Sensor High Error …..7475
Failure code [CA222] Ambient Press Sensor Low Error …..7477
Failure code [CA227] Sensor 2 Supply Volt High Error …..7479
Failure code [CA234] Eng Overspeed …..7480
Failure code [CA238] Ne Speed Sensor Supply Volt Error …..7481
Failure code [CA239] Ne Speed Sens Supply Volt High Error …..7482
Failure code [CA271] IMV/PCV1 Short Error …..7483
Failure code [CA272] IMV/PCV1 Open Error …..7484
Failure code [CA322] Inj #1(L#1) Open/Short Error …..7485
Failure code [CA324] Inj #3(L#3) Open/Short Error …..7487
Failure code [CA331] Inj #2(L#2) Open/Short Error …..7489
Failure code [CA332] Inj #4(L#4) Open/Short Error …..7491
Failure code [CA343] ECM Critical Internal Failure …..7493
Failure code [CA351] Injectors Drive Circuit Error …..7494
Failure code [CA352] Sensor 1 Supply Volt Low Error …..7495
Failure code [CA356] Mass Air Flow Sensor High Error …..7497
Failure code [CA357] Mass Air Flow Sensor Low Error …..7499
Failure code [CA386] Sensor 1 Supply Volt High Error …..7501
Failure code [CA435] Eng Oil Press Sw Error …..7502
Failure code [CA441] Battery Voltage Low Error …..7503
Failure code [CA442] Battery Voltage High Error …..7505
Failure code [CA449] Rail Press Very High Error …..7506
Failure code [CA451] Rail Press Sensor High Error …..7507
Failure code [CA452] Rail Press Sensor Low Error …..7509
Failure code [CA466] KVGT Motor Driver Position Error …..7511
Failure code [CA515] Rail Press Sens Sup Volt High Error …..7513
Failure code [CA516] Rail Press Sens Sup Volt Low Error …..7515
Failure code [CA553] Rail Press High Error …..7517
Failure code [CA555] Crankcase Press High Error 1 …..7518
Failure code [CA556] Crankcase Press High Error 2 …..7519
Failure code [CA559] Rail Press Low Error …..7520
Failure code [CA689] Eng Ne Speed Sensor Error …..7523
Failure code [CA691] Intake Air Temp Sens High Error …..7525
Failure code [CA692] Intake Air Temp Sens Low Error …..7527
Failure code [CA697] ECM Internal Temp Sensor High Error …..7529
Failure code [CA698] ECM Int Temp Sensor Low Error …..7530
Failure code [CA731] Eng Bkup Speed Sens Phase Error …..7531
Failure code [CA778] Eng Bkup Speed Sensor Error …..7534
Failure code [CA1117] Persistent Data Lost Error …..7538
Failure code [CA1695] Sensor 5 Supply Volt High Error …..7539
Failure code [CA1696] Sensor 5 Supply Volt Low Error …..7540
Failure code [CA1843] Crankcase Press Sens High Error …..7541
Failure code [CA1844] Crankcase Press Sens Low Error …..7543
Failure code [CA1896] EGR Valve Stuck Error …..7545
Failure code [CA1942] Crankcase Press Sens In Range Error …..7546
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error …..7547
Failure code [CA2185] Throt Sensor Sup Volt High Error …..7548
Failure code [CA2186] Throt Sensor Sup Volt Low Error …..7550
Failure code [CA2249] Rail Press Very Low Error …..7552
Failure code [CA2272] EGR Valve Pos Sens Low Error …..7553
Failure code [CA2311] IMV Solenoid Error …..7555
Failure code [CA2349] EGR Valve Solenoid Open Error …..7556
Failure code [CA2353] EGR Valve Solenoid Short Error …..7558
Failure code [CA2357] EGR Valve Servo Error …..7560
Failure code [CA2765] Inj Trim Data Error …..7561
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error …..7562
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error …..7564
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error …..7566
Failure code [CA3918] KVGT Stuck Error …..7568
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error …..7569
Failure code [CA3921] KVGT Servo Error 2 …..7570
Failure code [CA3922] KVGT Motor Driver Open Error …..7571
Failure code [CA3923] KVGT Motor Driver Short Error …..7573
Failure code [D110KB] Battery Relay Drive Short Circuit …..7575
Failure code [D19JKZ] Personal Code Relay Abnormality …..7577
Failure code [D811MC] KOMTRAX Error …..7580
Failure code [D862KA] GPS Antenna Open Circuit …..7581
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) …..7582
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) …..7584
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) …..7585
Failure code [DA20MC] Pump Controller Malfunction …..7587
Failure code [DA22KK] Pump Solenoid Power Low Error …..7588
Failure code [DA25KP] 5V Sensor 1 Power Abnormality …..7590
Failure code [DA29KQ] Model Selection Abnormality …..7592
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) …..7594
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) …..7596
Failure code [DA2QKR] CAN2 Discon (Pump Con) …..7597
Failure code [DA2RKR] CAN1 Discon (Pump Con) …..7599
Failure code [DAF0MB] Monitor ROM Abnormality …..7600
Failure code [DAF0MC] Monitor Error …..7601
Failure code [DAF8KB] Camera Power Supply Short Circuit …..7602
Failure code [DAF9KQ] Model Selection Abnormality …..7604
Failure code [DAFGMC] GPS Module Error …..7605
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) …..7606
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) …..7608
Failure code [DAFQKR] CAN2 Discon (Monitor) …..7609
Failure code [DAZ9KQ] A/C Model Selection Abnormality …..7610
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) …..7611
Failure code [DB2QKR] CAN2 Discon (Engine Con) …..7615
Failure code [DB2RKR] CAN1 Discon (Engine Con) …..7619
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit …..7623
Failure code [DHPAMA] Pump Press Sensor Abnormality …..7625
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality …..7627
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality …..7629
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality …..7631
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality …..7633
Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality …..7635
Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality …..7637
Failure code [DHX1MA] Overload Sensor Abnormality …..7639
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality …..7640
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality …..7642
Failure code [DV20KB] Travel Alarm Short Circuit …..7643
Failure code [DW43KA] Travel Speed Sol Open Circuit …..7645
Failure code [DW43KB] Travel Speed Sol Short Circuit …..7647
Failure code [DW45KA] Swing Brake Sol Open Circuit …..7649
Failure code [DW45KB] Swing Brake Sol Short Circuit …..7652
Failure code [DW91KA] Travel Junction Sol Open Circuit …..7654
Failure code [DW91KB] Travel Junction Sol Short Circuit …..7656
Failure code [DWA2KA] Attachment Sol Open Circuit …..7658
Failure code [DWA2KB] Attachment Sol Short Circuit …..7660
Failure code [DWJ0KA] Merge-divider Sol Open Circuit …..7662
Failure code [DWJ0KB] Merge-divider Sol Short Circuit …..7664
Failure code [DXA8KA] PC-EPC Sol Open Circuit …..7666
Failure code [DXA8KB] PC-EPC Sol Short Circuit …..7668
Failure code [DXE4KA] Attachment Flow EPC Open Circuit …..7670
Failure code [DXE4KB] Attachment Flow EPC Short Circuit …..7672
Failure code [DY20KA] Wiper Working Abnormality …..7674
Failure code [DY20MA] Wiper Parking Abnormality …..7676
Failure code [DY2CKB] Washer Drive Short Circuit …..7678
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit …..7680
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit …..7682
Troubleshooting of electrical system (E-mode) …..7684
E-1 Engine does not start (Engine does not crank) …..7684
E-2 Manual preheating system does not work …..7690
E-3 While preheating is working, preheating monitor does not light up …..7693
E-4 When starting switch is turned to ON position, machine monitor displays nothing …..7695
E-5 When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow …..7698
E-6 Engine coolant temperature monitor lights up in white while engine is running …..7699
E-7 Hydraulic oil temperature monitor lights up in white while engine is running …..7700
E-8 Charge level monitor lights up while engine is running …..7701
E-9 Fuel level monitor lights up in red while engine is running …..7702
E-10 Engine coolant temperature monitor lights up in red while engine is running …..7703
E-11 Hydraulic oil temperature monitor lights up in red while engine is running …..7704
E-12 Engine oil pressure monitor lights up in red while engine is running …..7705
E-13 Fuel gauge display does not move from minimum or maximum …..7706
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty) …..7707
E-15 Engine coolant temperature gauge display does not move from minimum or maximum …..7708
E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) …..7709
E-17 Hydraulic oil temperature gauge does not move from minimum or maximum …..7710
E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) …..7712
E-19 Some areas of machine monitor screen are not displayed …..7713
E-20 Function switch does not work …..7714
E-21 Automatic warm-up system does not operate (in cold season) …..7715
E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated …..7716
E-23 Auto-deceleration function does not operate or is not canceled while lever is operated …..7717
E-24 Working mode selection screen is not displayed while working mode selector switch is operated …..7718
E-25 Setting of engine and hydraulic pump is not changed while working mode is changed …..7719
E-26 Travel speed monitor does not change while travel speed switch is operated …..7720
E-27 Travel speed does not change while travel speed selection is changed …..7721
E-28 Alarm buzzer does not stop sounding …..7722
E-29 Service meter is not displayed, while starting switch is in OFF position …..7723
E-30 Service mode cannot be selected …..7724
E-31 Any of work equipment, swing and travel does not work …..7725
E-32 Any of work equipment, swing and travel cannot be locked …..7727
