Komatsu PC128UU-2 Manual

TEN00075-00
Operation&Maintenance
Manual
PC128UU -2
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC128UU-2 6290 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2005 Komatsu
Printed in U.S.A.
Komatsu America Corp.
July 2005

1-1
FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precau-
tions in this manual must be followed at all times when performing operation and maintenance. Most accidents are
caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents
can be prevented by knowing beforehand conditions that may cause hazard when performing operation and main-
tenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
●Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
●Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.
Storage location for the Operation and Maintenance Manual:
Manual luggage box behind operator's seat

FOREWORD FOREWORD
1-3

FOREWORD FOREWORD
1-4

FOREWORD SAFETY INFORMATION
1-5
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move LOCK LEVER (located
near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is are useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This gives information that is useful to know.
DANGER
WARNING
CAUTION
NOTICE
REMARKS

SAFETY INFORMATION FOREWORD
1-6
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your
responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: →(1))
Part No.
Part No.

FOREWORD INTRODUCTION
1-7
INTRODUCTION
This Komatsu HYDRAULIC EXCAVATOR is designed to be used mainly for the following works:
●Digging work
●Leveling work
●Ditching work
●Loading work
●Demolition work
See the section "RECOMMENDED APPLICATIONS (PAGE 3-83)" for further details.
DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's cab when
the operator's cab is facing the front and the sprocket is at the rear of the machine.
BREAKING-IN THE NEW MACHINE
CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating
the machine under severe conditions at the beginning can adversely affect the performance and shorten
the machine life.
Be sure to running-in the machine for the initial 100 hours (as indicated by the service meter).
During running-in operations, follow the precautions described in this manual.
●Idle the engine for 5 minutes after starting it up.
●Avoid operation with heavy loads or at high speeds.
●Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency.

PRODUCT INFORMATION FOREWORD
1-8
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO.
PLATE
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION
On the upper side of the engine cylinder head cover

FOREWORD PRODUCT INFORMATION
1-9
SERVICE METER LOCATION
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personal
Phone/Fax

CONTENTS FOREWORD
1-10
CONTENTS
FOREWORD
FOREWORD ......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-5
INTRODUCTION................................................................................................................................................... 1-7
DIRECTIONS OF MACHINE ...................................................................................................................... 1-7
BREAKING-IN THE NEW MACHINE ......................................................................................................... 1-7
PRODUCT INFORMATION .................................................................................................................................. 1-8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................................ 1-8
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION ......................................................................... 1-8
SERVICE METER LOCATION ................................................................................................................... 1-9
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ..................................................................... 1-9
SAFETY
SAFETY INFORMATION...................................................................................................................................... 2-2
POSITION FOR ATTACHING SAFETY LABELS................................................................................................ 2-4
POSITION FOR ATTACHING SAFETY LABELS....................................................................................... 2-5
SAFETY LABELS ....................................................................................................................................... 2-6
SAFETY INFORMATION.................................................................................................................................... 2-12
SAFETY MACHINE OPERATION...................................................................................................................... 2-21
BEFORE STARTING ENGINE ................................................................................................................. 2-21
AFTER STARTING ENGINE .................................................................................................................... 2-23
TRANSPORTATION................................................................................................................................. 2-29
BATTERY ................................................................................................................................................. 2-31
TOWING ................................................................................................................................................... 2-33
LIFTING OBJECTS WITH BUCKET ......................................................................................................... 2-34
SAFETY MAINTENANCE INFORMATION ........................................................................................................ 2-35
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW CONTROLS AND GAUGES........................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-4
MACHINE MONITOR ................................................................................................................................. 3-4

