Komatsu D155AX-6 User Manual
EEAM025000
Operation &
Maintenance Manual
D155AX
BULLDOZER
SERIAL NUMBER
D155AX - 80001
and up
-6
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning opera tion or maintenance.
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 thoroughly
and be sure that you understand them fully.
Keep this manual in the storage location f or the opera tion and ma intenance ma nual 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 manua l 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 count ry, consult Komatsu or your Komatsu distributor before operating
the machine.
Location to Keep Operation & Maintenance Manual
Operation and Maintenance Manual pocket at the rear of the
operator's seat
1-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
WARNING
CAUTION
Example of safety message using signal word
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
WARNING
When standing up from the operator's seat, always place
the lock lever in the LOCK position.
If you accidentally touch the control lev ers when they are
not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKS
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1-3
SAFETY INFORMATION FOREWORD
q 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 pr ocedur es.
Example of safety label using words
Safety labels using pictogram
Part No.
Safety pictograms use a picture to expre ss a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of h azardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the me thod of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations corres pond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-4
FOREWORD SAFETY INFORMATION
Noise emission levels 1
Two labels ind icating the machine noise level a re affixed on the
machine.
q Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
q If equipped with air suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleratio n
value for the body is less than or equal to 0.5 m/s².
q If equipped with mechanical suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s².
The actual acceleration value for the body is 0.52 m/s².
1-5
SAFETY INFORMATION FOREWORD
These values were determined using a representative machine and measured during the typical operating condition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(TRACTOR DOZER:) Dozing and spreading material through
forward/reversing motion
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
q Tire pressures (for wheeled machines), tension of
crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with
machine and schedule time to maintain terrain conditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size
of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjust-
ment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled
machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
1-6
FOREWORD SAFETY INFORMATION
6. Adjust the machine speed and travel path to minimize the
vibration level
q When pushing with bucket or blade, avoid sudden
loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over roug h ter-
rain
q Make the curve radius of traveling path as large as
possible
q Travel at low speed when traveling around sharp
curves
7. Minimize vibrations for long work cycle or long distance
traveling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
8. The following guidelines can be effective to m inimize risks
of low back pain
q Operate the machine only when you are in good
health.
q Provide breaks to reduce long periods of sitting in the
same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1-7
INTRODUCTION FOREWORD
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
q Dozing
q Cutting into hard or frozen ground or ditching
q Felling trees, removing stumps
q Pushing
q Ripping
For further details, see “WORK POSSIBLE USING BULLDOZER (3-127)“ and “RIPPER OPERATION (3-120)“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
(A) Front (E) Operator's seat
(B) Rear (F) Sprocket
(C) Left
(D) Right
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
1-8
FOREWORD INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot
be seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY 1
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be
fully aware that there are places that cannot be seen when operating the machine.
1-9
INTRODUCTION FOREWORD
BREAKING IN THE MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, ope rating the machine under full load before bre aking the machine in can adverse ly affect the perf ormance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idle for 15 seconds after star ting it. During this time, do not oper ate the control levers or fuel
control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
1-10
FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1
Under the front of the console box on the right side of the operator's seat.
The design of the nameplate differs according to the territory.
1-11
NECESSARY INFORMATION FOREWORD
EPA REGULATIONS, EN GINE NUMBER PLATE 1
q On the upper of the engine starting motor on the right side of the machine.
q This also acts as the EPA plate.
q This is on the top surface of the muffler mounting bracket on the left side of the machine.
q This also acts as the EPA plate.
EPA: Environmental Protection Agency, U.S.A.
1-12
FOREWORD NECESSARY INFORMATION
BLADE SERIAL NO. PLATE POSITION 1
This is located on the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION 1
This is located on the left side surface of ripper beam.
ROPS, FOPS NO. PLATE POSITION 1
This is at the top rear of the cab.