E-33 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position …..7729
E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position …..7731
E-35 Alarm does not sound during travel …..7733
E-36 Alarm does not stop sounding while machine is stopped …..7734
E-37 Horn does not sound …..7735
E-38 Horn does not stop sounding …..7736
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated …..7737
E-40 Wiper does not operate while wiper switch is operated …..7738
E-41 Window washer does not operate while window washer switch is operated …..7740
E-42 Boom Lower is not displayed correctly with monitoring function …..7741
E-43 Arm OUT is not displayed correctly with monitoring function …..7743
E-44 Arm IN is not displayed correctly with monitoring function …..7745
E-45 Boom Raise is not displayed correctly with monitoring function …..7747
E-46 Bucket Curl is not displayed correctly with monitoring function …..7749
E-47 Bucket Dump is not displayed correctly with monitoring function …..7751
E-48 Swing is not displayed correctly with monitoring function …..7753
E-49 Travel is not displayed correctly with monitoring function …..7755
E-50 Service is not displayed correctly with monitoring function …..7756
E-51 Attachment hydraulic circuit cannot be changed …..7758
E-52 KOMTRAX system does not operate normally …..7759
Troubleshooting of hydraulic and mechanical system (H-mode) …..7761
Information described in troubleshooting table (H-mode) …..7761
System chart of hydraulic and mechanical systems …..7762
Failure mode and cause table …..7764
H-1 All of work equipment, swing and travel operation lacks speed or power …..7772
H-2 Engine speed drops significantly or engine stalls …..7774
H-3 Any of work equipment, swing and travel does not work …..7775
H-4 Unusual sound is heard from around hydraulic pump …..7776
H-5 Fine control performance or response is poor …..7777
H-6 Boom speed or power is low …..7778
H-7 Arm speed or power is low …..7781
H-8 Bucket speed or power is low …..7783
H-9 Work equipment does not move in single operation …..7785
H-10 Hydraulic drift of boom is large …..7786
H-11 Hydraulic drift of arm is large …..7787
H-12 Hydraulic drift of bucket is large …..7788
H-13 Time lag of work equipment is large …..7789
H-14 In combined operation of work equipment , equipment having heavier load moves slower …..7791
H-15 In combined operation of swing and boom RAISE, boom rising speed is low …..7792
H-16 In combined operation of swing and travel, travel speed drops largely …..7793
H-17 Machine does not travel straight …..7794
H-18 Travel speed is slow …..7796
H-19 Machine is hard to steer or travel power is low …..7798
H-20 Travel speed does not change, or travel speed is too slow or fast …..7801
H-21 One of tracks does not run …..7802
H-22 Upper structure does not swing to the right or left …..7804
H-23 Upper structure swing only to the right or left …..7805
H-24 Swing acceleration or swing speed is low in both directions (right and left) …..7806
H-25 Swing acceleration performance is poor or swing speed is slow in only one direction …..7807
H-26 Upper structure overruns excessively when it stops swinging (both right and left) …..7808
H-27 Upper structure overruns excessively when it stops swinging (either right or left) …..7809
H-28 Shock is large when upper structure stops swinging …..7810
H-29 Large unusual noise is heard when upper structure stops swinging …..7811
H-30 Swing drift on a slope is large while swing parking brake is applied …..7812
H-31 Swing drift on a slope is large while swing parking brake is released …..7813
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed …..7814
H-33 Oil flow in attachment circuit cannot be controlled …..7815
Troubleshooting of engine (S-mode) …..7816
Information mentioned in troubleshooting table (S mode) …..7816
S-1 Engine does not crank when starting switch is turned to START position …..7817
S-2 Engine cranks but no exhaust smoke comes out …..7818
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) …..7819
S-4 Engine startability is poor …..7820
S-5 Engine does not pick up smoothly …..7822
S-6 Engine stops during operation …..7824
S-7 Engine runs rough or is unstable …..7826
S-8 Engine lacks power …..7827
S-9 Exhaust smoke is black …..7829
S-10 Engine oil consumption is excessive …..7831
S-11 Oil becomes contaminated quickly …..7832
S-12 Fuel consumption is excessive …..7833
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …..7834
S-14 Oil pressure drops …..7835
S-15 Fuel mixes into engine oil …..7836
S-16 Water mixes into engine oil (milky) …..7837
S-17 Coolant temperature rises too high (overheating) …..7838
S-18 Unusual noise is heard …..7839
S-19 Vibration is excessive …..7840
S-20 Air cannot be bled from fuel circuit …..7841
50 Disassembly and assembly …..7842
Table of contents …..7843
General information on disassembly and assembly …..7845
How to read this manual …..7845
Coating materials list …..7847
Special tools list …..7851
Sketches of special tools …..7855
Engine and cooling system …..7857
Removal and installation of supply pump assembly …..7857
Removal and installation of injector assembly …..7861
Removal and installation of cylinder head assembly …..7867
Removal and installation of radiator assembly …..7878
Removal and installation of hydraulic oil cooler assembly …..7880
Removal and installation of aftercooler assembly …..7883
Removal and installation of engine and main pump assembly …..7885
Removal and installation of engine front oil seal …..7891
Removal and installation of engine rear oil seal …..7892
Removal and installation of fuel cooler assembly …..7894
Removal and installation of fuel tank assembly …..7895
Removal and installation of KDOC assembly …..7898
Removal and installation of KCCV assembly …..7899
Removal and installation of air cleaner assembly …..7900
Removal and installation of fan belt …..7902
Power train system …..7904
Removal and installation of travel motor and final drive assembly …..7904
Disassembly and assembly of travel motor and final drive assembly …..7905
Removal and installation of swing motor and swing machinery assembly …..7940
Disassembly and assembly of swing machinery assembly …..7942
Removal and installation of swing circle assembly …..7948
Undercarriage and frame …..7949
Separation and connection of track …..7949
Removal and installation of sprocket …..7952
Removal and installation of idler and idler cushion assembly …..7953
Disassembly and assembly of idler assembly …..7954
Disassembly and assembly of idler cushion assembly …..7957
Disassembly and assembly of track roller assembly …..7960
Removal and installation of revolving frame assembly …..7963
Removal and installation of counterweight assembly [For machines with additional counterweight] …..7965
Hydraulic system …..7968
Removal and installation of center swivel joint assembly …..7968
Disassembly and assembly of center swivel joint assembly …..7970
Removal and installation of hydraulic tank assembly …..7971
Removal and installation of main pump assembly …..7974
Removal and installation of control valve assembly …..7978
Disassembly and assembly of control valve assembly …..7984
Disassembly and assembly of work equipment PPC valve assembly …..7986
Disassembly and assembly of travel PPC valve assembly …..7988
Work equipment …..7990
Removal and installation of work equipment assembly …..7990
Disassembly and assembly of work equipment cylinder assembly …..7994
Cab and its attachments …..7999
Removal and installation of operator's cab assembly …..7999
Removal and installation of operator's cab door …..8002
Removal and installation of operator's cab glass (adhered glass) …..8005
Removal and installation of front window assembly …..8016
Removal and installation of floor frame assembly …..8017
Removal and installation of air conditioner unit assembly …..8024
Removal and installation of air conditioner compressor assembly …..8028
Removal and installation of air conditioner condenser assembly …..8030
Removal and installation of operator's seat …..8032
Removal and installation of seat belt …..8033
Removal and installation of front wiper assembly …..8034
Electrical system …..8040
Removal and installation of engine controller assembly …..8040
Removal and installation of pump controller assembly …..8041
Removal and installation of machine monitor assembly …..8043
Removal and installation of mass air flow and temperature sensor …..8045
Removal and installation of KOMTRAX terminal assembly …..8046
60 Maintenance standard …..8048
Table of contents …..8049
Engine and cooling system …..8050
Engine mount …..8050
PTO …..8051
Cooling system …..8052
Power train …..8053
Swing circle …..8053
Swing machinery …..8054
Sprocket …..8055
Undercarriage and frame …..8056
Track frame …..8056
Idler cushion …..8057
Idler …..8058
Track roller …..8059
Carrier roller …..8060
Track shoe …..8061
Hydraulic system …..8066
Hydraulic tank …..8066
Main pump …..8067
Control valve …..8070
Swing motor …..8081
Travel motor …..8084
Work equipment and swing PPC valve …..8085
Travel PPC valve …..8088
Blade PPC valve …..8091
1st-line attachment PPC valve (with EPC valve) …..8093
Solenoid valve …..8096
Attachment circuit selector valve (for low pressure circuit) …..8098
Attachment circuit selector valve (for high pressure circuit) …..8099
Center swivel joint …..8100
Cab and its attachments …..8101
Cab mount and cab tipping stopper …..8101
Work equipment …..8102
Work equipment …..8102
Boom cylinder …..8111
Arm cylinder …..8112
Bucket cylinder …..8113
