Komatsu D155AX-76UP, D155AX-5 User Manual
EEAM023402
Operation &
Maintenance Manual
D155AX
BULLDOZER
SERIAL NUMBER
D155AX - 76243
and up
-5
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
q Machine equipped with cab
Inside of right and left doors
1-2
FOREWORD FOREWORD
q Machine equipped without cab
Back pocket of operator's seat
1-3
SAFETY INFORMATION FOREWORD
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 p otential hazardo us 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 levers when they are
not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKS
1-4
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.
FOREWORD SAFETY INFORMATION
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 mach in e th at m ay inv olv e ha za rd .
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to ind icate safety pro cedures.
Example of safety label using words
Part No.
Safety labels using pictogram
Safety pictograms use a picture to express a level o f hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-5
SAFETY INFORMATION FOREWORD
Noise emission levels 1
Two labels indicating the machine noise level are 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.
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 less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
1-6
FOREWORD SAFETY INFORMATION
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine
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 accordin g 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 con-
ditions
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 adjustme nt mec ha nis ms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
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 rough terrain
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 minimize risks of low back pain
q Operate the machine only when you are in good he alt h.
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 (3-118)“ and “RIPPER OPERATION (3-111)“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
Front
Left
Operator’s seat
Rear
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.
Right
Sprocket
1-8
FOREWORD INTRODUCTION
BREAKING IN THE MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, operat ing the machine under full load bef ore breaking the machine in can adversely 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 idling for 15 seconds after starting it. During this time, do not operate 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.
1-9
NECESSARY INFORMATION FOREWORD
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.
ENGINE SERIAL NO. PLATE AND POSITION (1) 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.
1-10
FOREWORD NECESSARY INFORMATION
ENGINE SERIAL NO. PLATE AND POSITION (2) 1
q This is the same content as engine serial No. plate (1).
q Located on the top of the air cleaner mounting bracket on the left of the machine.
q This also acts as the EPA plate.
EPA: Environmental Protection Agency, U.S.A.
BLADE SERIAL NO. PLATE POSITION 1
This is located on the upper right of blade back surface.
1-11
NECESSARY INFORMATION FOREWORD
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 located on the top left.
FOPS
ROPS
POSITION OF SERVICE METER 1
On top of the machine monitor
1-12
FOREWORD NECESSARY INFORMATION
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
MACHINE SERIAL NUMBER PLATE
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
Model
1-13
NECESSARY INFORMATION FOREWORD
1-14
FOREWORD NECESSARY INFORMATION
1-15
CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-4
Noise emission levels ............................................... ... .... ... ... ... .... ...................................... ........................1-6
Vibration levels............................................................................................................................................1-6
Guide to Reduce Vibration Levels on Machine..................................................................................1-7
INTRODUCTION................................................................................................................................................... 1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................................... 1-8
BREAKING IN THE MACHINE...................................................................................................................1-9
NECESSARY INFORMATION ...........................................................................................................................1-10
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE.....................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (1) ............................... .... ... ............................................1-10
ENGINE SERIAL NO. PLATE AND POSITION (2) ............................... .... ... ............................................1-11
BLADE SERIAL NO. PLATE POSITION .................................................................................................. 1-11
RIPPER SERIAL NO. PLATE POSITION............................................................................... ..................1-12
ROPS, FOPS NO. PLATE POSITION ...................................................................................................... 1-12
POSITION OF SERVICE METER .......................................................................................................... .. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................1-13
MACHINE SERIAL NUMBER PLATE . ... ... ... .... ... ... ... ... ....................................... ... .... ... ... ... .... ... ... ... ... ...... 1-13
SAFETY
SAFETY................................................................................................................................................................2-2
SAFETY LABELS.................................................................................................................................................2-4
POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4
SAFETY LABELS .................................. ... ... .... ...................................... .... ................................................. 2-5
GENERAL PRECAUTIONS ...............................................................................................................................2-11
PRECAUTIONS FOR OPERATION................................................................................................................... 2-20
BEFORE STARTING ENGINE .............. ... ... .... ... ....................................... ... ... ... ... .... ... ............................2-20
OPERATION.............................................................................................................................................2-22
TRANSPORTATION................................................................................................................................. 2-26
BATTERY .................................................................................................................................................2-27
TOWING ................................................................................................................................................... 2-29
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-30
1-16
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
FRONT PANEL........................................................................................................................................... 3-5
CHECK MONITOR GROUP......................................................... ... ... ... .... ... ... ... .... ........................... 3-7
CAUTION MONITOR GROUP .......................................................................................................... 3-9
EMERGENCY CAUTION ITEMS .................................................................................................... 3-11
METER GROUP.... ... ... ... .... ... ... ....................................... ... ... .... ...................................... ... .......... ... 3-14
