Komatsu D37PX-21 User Manual
EEAM024300
Operation &
Maintenance Manual
D31EX, PX-21
D37EX, PX-21
D39EX, PX-21
BULLDOZER
SERIAL NUMBER
D31EX-21 - 50501 and up
D31PX-21 - 50501 and up
D37EX-21 - 5709 and up
D37PX-21 - 5709 and up
D39EX-21 -1501 and up
D39PX-21 -1501 and up
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
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manu al carefully so that they shou ld be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediat ely contact Komatsu or your Komatsu distributor
to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.
In this manual, measurements are expressed in internationa l standard units (SI). For the reference purpose, weight units used in the p ast are also displayed in { }.
Storage location for the Operation and Maintenance
Manual:
If machine is equipped without cab.
Pocket at rear of operator's seat
If machine is equipped with a cab.
Pocket at rear of operator's seat
Inside of right and left doors
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 d eath
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 safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are n ot locked, this may ca use a serious inju ry 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
REMARK
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This gives information that is useful to know.
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 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 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 correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-4
FOREWORD SAFETY INFORMATION
Noise emission levels (D37EX, D37PX)
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 (D37EX, D37PX)
When used for its intended purpose, levels of vibratio n 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 condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.
1-5
SAFETY INFORMATION FOREWORD
Operating condition:
(WHEEL LOADER:) V-shape loading
( H Y DR A U LI C E XC AVAT O RS:) E x cav a t in g ( Dig g i ng- l oading-
rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through
forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travel-
ling, 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 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 Smoothing
q Cutting into hard or frozen ground or ditching
See the section “WORK POSSIBLE USING BULLDOZER (3-95)“ for further details.
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 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
This is at the front bottom right of the oper ator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE 1
This is at the front top of the engine on the left side machine.
EPA: Environmental Protection Agency, U.S.A.
1-9
NECESSARY INFORMATION FOREWORD
POSITION OF SERVICE METER 1
The service meter is provided at the lower part of the monitor
panel.
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN 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
1-10
FOREWORD NECESSARY INFORMATION
MACHINE SERIAL PLATE.
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
kg
kW
1-11
CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-3
Noise emission levels (D37EX, D37PX) .....................................................................................................1-5
Vibration levels (D37EX, D37PX) ...............................................................................................................1-5
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............................................................1-6
INTRODUCTION................................................................................................................................................... 1-8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.......................................................................1-8
NECESSARY INFORMATION .............................................................................................................................1-9
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................................ 1-9
ENGINE SERIAL NO. PLATE.....................................................................................................................1-9
POSITION OF SERVICE METER ............................................................................................................ 1-10
TABLE OF ENTER SERIAL NO. AND DISTRIBUTORN..........................................................................1-10
MACHINE SERIAL PLATE. ...................................................................................................................... 1-11
SAFETY
SAFETY................................................................................................................................................................2-2
SAFETY LABELS.................................................................................................................................................2-4
POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4
SAFETY LABELS ........ ... ... .... ... ... ... .... ...................................... .... ...................................... ........................2-5
GENERAL PRECAUTIONS ...............................................................................................................................2-10
PRECAUTIONS FOR OPERATION...................................................................................................................2-19
STARTING ENGINE................................................................................................................................. 2-19
OPERATION.............................................................................................................................................2-21
TRANSPORTATION................................................................................................................................. 2-24
BATTERY ................................................................................................................................................. 2-25
TOWING ...................................................................................................................................................2-27
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-28
1-12
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 SYSTEM ............................................................................................................3-6
EMERGENCY CAUTION ITEMS ...................................................................................................... 3-7
CAUTION CAUTION ITEMS .............................................................................................................3-9
METER GROUP.... ... ... ... .... ... ... ....................................... ... ... .... ...................................... ... ............. 3-11
LAMPS............................................................................................................................................. 3-20
METHOD OF USING MAINTENANCE MODE................................................................................ 3-21
SWITCHES............................................................................................................................................... 3-30
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-35
FUSE ........................................................................................................................................................ 3-41
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-42
DOOR - OPEN LOCK............................................................................................................................... 3-43
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-43
CAP, COVER WITH LOCK....................................................................................................................... 3-44
METHOD OF OPENING AND CLOSING CAP WITH LOCK ............................. .... ... ... ... ... .... ... ... ... 3-44
METHOD OF OPENING AND CLOSING COVER WITH LOCK..................................................... 3-45
DOOR POCKET ....................................................................................................................................... 3-45
ASHTRAY................................................................................................................................................. 3-46