FOREWORD CONTENTS
1-11
4-SYSTEM.................................................................................................................................................. 3-9
SWITCHES ............................................................................................................................................... 3-12
CONTROL LEVERS, PEDALS ................................................................................................................. 3-17
FRONT WINDOW..................................................................................................................................... 3-21
SLIDING DOOR........................................................................................................................................ 3-24
REAR WINDOW ....................................................................................................................................... 3-25
HAMMER FOR EMERGENCY ESCAPE.................................................................................................. 3-25
STOW-AWAY TYPE STEP....................................................................................................................... 3-26
CAP, COVER WITH LOCK....................................................................................................................... 3-28
ENGINE HOOD ........................................................................................................................................ 3-29
CAB REAR COVER.................................................................................................................................. 3-30
PUMP ROOM DOOR, BATTERY ROOM DOOR ..................................................................................... 3-31
DOOR AT FRONT OF TOOL BOX........................................................................................................... 3-32
FUSE ........................................................................................................................................................ 3-33
FUSIBLELINK ........................................................................................................................................... 3-33
POWER SOURCE FOR OPTION............................................................................................................. 3-34
CONTROLLER ......................................................................................................................................... 3-34
HANDLING AIR CONDITIONER .............................................................................................................. 3-35
RADIO....................................................................................................................................................... 3-38
OPERATION AND MAINTENANCE MANUAL HOLDER ......................................................................... 3-43
TOOL COMPARTMENT ........................................................................................................................... 3-43
GREASE GUN HOLDER.......................................................................................................................... 3-43
ASHTRAY ................................................................................................................................................. 3-43
MACHINE OPERATIONS AND CONTROLS..................................................................................................... 3-44
BEFORE STARTING ENGINE ................................................................................................................. 3-44
STARTING ENGINE ................................................................................................................................. 3-57
AFTER STARTING ENGINE .................................................................................................................... 3-60
STOPPING THE ENGINE ........................................................................................................................ 3-64
CHECK AFTER SHUT OFF ENGINE....................................................................................................... 3-64
MACHINE OPERATION ........................................................................................................................... 3-65
STEERING THE MACHINE...................................................................................................................... 3-69
SWINGING ............................................................................................................................................... 3-71
WORK EQUIPMENT CONTROLS AND OPERATIONS .......................................................................... 3-72
PROHIBITED OPERATIONS ................................................................................................................... 3-74
GENERAL OPERATION INFORMATION ................................................................................................ 3-78
TRAVELING ON SLOPES........................................................................................................................ 3-80
ESCAPE FROM MUD............................................................................................................................... 3-82
RECOMMENDED APPLICATIONS.......................................................................................................... 3-83
BUCKET REPLACEMENT ....................................................................................................................... 3-85
PARKING MACHINE ................................................................................................................................ 3-87
CHECK AFTER FINISHING WORK ......................................................................................................... 3-88
LOCKING.................................................................................................................................................. 3-89
HANDLING 4-SYSTEM ............................................................................................................................ 3-90
HANDLING ROAD LINER ...................................................................................................................... 3-104

CONTENTS FOREWORD
1-12
TRANSPORTATION......................................................................................................................................... 3-106
TRANSPORTATION PROCEDURE ....................................................................................................... 3-106
LOADING AND UNLOADING WITH TRAILER ...................................................................................... 3-107
LIFTING MACHINE................................................................................................................................. 3-113
COLD WEATHER OPERATION ...................................................................................................................... 3-115
COLD WEATHER OPERATION INFORMATION................................................................................... 3-115
AFTER DAILY WORK COMPLETION .................................................................................................... 3-117
AFTER COLD WEATHER SEASON ...................................................................................................... 3-118
LONG TERM STORAGE.................................................................................................................................. 3-119
BEFORE STORAGE............................................................................................................................... 3-119
DURING STORAGE ............................................................................................................................... 3-119
AFTER STORAGE.................................................................................................................................. 3-120
TROUBLESHOOTING...................................................................................................................................... 3-121
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-121
PHENOMENA THAT ARE NOT FAILURES ........................................................................................... 3-121
TOWING THE MACHINE ....................................................................................................................... 3-124
LIGHTWEIGHT TOWING HOOK............................................................................................................ 3-125
PRECAUTIONS ON PARTICULAR JOBSITES ..................................................................................... 3-125
DISCHARGED BATTERY ...................................................................................................................... 3-126
OTHER TROUBLE ................................................................................................................................. 3-131
MAINTENANCE
MAINTENANCE INFORMATION ......................................................................................................................... 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................................... 4-5
ELECTRIC SYSTEM MAINTENANCE ....................................................................................................... 4-9
WEAR PARTS LIST ........................................................................................................................................... 4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE............. 4-12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR
PRODUCTS OTHER THAN KOMATSU GENUINE OIL .......................................................................... 4-13
TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 4-14
TIGHTENING TORQUE LIST................................................................................................................... 4-14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-15
SAFETY CRITICAL PARTS...................................................................................................................... 4-15
MAINTENANCE SCHEDULE............................................................................................................................. 4-16
MAINTENANCE SCHEDULE CHART ......................................................................................................4-16

