Komatsu D65EX PX-12, D65E PX-12 User Manual
Operation & Maintenance
D65EX,PX-12
Manual
SEAM001 202
BULLDOZER
SERIAL NUMBERS
/
D65E,P :60001 and up
D65EX,PX :60001
I. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual
has been lost or has become dirty and can not be read, request a replacement manual from
Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
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.
This manual may contain attachments and optional equipment that are not available in your
area. Consult Komatsu or your Komatsu distributor for those items you may require.
WARNING
A
Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death.
Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance.
Some actions involved in operation and maintenance of the machine can cause a serious
accident, if they are not done in a manner described in this manual.
The procedures and precautions given in this manual apply only to intended uses of
the machine. If you use your machine for any unintended uses that are not specifically
prohibited, you must be sure that it is safe for you and others. In no event should you
or others engage in prohibited uses or actions as described in this manual.
Komatsu delivers machines that comply with all applicable regulations and standards
of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain
safety devices and specifications that are necessary for use in your country. If there is
any question about whether your product complies with the applicable standards and
regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
The description of safety is given in SAFETY INFORMATION on page O-2 and in
SAFETY from page I-1.
O-l
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and
maintenance.
To identify safety messages in this manual and on machine labels, the following signal
words are used.
DANGER -
A
WARNING -
A
CAUTION -
A
NOTICE -
Safety precautions are described in SAFETY from page l-l.
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, you must be sure that you and others can do
such procedures and actions safely and without damaging the machine. If you are unsure
about the safety of some procedures, contact Komatsu or a Komatsu distributor.
This word is used on safety messages and safety labels where there is a
high probability of serious injury or death if the hazard is not avoided.
These safety messages or labels usually describe precautions that must
be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine.
This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or
death if the hazard is not avoided. These safety messages or labels
usually describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious damage to the
machine.
This word is used on safety messages and safety labels for hazards
which could result in minor or moderate injury if the hazard is not
avoided. This word might also be word for hazards where the only result
could be damage to the machine.
This word is used for precautions that must be taken to avoid actions
which could shorten the life of the machine.
o-2
3. INTRODUCTION
3.1 INTENDED USE
This Komatsu BULLDOZER is designed to be used mainly for the following work:
l Dozing
l Smoothing
l Cutting into hard or frozen ground or ditching.
l Felling trees, removing stumps
See the section “12.10 WORK POSSIBLE USING BULLDOZER” for further details.
3.2 FEATURES
HIGH PRODUCTIVITY
l Powerful S6D125(6D125 for D65E) engine and large-capacity blade provide high productivity.
l Low drive and long truck undercarriages are extraordinarily tough and offer excellent grad-
ing ability and stability.
HIGH MANEUVERABILITY
l Wrist control type single-lever for steering/directional change makes operations smooth and
easy.
l Wrist control type single-lever for blade control with PPC (Proportional Pressure Control)
and CLSS (Closed-center Load Sensing System) assures precise and responsive operation.
l Hydrostatic steering system (HSS) provides extra-smooth, speedy and powerful steering.
(D65EX-12 and D65PX-12)
OPERATOR COMFORT
l Rubber-mounted power-train and valves substantially reduce noise and vibration.
l Pressurized cab with wide view and oil damper suspension offers a comfortable operating
environment.
EASY MAINTENANCE AND HIGH DURABILITY
l Simple hull frame and monocoque track frames with pivot shafts assure greater reliability.
l Unique modular design facilitates the removal of power-train components.
l Larger-sized undercarriage components extend life.
3.3 BREAKING IN THE MACHINE
Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect
the performance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.)
During breaking in:
l Idle the engine for 5 minutes after starting it up.
l Avoid operation with heavy loads or at high speeds.
l Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in
cases of emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are
only those that apply when this product is used for the specified purpose. If the machine is
used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for
safety. All consideration of safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circum-
stances.
o-3
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE
POSITION
This is at the front bottom right of the operator’s seat.
4.2 ENGINE SERIAL NO. PLATE
POSITION
This is in the center of the engine cylinder
left
side of the machine.
block on the
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Adress:
Phone:
Service personnel for your machine:
REMARKS
o-4
5. CONTENTS
1. Foreword . . . . . . . . .
2. Safety information
3. Introduction
4. Location of plates, table to enter serial No. and distributor
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SAFETY
6. General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Precautions during operation
7.1. Before starting engine
7.2.
7.3.
7.4. Battery
7.5.
8. Precautions for maintenance
8.1
8.2 During maintenance
9. Position for attaching safety labels
Operating machine ..........
Transportation ...............
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Towing
Before carrying out maintenance
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......... l-9
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O-l
o-2
o-3
1-2
1-16
1-17
1-17
1-19
1-24
OPERATION
10. General view
10.1.
10.2. General view of controls and gauges
Explanation of components
11.