LUNCHBOX HOLDER BELT.................................................................................................................... 3-46
CUP HOLDER .......................................................................................................................................... 3-46
TOOL BOX................................................................................................................................................ 3-47
GREASE PUMP HOLDER........................................................................................................................ 3-47
CAR STEREO, HANDLING...................................................................................................................... 3-48
EXPLANATION OF COMPONENTS............................................................................................... 3-48
METOD OF OPERATION................................................................................................................ 3-53
PRECAUTION WHEN USING......................... ... ... ... .... ...................................... .... ... ... ... ... .... ... ... ... 3-55
AIR CONDITIONER, HANDLING ............................................................................................................. 3-56
EXPLANATION OF PARTS............................................................................................................. 3-56
PREVENTION METHOD OF ENTRY OF DUST............................................................................. 3-58
PRECAUTION WHEN USING AIR CONDITIONER........................................................................ 3-58
INSPECTION DURING OFF-SEASON........................................................................................... 3-58
PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-59
CLEANING AIR FILTER.................................................................................................................. 3-59
ACCUMULATOR, HANDLING.................................................................................................................. 3-60
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR............................................................................................................................. 3-60
OPERATION....................................................................................................................................................... 3-61
CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-61
WALK-AROUND CHECK ................................................................................................................ 3-61
CHECK BEFORE STARTING............................................ ... .... ... ... ... ... .... ... ... ... .... ......................... 3-63
1-13
CONTENTS
ADJUSTMENT.................................................................................................................................3-72
OPERATION AND CHECK BEFORE STARTING ENGINE............................................................3-75
STARTING ENGINE................................................................................................................................. 3-77
NORMAL STARTING ...................................... ... .... ... ... ... .... ... ... ....................................... ... ... ......... 3-77
STARTING IN COLD WEATHER....................................................................................................3-79
OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................... 3-81
BREAKING IN THE NEW MACHINE ..............................................................................................3-81
WARMING UP OPERATIONS ............... ...................................... .... ... ... ... ... .... ... ... ... .... ... ...............3-81
STARTING IN COLD WEATHER....................................................................................................3-82
STOPPING ENGINE . ... ... ... ....................................... ... .... ... ....................................... ... ... ... .... ..................3-84
MACHINE OPERATION ........................................................................................................................... 3-85
MOVING MACHINE................................................................... ... ....................................... ... ......... 3-85
STOPPING MACHINE..................................................................................................................... 3-88
SHIFTING GEARS....................................................................................................................................3-89
SHIFTING BETWEEN FORWARD AND REVERSE ................................................................................3-90
STEERING MACHINE.............................................................................................................................. 3-91
NORMAL TURNING............................................... ... ....................................... ... ... .........................3-91
TURNING WHILE DESCENDING A SLOPE............................. ... .... ... .......................................... .. 3-92
PRECAUTIONS FOR OPERATION ......................................................................................................... 3-93
PAY ATTENTION TO GAUGES......................................................................................................3-93
PERMISSIBLE WATER DEPTH...................................................................................................... 3-93
METHOD OF USING BRAKES .......................................................................................................3-93
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..........................................................3-93
PRECAUTIONS ON SLOPES.........................................................................................................3-94
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-94
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL
OBSTRUCT THE VIEW.................................................................................................................. 3-94
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY..................................................... 3-94
WORK POSSIBLE USING BULLDOZER .................................................................................................3-95
DOZING........................................................................................................................................... 3-95
SMOOTHING...................................................................................................................................3-95
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................... 3-96
FELLING TREES, REMOVING STUMPS ....................................................................................... 3-96
SIDE-CUTTING OPERATIONS....................................................................................................... 3-96
PARKING MACHINE ....................................... ... ....................................... ... ............................................ 3-97
CHECK AFTER FINISHING WORK ...................................... ... .... ... ... ... .... ... ... ... ... ................................... 3-98
BEFORE STARTING ENGINE........................................................................................................ 3-98
AFTER STARTING ENGINE...........................................................................................................3-98
LOCKING..................................................................................................................................................3-99
TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-100
OPERATION METHOD.................................................................................................................3-100
INSPECTION AND ADJUSTMENT...............................................................................................3-100
INSPECTION AND REPAIR.......................................................................................................... 3-101
TRANSPORTATION......................................................................................................................................... 3-103