FOREWORD CONTENTS
1-13
MAINTENANCE PROCEDURE.......................................................................................................................... 4-18
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................... 4-18
WHEN REQUIRED ................................................................................................................................... 4-19
CHECK BEFORE STARTING .................................................................................................................. 4-41
EVERY 50 HOURS MAINTENANCE........................................................................................................ 4-42
EVERY 100 HOURS MAINTENANCE...................................................................................................... 4-43
EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-46
EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-52
EVERY 1000 HOURS MAINTENANCE....................................................................................................4-58
EVERY 2000 HOURS MAINTENANCE....................................................................................................4-60
EVERY 4000 HOURS MAINTENENCE....................................................................................................4-66
EVERY 5000 HOURS MAINTENANCE....................................................................................................4-67
SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2
ATTACHMENTS AND OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
PRECAUTIONS WHEN INSTALLING ATTACHMENTS ............................................................................ 6-4
HANDLING BUCKET WITH HOOK ..................................................................................................................... 6-5
CHECKING FOR DAMAGE TO BUCKET WITH HOOK ............................................................................ 6-5
PROHIBITED OPERATIONS ..................................................................................................................... 6-5
HANDLING CAR HEATER................................................................................................................................... 6-6
EXPLANATION OF COMPONENTS .......................................................................................................... 6-6
PREPARING CAR HEATER....................................................................................................................... 6-6
LOCATION OF FIRE EXTINGUISHER ...................................................................................................... 6-7
INTRODUCTION OF ATTACHMENTS ................................................................................................................ 6-8
SPECIFICATION, USE............................................................................................................................... 6-8
ATTACHMENT INSTALLATION COMBINATION TABLE .................................................................................. 6-9
ATTACHMENT COMBINATIONS............................................................................................................... 6-9
SELECTION OF TRACK SHOES............................................................................................................. 6-10
INDEX ................................................................................................................................................................... 7-1

CONTENTS FOREWORD
1-14
MEMO

2-1
SAFETY
21
WARNING
Please be sure that you fully understand this manual and the
precautions related to safety for the machine. When operat-
ing or servicing the machine, always follow these precau-
tions strictly.

SAFETY INFORMATION SAFETY
2-2
SAFETY INFORMATION
POSITION FOR ATTACHING SAFETY LABELS ................................................................................................. 2-4
POSITION FOR ATTACHING SAFETY LABELS ............................................................................................2-5
SAFETY LABELS............................................................................................................................................. 2-6
SAFETY INFORMATION .................................................................................................................................... 2-12
SAFETY RULES ....................................................................................................................................... 2-12
IF ABNORMALITIES ARE FOUND .......................................................................................................... 2-12
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS ................................................................... 2-12
FIRE EXTINGUISHER AND FIRST AID KIT ............................................................................................ 2-12
SAFETY EQUIPMENT.............................................................................................................................. 2-13
KEEP MACHINE CLEAN.......................................................................................................................... 2-13
KEEP OPERATOR'S COMPARTMENT CLEAN ...................................................................................... 2-13
LEAVING OPERATOR'S SEAT WITH LOCK........................................................................................... 2-13
HANDRAILS AND STEPS ........................................................................................................................ 2-14
MOUNTING AND DISMOUNTING ........................................................................................................... 2-15
NO PERSONS ON ATTACHMENTS........................................................................................................ 2-15
BURN PREVENTION ............................................................................................................................... 2-15
FIRE PREVENTION AND EXPLOSION PREVENTION........................................................................... 2-16
ACTION IF FIRE OCCURS ...................................................................................................................... 2-17
WINDSHIELD WASHER FLUID ............................................................................................................... 2-17
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION ......................... 2-17
ATTACHMENT INSTALLATION............................................................................................................... 2-17
ATTACHMENT COMBINATIONS............................................................................................................. 2-18
CAB WIDOW GLASSES........................................................................................................................... 2-18
UNAUTHORIZED MODIFICATIONS........................................................................................................ 2-18
SAFETY AT JOBSITE .............................................................................................................................. 2-18
WORKING ON LOOSE GROUND............................................................................................................ 2-18
DISTANCE TO HIGH VOLTAGE CABLES............................................................................................... 2-19
ENSURE GOOD VISIBILITY .................................................................................................................... 2-19
VENTILATION FOR ENCLOSED AREA .................................................................................................. 2-20
SIGNALMAN'S SIGNAL AND SIGNS....................................................................................................... 2-20
EMERGENCY EXIT FROM OPERATOR'S CAB...................................................................................... 2-20
ASBESTOS DUST HAZARD PREVENTION............................................................................................ 2-20