POSITION OF SERVICE METER 1
On top of the machine monitor
1-13
NECESSARY INFORMATION FOREWORD
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
Distributor
Address
Phone
Service personnel for your
machine:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
1-14
FOREWORD NECESSARY INFORMATION
MACHINE SERIAL NUMBER PLATE
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manuafacturer
1-15
NECESSARY INFORMATION FOREWORD
1-16
CONTENTS
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
Noise emission levels ................................................................................................................................. 1-5
Vibration levels................................ ... ... .... ... ... ....................................... ... ... ... .... ... ... ... ............................... 1-5
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-6
INTRODUCTION................................................................................................................................................... 1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........... .... ... .......................................... ... ... ... .. 1-8
VISIBILITY FROM OPERATOR'S SEAT.................................................................................................... 1-9
PROXIMITY VISIBILITY.................................................................................................................... 1-9
12M CIRCUMFERENCE VISIBILITY .......... .... .......................................... ... ... ... .... ... ... ... ... .... ... ........ 1-9
BREAKING IN THE MACHINE.................................................................................................................1-10
NECESSARY INFORMATION ........................................................................................................................... 1-11
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE .................................... 1-11
EPA REGULATIONS, ENGINE NUMBER PLATE................................................................................... 1-12
BLADE SERIAL NO. PLATE POSITION .............. .... ... ... ... .... ... ... ... .... ... ... ... .......................................... ... 1-13
RIPPER SERIAL NO. PLATE POSITION................................................................................................. 1-13
ROPS, FOPS NO. PLATE POSITION...................................................................................................... 1-13
POSITION OF SERVICE METER ............................................................................................................ 1-13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-14
MACHINE SERIAL NUMBER PLATE....................................................................................................... 1-15
SAFETY
SAFETY................................................................................................................................................................ 2-2
SAFETY LABELS................................................................................................................................................. 2-4
POSITIONS OF SAFETY PICTOGRAMS ....................................................................... ... ... ... ... .... ... ... ... ..2-4
SAFETY LABELS ....................................................................................................................................... 2-5
GENERAL PRECAUTIONS ................................................................................................................................. 2-9
PRECAUTIONS FOR OPERATION................................................................................................................... 2-18
BEFORE STARTING ENGINE ................................................................................................................. 2-18
OPERATION............................................................................................................................................. 2-19
TRANSPORTATION................................................................................................................................. 2-23
BATTERY ................................................................................................................................................. 2-24
TOWING................................................................................................................................................... 2-26
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-27
1-17
CONTENTS
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS....................................................................................................................3-5
MACHINE MONITOR .................................................................................................................................3-5
BASIC OPERATION OF MACHINE MONITOR ................................................................................ 3-6
BASIC CHECK MONITORS..............................................................................................................3-9
CAUTION MONITORS ................. ... ... .... ... ... ... ....................................... ... ... .... ... ... ... .... ... ...............3-10
EMERGENCY MONITORS .......... ... ... ....................................... ... .... ... ... ... ...................................... 3-12
METER DISPLAY PORTION...........................................................................................................3-14
MONITOR SWITCHES PORTION ............................ ... ... .......................................... .... ... ... ............3-21
HANDLING FUNCTION SWITCHES......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ..................3-26
SPEED RANGE DISPLAY............................................................................................................... 3-48
SWITCHES............................................................................................................................................... 3-49
CONTROL LEVERS, PEDALS.................................................................................................................3-53
DUST INDICATOR ................................................................................................................................... 3-61
FUSE BOX................................................................................................................................................3-61
CIRCUIT BREAKER........................................................................................................................3-63
CIRCUIT BREAKER FOR MAIN POWER SUPPLY........................................................................ 3-63
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-64
DOOR POCKET .......................................................................................................................................3-65
ASHTRAY................................................................................................................................................. 3-65
HANDLING AIR CONDITIONER .............................................................................................................. 3-66
GENERAL LOCATIONS OF CONTROL PANEL ............................................................................ 3-66
METHOD OF OPERATION............................................. .... ... ... ... .... ... ...................................... .... ..3-70
PRECAUTIONS WHEN USING AIR CONDITIONER ..................................................................... 3-76