TRANSPORTATION MEANS.................................................................................................................3-103
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-103
REMOVING CAB................... ... ... ... .... ... ... ....................................... ... ... .... ............................................. 3-103
1-14
CONTENTS
LOADING, UNLOADING WORK.... ... ....................................... ... ... .... ... ... ... ... .... ... ... ... ........................... 3-104
LIFTING MACHINE................................................................................................................................. 3-108
COLD WEATHER OPERATION...................................................................................................................... 3-109
PRECAUTIONS FOR LOW TEMPERATURE............................. ... .... ... ... ... ... .... ... ... ... .... ... ... ................. 3-109
AFTER COMPLETION OF WORK......................................................................................................... 3-111
AFTER COLD WEATHER...................................................................................................................... 3-111
LONG-TERM STORAGE..................................................................................................................................3-112
BEFORE STORAGE............................................................................................................................... 3-112
DURING STORAGE............................................................................................................................... 3-112
AFTER STORAGE.................................................................................................................................. 3-112
TROUBLESHOOTING...................................................................................................................................... 3-113
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-113
MACHINE TOWING METHOD............................. .... ... ... ... ....................................... ... .... ... .................... 3-113
WHEN IT IS POSSIBLE TO START ENGINE.............................. ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... . 3-114
WHEN ENGINE DOES NOT START ................................. ... .... ... ... ... ... ........................................ 3-115
IF BATTERY IS DISCHARGED.............................................................................................................. 3-120
REMOVE AND INSTALL BATTERY ............................... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... ........... 3-121
PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-121
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-122
WHEN ENGINE DOES NOT STOP........................................................................................................ 3-124
OTHER TROUBLE ................................................................................................................................. 3-125
ELECTRICAL SYSTEM................................................................................................................. 3-125
MONITOR PANEL......................................................................................................................... 3-126
CHASSIS....................................................................................................................................... 3-127
ENGINE......................................................................................................................................... 3-128
MAINTENANCE
GUIDE TO MAINTENANCE................................................................................................................................. 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
OIL..................................................................................................................................................... 4-5
FUEL.................................................................................................................................................. 4-5
COOLANT ......................................................................................................................................... 4-6
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)......................................................... 4-6
STORING OIL AND FUEL................................................................................................................. 4-7
FILTERS............................................................................................................................................ 4-7
RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-8
WEAR PARTS LIST............................................................................................................................................. 4-9
WEAR PARTS LIST.................................................................................................................................... 4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .................... 4-11
1-15
CONTENTS
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS .........................................................4-11
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 ...............................................................................................................4-17
MAINTENANCE SCHEDULE CHART......................................................................................................4-17
WHEN REQUIRED.......................................................................................................................... 4-17
CHECK BEFORE STARTING ......................................................................................................... 4-17
EVERY 50 HOURS SERVICE................... ......................................................................................4-17
EVERY 250 HOURS SERVICE....................................................................................................... 4-17
EVERY 500 HOURS SERVICE....................................................................................................... 4-17
EVERY 1000 HOURS SERVICE.....................................................................................................4-17
EVERY 2000 HOURS SERVICE.....................................................................................................4-18
EVERY 4000 HOURS SERVICE.....................................................................................................4-18
SERVICE PROCEDURE .................................................................................................................................... 4-19
WHEN REQUIRED................ ... ....................................... ... ... ... ....................................... ... .... ..................4-19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-19
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-23
CHECK TRACK SHOE TENSION, ADJUST...................................................................................4-25
CHECK AND TIGHTEN TRACK SHOE BOLTS..............................................................................4-27
CHECK ELECTRICAL INTAKE AIR HEATER ................................................................................ 4-27
REVERSE AND REPLACE END BITS AND CUTTING EDGES..................................................... 4-28
CHECK IDLER OIL LEVEL, ADD OIL ............................................................................................. 4-29
ADJUST IDLER CLEARANCE ............................................... ... ... .... ... ...................................... .... .. 4-29
ADJUST PLAY IN CENTER BALL ..................................................................................................4-30
GREASE DOOR HINGE..................................................................................................................4-30
CHECK DOOR LOCK STRIKER..................................................................................................... 4-31
CHECK, ADJUST AIR CONDITIONER ........................................................................................... 4-31
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................. 4-33