SWITCHES...................................................................................................................................... 3-18
LAMPS............................................................................................................................................. 3-21
METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-23
SWITCHES............................................................................................................................................... 3-32
CONTROL LEVERS, PEDALS................................................................................................................. 3-37
DUST INDICATOR ................................................................................................................................... 3-44
POWER SOURCE.......................................................................... .... ... ... ... ... .... ... ... ................................ 3-44
FUSE BOX.. .... ... ... ... ... .... ...................................... .... ... ... ....................................... ... ... ............................. 3-45
CIRCUIT BREAKER........................................................................................................................3-47
CIRCUIT BREAKER FOR MAIN POWER SUPPLY........................................................................ 3-47
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-48
DOOR POCKET ....................................................................................................................................... 3-49
ASHTRAY................................................................................................................................................. 3-49
CAR RADIO, HANDLING ......................................................................................................................... 3-50
EXPLANATION OF COMPONENTS............................................................................................... 3-50
METHOD OF USE........................................................................................................................... 3-52
PRECAUTIONS WHEN USING ...................................................................................................... 3-54
CAR STEREO, HANDLING...................................................................................................................... 3-55
EXPLANATION OF COMPONENTS............................................................................................... 3-55
METHOD OF OPERATION.............................................................................................................3-58
PRECAUTION WHEN USING......................... ... ... ... .... ...................................... .... ... ... ... ... .... ... ... ... 3-60
AIR CONDITIONER.................................................................................................................................. 3-61
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ....................... ... ... ... ... .... ... ... ... 3-61
METHOD OF OPERATION.............................................................................................................3-63
PRECAUTIONS WHEN USING ...................................................................................................... 3-64
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......... 3-64
CHECKS DURING OFF-SEASON.................................................................................................. 3-64
PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-65
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-65
CLEANING AIR FILTER.................................................................................................................. 3-65
SKILLFUL USE OF AIR-CONDITIONER ........................................................................................ 3-66
HEATER, HANDLING............................................................................................................................... 3-67
METHOD OF OPERATION.............................................................................................................3-67
CLEANING AIR FILTER.................................................................................................................. 3-67
ACCUMULATOR, HANDLING.................................................................................................................. 3-68
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
1-17
CONTENTS
ACCUMULATOR............................................................................................................................. 3-68
OPERATION.......................................................................................................................................................3-69
CHECK BEFORE STARTING ENGINE, ADJUST................................. .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 3-69
WALK-AROUND CHECK ................................................................................................................3-69
CHECK BEFORE STARTING ......................................................................................................... 3-71
ADJUSTMENT.................................................................................................................................3-82
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-86
STARTING ENGINE................................................................................................................................. 3-88
NORMAL STARTING ............ .... ... ... ... .... ... ... ... ....................................... ... ... .... ...............................3-88
STARTING IN COLD WEATHER.................................................................................................... 3-90
OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-93
WARMING UP OPERATIONS ............................................................................ ... ... .... ... ... ... ... .... .. 3-93
IN COLD AREAS.......................................................... ... .... ... ... ... .... ... ... ......................................... 3-94
STOPPING ENGINE . ... ... ... ....................................... ... .... ... ....................................... ... ... ... ......................3-95
MOVING MACHINE.................................................................................................................................. 3-96
STOPPING MACHINE..................................... ... ... ... ....................................... ... ... .... ...............................3-98
SHIFTING GEAR...................................................................................................................................... 3-99
SHIFTING BETWEEN FORWARD AND REVERSE ..............................................................................3-102
STEERING MACHINE............................................................................................................................ 3-104
NORMAL TURNING............................................................................... ... .................................... 3-104
TURNING WHILE DESCENDING A SLOPE............................. ... .... ......................................... .... 3-105
PRECAUTIONS FOR OPERATION .......................................................................................................3-106
PAY ATTENTION TO GAUGES....................................................................................................3-106
PERMISSIBLE WATER DEPTH.................................................................................................... 3-106
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................3-106
PRECAUTIONS ON SLOPE ......................................................................................................... 3-107
METHOD OF USING BRAKES ..................................................................................................... 3-107