INSPECTION AND MAINTENANCE OF AIR CONDITIONER EQUIPPED MACHINE................... 3-77
OPERATION.......................................................................................................................................................3-78
CHECK BEFORE STARTING ENGINE, ADJUST................................. .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 3-78
WALK-AROUND CHECK ................................................................................................................3-78
CHECK BEFORE STARTING .........................................................................................................3-79
ADJUSTMENT.................................................................................................................................3-89
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-93
STARTING ENGINE................................................................................................................................. 3-95
NORMAL STARTING ................ ...................................... .... ... ... ... ....................................... ... ......... 3-95
STARTING IN COLD WEATHER.................................................................................................... 3-97
OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................3-100
WARMING UP OPERATIONS .................................. ... ... .... ... ... ... .... ... .......................................... 3-100
IN COLD AREAS.......................................................... ... .... ... ... ... .... ... ... ... ... .................................3-101
STOPPING ENGINE . ... ... ... ....................................... ... .... ... ... ....................................... ... ... .... ................3-102
MOVING MACHINE................................................................................................................................ 3-103
STOPPING MACHINE. ....................................... ... ... ... .... ... ....................................... ... ... ... .... ................ 3-105
SHIFTING GEAR.................................................................................................................................... 3-106
SHIFTING BETWEEN FORWARD AND REVERSE ..............................................................................3-112
1-18
CONTENTS
STEERING MACHINE............................................................................................................................ 3-114
NORMAL TURNING...................................................................................................................... 3-114
TURNING WHILE DESCENDING A SLOPE................................................................................. 3-115
PRECAUTIONS FOR OPERATION.................................. .... ... ... ... .... ... ... ... ... .... ... ... .............................. 3-116
PAY ATTENTION TO GAUGES.................................................................................................... 3-116
PERMISSIBLE WATER DEPTH...................... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ........................... 3-116
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................ 3-116
PRECAUTIONS ON SLOPE ......................................................................................................... 3-116
METHOD OF USING BRAKES ..................................................................................................... 3-117
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS......................................... 3-117
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-117
PARKING MACHINE.............................................................................................................................. 3-118
CHECK AFTER STOPPING ENGINE .................................................................................................... 3-119
CHECK AFTER FINISHING WORK ....................................................................................................... 3-120
LOCKING................................................................................................................................................ 3-120
RIPPER OPERATION ............................................................................................................................ 3-120
EFFECTIVE METHOD OF USE.................................................................................................... 3-120
DIGGING UP BOULDERS OR ROCKBED ................................................................................... 3-121
OPERATING ON SLOPES............................................................................................................ 3-121
METHOD OF OPERATING PIN PULLER..................................................................................... 3-122
OPERATING METHOD FOR RIPPING OPERATIONS ........................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... . 3-123
BASIC OPERATING METHOD....................................... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ....... 3-123
RIPPING BY CLIFFS................................... .... ... ... ... ..................................................................... 3-124
RIPPING BY SLOPE FACES........................................................................................................ 3-124
DIGGING UP BOULDERS .... ... ... .... ... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... ... ........... 3-125
PRECAUTIONS WHEN RIPPING................................................................................................. 3-126
WORK POSSIBLE USING BULLDOZER............................................................................................... 3-127
DOZING......................................................................................................................................... 3-127
SMOOTHING................................................................................................................................. 3-128
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................. 3-128
FELLING TREES, REMOVING STUMPS..................................................................................... 3-128
PUSHER OPERATIONS.......................................... .... ...................................... .... ... ... ... ... .... ... .... 3-129
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................. 3-129
BLADE ADJUSTMENT.................................................................................................................. 3-129
METHOD OF ANGLING BLADE................................................................................................... 3-131
ADJUSTING TILT AMOUNT . ... ... ....................................... ... .... ... ... ... ....................................... ... . 3-132
ADJUSTING RIPPER...................................................................... ... ... .... ... ... .............................. 3-134
ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-135
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................................................ ... .... ... ... . 3-136
OPERATION METHOD................................................................................................................. 3-136
INSPECTION AND ADJUSTING................................................................................................... 3-137
INSPECTION AND REPAIR ..........................................................................................................