Blade cylinder …..8114
80 Appendix …..8116
Table of contents …..8117
Air conditioner components …..8118
Precautions for refrigerant …..8118
Air conditioner component …..8119
Configuration and function of refrigeration cycle …..8122
Outline of refrigeration cycle …..8123
Air conditioner unit …..8125
Dual pressure switch …..8130
Air conditioner controller …..8131
Compressor …..8132
Air conditioner condenser …..8133
Sunlight sensor …..8135
Outer temperature sensor (outside air temperature sensor) …..8136
Procedure for testing and troubleshooting …..8137
Circuit diagram and arrangement of connector pins …..8139
System diagram …..8141
Input and output signals of the air conditioner controller …..8142
Air conditioner unit …..8144
Parts and connectors layout …..8146
Testing air leakage (duct) …..8152
Testing with self-diagnosis function …..8155
Testing vent (mode) changeover …..8158
Testing FRESH/RECIRC air changeover …..8159
Testing sunlight sensor …..8160
Testing (dual) pressure switch for refrigerant …..8161
Testing relays …..8163
Troubleshooting chart 1 …..8164
Troubleshooting chart 2 …..8165
Information in troubleshooting table …..8168
Failure code list related to air conditioner …..8169
Failure code [879AKA] A/C Inner Sensor Open Circuit …..8170
Failure code [879AKB] A/C Inner Sensor Short Circuit …..8171
Failure code [879BKA] A/C Outer Sensor Open Circuit …..8172
Failure code [879BKB] A/C Outer Sensor Short Circuit …..8174
Failure code [879CKA] Ventilating Sensor Open Circuit …..8176
Failure code [879CKB] Ventilating Sensor Short Circuit …..8177
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit …..8178
Failure code [879EMC] Ventilation Damper Abnormality …..8180
Failure code [879FMC] Air Mix Damper Abnormality …..8181
Failure code [879GKX] Refrigerant Abnormality …..8182
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …..8183
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …..8185
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …..8188
A-4 Troubleshooting for FRESH/RECIRC air changeover …..8190
Troubleshooting with gauge pressure …..8192
Connection of service tool …..8195
Precautions for disconnecting and connecting refrigerant piping …..8197
Handling of compressor oil …..8199
Desiccant replacement …..8201
90 Diagrams and drawings …..8204
Table of contents …..8205
Hydraulic circuit diagram …..8206
Symbols in hydraulic circuit diagram …..8206
Hydraulic circuit diagram…..8210
Electric circuit diagram …..8211
Symbols in electric circuit diagram …..8211
Electrical circuit diagram…..8215
Electrical circuit diagram for air conditioner unit…..8221
TEN00003-01 – Hydraulic Excavator PC138US-2, PC138USLC-2E0 Operation & Maintenance Manual…..8232
COVER…..8232
FOREWORD…..8233
FOREWORD…..8234
SAFETY INFORMATION…..8237
INTRODUCTION…..8239
DIRECTIONS OF MACHINE…..8239
PRODUCT INFORMATION…..8240
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..8240
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..8240
EPA NAMEPLATE…..8241
SERVICE METER LOCATION…..8241
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..8242
CONTENTS…..8243
SAFETY…..8247
SAFETY INFORMATION…..8248
SAFETY LABELS…..8250
LOCATION OF SAFETY LABELS…..8251
SAFETY LABELS…..8252
SAFETY INFORMATION…..8257
SAFETY RULES…..8257
IF PROBLEMS ARE FOUND…..8257
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..8257
FIRE EXTINGUISHER AND FIRST AID KIT…..8257
SAFETY EQUIPMENT…..8257
KEEP MACHINE CLEAN…..8258
KEEP OPERATOR'S COMPARTMENT CLEAN…..8258
LEAVING OPERATOR'S SEAT WITH LOCK…..8258
HANDRAILS AND STEPS…..8259
MOUNTING AND DISMOUNTING…..8259
NO PERSONS ON ATTACHMENTS…..8259
DO NOT GET CAUGHT IN ARTICULATED PORTION…..8259
BURN PREVENTION…..8260
FIRE PREVENTION AND EXPLOSION PREVENTION…..8260
ACTION IF FIRE OCCURS…..8261
WINDSHIELD WASHER FLUID…..8261
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..8261
ATTACHMENT INSTALLATION…..8262
ATTACHMENT COMBINATIONS…..8262
CAB WINDOW GLASSES…..8262
UNAUTHORIZED MODIFICATIONS…..8262
SAFETY AT JOBSITE…..8262
WORKING ON LOOSE GROUND…..8263
DISTANCE TO HIGH VOLTAGE CABLES…..8263
ENSURE GOOD VISIBILITY…..8263
VENTILATION FOR ENCLOSED AREA…..8264
SIGNALMAN'S SIGNAL AND SIGNS…..8264
EMERGENCY EXIT FROM OPERATOR'S CAB…..8264
ASBESTOS DUST HAZARD PREVENTION…..8264
SAFETY MACHINE OPERATION…..8265
STARTING ENGINE…..8265
CHECKS BEFORE STARTING ENGINE…..8265
SAFETY RULES FOR STARTING ENGINE…..8265
STARTING ENGINE IN COLD WEATHER…..8266
OPERATION…..8267
CHECKS BEFORE OPERATION…..8267
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..8267
SAFETY RULES FOR TRAVELING…..8268
TRAVELING ON SLOPES…..8269
OPERATIONS ON SLOPES…..8270
PROHIBITED OPERATIONS…..8270
OPERATIONS ON SNOW…..8271
PARKING MACHINE…..8272
TRANSPORTATION…..8273
LOADING AND UNLOADING…..8273
SHIPPING THE MACHINE…..8273
BATTERY…..8274
BATTERY HAZARD PREVENTION…..8274
STARTING ENGINE WITH BOOSTER CABLES…..8275
TOWING…..8276
SAFETY RULES FOR TOWING…..8276
LIFTING OBJECTS WITH BUCKET…..8277
SAFETY RULES FOR LIFTING OBJECTS…..8277
SAFETY MAINTENANCE INFORMATION…..8278
WARNING TAG…..8278
KEEP WORK PLACE CLEAN AND TIDY…..8278
APPOINT LEADER WHEN WORKING WITH OTHERS…..8278
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..8279
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..8280
PROPER TOOLS…..8280
ACCUMULATOR…..8280
PERSONNEL…..8281
ATTACHMENTS…..8281
WORK UNDER THE MACHINE…..8281
NOISE…..8281
WHEN USING HAMMER…..8281
WELDING WORKS…..8282
REMOVING BATTERY TERMINALS…..8282
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..8282
DO NOT DISASSEMBLE RECOIL SPRINGS…..8282
SAFETY RULES FOR HIGH-PRESSURE OIL…..8283
SAFETY HANDLING HIGH-PRESSURE HOSES…..8283
WASTE MATERIALS…..8283
AIR CONDITIONER MAINTENANCE…..8283
COMPRESSED AIR…..8284
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..8284
OPERATION…..8285
MACHINE VIEW ILLUSTRATIONS…..8286
OVERALL MACHINE VIEW…..8286
CONTROLS AND GAUGES…..8287
DETAILED CONTROLS AND GAUGES…..8288
MONITORING SYSTEM…..8288
SWITCHES…..8300
CONTROL LEVERS AND PEDALS…..8305
SUN ROOF…..8308
WINDSHIELD…..8309
SLIDING DOOR…..8314
EMERGENCY ESCAPE HAMMER…..8314
CAP WITH LOCK…..8316
ENGINE HOOD…..8317
CAB REAR COVER…..8318
PUMP ROOM DOOR, BATTERY ROOM DOOR…..8319
DOOR AT FRONT OF TOOL BOX…..8320
FUSE…..8321
FUSIBLE LINK…..8322
AUXILIARY ELECTRIC POWER…..8322
CONTROLLERS…..8323
AIR CONDITIONER CONTROLS…..8324
RADIO…..8330
ACCUMULATOR…..8335
OPERATION MANUAL STORAGE…..8336
TOOL BOX…..8336
GREASE PUMP HOLDER…..8336
HOT AND COOL BOX…..8336
ASHTRAY…..8337
FIRE EXTINGUISHER…..8337
MACHINE OPERATIONS AND CONTROLS…..8338
BEFORE STARTING ENGINE…..8338
STARTING ENGINE…..8354
AFTER STARTING ENGINE…..8359
STOPPING THE ENGINE…..8362
MACHINE OPERATION…..8363
STEERING THE MACHINE…..8367
SWINGING…..8369
WORK EQUIPMENT CONTROLS AND OPERATIONS…..8370
WORKING MODE…..8372
PROHIBITED OPERATIONS…..8373
GENERAL OPERATION INFORMATION…..8375
TRAVELING ON SLOPES…..8377
ESCAPE FROM MUD…..8379
RECOMMENDED APPLICATIONS…..8380
BUCKET REPLACEMENT AND INVERSION…..8382
PARKING MACHINE…..8384
MACHINE INSPECTION AFTER DAILY WORK…..8386
ROAD LINERS…..8387
TRANSPORTATION…..8389
TRANSPORTATION PROCEDURE…..8389
LOADING AND UNLOADING WITH TRAILER…..8389
LIFTING MACHINE…..8395
COLD WEATHER OPERATION…..8397
COLD WEATHER OPERATION INFORMATION…..8397
AFTER DAILY WORK COMPLETION…..8399
AFTER COLD WEATHER SEASON…..8399
LONG TERM STORAGE…..8400
BEFORE STORAGE…..8400
DURING STORAGE…..8400
AFTER STORAGE…..8400
TROUBLES AND ACTIONS…..8401
RUNNING OUT OF FUEL…..8401
PHENOMENA THAT ARE NOT FAILURES…..8401
TOWING THE MACHINE…..8402
LIGHTWEIGHT TOWING HOOK…..8402
SEVERE JOB CONDITION…..8402
DISCHARGED BATTERY…..8403
OTHER TROUBLE…..8407
MAINTENANCE…..8413
MAINTENANCE INFORMATION…..8414
OUTLINE OF SERVICE…..8416
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..8416
ELECTRIC SYSTEM MAINTENANCE…..8419
WEAR PARTS…..8420
WEAR PARTS LIST…..8420
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..8421
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..8422
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..8423
TIGHTENING TORQUE SPECIFICATIONS…..8424
TIGHTENING TORQUE LIST…..8424
SAFETY CRITICAL PARTS…..8425
SAFETY CRITICAL PARTS LIST…..8425
MAINTENANCE SCHEDULE…..8426
MAINTENANCE SCHEDULE CHART…..8426
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..8427
MAINTENANCE PROCEDURE…..8428
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..8428
REPLACE FUEL FILTER CARTRIDGE…..8468
WHEN REQUIRED…..8429
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..8429
CLEAN INSIDE OF COOLING SYSTEM…..8433
CHECK AND TIGHTEN TRACK SHOE BOLTS…..8436
CHECK AND ADJUST TRACK TENSION…..8437
CHECK ROAD LINERS…..8439
REPLACE ROAD LINERS…..8439
CHECK ELECTRICAL INTAKE AIR HEATER…..8439
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..8440
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..8443
ADJUST BUCKET CLEARANCE…..8444
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..8445
CHECK AND MAINTENANCE AIR CONDITIONER…..8446
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…..8447
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT…..8448
WASH WASHABLE FLOOR…..8449
BLEEDING AIR FROM HYDRAULIC SYSTEM…..8452
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…..8454
CHECK BEFORE STARTING…..8456
EVERY 50 HOURS MAINTENANCE…..8457
DRAIN WATER FROM FUEL TANK…..8457
EVERY 100 HOURS MAINTENANCE…..8458
LUBRICATING…..8458
CHECK SWING MACHINERY CASE OIL, ADD OIL…..8459
EVERY 250 HOURS MAINTENANCE…..8460
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..8460
CHECK LEVEL OF BATTERY ELECTROLYTE…..8461