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS .........................................3-107
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-107
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY.....................3-108
PARKING MACHINE ............. ... ... ....................................... ... ....................................... ... .......................3-108
CHECK AFTER STOPPING ENGINE ....................................................................................................3-109
CHECK AFTER FINISHING WORK ............ .... ... ... ... ... .... ...................................... .... ... ... ... .... ... ... ... ... .... 3-110
LOCKING................................................................................................................................................3-110
RIPPER OPERATION ............................................................................................................................3-111
EFFECTIVE METHOD OF USE.................................................................................................... 3-111
DIGGING UP BOULDERS OR ROCKBED ................................................................................... 3-111
OPERATING ON SLOPES............................................................................................................ 3-112
METHOD OF OPERATING PIN PULLER.....................................................................................3-112
OPERATING METHOD FOR RIPPING OPERATIONS ......................................................................... 3-113
BASIC OPERATING METHOD ..................................................................................................... 3-11
RIPPING BY CLIFFS..................................................................................................................... 3-114
RIPPING BY SLOPE FACES ........................................................................................................3-114
DIGGING UP BOULDERS ............................................................................................................3-115
PRECAUTIONS WHEN RIPPING.................................................................................................3-116
WORK POSSIBLE USING BULLDOZER ............................................................................................... 3-118
3
1-18
CONTENTS
DOZING......................................................................................................................................... 3-118
SMOOTHING................................................................................................................................. 3-118
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................. 3-119
FELLING TREES, REMOVING STUMPS..................................................................................... 3-119
PUSHER OPERATIONS.............................................................................. ... ... .... ... ... ... .............. 3-119
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................. 3-120
METHOD OF ANGLING BLADE................................................................................................... 3-120
ADJUSTING TILT AMOUNT . ....................................... ... ... ... .... ...................................... ... .... ... .... 3-122
ADJUSTING RIPPER...................................................................... ... ... .... .................................... 3-124
ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-125
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................................................ ... .... ... ... . 3-126
OPERATION METHOD................................................................................................................. 3-126
INSPECTION AND ADJUSTING................................................................................................... 3-127
INSPECTION AND REPAIR .......................................................................................................... 3-128
TRANSPORTATION......................................................................................................................................... 3-130
LOADING, UNLOADING WORK.................................... ... .... ... ... ... .... ... ... ....................................... ....... 3-130
PRECAUTIONS FOR LOADING................................. ... ... .... ... ....................................... ... ... ... ... .... ....... 3-130
METHOD OF LIFTING MACHINE.......................................................................................................... 3-131
PRECAUTIONS FOR TRANSPORTATION ............................. ... ... .... ... ... ... ... .... ... ... ... .... ....................... 3-132
TRAVELING ON ROADS ........ .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ... ... ........................... 3-132
REMOVAL OF CAB................................................................................................................................ 3-133
COLD WEATHER OPERATION...................................................................................................................... 3-135
PRECAUTIONS FOR LOW TEMPERATURE................................................................. ... ... ... ... .... ... ... . 3-135
FUEL AND LUBRICANTS .............................................................................................................3-135
COOLANT ..................................................................................................................................... 3-135
BATTERY...................................................................................................................................... 3-136
AFTER COMPLETION OF WORK......................................................................................................... 3-136
AFTER COLD WEATHER...................................................................................................................... 3-137
LONG-TERM STORAGE..................................................................................................................................3-138
BEFORE STORAGE............................................................................................................................... 3-138
DURING STORAGE............................................................................................................................... 3-138
AFTER STORAGE.................................................................................................................................. 3-138
TROUBLESHOOTING...................................................................................................................................... 3-139
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-139
PROCEDURE FOR BLEEDING AIR............................................................................................. 3-139
METHOD OF TOWING MACHINE.........................................................................................................3-141
IF BATTERY IS DISCHARGED.............................................................................................................. 3-142
REMOVAL AND INSTALLATION OF BATTERY .......................................................................... 3-142
PRECAUTIONS WHEN CHARGING BATTERY........................................................................... 3-143
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-143
OTHER TROUBLE ................................................................................................................................. 3-146
ELECTRICAL SYSTEM................................................................................................................. 3-146
MONITOR PANEL.........................................................................................................................3-147
CHASSIS........................................................................................................................