3-137
TRANSPORTATION......................................................................................................................................... 3-139
LOADING, UNLOADING WORK.................................... ... .... ... ... ... .... ... ... ... ... .... .................................... 3-139
LOADING....................................................................................................................................... 3-139
SECURING MACHINE..................................................................................................................3-140
1-19
CONTENTS
UNLOADING .................................................................................................................................3-141
METHOD OF LIFTING MACHINE..........................................................................................................3-142
PRECAUTIONS FOR TRANSPORTATION ...........................................................................................3-144
TRAVELING ON ROADS .......................................................................................................................3-144
REMOVAL OF CAB................................................................................................................................ 3-145
COLD WEATHER OPERATION ......................................................................................................................3-147
PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-147
FUEL AND LUBRICANTS ............... ... .... ... ... ... ... ....................................... ... .... ... ... .......................3-147
COOLANT .....................................................................................................................................3-147
BATTERY ...................................................................................................................................... 3-148
AFTER COMPLETION OF WORK ........... ... .... ... ... ... ... .... ... ... ... ....................................... ... .... ... ... ... ... .... 3-149
AFTER COLD WEATHER ..................... ... ... .... ... ....................................... ... ... ... ... .... ... ... ... ....................3-149
LONG-TERM STORAGE..................................................................................................................................3-150
BEFORE STORAGE . ... ... ... .... ...................................... .... ... ... ... ....................................... ... .... ................3-150
DURING STORAGE ................. ... ... .... ... ... ... .... ...................................... .... ... ... ... .................................... 3-150
AFTER STORAGE.... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... .... ............................................. 3-150
TROUBLESHOOTING...................................................................................................................................... 3-151
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-151
PROCEDURE FOR BLEEDING AIR.............................................................................................3-151
METHOD OF TOWING MACHINE.........................................................................................................3-153
IF BATTERY IS DISCHARGED.............................................................................................................. 3-154
REMOVAL AND INSTALLATION OF BATTERY .......................................................................... 3-154
PRECAUTIONS WHEN CHARGING BATTERY...........................................................................3-155
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-155
OTHER TROUBLE ................................... ... .... ... ....................................... ... ... ... ... .... .............................3-158
ELECTRICAL SYSTEM.................................................................................................................3-158
ELECTRONIC CONTROL SYSTEM ...... ... ... ... ... .... ... ... ... .... ... ... ... .................................................3-159
CHASSIS.......................................................................................................................................3-160
ENGINE......................................................................................................................................... 3-161
POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS............................................ 3-162
MAINTENANCE
GUIDES TO MAINTENANCE...............................................................................................................................4-2
OUTLINES OF SERVICE .....................................................................................................................................4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-5
OIL.....................................................................................................................................................4-5
FUEL..................................................................................................................................................4-6
COOLANT AND WATER FOR DILUTION.........................................................................................4-6
GREASE............................................................................................................................................ 4-7
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-7
STORING OIL AND FUEL..... .... ... ....................................... ... ... ... .... ...................................... ... ........ 4-8
FILTERS............................................................................................................................................4-8
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-8
1-20
CONTENTS
WEAR PARTS LIST........................................................................................................................................... 4-10
WEAR PARTS LIST.................................................................................................................................. 4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........................................................................................................................................... 4-14
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-15
TORQUE LIST.......................................................................................................................................... 4-15
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16
SAFETY CRITICAL PARTS...................................................................................................................... 4-16
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-18
MAINTENANCE SCHEDULE CHART......................................................................................................4-18
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) .................................... 4-18
WHEN REQUIRED.......................... ...................................... .... ... ... ... ............................................. 4-18
CHECK BEFORE STARTING......................................... ... ... .... ... ... ... ... .... ...................................... 4-18
EVERY 250 HOURS SERVICE....................................................................................................... 4-18
EVERY 500 HOURS SERVICE....................................................................................................... 4-18
EVERY 1000 HOURS SERVICE..................................................................................................... 4-19
EVERY 2000 HOURS SERVICE..................................................................................................... 4-19
EVERY 4000 HOURS SERVICE..................................................................................................... 4-19