CHECK AND ADJUST COOLING FAN BELT TENSION…..8463
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..8464
EVERY 500 HOURS MAINTENANCE…..8465
LUBRICATING…..8465
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..8467
REPLACE FUEL FILTER CARTRIDGE…..8468
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..8469
LUBRICATE SWING CIRCLE…..8469
CLEAN, CHECK RADIATOR FINS, AIR COOLER FINS, OIL COOLER FINS, CONDENSER FINS…..8469
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..8470
EVERY 1000 HOURS MAINTENANCE…..8472
CHANGE OIL IN SWING MACHINERY CASE…..8472
CHANGE OIL IN FINAL DRIVE CASE…..8473
REPLACE HYDRAULIC OIL FILTER ELEMENT…..8474
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..8474
CHECK PLAY TURBOCHARGER ROTOR…..8474
EVERY 2000 HOURS MAINTENANCE…..8475
CHECK PTO GEAR CASE, ADD OIL…..8475
CLEAN HYDRAULIC TANK STRAINER…..8476
CLEAN, CHECK TURBOCHARGER…..8476
CHECK ALTERNATOR, STARTING MOTOR…..8476
CHECK ENGINE VALVE CLEARANCE, ADJUST…..8476
EVERY 4000 HOURS MAINTENANCE…..8477
CHECK WATER PUMP…..8477
EVERY 5000 HOURS MAINTENANCE…..8478
CHANGE OIL IN HYDRAULIC TANK…..8478
SPECIFICATIONS…..8479
SPECIFICATIONS…..8480
ATTACHMENTS, OPTIONS…..8483
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..8484
SAFETY FIRST…..8484
ATTACHMENT INSTALLATION…..8485
BUCKET WITH HOOK…..8486
HOOK CONDITION…..8486
PROHIBITED OPERATIONS…..8486
AIR CONDITIONER…..8487
AIR CONDITIONER CONTROL PANEL…..8487
AIR CONDITIONER CONTROLS…..8492
AIR CONDITIONER MAINTENANCE…..8492
MACHINE READY FOR ATTACHMENT…..8493
LOCATIONS…..8493
HYDRAULIC CIRCUIT…..8496
ATTACHMENT REMOVAL AND INSTALLATION…..8497
ATTACHMENT OPERATIONS…..8501
LONG TERM STORAGE…..8504
SPECIFICATIONS…..8504
ATTACHMENT GUIDE…..8505
OTHER ATTACHMENTS…..8505
ATTACHMENT COMBINATIONS…..8506
SELECTION OF TRACK SHOES…..8507
RECOMMENDED ATTACHMENT OPERATIONS…..8508
HYDRAULIC BREAKER…..8508
INDEX…..8513
TEN00075-00 – Hydraulic Excavator PC128UU-2 Operation & Maintenance Manual…..8517
COVER…..8517
FOREWORD…..8518
FOREWORD…..8519
SAFETY INFORMATION…..8522
INTRODUCTION…..8524
DIRECTIONS OF MACHINE…..8524
BREAKING-IN THE NEW MACHINE…..8524
PRODUCT INFORMATION…..8525
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..8525
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..8525
SERVICE METER LOCATION…..8526
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..8526
CONTENTS…..8527
SAFETY…..8532
SAFETY INFORMATION…..8533
POSITION FOR ATTACHING SAFETY LABELS…..8535
POSITION FOR ATTACHING SAFETY LABELS…..8536
SAFETY LABELS…..8537
SAFETY INFORMATION…..8543
SAFETY RULES…..8543
IF ABNORMALITIES ARE FOUND…..8543
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..8543
FIRE EXTINGUISHER AND FIRST AID KIT…..8543
SAFETY EQUIPMENT…..8544
KEEP MACHINE CLEAN…..8544
KEEP OPERATOR'S COMPARTMENT CLEAN…..8544
LEAVING OPERATOR'S SEAT WITH LOCK…..8544
HANDRAILS AND STEPS…..8545
MOUNTING AND DISMOUNTING…..8546
NO PERSONS ON ATTACHMENTS…..8546
BURN PREVENTION…..8546
FIRE PREVENTION AND EXPLOSION PREVENTION…..8547
ACTION IF FIRE OCCURS…..8548
WINDSHIELD WASHER FLUID…..8548
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..8548
ATTACHMENT INSTALLATION…..8548
ATTACHMENT COMBINATIONS…..8549
CAB WIDOW GLASSES…..8549
UNAUTHORIZED MODIFICATIONS…..8549
SAFETY AT JOBSITE…..8549
WORKING ON LOOSE GROUND…..8549
DISTANCE TO HIGH VOLTAGE CABLES…..8550
ENSURE GOOD VISIBILITY…..8550
VENTILATION FOR ENCLOSED AREA…..8551
SIGNALMAN'S SIGNAL AND SIGNS…..8551
EMERGENCY EXIT FROM OPERATOR'S CAB…..8551
ASBESTOS DUST HAZARD PREVENTION…..8551
SAFETY MACHINE OPERATION…..8552
BEFORE STARTING ENGINE…..8552
CHECKS BEFORE STARTING ENGINE…..8552
SAFETY RULES FOR STARTING ENGINE…..8553
STARTING ENGINE IN COLD WEATHER…..8553
AFTER STARTING ENGINE…..8554
CHECKS AFTER STARTING ENGINE…..8554
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..8554
SAFETY RULES FOR TRAVELING…..8555
TRAVELING ON SLOPES…..8556
OPERATIONS ON SLOPES…..8557
PROHIBITED OPERATIONS…..8557
OPERATIONS ON SNOW…..8559
PARKING MACHINE…..8559
TRANSPORTATION…..8560
LOADING AND UNLOADING…..8560
SHIPPING THE MACHINE…..8561
BATTERY…..8562
BATTERY HAZARD PREVENTION…..8562
STARTING ENGINE WITH BOOSTER CABLES…..8563
TOWING…..8564
SAFETY RULES FOR TOWING…..8564
LIFTING OBJECTS WITH BUCKET…..8565
SAFETY RULES FOR LIFTING OBJECTS…..8565
SAFETY MAINTENANCE INFORMATION…..8566
WARNING TAG…..8566
KEEP WORK PLACE CLEAN AND TIDY…..8566
APPOINT LEADER WHEN WORKING WITH OTHERS…..8566
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..8567
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..8568
PROPER TOOLS…..8568
ACCUMULATOR…..8569
PERSONNEL…..8569
ATTACHMENTS…..8569
WORK UNDER THE MACHINE…..8569
NOISE…..8570
WHEN USING HAMMER…..8570
WELDING WORKS…..8570
REMOVING BATTERY TERMINALS…..8570
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..8571
DO NOT DISASSEMBLE RECOIL SPRINGS…..8571
SAFETY RULES FOR HIGH-PRESSURE OIL…..8571
WASTE MATERIALS…..8572
AIR CONDITIONER MAINTENANCE…..8572
COMPRESSED AIR…..8572
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..8573
OPERATION…..8574
GENERAL VIEW…..8575
GENERAL VIEW OF MACHINE…..8575
GENERAL VIEW CONTROLS AND GAUGES…..8576
EXPLANATION OF COMPONENTS…..8577
MACHINE MONITOR…..8577
4-SYSTEM…..8582
SWITCHES…..8585
CONTROL LEVERS, PEDALS…..8590
FRONT WINDOW…..8594
SLIDING DOOR…..8597
REAR WINDOW…..8598
HAMMER FOR EMERGENCY ESCAPE…..8598
STOW-AWAY TYPE STEP…..8599
CAP, COVER WITH LOCK…..8601
ENGINE HOOD…..8602
CAB REAR COVER…..8603
PUMP ROOM DOOR, BATTERY ROOM DOOR…..8604
DOOR AT FRONT OF TOOL BOX…..8605
FUSE…..8606
FUSIBLELINK…..8606
POWER SOURCE FOR OPTION…..8607
CONTROLLER…..8607
HANDLING AIR CONDITIONER…..8608
RADIO…..8611
OPERATION AND MAINTENANCE MANUAL HOLDER…..8616
TOOL COMPARTMENT…..8616
GREASE GUN HOLDER…..8616
ASHTRAY…..8616
MACHINE OPERATIONS AND CONTROLS…..8617
BEFORE STARTING ENGINE…..8617
STARTING ENGINE…..8630
AFTER STARTING ENGINE…..8633
STOPPING THE ENGINE…..8637
CHECK AFTER SHUT OFF ENGINE…..8637
MACHINE OPERATION…..8638
STEERING THE MACHINE…..8642
SWINGING…..8644
WORK EQUIPMENT CONTROLS AND OPERATIONS…..8645
PROHIBITED OPERATIONS…..8647
GENERAL OPERATION INFORMATION…..8651
TRAVELING ON SLOPES…..8653
ESCAPE FROM MUD…..8655
RECOMMENDED APPLICATIONS…..8656
BUCKET REPLACEMENT…..8658
PARKING MACHINE…..8660
CHECK AFTER FINISHING WORK…..8661
LOCKING…..8662
HANDLING 4-SYSTEM…..8663
HANDLING ROAD LINER…..8677
TRANSPORTATION…..8679
TRANSPORTATION PROCEDURE…..8679
LOADING AND UNLOADING WITH TRAILER…..8680
LIFTING MACHINE…..8686
COLD WEATHER OPERATION…..8688
COLD WEATHER OPERATION INFORMATION…..8688
AFTER DAILY WORK COMPLETION…..8690
AFTER COLD WEATHER SEASON…..8691
LONG TERM STORAGE…..8692
BEFORE STORAGE…..8692
DURING STORAGE…..8692
AFTER STORAGE…..8693
TROUBLESHOOTING…..8694
AFTER RUNNING OUT OF FUEL…..8694
PHENOMENA THAT ARE NOT FAILURES…..8694
TOWING THE MACHINE…..8697
LIGHTWEIGHT TOWING HOOK…..8698
PRECAUTIONS ON PARTICULAR JOBSITES…..8698
DISCHARGED BATTERY…..8699
OTHER TROUBLE…..8704
MAINTENANCE…..8710
MAINTENANCE INFORMATION…..8711
OUTLINE OF SERVICE…..8714
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..8714
ELECTRIC SYSTEM MAINTENANCE…..8718
WEAR PARTS LIST…..8719
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..8720
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..8721
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..8722
TIGHTENING TORQUE SPECIFICATIONS…..8723
TIGHTENING TORQUE LIST…..8723
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..8724
SAFETY CRITICAL PARTS…..8724
MAINTENANCE SCHEDULE…..8725
MAINTENANCE SCHEDULE CHART…..8725
MAINTENANCE PROCEDURE…..8727
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250…..8727
REPLACE FUEL FILTER CARTRIDGE…..8761
CHECK ENGINE VALVE CLEARANCE, ADJUST…..8770
WHEN REQUIRED…..8728
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..8728
CLEAN INSIDE OF COOLING SYSTEM…..8731
CHECK AND TIGHTEN TRACK SHOE BOLTS…..8734
CHECK AND ADJUST TRACK TENSION…..8735
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)…..8737
CHECK ELECTRICAL INTAKE AIR HEATER…..8737
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..8738
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..8741
ADJUST BUCKET CLEARANCE…..8742
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..8743
CHECK AND ADJUST AIR CONDITIONER (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)…..8744
WASHING WASHABLE FLOOR…..8745
BLEEDING AIR FROM HYDRAULIC SYSTEM…..8748
CHECK BEFORE STARTING…..8750
EVERY 50 HOURS MAINTENANCE…..8751
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..8751
EVERY 100 HOURS MAINTENANCE…..8752
LUBRICATING…..8752
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..8754
EVERY 250 HOURS MAINTENANCE…..8755
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..8755
CHECK LEVEL OF BATTERY ELECTROLYTE…..8756
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..8758
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..8759
EVERY 500 HOURS MAINTENANCE…..8761
REPLACE FUEL FILTER CARTRIDGE…..8761
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..8762
LUBRICATE SWING CIRCLE (2 POINTS)…..8762
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..8763
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…..8764
REPLACE HYDRAULIC FILTER ELEMENT…..8765
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..8766
EVERY 1000 HOURS MAINTENANCE…..8767
CHANGE OIL IN SWING MACHINERY CASE…..8767
CHANGE OIL IN FINAL DRIVE CASE…..8768
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..8768
CHECK PLAY OF TURBOCHARGER ROTOR…..8768
CHECK FAN BELT TENSION AND REPLACE FAN BELT…..8768
EVERY 2000 HOURS MAINTENANCE…..8769