REPLACE WIPER BLADE ........................ ... ....................................... ... ... ... .... ... ... ... .... ... ... ... .........4-33
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM.....................................................4-34
PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM................. 4-35
CHECK BEFORE STARTING ............... ... ... .... ... ... ... ... .... ... ... ... ....................................... ... .... ... ... ... ......... 4-36
EVERY 50 HOURS SERVICE..................................................................................................................4-37
DRAIN WATER, SEDIMENT FROM FUEL TANK...........................................................................4-37
EVERY 250 HOURS SERVICE................................................................................................................ 4-38
LUBRICATING.................................................................................................................................4-38
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..................................................................4-40
CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-41
CHECK BRAKE PERFORMANCE..................................................................................................4-43
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................4-44
EVERY 500 HOURS SERVICE................................................................................................................ 4-45
REPLACE FUEL FILTER CARTRIDGE ....................................... .... ... ... ... ... .... ... ... ... .... ..................4-45
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................4-48
1-16
CONTENTS
REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-49
CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS......................................................... 4-50
EVERY 1000 HOURS SERVICE.............................................................................................................. 4-51
CHANGE OIL IN FINAL DRIVE CASE............................................................................................ 4-51
CHECK FAN BELT TENSION, ADJUST......................................................................................... 4-51
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER........................................................... 4-51
CHECK PLAY OF TURBOCHARGER ROTOR ................. ... .... ... ... ... ... .... ... ... ... .... ......................... 4-52
CHECK FOR LOOSE ROPS MOUNT BOLTS................................................................................ 4-52
EVERY 2000 HOURS SERVICE.............................................................................................................. 4-53
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION
STRAINER....................................................................................................................................... 4-53
CLEAN, CHECK TURBOCHARGER............................................................................................... 4-55
CHECK VIBRATION DAMPER ................................ .... ...................................... .... ... ... ... ... .... ... ... ... 4-55
CHECK ALTERNATOR, STARTING MOTOR .......................... ......................................... .... ... ... ... 4-55
CHECK ENGINE VALVE CLEARANCE, ADJUST.......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-55
EVERY 4000 HOURS SERVICE.............................................................................................................. 4-56
CHECK WATER PUMP................................... ... ....................................... ... ... ... .... ... ... ... ... .... ... ...... 4-56
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................ 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
HANDLING HYDRAULIC RIPPER....................................................................................................................... 6-3
GENERAL VIEW............................................................. ... .... ... ... ....................................... ........................ 6-3
EXPLANATION OF COMPONENTS.......................................................................................................... 6-4
OPERATION............................................................................................................................................... 6-5
CHECK BEFORE STARTING ENGINE, ADJUST ............................. ... .... ... ... ... .... ... ... ... ... .... ... ... ... .. 6-5
PRECAUTIONS WHEN OPERATING............................................................................................... 6-5
ADUSTING POSTURE OF WORK EQUIPMENT ............................................................................. 6-5
TROUBLESHOOTING................................................................................................................................ 6-6
OTHER TROUBLE...................................... .... ...................................... .... ........................................ 6-6
MAINTENANCE.......................................................................................................................................... 6-6
EVERY 250 HOURS SERVICE.........................................................................................................6-6
DELUXE SEAT..................................................................................................................................................... 6-7
HEADREST .......................................................................................................................................................... 6-9
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................. 6-10
1-17
CONTENTS
INDEX
COLOPHON
1-18
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
POSITION OF SAFETY PICTOGRAMS......................................................................................................2-42
SAFETY LABELS.........................................................................................................................................2-52
GENERAL PRECAUTIONS
Safety rules................................................................................................................................................2-102
If abnormalities are found................................ .... ... ... ... ... .... ... ... ... .... ... .......................................................2-102
Clothing and personal protective items......................................................................................................2-102
Fire extinguisher and first aid kit ................................................................................................................2-102
Safety features...........................................................................................................................................2-112
Keep machine clean................................................................................................................................... 2-112
Inside operator's compertment................................................................................................................... 2-112
Always apply lock when leaving operator's seat........................................................................................ 2-112
Handrails and steps ...................................................................................... ... ... ... ... .... ... ..........................2-122
Mounting and dismounting......................................................................................................................... 2-132
No people on attachment........................................................................................................................... 2-132
Crushing or cutting prevention...................................................................................................................2-132
Prevention of burns....................................................................................................................................2-132
Fire prevention...........................................................................................................................................2-142
Action if fire occurs.....................................................................................................................................2-152