............... 3-148
ENGINE......................................................................................................................................... 3-149
1-19
CONTENTS
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............................................................................................................................................4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ....................................................................4-7
STORING OIL AND FUEL..... ....................................... ... .... ... ....................................... ... ... ... ... ........ 4-8
FILTERS............................................................................................................................................4-8
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-8
HANDLING HYDRAULIC RELATED EQUIPMENT.................................................................................... 4-9
WEAR PARTS LIST ........................................................................................................................................... 4-10
WEAR PARTS LIST..................................................................................................................................4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-12
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............4-13
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....................................................................................................... 4-19
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................................................ ... ... ....................................... ... .... ... ............................4-21
CHECK BEFORE STARTING ......................................... ... ... ... .... ... ... ... .... ... ... ......................................... 4-45
EVERY 250 HOURS SERVICE................................................................................................................ 4-46
EVERY 500 HOURS SERVICE................................................................................................................ 4-55
EVERY 1000 HOURS SERVICE..............................................................................................................4-63
EVERY 2000 HOURS SERVICE..............................................................................................................4-71
1-20
CONTENTS
EVERY 4000 HOURS SERVICE................................................................. ............................................. 4-75
EVERY 8000 HOURS SERVICE................................................................. ............................................. 4-78
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
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
INDEX
COLOPHON
1-21
CONTENTS
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 .............................................................................................................................................2-112
General Precautions
Safety Rules............................................................................................................................................... 2-112
If Abnormalities are Found.........................................................................................................................2-112
Clothing and Personal Protective Items..................................................................................................... 2-112
Fire Extinguisher and First Aid Kit..............................................................................................................2-112
Safety Features.......................................................................................................................................... 2-122
Keep Machine Clean..................................................................................................................................2-122
Inside Operator's Compartment.................................................................................................................2-122
Always Apply Lock when Leaving Operator's Seat............................. ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... .......2-132
Handrails and Steps..................................... ... .... ... ... ... ... ....................................... ... .... ... ..........................2-132
Mounting and Dismounting ........................................................................................................................ 2-142
No People on Attachments ........................................................................................................................ 2-142
Prevention of Burns.................................................................................................................................... 2-142
Fire Prevention...........................................................................................................................................2-152
Action if Fire Occurs .. ... ... ... ... .... ... ....................................... ... ... ... .... ... ... ... .................................................2-162
Window Washer Liquid .............................................................................................................................. 2-162
Precautions when Using ROPS ................................................................................................................. 2-162
Precautions for Attachments........ ... ... .... ... ... ... .... ... .................................................................................... 2-172
Unauthorized Modification..........................................................................................................................2-172
Safety at Worksite...................................................................................................................................... 2-172
Working on Loose Ground..................................................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ....................2-172
Do not Go Close to High-Voltage Cables...................................................................................................2-182
Ensure Good Visibility................................................................................................................................2-182
Ventilation for Enclosed Areas...................................................................................................................2-182
Checking Signalman's Signals and Signs.................................................................................................. 2-192
Be Careful About Asbestos Dust................................................................................................................2-192
2-2
SAFETY SAFETY
Precautions for Operation................................................... ... ... ... .... ... ... ... .... ... ... ..............................................2-202
Before Starting Engine.................................... ... ... ... .... ... ... ... .... ... ... ... ........................................................ 2-202
Checks Before Starting Engine........................................................................................................... 2-202
Precautions when Starting.................................................................................................................. 2-202