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…..8769
CLEAN HYDRAULIC TANK STRAINER…..8770
CLEAN, CHECK TURBOCHARGER…..8770
CHECK ALTERNATOR, STARTING MOTOR…..8770
CHECK ENGINE VALVE CLEARANCE, ADJUST…..8770
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)…..8771
EVERY 4000 HOURS MAINTENENCE…..8775
CHECK WATER PUMP…..8775
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…..8775
EVERY 5000 HOURS MAINTENANCE…..8776
CHANGE OIL IN HYDRAULIC TANK…..8776
SPECIFICATIONS…..8778
SPECIFICATIONS…..8779
ATTACHMENTS AND OPTIONS…..8782
GENERAL PRECAUTIONS…..8783
PRECAUTIONS RELATED TO SAFETY…..8783
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..8785
HANDLING BUCKET WITH HOOK…..8786
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..8786
PROHIBITED OPERATIONS…..8786
HANDLING CAR HEATER…..8787
EXPLANATION OF COMPONENTS…..8787
PREPARING CAR HEATER…..8787
LOCATION OF FIRE EXTINGUISHER…..8788
INTRODUCTION OF ATTACHMENTS…..8789
SPECIFICATION, USE…..8789
ATTACHMENT INSTALLATION COMBINATION TABLE…..8790
ATTACHMENT COMBINATIONS…..8790
SELECTION OF TRACK SHOES…..8791
INDEX…..8792
TEN00076-01 – Hydraulic Excavator GALEO PC138US-2, PC138USLC-2 Operation & Maintenance Manual…..8796
COVER…..8796
FOREWORD…..8797
FOREWORD…..8798
SAFETY INFORMATION…..8801
INTRODUCTION…..8803
DIRECTIONS OF MACHINE…..8803
BREAKING-IN THE NEW MACHINE…..8803
PRODUCT INFORMATION…..8804
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..8804
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…..8804
EPA NAMEPLATE…..8805
SERVICE METER LOCATION…..8805
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..8806
CONTENTS…..8807
SAFETY…..8811
SAFETY INFORMATION…..8812
SAFETY LABELS…..8814
LOCATION OF SAFETY LABELS…..8815
SAFETY LABELS…..8816
SAFETY INFORMATION…..8821
SAFETY RULES…..8821
IF PROBLEMS ARE FOUND…..8821
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…..8821
FIRE EXTINGUISHER AND FIRST AID KIT…..8821
SAFETY EQUIPMENT…..8821
KEEP MACHINE CLEAN…..8822
KEEP OPERATOR'S COMPARTMENT CLEAN…..8822
LEAVING OPERATOR'S SEAT WITH LOCK…..8822
HANDRAILS AND STEPS…..8823
MOUNTING AND DISMOUNTING…..8823
NO PERSONS ON ATTACHMENTS…..8823
DO NOT GET CAUGHT IN ARTICULATED PORTION…..8823
BURN PREVENTION…..8824
FIRE PREVENTION AND EXPLOSION PREVENTION…..8824
ACTION IF FIRE OCCURS…..8825
WINDSHIELD WASHER FLUID…..8825
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…..8825
ATTACHMENT INSTALLATION…..8826
ATTACHMENT COMBINATIONS…..8826
CAB WINDOW GLASSES…..8826
UNAUTHORIZED MODIFICATIONS…..8826
SAFETY AT JOBSITE…..8826
WORKING ON LOOSE GROUND…..8827
DISTANCE TO HIGH VOLTAGE CABLES…..8827
ENSURE GOOD VISIBILITY…..8827
VENTILATION FOR ENCLOSED AREA…..8828
SIGNALMAN'S SIGNAL AND SIGNS…..8828
EMERGENCY EXIT FROM OPERATOR'S CAB…..8828
ASBESTOS DUST HAZARD PREVENTION…..8828
SAFETY MACHINE OPERATION…..8829
STARTING ENGINE…..8829
CHECKS BEFORE STARTING ENGINE…..8829
SAFETY RULES FOR STARTING ENGINE…..8829
STARTING ENGINE IN COLD WEATHER…..8830
OPERATION…..8831
CHECKS BEFORE OPERATION…..8831
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…..8831
SAFETY RULES FOR TRAVELING…..8832
TRAVELING ON SLOPES…..8833
OPERATIONS ON SLOPES …..8834
PROHIBITED OPERATIONS…..8834
OPERATIONS ON SNOW…..8835
PARKING MACHINE…..8836
TRANSPORTATION…..8837
LOADING AND UNLOADING…..8837
SHIPPING THE MACHINE…..8837
BATTERY…..8838
BATTERY HAZARD PREVENTION…..8838
STARTING ENGINE WITH BOOSTER CABLES…..8839
TOWING…..8840
SAFETY RULES FOR TOWING…..8840
LIFTING OBJECTS WITH BUCKET…..8841
SAFETY RULES FOR LIFTING OBJECTS…..8841
SAFETY MAINTENANCE INFORMATION…..8842
WARNING TAG…..8842
KEEP WORK PLACE CLEAN AND TIDY…..8842
APPOINT LEADER WHEN WORKING WITH OTHERS…..8842
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…..8843
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…..8844
PROPER TOOLS…..8844
ACCUMULATOR…..8844
PERSONNEL…..8845
ATTACHMENTS…..8845
WORK UNDER THE MACHINE…..8845
NOISE…..8845
WHEN USING HAMMER…..8845
WELDING WORKS…..8846
REMOVING BATTERY TERMINALS…..8846
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…..8846
DO NOT DISASSEMBLE RECOIL SPRINGS…..8846
SAFETY RULES FOR HIGH-PRESSURE OIL…..8847
SAFETY HANDLING HIGH-PRESSURE HOSES…..8847
WASTE MATERIALS…..8847
AIR CONDITIONER MAINTENANCE…..8847
COMPRESSED AIR…..8848
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..8848
OPERATION…..8849
MACHINE VIEW ILLUSTRATIONS…..8850
OVERALL MACHINE VIEW…..8850
CONTROLS AND GAUGES…..8851
DETAILED CONTROLS AND GAUGES…..8852
MONITORING SYSTEM…..8852
SWITCHES…..8864
CONTROL LEVERS AND PEDALS…..8869
SUN ROOF…..8872
WINDSHIELD…..8873
SLIDING DOOR…..8878
EMERGENCY ESCAPE HAMMER…..8878
CAP WITH LOCK…..8880
ENGINE HOOD…..8881
CAB REAR COVER…..8882
PUMP ROOM DOOR, BATTERY ROOM DOOR…..8883
DOOR AT FRONT OF TOOL BOX…..8884
FUSE…..8885
FUSIBLE LINK…..8886
AUXILIARY ELECTRIC POWER…..8886
CONTROLLERS…..8887
AIR CONDITIONER CONTROLS…..8888
RADIO…..8893
OPERATION MANUAL STORAGE…..8898
TOOL BOX…..8898
GREASE PUMP HOLDER…..8898
HOT AND COOL BOX…..8898
ASHTRAY…..8899
FIRE EXTINGUISHER…..8899
MACHINE OPERATIONS AND CONTROLS…..8900
BEFORE STARTING ENGINE…..8900
STARTING ENGINE…..8916
AFTER STARTING ENGINE…..8921
STOPPING THE ENGINE…..8924
MACHINE OPERATION…..8925
STEERING THE MACHINE…..8929
SWINGING…..8931
WORK EQUIPMENT CONTROLS AND OPERATIONS…..8932
WORKING MODE…..8934
PROHIBITED OPERATIONS…..8934
GENERAL OPERATION INFORMATION…..8937
TRAVELING ON SLOPES…..8939
ESCAPE FROM MUD…..8941
RECOMMENDED APPLICATIONS…..8942
BUCKET REPLACEMENT AND INVERSION…..8944
PARKING MACHINE…..8946
MACHINE INSPECTION AFTER DAILY WORK…..8948
LOCKING…..8948
ROAD LINERS…..8949
TRANSPORTATION…..8951
TRANSPORTATION PROCEDURE…..8951
LOADING AND UNLOADING WITH TRAILER…..8951
LIFTING MACHINE…..8958
COLD WEATHER OPERATION…..8960
COLD WEATHER OPERATION INFORMATION…..8960
AFTER DAILY WORK COMPLETION…..8962
AFTER COLD WEATHER SEASON…..8962
LONG TERM STORAGE…..8963
BEFORE STORAGE…..8963
DURING STORAGE…..8963
AFTER STORAGE…..8963
TROUBLES AND ACTIONS…..8964
RUNNING OUT OF FUEL…..8964
PHENOMENA THAT ARE NOT FAILURES…..8964
TOWING THE MACHINE…..8965
LIGHTWEIGHT TOWING HOOK…..8966
SEVERE JOB CONDITION…..8966
DISCHARGED BATTERY…..8967
OTHER TROUBLE…..8971
MAINTENANCE…..8977
MAINTENANCE INFORMATION…..8978
OUTLINE OF SERVICE…..8980
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..8980
ELECTRIC SYSTEM MAINTENANCE…..8983
WEAR PARTS…..8984
WEAR PARTS LIST…..8984
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..8985
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..8986
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..8987
TIGHTENING TORQUE SPECIFICATIONS…..8988
TIGHTENING TORQUE LIST…..8988
SAFETY CRITICAL PARTS…..8989
SAFETY CRITICAL PARTS LIST…..8989
MAINTENANCE SCHEDULE…..8990
MAINTENANCE SCHEDULE CHART…..8990
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..8991
MAINTENANCE PROCEDURE…..8992
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…..8992
WHEN REQUIRED…..8993
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..8993
CLEAN INSIDE OF COOLING SYSTEM…..8997
CHECK AND TIGHTEN TRACK SHOE BOLTS…..9000
CHECK AND ADJUST TRACK TENSION…..9001
CHECK ROAD LINERS…..9003
REPLACE ROAD LINERS…..9003
CHECK ELECTRICAL INTAKE AIR HEATER…..9003
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..9004
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..9007
ADJUST BUCKET CLEARANCE…..9008
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..9009
CHECK AND MAINTENANCE AIR CONDITIONER…..9010
CHECK, CLEAN AND LUBRICATE CAB SLIDE DOOR RAIL AND ROLLER…..9011
REPLACE BREAKER CIRCUIT ADDITIONAL OIL FILTER ELEMENT (IF EQUIPPED)…..9012
WASH WASHABLE FLOOR…..9013
BLEEDING AIR FROM HYDRAULIC SYSTEM…..9016
CHECK BEFORE STARTING…..9018
EVERY 50 HOURS MAINTENANCE…..9019
DRAIN WATER FROM FUEL TANK…..9019
EVERY 100 HOURS MAINTENANCE…..9020
LUBRICATING…..9020
CHECK SWING MACHINERY CASE OIL, ADD OIL…..9021
EVERY 250 HOURS MAINTENANCE…..9022
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..9022
CHECK LEVEL OF BATTERY ELECTROLYTE…..9023
CHECK AND ADJUST COOLING FAN BELT TENSION…..9025
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..9026
EVERY 500 HOURS MAINTENANCE…..9027
LUBRICATING…..9027
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..9029
REPLACE FUEL FILTER CARTRIDGE…..9030
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..9031
LUBRICATE SWING CIRCLE…..9031
CLEAN, CHECK RADIATOR FINS, AIR COOLER FINS, OIL COOLER FINS, CONDENSER FINS…..9031
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..9032
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..9034
EVERY 1000 HOURS MAINTENANCE…..9035
CHANGE OIL IN SWING MACHINERY CASE…..9035
CHANGE OIL IN FINAL DRIVE CASE…..9036
REPLACE HYDRAULIC OIL FILTER ELEMENT…..9037
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..9037
CHECK PLAY TURBOCHARGER ROTOR…..9037
EVERY 2000 HOURS MAINTENANCE…..9038
CHECK PTO GEAR CASE, ADD OIL…..9038
CLEAN HYDRAULIC TANK STRAINER…..9039
CLEAN, CHECK TURBOCHARGER…..9039
CHECK ALTERNATOR, STARTING MOTOR…..9039
CHECK ENGINE VALVE CLEARANCE, ADJUST…..9039
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)…..9040
EVERY 4000 HOURS MAINTENANCE…..9044
CHECK WATER PUMP…..9044
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…..9044
EVERY 5000 HOURS MAINTENANCE…..9045
CHANGE OIL IN HYDRAULIC TANK…..9045
SPECIFICATIONS…..9047
SPECIFICATIONS…..9048
ATTACHMENTS, OPTIONS…..9051
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..9052
SAFETY FIRST…..9052
ATTACHMENT INSTALLATION…..9053
BUCKET WITH HOOK…..9054
HOOK CONDITION…..9054
PROHIBITED OPERATIONS…..9054