Window washer liquid ................................................................................................................................2-152
Precautions when using ROPS (Roll Over Protective Structure).................................. ... ... ... .... ... ... ... ... .... 2-152
Precautions for attachments ........................................... .... ... ... ... .... ..........................................................2-152
Unauthorized medification..........................................................................................................................2-152
Safety at worksite....................................................................................................................................... 2-162
Working on loose ground........................................................................................................................... 2-162
Do not go close to high-voltage cables ......................................................................................................2-162
Ensure good visibility .................................................................................................................................2-172
Ventilation for enclosed aresa.................................................................................................................... 2-172
Checking signalman's signals and signs.................................................................................................... 2-172
Emergency exit from operator's cab ..........................................................................................................2-172
Be careful about asbestos dust..................................................................................................................2-182
PRECAUTIONS FOR OPERATIONS............................................................................................................... 2-192
STARTING ENGINE..................................................................................................................................2-192
Checks before starting engine ............................................................................................................2-192
Precautions when starting.................. ... ... .... ... ... ... ... .... ... ... ... .... ... .......................................................2-192
Precautions in cold areas.................................................................................................................... 2-202
OPERATION.............................................................................................................................................. 2-212
Checks before operation.....................................................................................................................2-212
Precautions for moving machine forward or in reverse.......................................................................2-212
Precautions when traveling...................... .... ... ... ... ... .... ... ... ... ....................................... ... ....................2-212
Traveling on slopes............................................................................................................................. 2-222
Using brakes............................... .... ... ....................................... ... .......................................................2-222
Operate carefully on snow ..................................................................................................................2-232
Parking machine...... ... ... .... ... ... ... .... ... ... ....................................... ... ... .... ... ... ... .................................... 2-232
TRANSPORTATION..................................................................................................................................2-242
Loading and unloading........................................................................................................................2-242
Shipping.............................................................................................................................................. 2-242
BATTERY...................................................................................................................................................2-252
Battery hazard prevention..................... ... .... ... ... ... ... .... ...................................... .... ... ... ... ....................2-252
Starting with booster cable.................................................................................................................. 2-262
TOWING .................................................................................................................................................... 2-272
When towing ....................................................................................................................................... 2-272
2-2
SAFETY SAFETY
PRECAUTIONS FOR MAINTENANCE ............................................................................................................2-282
Warning tag................................................................................................................................................ 2-282
Keep work place clean and tidy............... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... .................... 2-282
Appoint leader when working with others .................................................................................................. 2-282
Stop engine before carrying out inspection and maintenance................................................................... 2-282
Two workers for maintenance when engine is running.............................................................................. 2-292
Proper tools........................ ...................................... .... ... ... ... ..................................................................... 2-302
No unauthorized personnel into area......................................................................................................... 2-302
Attachments............................................................................................................................................... 2-302
Work under the machine.................................... ....................................... ... ... ... .... ... ... ... .... ....................... 2-312
Noise.......................................................................................................................................................... 2-312
Precautions when using hammer............................................................................................................... 2-312
Repair welding........................................................................................................................................... 2-312
Removing battery terminal.... ... ... .... .......................................... .......................................... ....................... 2-312
Precautions when Using high-pressure grease to adjust track tension ..................................................... 2-322
Do not disassemble recoil spring............................................................................................................... 2-322
Precaution with high-pressure oil............................................................................................................... 2-322
Handling high-pressure hoses ................................................................................................................... 2-332
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
The following warning signes and safety labels are used on this machine.
q Be sure that you fully understand the correct position and content of labels.
q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels
to peel off.
q There are also other labels in addition to the warning signes and safety labels. Handle those labels in the
same way.
q If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the p art
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
POSITIONS OF SAFETY PICTOGRAMS 2
2-4
SAFETY SAFETY LABELS
SAFETY LABELS 2
(1) Caution before operating machine (09651-A0481)
q Warning!
q Read manual before operation, maintaince, disassembly,
assembly and transportation.