EVERY 8000 HOURS SERVICE..................................................................................................... 4-19
SERVICE PROCEDURE .................................................................................................................................... 4-20
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) ............................................. 4-20
WHEN REQUIRED................................................................................................................................... 4-20
CHECK BEFORE STARTING .................................................................................................................. 4-39
EVERY 250 HOURS SERVICE................................................................................................................4-40
EVERY 500 HOURS SERVICE................................................................................................................4-48
EVERY 1000 HOURS SERVICE.............................................................................................................. 4-55
EVERY 2000 HOURS SERVICE.............................................................................................................. 4-65
EVERY 4000 HOURS SERVICE.............................................................................................................. 4-72
EVERY 8000 HOURS SERVICE.............................................................................................................. 4-76
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................ 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
INTRODUCTION OF ATTACHMENTS AND OPTIONS ...................................................................................... 6-3
INTRODUCTION OF ATTACHMENTS AND OPTIONS............................................................................. 6-3
1-21
CONTENTS
HEADREST, HANDLING .....................................................................................................................................6-4
CAP WITH LOCK, HANDLING ............................................................................................................................ 6-5
METHOD OF OPENING AND CLOSING CAP WITH LOCK................................. .... ... ... ... .... ... ... ... ... .... ... . 6-5
PROCEDURE FOR SELECTING RIPPER POINT...............................................................................................6-6
PROCEDURE FOR SELECTING RIPPER POINT..................................................................................... 6-6
HANDLING MACHINES EQUIPPED WITH KOMTRAX......................................................................................6-7
BASIC PRECAUTIONS .................. .... ... ... ....................................... ... ... .... ... ... ... ... .... ................................. 6-7
INDEX
COLOPHON
1-22
SAFETY
12
WARNING
Please be sure that you fully underst an d this manual an d the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
SAFETY SAFETY
SAFETY 2
Safety Labels .. .... ... ... ... .... ...................................... .... ... ... ... ... .... ... ... ...................................................................2-42
Positions of Safety Pictograms ....................................................................................................................2-42
Safety Labels ...............................................................................................................................................2-52
General Precautions
Safety Rules................................................................................................................................................. 2-92
If Abnormalities are Found...........................................................................................................................2-92
Clothing and Personal Protective Items.......................................................................................................2-92
Fire Extinguisher and First Aid Kit................................................................................................................2-92
Safety Features.......................................................................................................................................... 2-102
Keep Machine Clean..................................................................................................................................2-102
Inside Operator's Compartment.................................................................................................................2-102
Always Apply Lock when Leaving Operator's Seat............................. ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... .......2-102
Handrails and Steps..................................... ... .... ... ... ... ... .... ... ....................................... ... ..........................2-112
Mounting and Dismounting ........................................................................................................................ 2-122
No People on Attachments ........................................................................................................................ 2-122
Prevention of Burns.................................................................................................................................... 2-122
Fire Prevention...........................................................................................................................................2-122
Action if Fire Occurs .. ... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... .... ............................................. 2-132
Window Washer Liquid .............................................................................................................................. 2-132
Precautions when Using ROPS ................................................................................................................. 2-142
Precautions for Attachments........ ... ... .... ... ... ... .... ... ... ... .......................................... ... .... ... ..........................2-142
Unauthorized Modification..........................................................................................................................2-142
Safety at Worksite...................................................................................................................................... 2-152
Working on Loose Ground........................................................ .......................................... ... ....................2-152
Do not Go Close to High-Voltage Cables...................................................................................................2-152
Ensure Good Visibility................................................................................................................................2-162
Ventilation for Enclosed Areas...................................................................................................................2-162
Checking Signalman's Signals and Signs.................................................................................................. 2-162
Be Careful About Asbestos Dust................................................................................................................2-172
Precautions for Operation ................................................................................................................................. 2-182
Before Starting Engine...............................................................................................................................2-182
Checks Before Starting Engine...........................................................................................................2-182
Precautions when Starting................................................................. .... ... ... ... ... .... ... ... ... ....................2-182
Precautions in Cold Areas ..................................................................................................................2-192