AIR CONDITIONER…..9055
AIR CONDITIONER CONTROL PANEL…..9055
AIR CONDITIONER CONTROLS…..9060
AIR CONDITIONER MAINTENANCE…..9060
MACHINE READY FOR ATTACHMENT…..9061
LOCATIONS…..9061
HYDRAULIC CIRCUIT…..9064
ATTACHMENT REMOVAL AND INSTALLATION…..9065
ATTACHMENT OPERATIONS…..9069
LONG TERM STORAGE…..9072
SPECIFICATIONS…..9072
ATTACHMENT GUIDE…..9073
OTHER ATTACHMENTS…..9073
ATTACHMENT COMBINATIONS…..9074
SELECTION OF TRACK SHOES…..9075
RECOMMENDED ATTACHMENT OPERATIONS…..9076
HYDRAULIC BREAKER…..9076
CRUSHER…..9081
INDEX…..9085
TEN00189-07 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual…..9089
COVER…..9089
FOREWORD…..9090
BEFORE READING THIS MANUAL…..9091
SAFETY INFORMATION…..9092
INTRODUCTION…..9093
USE OF MACHINE…..9093
DIRECTIONS OF MACHINE…..9093
VISIBILITY FROM OPERATOR'S SEAT…..9093
PRODUCT INFORMATION…..9094
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..9094
EPA REGULATIONS, ENGINE NUMBER PLATE…..9094
SERVICE METER LOCATION…..9095
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..9095
CONTENTS…..9096
SAFETY…..9100
SAFETY…..9101
SAFETY LABELS…..9104
LOCATION OF SAFETY LABELS…..9105
SAFETY LABELS…..9106
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..9113
PRECAUTIONS BEFORE STARTING OPERATION…..9113
PREPARATIONS FOR SAFE OPERATION…..9113
FIRE PREVENTION…..9115
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..9116
DO NOT GET CAUGHT IN WORK EQUIPMENT…..9118
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..9118
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..9119
UNAUTHORIZED MODIFICATION…..9119
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..9119
PRECAUTIONS RELATED TO CAB GLASS…..9119
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..9120
PRECAUTIONS FOR OPERATION…..9121
PRECAUTIONS FOR JOBSITE…..9121
STARTING ENGINE…..9123
OPERATION…..9125
TRANSPORTATION…..9133
TOWING…..9134
LIFTING OBJECTS WITH BUCKET…..9135
PRECAUTIONS FOR MAINTENANCE…..9136
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..9136
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..9140
OPERATION…..9146
MACHINE VIEW ILLUSTRATIONS…..9147
OVERALL MACHINE VIEW…..9147
CONTROLS AND GAUGES…..9148
DETAILED CONTROLS AND GAUGES…..9150
MONITORING SYSTEM…..9150
SWITCHES…..9213
CONTROL LEVERS AND PEDALS…..9218
SUN ROOF…..9222
WINDSHIELD…..9223
SLIDING DOOR…..9229
EMERGENCY ESCAPE HAMMER…..9230
CAP WITH LOCK…..9231
ENGINE HOOD…..9232
CAB REAR COVER…..9233
PUMP ROOM DOOR, BATTERY ROOM DOOR…..9234
DOOR AT FRONT OF TOOL BOX…..9235
AIR CONDITIONER CONTROLS…..9236
RADIO…..9249
FUSE…..9254
FUSIBLE LINK…..9255
AUXILIARY ELECTRIC POWER…..9256
CONTROLLERS…..9257
OPERATION MANUAL STORAGE…..9258
TOOL BOX…..9258
GREASE PUMP HOLDER…..9258
CUP HOLDER…..9258
ASHTRAY…..9259
FIRE EXTINGUISHER…..9259
MACHINE OPERATIONS AND CONTROLS…..9260
BEFORE STARTING ENGINE…..9260
STARTING ENGINE…..9282
AFTER STARTING ENGINE…..9287
STOPPING THE ENGINE…..9298
MACHINE OPERATION…..9299
STEERING THE MACHINE…..9303
SWINGING…..9305
WORK EQUIPMENT CONTROLS AND OPERATIONS…..9306
WORKING MODE…..9308
PROHIBITED OPERATIONS…..9309
GENERAL OPERATION INFORMATION…..9311
TRAVELING ON SLOPES…..9314
ESCAPE FROM MUD…..9316
RECOMMENDED APPLICATIONS…..9317
BUCKET REPLACEMENT AND INVERSION…..9319
PARKING MACHINE…..9322
MACHINE INSPECTION AFTER DAILY WORK…..9323
LOCKING…..9324
ROAD LINERS…..9325
TRANSPORTATION…..9327
TRANSPORTATION PROCEDURE…..9327
LOADING AND UNLOADING WITH TRAILER…..9328
LIFTING MACHINE…..9335
COLD WEATHER OPERATION…..9337
COLD WEATHER OPERATION INFORMATION…..9337
AFTER DAILY WORK COMPLETION…..9339
AFTER COLD WEATHER SEASON…..9339
LONG TERM STORAGE…..9340
BEFORE STORAGE…..9340
DURING STORAGE…..9341
AFTER STORAGE…..9341
STARTING MACHINE AFTER LONG-TERM STORAGE…..9341
TROUBLES AND ACTIONS…..9342
RUNNING OUT OF FUEL…..9342
PHENOMENA THAT ARE NOT FAILURES…..9343
TOWING THE MACHINE…..9344
LIGHTWEIGHT TOWING HOOK…..9345
SEVERE JOB CONDITION…..9345
DISCHARGED BATTERY…..9346
OTHER TROUBLE…..9351
MAINTENANCE…..9356
MAINTENANCE INFORMATION…..9357
OUTLINE OF SERVICE…..9359
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..9359
ELECTRIC SYSTEM MAINTENANCE…..9362
WEAR PARTS…..9363
WEAR PARTS LIST…..9363
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..9364
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..9365
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..9366
TIGHTENING TORQUE SPECIFICATIONS…..9367
TIGHTENING TORQUE LIST…..9367
SAFETY CRITICAL PARTS…..9368
SAFETY CRITICAL PARTS LIST…..9368
MAINTENANCE SCHEDULE…..9370
MAINTENANCE SCHEDULE CHART…..9370
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..9372
MAINTENANCE PROCEDURE…..9373
WHEN REQUIRED…..9373
CHECK BEFORE STARTING…..9403
EVERY 100 HOURS MAINTENANCE…..9404
EVERY 250 HOURS MAINTENANCE…..9406
EVERY 500 HOURS MAINTENANCE…..9414
EVERY 1000 HOURS MAINTENANCE…..9423
EVERY 2000 HOURS MAINTENANCE…..9430
EVERY 4000 HOURS MAINTENANCE…..9434
EVERY 5000 HOURS MAINTENANCE…..9436
EVERY 8000 HOURS MAINTENANCE…..9438
SPECIFICATIONS…..9440
SPECIFICATIONS…..9441
ATTACHMENTS, OPTIONS…..9444
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..9445
SAFETY FIRST…..9445
ATTACHMENT INSTALLATION…..9446
BUCKET WITH HOOK…..9447
HOOK CONDITION…..9447
PROHIBITED OPERATIONS…..9447
MACHINE READY FOR ATTACHMENT…..9448
LOCATIONS…..9448
HYDRAULIC CIRCUIT…..9451
ATTACHMENT REMOVAL AND INSTALLATION…..9452
ATTACHMENT OPERATIONS…..9456
LONG TERM STORAGE…..9460
SPECIFICATIONS…..9460
HANDLING DOUBLE OFFSET BOOM…..9461
MACHINE VIEW ILLUSTRATIONS…..9461
DETAILED CONTROLS…..9463
MACHINE OPERATIONS AND CONTROLS…..9467
MAINTENANCE…..9469
SPECIFICATIONS…..9472
ATTACHMENT GUIDE…..9473
ATTACHMENT COMBINATIONS…..9474
TRACK SHOES SELECTION…..9475
RECOMMENDED ATTACHMENT OPERATIONS…..9476
HYDRAULIC BREAKER…..9476
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..9481
BASIC PRECAUTIONS…..9481
INDEX…..9482
TEN00495-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual…..9486
COVER…..9486
FOREWORD…..9487
BEFORE READING THIS MANUAL…..9488
SAFETY INFORMATION…..9489
INTRODUCTION…..9490
USE OF MACHINE…..9490
DIRECTIONS OF MACHINE…..9490
VISIBILITY FROM OPERATOR'S SEAT…..9490
PROTECTIVE STRUCTURE…..9490
PRODUCT INFORMATION…..9491
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..9491
EPA REGULATIONS, ENGINE NUMBER PLATE…..9491
SERVICE METER LOCATION…..9492
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..9492
CONTENTS…..9493
SAFETY…..9497
SAFETY…..9498
SAFETY LABELS…..9501
LOCATION OF SAFETY LABELS…..9502
SAFETY LABELS…..9503
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..9511
PRECAUTIONS BEFORE STARTING OPERATION…..9511
PREPARATIONS FOR SAFE OPERATION…..9511
FIRE PREVENTION…..9513
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..9514
DO NOT GET CAUGHT IN WORK EQUIPMENT…..9516
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..9516
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..9517
UNAUTHORIZED MODIFICATION…..9517
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..9517
PRECAUTIONS RELATED TO CAB GLASS…..9517
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..9518
PRECAUTIONS FOR OPERATION…..9519
PRECAUTIONS FOR JOBSITE…..9519
STARTING ENGINE…..9521
OPERATION…..9523
TRANSPORTATION…..9531
TOWING…..9532
LIFTING OBJECTS WITH BUCKET…..9533
PRECAUTIONS FOR MAINTENANCE…..9534
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..9534
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..9538
OPERATION…..9545
MACHINE VIEW ILLUSTRATIONS…..9546
OVERALL MACHINE VIEW…..9546
CONTROLS AND GAUGES…..9547
DETAILED CONTROLS AND GAUGES…..9549
MONITORING SYSTEM…..9549
SWITCHES…..9612
CONTROL LEVERS AND PEDALS…..9617
SUN ROOF…..9621
WINDSHIELD…..9622
SLIDING DOOR…..9628
EMERGENCY ESCAPE HAMMER…..9629
CAP WITH LOCK…..9630
ENGINE HOOD…..9631
CAB REAR COVER…..9632
PUMP ROOM DOOR, BATTERY ROOM DOOR…..9633
DOOR AT FRONT OF TOOL BOX…..9634
AIR CONDITIONER CONTROLS…..9635
RADIO…..9648
FUSE…..9653
FUSIBLE LINK…..9654
AUXILIARY ELECTRIC POWER…..9655
CONTROLLERS…..9656
OPERATION MANUAL STORAGE…..9657
TOOL BOX…..9657
GREASE PUMP HOLDER…..9657
CUP HOLDER…..9657
ASHTRAY…..9658
FIRE EXTINGUISHER…..9658
MACHINE OPERATIONS AND CONTROLS…..9659
BEFORE STARTING ENGINE…..9659
STARTING ENGINE…..9681
AFTER STARTING ENGINE…..9686
STOPPING THE ENGINE…..9697
MACHINE OPERATION…..9698
STEERING THE MACHINE…..9702
SWINGING…..9704
WORK EQUIPMENT CONTROLS AND OPERATIONS…..9705
WORKING MODE…..9707
PROHIBITED OPERATIONS…..9708
GENERAL OPERATION INFORMATION…..9710
TRAVELING ON SLOPES…..9713
ESCAPE FROM MUD…..9715
RECOMMENDED APPLICATIONS…..9716
BUCKET REPLACEMENT AND INVERSION…..9718
PARKING MACHINE…..9721
MACHINE INSPECTION AFTER DAILY WORK…..9722
LOCKING…..9723
ROAD LINERS…..9724
TRANSPORTATION…..9726
TRANSPORTATION PROCEDURE…..9726
LOADING AND UNLOADING WITH TRAILER…..9727
LIFTING MACHINE…..9734
COLD WEATHER OPERATION…..9736
COLD WEATHER OPERATION INFORMATION…..9736
AFTER DAILY WORK COMPLETION…..9738
AFTER COLD WEATHER SEASON…..9738
LONG TERM STORAGE…..9739
BEFORE STORAGE…..9739
DURING STORAGE…..9740
AFTER STORAGE…..9740
STARTING MACHINE AFTER LONG-TERM STORAGE…..9740
TROUBLES AND ACTIONS…..9741
RUNNING OUT OF FUEL…..9741
PHENOMENA THAT ARE NOT FAILURES…..9742
TOWING THE MACHINE…..9743
LIGHTWEIGHT TOWING HOOK…..9744
SEVERE JOB CONDITION…..9744
DISCHARGED BATTERY…..9745
OTHER TROUBLE…..9750
MAINTENANCE…..9755
MAINTENANCE INFORMATION…..9756
OUTLINE OF SERVICE…..9758
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..9758
ELECTRIC SYSTEM MAINTENANCE…..9761
WEAR PARTS…..9762
WEAR PARTS LIST…..9762
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..9763