SAFETY SAFETY INFORMATION
2-3
SAFETY MACHINE OPERATION ...................................................................................................................... 2-21
BEFORE STARTING ENGINE ...................................................................................................................... 2-21
CHECKS BEFORE STARTING ENGINE ................................................................................................. 2-21
SAFETY RULES FOR STARTING ENGINE ............................................................................................ 2-22
STARTING ENGINE IN COLD WEATHER .............................................................................................. 2-22
AFTER STARTING ENGINE ......................................................................................................................... 2-23
CHECKS AFTER STARTING ENGINE ....................................................................................................2-23
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS ................................................................. 2-23
SAFETY RULES FOR TRAVELING ......................................................................................................... 2-24
TRAVELING ON SLOPES........................................................................................................................ 2-25
OPERATIONS ON SLOPES..................................................................................................................... 2-26
PROHIBITED OPERATIONS ................................................................................................................... 2-26
OPERATIONS ON SNOW........................................................................................................................ 2-28
PARKING MACHINE ................................................................................................................................ 2-28
TRANSPORTATION...................................................................................................................................... 2-29
LOADING AND UNLOADING................................................................................................................... 2-29
SHIPPING THE MACHINE ....................................................................................................................... 2-30
BATTERY ...................................................................................................................................................... 2-31
BATTERY HAZARD PREVENTION ......................................................................................................... 2-31
STARTING ENGINE WITH BOOSTER CABLES ..................................................................................... 2-32
TOWING ........................................................................................................................................................ 2-33
SAFETY RULES FOR TOWING............................................................................................................... 2-33
LIFTING OBJECTS WITH BUCKET.............................................................................................................. 2-34
SAFETY RULES FOR LIFTING OBJECTS .............................................................................................. 2-34
SAFETY MAINTENANCE INFORMATION......................................................................................................... 2-35
WARNING TAG ........................................................................................................................................ 2-35
KEEP WORK PLACE CLEAN AND TIDY................................................................................................. 2-35
APPOINT LEADER WHEN WORKING WITH OTHERS .......................................................................... 2-35
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.................................................................. 2-36
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ................................................. 2-37
PROPER TOOLS...................................................................................................................................... 2-37
ACCUMULATOR ...................................................................................................................................... 2-38
PERSONNEL............................................................................................................................................ 2-38
ATTACHMENTS ....................................................................................................................................... 2-38
WORK UNDER THE MACHINE ............................................................................................................... 2-38
NOISE....................................................................................................................................................... 2-39
WHEN USING HAMMER.......................................................................................................................... 2-39
WELDING WORKS................................................................................................................................... 2-39
REMOVING BATTERY TERMINALS ....................................................................................................... 2-39
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION .............. 2-40
DO NOT DISASSEMBLE RECOIL SPRINGS.......................................................................................... 2-40
SAFETY RULES FOR HIGH-PRESSURE OIL......................................................................................... 2-40
SAFETY HANDLING HIGH-PRESSURE HOSES.................................................................................... 2-41
WASTE MATERIALS................................................................................................................................ 2-41
AIR CONDITIONER MAINTENANCE....................................................................................................... 2-41
COMPRESSED AIR ................................................................................................................................. 2-41
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................................. 2-42

POSITION FOR ATTACHING SAFETY LABELS SAFETY
2-4
POSITION FOR ATTACHING SAFETY LABELS
The following warning signes and safety labels are used on this machine.
●Be sure that you fully understand the correct position and content of labels.
●To ensure that the content of labels can be read properly. Be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline, there may cause the labels to
peel off.
●There are also other labels in addition to the warning signes and safety labels. Handle those labels in the
same way.
●If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

SAFETY POSITION FOR ATTACHING SAFETY LABELS
2-5
POSITION FOR ATTACHING SAFETY LABELS