(2) Caution before moving in reverse (09802-13000)
WARNING
To prevents 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) Caution for leaving operator's seat (09654-B0481)
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) Caution with high-temperature coolant, hydraulic oil
(09653-A0481)
q Never remove the cap when the engine is at operating
(high) temperature. Stream or high temperature oil blowing
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 for accumulator (09659-A057B) (If equipped)
q There is the hazard of explotion causing injury.
q Do not disassemble the accumulator, make holes in it, cut
it, hit it roll it or bring it near flame.
(6) Caution for adjusting track tension (09657-A0881)
The safety label is attached to the rear side of the track adjust-
ment window cover.
q Sign indicates a hazard or flining plug from track adjuster
that could cause injury.
q Read the manual and adjusting track for safe and proper
handling.
(7) Caution for battery cable (09808-A0881)
q Sing indicates an electric hazard from handling the cable.
q Read the manual for save and proper hand lin g.
2-6
SAFETY SAFETY LABELS
(8) Caution for battery (This plate is stick on the machine by the
battery maker)
DANGER/POISON
EXPLOSIVE GASES
Cigarettes, flames or sparks could cause battery to explode.
Always shield eyes and face from battery.
Do not charge or use booster cables or adjust post connections
without order instruction and training.
KEEP VENT CAPS TIGHT AND LEVEL POISON causes
severe burns contains sulfuric acid in event of accident flush
with water and call a physician immediately.
KEEP OUT OF REACH OF CHILDREN
(9) Caution for engine running (09667-A0481)
q Sign indicates a hazard of rotating parts, such as belt.
q Turn off before inspection and maintenance.
(10) Caution for approach when machine moving
(09806-B1201)
q Sign indicates a hazard of being run over by moving e quip -
ment.
q Keep a safe distance from equipment when it is moving.
2-7
SAFETY LABELS SAFETY
(11) Caution for ROPS (09620-A2000)
ROPS/FOBS CERTIFICATION
This protective structure complies with the standard provided
that it is properly equipped on the machine which mass is less
than the specified maximum mass.
MODEL MACHINE MODEL FOPS LEVEL No.
SERIAL No. MAX. MASS (kg)
WARNING
q If some modification is applied to the ROPS or FOPS, it
might not enough strength and might not be complied
with the standard. Consult Komatsu distributor before
altering.
q ROPS or FOBS may provide less protection if it has
been structurally damaged or involved roll-over. Consult Komatsu distributor in that case.
q Always wear seat belt when moving
(12) Prohibition of jump start (09842-A0481)
q Start the engine only after sitting down in the operator’s
seat.
q Do not attempt to start the engine by short-circuiting the
engine starting circuit. Such an act may cause a serious
bodily injury or fire.
2-8
SAFETY SAFETY LABELS
(13) Caution with high-temperature parts (09817-A0753)
q Sign indicates a burn hazard from touching heated parts,
such as engine, motor, or muffler during or right after operation.
q Never toch when hot.
2-9
GENERAL PRECAUTIONS SAFETY
GENERAL PRECAUTIONS 2
SAFETY RULES
q Only trained and authorized personnel can operate and maintain the machine.
q Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
q If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine
may be severly impaired putting yourself and everyone else on your jobsite in danger.
q When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND
If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warn ing devices or monitor ), re port to the pe rson
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
q Do not wear loose clothing and accessori es. There is a hazard th at they may catch o n control levers or other
protruding parts.
q If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
q Always wear a hard hat and safety shoes. If the nature of
the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
q Check that all protective equipment functions properly
before using it.
FIRE EXTINGUISHER AND FIRST AID KIT
Always follow the precautions below to prepare for action if any injury or fire should occur.
q Be sure that fire extinguishers have been provided and
read the labels to ensure that you know how to use them in
emergencies.
q Carry out periodic inspection and maintenance to ensure
that the fire extinguisher can always be used.
q Provide a first aid kit at the storage point. Carry out peri-
odic checks and add to the contents if necessary.
2-10
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