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..9764
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..9765
TIGHTENING TORQUE SPECIFICATIONS…..9766
TIGHTENING TORQUE LIST…..9766
SAFETY CRITICAL PARTS…..9767
SAFETY CRITICAL PARTS LIST…..9767
MAINTENANCE SCHEDULE…..9769
MAINTENANCE SCHEDULE CHART…..9769
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..9771
MAINTENANCE PROCEDURE…..9772
WHEN REQUIRED…..9772
CHECK BEFORE STARTING…..9802
EVERY 100 HOURS MAINTENANCE…..9803
EVERY 250 HOURS MAINTENANCE…..9805
EVERY 500 HOURS MAINTENANCE…..9813
EVERY 1000 HOURS MAINTENANCE…..9822
EVERY 2000 HOURS MAINTENANCE…..9829
EVERY 4000 HOURS MAINTENANCE…..9833
EVERY 5000 HOURS MAINTENANCE…..9835
EVERY 8000 HOURS MAINTENANCE…..9837
SPECIFICATIONS…..9839
SPECIFICATIONS…..9840
ATTACHMENTS, OPTIONS…..9843
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..9844
SAFETY FIRST…..9844
ATTACHMENT INSTALLATION…..9845
BUCKET WITH HOOK…..9846
HOOK CONDITION…..9846
PROHIBITED OPERATIONS…..9846
MACHINE READY FOR ATTACHMENT…..9847
LOCATIONS…..9847
HYDRAULIC CIRCUIT…..9850
ATTACHMENT REMOVAL AND INSTALLATION…..9851
ATTACHMENT OPERATIONS…..9855
LONG TERM STORAGE…..9859
SPECIFICATIONS…..9859
HANDLING DOUBLE OFFSET BOOM…..9860
MACHINE VIEW ILLUSTRATIONS…..9860
DETAILED CONTROLS…..9862
MACHINE OPERATIONS AND CONTROLS…..9866
MAINTENANCE…..9868
SPECIFICATIONS…..9871
ATTACHMENT GUIDE…..9872
ATTACHMENT COMBINATIONS…..9873
TRACK SHOES SELECTION…..9874
RECOMMENDED ATTACHMENT OPERATIONS…..9875
HYDRAULIC BREAKER…..9875
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..9880
BASIC PRECAUTIONS…..9880
INDEX…..9881
TEN00530-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual…..9885
COVER…..9885
FOREWORD…..9886
BEFORE READING THIS MANUAL…..9887
SAFETY INFORMATION…..9888
INTRODUCTION…..9889
USE OF MACHINE…..9889
DIRECTIONS OF MACHINE…..9889
VISIBILITY FROM OPERATOR'S SEAT…..9889
PROTECTIVE STRUCTURE…..9889
PRODUCT INFORMATION…..9890
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..9890
EPA REGULATIONS, ENGINE NUMBER PLATE…..9890
SERVICE METER LOCATION…..9891
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..9891
CONTENTS…..9892
SAFETY…..9896
SAFETY…..9897
SAFETY LABELS…..9900
LOCATION OF SAFETY LABELS…..9901
SAFETY LABELS…..9902
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..9910
PRECAUTIONS BEFORE STARTING OPERATION…..9910
PREPARATIONS FOR SAFE OPERATION…..9910
FIRE PREVENTION…..9912
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..9913
DO NOT GET CAUGHT IN WORK EQUIPMENT…..9915
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..9915
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..9916
UNAUTHORIZED MODIFICATION…..9916
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..9916
PRECAUTIONS RELATED TO CAB GLASS…..9916
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..9917
PRECAUTIONS FOR OPERATION…..9918
PRECAUTIONS FOR JOBSITE…..9918
STARTING ENGINE…..9920
OPERATION…..9922
TRANSPORTATION…..9930
TOWING…..9931
LIFTING OBJECTS WITH BUCKET…..9932
PRECAUTIONS FOR MAINTENANCE…..9933
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..9933
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..9937
OPERATION…..9944
MACHINE VIEW ILLUSTRATIONS…..9945
OVERALL MACHINE VIEW…..9945
CONTROLS AND GAUGES…..9946
DETAILED CONTROLS AND GAUGES…..9948
MONITORING SYSTEM…..9948
SWITCHES…..10011
CONTROL LEVERS AND PEDALS…..10016
SUN ROOF…..10020
WINDSHIELD…..10021
SLIDING DOOR…..10027
EMERGENCY ESCAPE HAMMER…..10028
CAP WITH LOCK…..10029
ENGINE HOOD…..10030
CAB REAR COVER…..10031
PUMP ROOM DOOR, BATTERY ROOM DOOR…..10032
DOOR AT FRONT OF TOOL BOX…..10033
AIR CONDITIONER CONTROLS…..10034
RADIO…..10047
FUSE…..10052
FUSIBLE LINK…..10053
AUXILIARY ELECTRIC POWER…..10054
CONTROLLERS…..10055
OPERATION MANUAL STORAGE…..10056
TOOL BOX…..10056
GREASE PUMP HOLDER…..10056
CUP HOLDER…..10056
ASHTRAY…..10057
FIRE EXTINGUISHER…..10057
MACHINE OPERATIONS AND CONTROLS…..10058
BEFORE STARTING ENGINE…..10058
STARTING ENGINE…..10080
AFTER STARTING ENGINE…..10085
STOPPING THE ENGINE…..10096
MACHINE OPERATION…..10097
STEERING THE MACHINE…..10101
SWINGING…..10103
WORK EQUIPMENT CONTROLS AND OPERATIONS…..10104
WORKING MODE…..10106
PROHIBITED OPERATIONS…..10107
GENERAL OPERATION INFORMATION…..10109
TRAVELING ON SLOPES…..10112
ESCAPE FROM MUD…..10114
RECOMMENDED APPLICATIONS…..10115
BUCKET REPLACEMENT AND INVERSION…..10117
PARKING MACHINE…..10120
MACHINE INSPECTION AFTER DAILY WORK…..10121
LOCKING…..10122
ROAD LINERS…..10123
TRANSPORTATION…..10125
TRANSPORTATION PROCEDURE…..10125
LOADING AND UNLOADING WITH TRAILER…..10126
LIFTING MACHINE…..10133
COLD WEATHER OPERATION…..10135
COLD WEATHER OPERATION INFORMATION…..10135
AFTER DAILY WORK COMPLETION…..10137
AFTER COLD WEATHER SEASON…..10137
LONG TERM STORAGE…..10138
BEFORE STORAGE…..10138
DURING STORAGE…..10139
AFTER STORAGE…..10139
STARTING MACHINE AFTER LONG-TERM STORAGE…..10139
TROUBLES AND ACTIONS…..10140
RUNNING OUT OF FUEL…..10140
PHENOMENA THAT ARE NOT FAILURES…..10141
TOWING THE MACHINE…..10142
LIGHTWEIGHT TOWING HOOK…..10143
SEVERE JOB CONDITION…..10143
DISCHARGED BATTERY…..10144
OTHER TROUBLE…..10149
MAITENANCE…..10154
MAINTENANCE INFORMATION…..10155
OUTLINE OF SERVICE…..10157
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..10157
ELECTRIC SYSTEM MAINTENANCE…..10160
WEAR PARTS…..10161
WEAR PARTS LIST…..10161
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..10162
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..10163
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..10164
TIGHTENING TORQUE SPECIFICATIONS…..10165
TIGHTENING TORQUE LIST…..10165
SAFETY CRITICAL PARTS…..10166
SAFETY CRITICAL PARTS LIST…..10166
MAINTENANCE SCHEDULE…..10168
MAINTENANCE SCHEDULE CHART…..10168
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..10170
MAINTENANCE PROCEDURE…..10171
WHEN REQUIRED…..10171
CHECK BEFORE STARTING…..10201
EVERY 100 HOURS MAINTENANCE…..10202
EVERY 250 HOURS MAINTENANCE…..10204
EVERY 500 HOURS MAINTENANCE…..10212
EVERY 1000 HOURS MAINTENANCE…..10221
EVERY 2000 HOURS MAINTENANCE…..10228
EVERY 4000 HOURS MAINTENANCE…..10232
EVERY 5000 HOURS MAINTENANCE…..10234
EVERY 8000 HOURS MAINTENANCE…..10236
SPECIFICATIONS…..10238
SPECIFICATIONS…..10239
ATTACHMENTS, OPTIONS…..10242
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..10243
SAFETY FIRST…..10243
ATTACHMENT INSTALLATION…..10244
BUCKET WITH HOOK…..10245
HOOK CONDITION…..10245
PROHIBITED OPERATIONS…..10245
MACHINE READY FOR ATTACHMENT…..10246
LOCATIONS…..10246
HYDRAULIC CIRCUIT…..10249
ATTACHMENT REMOVAL AND INSTALLATION…..10250
ATTACHMENT OPERATIONS…..10254
LONG TERM STORAGE…..10258
SPECIFICATIONS…..10258
HANDLING DOUBLE OFFSET BOOM…..10259
MACHINE VIEW ILLUSTRATIONS…..10259
DETAILED CONTROLS…..10261
MACHINE OPERATIONS AND CONTROLS…..10265
MAINTENANCE…..10267
SPECIFICATIONS…..10270
ATTACHMENT GUIDE…..10271
ATTACHMENT COMBINATIONS…..10272
TRACK SHOES SELECTION…..10273
RECOMMENDED ATTACHMENT OPERATIONS…..10274
HYDRAULIC BREAKER…..10274
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..10279
BASIC PRECAUTIONS…..10279
INDEX…..10280
TEN00546-00 – Hydraulic Excavator PC138US-8, PC138USLC-8 Operation & Maintenance Manual…..10284
COVER…..10284
FOREWORD …..10285
BEFORE READING THIS MANUAL…..10286
SAFETY INFORMATION…..10287
INTRODUCTION…..10288
USE OF MACHINE…..10288
DIRECTIONS OF MACHINE…..10288
VISIBILITY FROM OPERATOR'S SEAT…..10288
PROTECTIVE STRUCTURE…..10288
PRODUCT INFORMATION…..10289
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..10289
EPA REGULATIONS, ENGINE NUMBER PLATE…..10289
SERVICE METER LOCATION…..10290
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…..10290
CONTENTS…..10291
SAFETY…..10295
SAFETY…..10296
SAFETY LABELS…..10299
LOCATION OF SAFETY LABELS…..10300
SAFETY LABELS…..10301
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…..10309
PRECAUTIONS BEFORE STARTING OPERATION…..10309
PREPARATIONS FOR SAFE OPERATION…..10309
FIRE PREVENTION…..10311
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…..10312
DO NOT GET CAUGHT IN WORK EQUIPMENT…..10314
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…..10314
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS…..10315
UNAUTHORIZED MODIFICATION…..10315
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…..10315
PRECAUTIONS RELATED TO CAB GLASS…..10315
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…..10316
PRECAUTIONS FOR OPERATION…..10317
PRECAUTIONS FOR JOBSITE…..10317
STARTING ENGINE…..10319
OPERATION…..10321
TRANSPORTATION…..10329
TOWING…..10330
LIFTING OBJECTS WITH BUCKET…..10331
PRECAUTIONS FOR MAINTENANCE…..10332
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…..10332
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…..10336
OPERATION…..10343
MACHINE VIEW ILLUSTRATIONS…..10344
OVERALL MACHINE VIEW…..10344
CONTROLS AND GAUGES…..10345
DETAILED CONTROLS AND GAUGES…..10347
MONITORING SYSTEM…..10347
SWITCHES…..10410
CONTROL LEVERS AND PEDALS…..10415
SUN ROOF…..10419
WINDSHIELD…..10420
SLIDING DOOR…..10426
EMERGENCY ESCAPE HAMMER…..10427
CAP WITH LOCK…..10428
ENGINE HOOD…..10429
CAB REAR COVER…..10430
PUMP ROOM DOOR, BATTERY ROOM DOOR…..10431
DOOR AT FRONT OF TOOL BOX…..10432
AIR CONDITIONER CONTROLS…..10433
RADIO…..10446
FUSE…..10451
FUSIBLE LINK…..10452
AUXILIARY ELECTRIC POWER…..10453
CONTROLLERS…..10454
OPERATION MANUAL STORAGE…..10455
TOOL BOX…..10455
GREASE PUMP HOLDER…..10455
CUP HOLDER…..10455
ASHTRAY…..10456
FIRE EXTINGUISHER…..10456
MACHINE OPERATIONS AND CONTROLS…..10457
BEFORE STARTING ENGINE…..10457
STARTING ENGINE…..10479
AFTER STARTING ENGINE…..10484