Precautions in Cold Areas .................................................................................................................. 2-212
Operation................................................................................................................................................... 2-222
Checks Before Operation.................................................................................................................... 2-222
Precautions for Moving Machine Forward or in Reverse.................................................................... 2-222
Precautions when Traveling................................................................................................................ 2-232
Traveling on Slopes............................................................................................................................ 2-242
Prohibited Operations......................................................................................................................... 2-242
Using Brakes....................................................................................................................................... 2-242
Operate Carefully on Snow................................................................................................................. 2-242
Parking Machine................................................................................................................................. 2-252
Transportation............................................................................................................................................ 2-262
Shipping.............................................................................................................................................. 2-262
Battery........................................................................................................................................................ 2-272
Battery Hazard Prevention.................................................................................................................. 2-272
Starting with Booster Cable ................................................................................................................ 2-282
Towing ....................................................................................................................................................... 2-292
When Towing...................................................................................................................................... 2-292
Precautions for Maintenance ....................... ... .... ... ... ... ... .... .............................................................................. 2-302
Warning Tag .............................................................................................................................................. 2-302
Keep Work Place Clean and Tidy... ... ... .......................................... .......................................... ................. 2-302
Appoint Leader when Working with Others.................. ... ... ... .... ... ... ... .... ... ................................................. 2-302
Stop Engine Before Carrying Out Inspection and Maintenance ................................................................ 2-312
Two Workers for Maintenance when Engine is Running ........................................................................... 2-322
Proper Tools ............ ... ... .... ...................................... .... ... ... ....................................... ... .............................. 2-322
Handling Accumulator................................................................................................................................ 2-332
Personnel................................................................................................................................................... 2-332
Attachments............................................................................................................................................... 2-332
Work Under the Machine ........................................................................................................................... 2-332
Noise........................................................................................................................
Precautions when Using Hammer ............................................................................................................. 2-342
Repair Welding .......................................................................................................................................... 2-342
Removing Battery Terminal ........ .... ... ... ... .... ... ... ... ... .... .......................................... .................................... 2-342
Precautions when Using High-Pressure Grease to Adjust Track Tension................................ ... ... .... ... ... . 2-342
Do not Disassemble Recoil Spring ............................................................................................................ 2-352
Precaution with High-Pressure Oil............................................................................................................. 2-352
Precaution for High Fuel Pressure............................... ... ... ... .... ... .......................................... ... ................. 2-352
Handling High-Pressure Hoses.................................................................................................................. 2-352
Precaution for High Voltage...................................................................... ... ... ... ........................................ 2-362
Waste Material........................................................................................................................................... 2-362
Maintenance for Air Conditioner ................................................................................................................ 2-362
Compressed Air......................................................................................................................................... 2-362
Periodic Replacement of Safety Critical Parts ........................................................................................... 2-362
.................................. 2-342
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
POSITIONS OF SAFETY PICTOGRAMS 2
2-4
SAFETY SAFETY LABELS
SAFETY LABELS 2
(1) Precautions for operation, inspection, and maintenance
(09651-A0641)
q Warning!
q Read manual before operation, maintaince, disassembly,
assembly and transportation.
(2) Precautions 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.
To prevent SEVERE INJURY or
DEATH, do the following before
moving machine or its attachments
. Honk horn to alert people
nearby.
. Be sure no one is on or near
the machine.
. Use spotter if view is ob-
structed.
Follow above even if the
machine is equipped with
back-up alarm and mirrors.
09802-13000
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) Precautions 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) Precautions 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.
(7) Precautions for use of seat belt
(195-98-12940)
CAUTION
q ALWAYS USE SEAT BELT WHEN OPERATING
MACHINE.
q ALWAYS CHECK CONDITION OF THE SEAT BELT, THE
CONNECTING BRACKETS AND THE TIGHTENING
BOLTS.
q ADJUST SEAT TO ALLOW FULL BREAK PEDAL WITH
OPERATOR’S BACK AGAINST SEAT BACK.
q AFTER ADJUSTING THE HEIGHT, FORE AND AFT
POSITION OF THE SEAT, TIGHTEN THE TETHER BELT
BEFORE SITTING IN THE SEAT.
2-6
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