Operation ...................................................................................................................................................2-192
Checks Before Operation....................................................................................................................2-192
Precautions for Moving Machine Forward or in Reverse....................................................................2-202
Precautions when Traveling.................. ... .... ... ... ... ... .... ... ... ... .... ... .......................................................2-202
Traveling on Slopes ............................................................................................................................2-212
Prohibited Operations .........................................................................................................................2-212
Using Brakes...................... ... ....................................... ... ... ... .... ... ... ... .... ............................................. 2-212
Operate Carefully on Snow.................................................................................................................2-222
Parking Machine.......................................... ... ... ... ....................................... ... ... .... ... ... .......................2-222
Transportation............................................................................................................................................ 2-232
Shipping.............................................................................................................................................. 2-232
Battery........................................................................................................................................................ 2-242
Battery Hazard Prevention.............................. ... ... ... .... ... ... ... .... ..........................................................2-242
Starting with Booster Cable ................................................................................................................ 2-252
Towing........................................................................................................................................................2-262
When Towing...................................................................................................................................... 2-262
2-2
SAFETY SAFETY
Precautions for Maintenance ....................... ... .... ... ... ... ... .... ... ... ... .......................................... ........................... 2-272
Warning Tag .............................................................................................................................................. 2-272
Keep Work Place Clean and Tidy... ... ... ... .... ... .......................................... ... ... ........................................... 2-272
Appoint Leader when Working with Others.................. ... ... ... .... ... ... ... .... ... ................................................. 2-272
Stop Engine Before Carrying Out Inspection and Maintenance ................................................................2-282
Two Workers for Maintenance when Engine is Running ........................................................................... 2-282
Proper Tools ............ ... ... .... ... ... ....................................... ... ... .... ... .............................................................. 2-292
Handling Accumulator................................................................................................................................ 2-292
Personnel...................................................................................................................................................2-292
Attachments............................................................................................................................................... 2-302
Work Under the Machine ........................................................................................................................... 2-302
Noise.......................................................................................................................................................... 2-302
Precautions when Using Hammer ............................................................................................................. 2-302
Repair Welding .......................................................................................................................................... 2-302
Removing Battery Terminal ........ .... ... ... ... .... ... ... ... ... .... ... ... ... .... .......................................... ... .................... 2-312
Precautions when Using High-Pressure Grease to Adjust Track Tension................................................. 2-312
Do not Disassemble Recoil Spring ............................................................................................................ 2-312
Precaution with High-Pressure Oil............................................................................................................. 2-312
Precaution for High Fuel Pressure............................... ... ... ... .... ... ... ... .... .................................................... 2-322
Handing High-Pressure Hoses .................................................................................................................. 2-322
Precaution for High Voltage...................................................................... ... ... ... .... ... ... .............................. 2-322
Waste Material........................................................................................................................................... 2-332
Maintenance for Air Conditioner ................................................................................................................ 2-332
Compressed Air......................................................................................................................................... 2-332
Periodic Replacement of Safety Critical Parts ........................................................................................... 2-332
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
POSITIONS OF SAFETY PICTOGRAMS 2
2-4
SAFETY SAFETY LABELS
SAFETY LABELS 2
(1) Caution for operation, inspection, and maintenance
(09651-A0641)
q Warning!
q Read manual before operation, maintaince, disassembly,
assembly and transportation.
(2) Caution when traveling in reverse (09802-13000)
WARNING
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:
q Honk horn to alert people nearby.
q Be sure no one is on or near the machine.
q Use spotter if view is obstructed.
Follow above even if the machine is equipped with backup alarm and mirrors.
(3) Warning for leaving operator's seat (09654-B0641)
q Sign indicates a hazard of unexpected m oving of stopped
machine.
q Lower working device to ground, move safety lever to lock
position and take engine key with you before leaving
machine.
2-5
SAFETY LABELS SAFETY
(4) Warning for hot water hazard (09653-A0481)
q Never remove the cap when the engine is at operating
(High) temperature. S t re am or h igh temp er ature oil blowin g
up from the radiator or hydraulic tank, will cause personal
injury and / or burns.
q Never remove the radiator or hydraulic tank oil filler when
cooling water or hydraulic oil is at high temperatures.
(5) Caution when adjusting track tension (09657-A0881)
Safety label is attached to the back side of the inspection cover
of the track frame.
q Sign indicates a hazzard of flying plug from track adjuster
that could cause injury.
q Read the manual and adjusting track for safe and proper
handling.
(6) Caution for handling accumulator (09659-A057B)
q There is the hazard of explotion causing injury.
q Do not disassemble the accumulator, make holes in it, weld
it, cut it, hit it, roll it or bring it near flame.
2-6
Loading...