STOPPING THE ENGINE…..10495
MACHINE OPERATION…..10496
STEERING THE MACHINE…..10500
SWINGING…..10502
WORK EQUIPMENT CONTROLS AND OPERATIONS…..10503
WORKING MODE…..10505
PROHIBITED OPERATIONS…..10506
GENERAL OPERATION INFORMATION…..10508
TRAVELING ON SLOPES…..10511
ESCAPE FROM MUD…..10513
RECOMMENDED APPLICATIONS…..10514
BUCKET REPLACEMENT AND INVERSION…..10516
PARKING MACHINE…..10519
MACHINE INSPECTION AFTER DAILY WORK…..10520
LOCKING…..10521
ROAD LINERS…..10522
TRANSPORTATION…..10524
TRANSPORTATION PROCEDURE…..10524
LOADING AND UNLOADING WITH TRAILER…..10525
LIFTING MACHINE…..10532
COLD WEATHER OPERATION…..10534
COLD WEATHER OPERATION INFORMATION…..10534
AFTER DAILY WORK COMPLETION…..10536
AFTER COLD WEATHER SEASON…..10536
LONG TERM STORAGE…..10537
BEFORE STORAGE…..10537
DURING STORAGE…..10538
AFTER STORAGE…..10538
STARTING MACHINE AFTER LONG-TERM STORAGE…..10538
TROUBLES AND ACTIONS…..10539
RUNNING OUT OF FUEL…..10539
PHENOMENA THAT ARE NOT FAILURES…..10540
TOWING THE MACHINE…..10541
LIGHTWEIGHT TOWING HOOK…..10542
SEVERE JOB CONDITION…..10542
DISCHARGED BATTERY…..10543
OTHER TROUBLE…..10548
MAINTENANCE…..10553
MAINTENANCE INFORMATION…..10554
OUTLINE OF SERVICE…..10556
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..10556
ELECTRIC SYSTEM MAINTENANCE…..10559
WEAR PARTS…..10560
WEAR PARTS LIST…..10560
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..10561
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..10562
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…..10563
TIGHTENING TORQUE SPECIFICATIONS…..10564
TIGHTENING TORQUE LIST…..10564
SAFETY CRITICAL PARTS…..10565
SAFETY CRITICAL PARTS LIST…..10565
MAINTENANCE SCHEDULE…..10567
MAINTENANCE SCHEDULE CHART…..10567
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..10569
MAINTENANCE PROCEDURE…..10570
WHEN REQUIRED…..10570
CHECK BEFORE STARTING…..10600
EVERY 100 HOURS MAINTENANCE…..10601
EVERY 250 HOURS MAINTENANCE…..10603
EVERY 500 HOURS MAINTENANCE…..10611
EVERY 1000 HOURS MAINTENANCE…..10620
EVERY 2000 HOURS MAINTENANCE…..10627
EVERY 4000 HOURS MAINTENANCE…..10631
EVERY 5000 HOURS MAINTENANCE…..10633
EVERY 8000 HOURS MAINTENANCE…..10635
SPECIFICATIONS…..10637
SPECIFICATIONS…..10638
ATTACHMENTS, OPTIONS…..10641
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION…..10642
SAFETY FIRST…..10642
ATTACHMENT INSTALLATION…..10643
BUCKET WITH HOOK…..10644
HOOK CONDITION…..10644
PROHIBITED OPERATIONS…..10644
MACHINE READY FOR ATTACHMENT…..10645
LOCATIONS…..10645
HYDRAULIC CIRCUIT…..10648
ATTACHMENT REMOVAL AND INSTALLATION…..10649
ATTACHMENT OPERATIONS…..10653
LONG TERM STORAGE…..10657
SPECIFICATIONS…..10657
HANDLING DOUBLE OFFSET BOOM…..10658
MACHINE VIEW ILLUSTRATIONS…..10658
DETAILED CONTROLS…..10660
MACHINE OPERATIONS AND CONTROLS…..10664
MAINTENANCE…..10666
SPECIFICATIONS…..10669
ATTACHMENT GUIDE…..10670
ATTACHMENT COMBINATIONS…..10671
TRACK SHOES SELECTION…..10672
RECOMMENDED ATTACHMENT OPERATIONS…..10673
HYDRAULIC BREAKER…..10673
HANDLING MACHINES EQUIPPED WITH KOMTRAX…..10678
BASIC PRECAUTIONS…..10678
INDEX…..10679
TEN00604-01 – Hydraulic Excavator PC138USLC-10 Operation & Maintenance Manual…..10683
COVER…..10683
FOREWORD …..10684
BEFORE READING THIS MANUAL …..10685
SAFETY INFORMATION …..10686
INTRODUCTION …..10687
USE OF MACHINE …..10687
DIRECTIONS OF MACHINE …..10687
VISIBILITY FROM OPERATOR'S SEAT …..10687
PRODUCT INFORMATION …..10688
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE …..10688
EPA REGULATIONS, ENGINE NUMBER PLATE …..10688
SERVICE METER LOCATION …..10689
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR …..10689
CONTENTS …..10690
SAFETY …..10694
SAFETY …..10695
SAFETY LABELS …..10697
LOCATION OF SAFETY LABELS …..10698
SAFETY LABELS …..10699
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE …..10707
PRECAUTIONS BEFORE STARTING OPERATION …..10707
PREPARATIONS FOR SAFE OPERATION …..10708
FIRE PREVENTION …..10710
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE …..10712
DO NOT GET CAUGHT IN WORK EQUIPMENT …..10713
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …..10714
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS …..10715
UNAUTHORIZED MODIFICATION …..10715
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS …..10716
PRECAUTIONS RELATED TO CAB GLASS …..10716
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING …..10716
PRECAUTIONS FOR OPERATION …..10717
PRECAUTIONS FOR JOBSITE …..10717
STARTING ENGINE …..10720
OPERATION …..10723
TRANSPORTATION …..10730
TOWING …..10731
SAFETY RULES FOR LIFTING OPERATIONS …..10732
PRECAUTIONS FOR MAINTENANCE …..10733
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE …..10733
PRECAUTIONS FOR INSPECTION AND MAINTENANCE …..10737
OPERATION …..10744
GENERAL VIEW …..10745
GENERAL VIEW OF MACHINE …..10745
GENERAL VIEW OF CONTROLS AND GAUGES …..10747
EXPLANATION OF COMPONENTS …..10749
MACHINE MONITOR …..10749
SWITCHES …..10818
CONTROL LEVERS AND PEDALS …..10824
CEILING WINDOW …..10827
OPEN AND CLOSE CAB FRONT WINDOW …..10828
SLIDE DOOR …..10833
EMERGENCY ESCAPE HAMMER …..10834
OPEN AND CLOSE ENGINE HOOD …..10835
PUMP ROOM DOOR, BATTERY ROOM DOOR …..10836
TOOL BOX FRONT DOOR …..10837
CAPS AND COVERS WITH LOCK …..10838
OPERATION AND MAINTENANCE MANUAL POCKET …..10840
CUP HOLDER …..10840
ASHTRAY …..10841
HANDLING AIR CONDITIONER …..10842
HANDLING RADIO …..10854
AUXILIARY ELECTRIC POWER …..10859
FUSE …..10861
FUSIBLE LINK …..10862
TOOLBOX …..10863
GREASE PUMP HOLDER …..10863
FIRE EXTINGUISHER …..10863
BATTERY DISCONNECT SWITCH …..10864
SYSTEM OPERATING LAMP …..10865
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) …..10866
HANDLING MACHINES EQUIPPED WITH KOMTRAX …..10867
MACHINE OPERATIONS AND CONTROLS …..10869
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE …..10869
STARTING ENGINE …..10889
OPERATIONS AND CHECKS AFTER STARTING ENGINE …..10894
STOPPING ENGINE …..10906
MACHINE OPERATION …..10907
STEERING MACHINE …..10911
SWINGING MACHINE …..10913
WORK EQUIPMENT CONTROLS AND OPERATIONS …..10914
WORKING MODE …..10916
PROHIBITED OPERATIONS …..10918
RULES FOR OPERATION …..10921
RULES FOR WORKING ON SLOPE …..10924
ESCAPE FROM MUD …..10926
RECOMMENDED APPLICATIONS …..10927
REPLACING AND INVERTING BUCKET …..10929
PARKING MACHINE …..10932
AFTER DAILY WORK COMPLETION …..10933
LOCK …..10934
HANDLING ROAD LINERS …..10935
TRANSPORTATION …..10937
TRANSPORTATION PROCEDURE …..10937
LOADING AND UNLOADING WITH TRAILER …..10938
LIFTING MACHINE …..10946
COLD WEATHER OPERATION …..10948
COLD WEATHER OPERATION INFORMATION …..10948
AFTER DAILY WORK COMPLETION …..10950
AFTER COLD WEATHER SEASON …..10950
LONG-TERM STORAGE …..10951
BEFORE STORAGE …..10951
DURING STORAGE …..10951
AFTER STORAGE …..10952
STARTING MACHINE AFTER LONG-TERM STORAGE …..10952
TROUBLES AND ACTIONS …..10953
RUNNING OUT OF FUEL …..10953
PHENOMENA THAT ARE NOT FAILURES …..10953
TOWING MACHINE …..10954
LIGHTWEIGHT TOWING HOLE …..10955
SEVERE JOB CONDITION …..10955
DISCHARGED BATTERY …..10956
OTHER TROUBLE …..10961
MAINTENANCE …..10968
RULES FOR MAINTENANCE …..10969
SERVICE METER READING …..10969
KOMATSU GENUINE REPLACEMENT PARTS …..10969
KOMATSU GENUINE LUBRICANTS …..10969
ALWAYS USE CLEAN WASHER FLUID …..10969
FRESH AND CLEAN LUBRICANTS …..10969
CHECK DRAINED OIL AND USED FILTER …..10969
CAUTION FOR REFILLING OIL OR FUEL …..10969
WELDING INSTRUCTIONS …..10969
DO NOT DROP THINGS INSIDE MACHINE …..10969
DUSTY JOBSITES …..10970
AVOID MIXING OIL …..10970
LOCKING INSPECTION COVERS …..10970
BLEED AIR FROM HYDRAULIC CIRCUIT …..10970
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES …..10970
CHECKS AFTER INSPECTION AND MAINTENANCE …..10970
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE …..10970
OUTLINE OF MAINTENANCE …..10971
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC …..10971
HANDLING ELECTRICAL COMPONENTS …..10974
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS …..10975
TIGHTENING TORQUE LIST …..10975
MAINTENANCE SCHEDULE …..10976
MAINTENANCE SCHEDULE TABLE …..10976
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER …..10978
MAINTENANCE PROCEDURE …..10979
WHEN REQUIRED …..10979
CHECKS BEFORE STARTING …..11008
EVERY 100 HOURS MAINTENANCE …..11009
EVERY 250 HOURS MAINTENANCE …..11011
EVERY 500 HOURS MAINTENANCE …..11017
EVERY 1000 HOURS MAINTENANCE …..11025
EVERY 2000 HOURS MAINTENANCE …..11031
EVERY 4000 HOURS MAINTENANCE …..11040
EVERY 5000 HOURS MAINTENANCE …..11042
EVERY 8000 HOURS MAINTENANCE …..11044
SPECIFICATIONS …..11046
SPECIFICATIONS …..11047
ATTACHMENTS AND OPTIONS …..11050
GENERAL PRECAUTIONS …..11051
PRECAUTIONS FOR SAFETY …..11051
INSTALLING ATTACHMENTS …..11052
BUCKET WITH HOOK …..11053
HOOK CONDITION …..11053
PROHIBITED OPERATIONS …..11053
MACHINE READY FOR INSTALLATION OF ATTACHMENT …..11054
EXPLANATION OF COMPONENTS …..11054
HYDRAULIC CIRCUIT …..11057
REMOVAL AND INSTALLATION OF ATTACHMENT …..11059
OPERATION …..11063
LONG-TERM STORAGE …..11066
SPECIFICATIONS …..11066
ATTACHMENTS AND OPTIONS …..11067
ATTACHMENT COMBINATIONS …..11068
TRACK SHOES SELECTION …..11069
RECOMMENDED ATTACHMENT OPERATIONS …..11070
HYDRAULIC BREAKER …..11070
REPLACEMENT PARTS …..11076
SAFETY CRITICAL PARTS …..11077
SAFETY CRITICAL PARTS LIST …..11077
CONSUMABLE PARTS …..11079
CONSUMABLE PARTS LIST …..11079
RECOMMENDED FUEL, COOLANT, AND LUBRICANT …..11080
LUBRICATION CHART …..11081
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE: …..11083
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL …..11085
INDEX …..11086
Komatsu Hydraulic Excavator PC128UU, PC128US, PC138US, PC138USLC, PC138USLC-E0, PC158US Repair Service Manuals
INSTANT DOWNLOAD