11. 1. Front panel (meters, lamps, switches)
11. 2. Switches
11. 3. Control levers and pedals
11. 4. Fuse box
11. 5. Grease pump holder
11. 6. Shovel holder
11. 7. Door-open lock (machines equipped with cab)
11. 8. Sash glass intermediate lock (machines equipped with cab)
11. 9. Cap with lock
11 .lO. Hot and cool box (machines equipped with cab)
11 .I 1. Door pocket (machines equipped with cab)
11.12. Ashtray (machines equipped with cab)
11.13. Tool box
11.14. Using car radio (machines equipped with cab)
11 .I 5. Using car stereo (machines equipped with cab)
11.16. Handling air conditioner (machines equipped with cab)
11.17. Handling heater (machines equipped with cab)
General view of machine
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2-2
2-2
2-3
2-6
2-7
2-22
2-29
2730
2-30
2-30
2-31
2-32
2-32
2-32
2-32
2-33
2-37
2-43
2-47
o-5
12. Operation
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12. 1. Check before starting engine
12. 2. Starting engine
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: .........................................................
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12. 3. Operations and checks after starting engine
12. 4. Moving machine
12. 5. Shifting gear
12. 6. Shifting between forward and reverse
12. 7. Steering machine
12. 8. Stopping machine
12. 9. Precautions for operation
12.10. Work possible using bulldozer
12.11. Adjusting posture of work equipment
12.12. Parking machine
12.13. Check after finishing work
12.14. Stopping engine
12.15. Check after stopping engine
12.16. Locking
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12.17. Tips for longer undercarriage life
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13. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1. Loading, unloading work
13.2. Precautions for loading
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. . . . . . . . . . . . . . . . . . . . . . . . .
13.3. Precautions for transportation . . . . . . . . . . . . . . . . .
13.4. Precautions when removing work equipment
13.5. Removing cab (machines equipped with cab)
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2-48
2-48
2-58
2-64
2-66
2-67
2-68
2-69
2-73
2-74
2-76
2-77
2-80
2-81
2-82
2-83
2-83
2-84
2-87
2-87
2-88
2-89
2-89
14. Cold weather operation
14.1. Precautions for low temperature
14.2. After completion of work
14.3. After cold weather
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15. Long-term storage (more than one month)
15.1. Before storage
15.2. During storage
15.3. After storage
16. Troubleshooting
16.1. After running out of fuel
16.2. If battery is discharged
16.3. Other trouble
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2-90
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2-92
2-92
2-93
2-93
2-93
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2-95
2-95
2-95
2-98
O-6
MAINTENANCE
Guides to maintenance
17.
5. CONTENTS
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3-2
Outlines of service
18.
18.1.
18.2.
Wear parts list
19.
Use of fuel, coolant and lubricants according to ambient temperature
20.
Standard tightening torques for bolts and nuts
21.
21 .I.
21 .2.
Periodic
22.
Maintenance schedule chart
23.
Service
24.
24.1.
24.2. Check before starting
24.3.
24.4.
24.5.
24.6.
24.7.
24.8.
Outline of oil, fuel, coolant
Relating to electric system
Introduction of necessary tools
Torque list
replacement
procedure
When required
Every 50 hours service
Every 250 hours service
Every 500 hours
Every 1000 hours service
Every 2000 hours service
Every 4000 hours service
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of safety critical
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service
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parts .....................................................................................
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3-5
3-5
3-8
3-9
3-10
3-l 4
3-14
3-l 5
3-l 6
3-20
3-23
3-23
3-42
3-47
3-48
3-60
3-64
3-69
3-72
SPECIFICATIONS
25. Specifications
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OPTIONS, ATTACHMENTS
General
26.
26.1.
Using seat belt
27.
27.1.
27.2.
Handling
28.
29.
Handling accumulator
29.1.
precautions
Precautions related
Fasten the belt and
Adjust the belt length in the following manner
deluxe
Method of releasing pressure in operating circuit on machine equipped
with accumulator
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to safety ..........................................................................................................
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remove it in the
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seat
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following manner
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4-2
5-2
5-2
5-3
5-3
5-3
5-5
5-7
5-7
o-7
SAFETY
WARNING
A
Read and follow all safety precautions. Failure to do so may result in serious injury or
death.
This safety section also contains precautions for optional equipment and attachments.
l-l
6. GENERAL PRECAUTIONS
SAFETY RULES
l ONLY trained and authorized personnel can operate and maintain the machine.
l Follow all safety rules, precautions and instructions when operating or performing main-
tenance on the machine.
l When working with another operator or a person on worksite traffic duty, be sure all
personnel understand all hand signals that are to be used.
SAFETY FEATURES
Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged.
Proper position -+ See “12.1 .I WALK-AROUND CHECK”.
Use safety features such as safety lock and seat belts properly.
NEVER remove any safety features. ALWAYS keep them in good operating condition.
Safety lever -+ See “12.12 PARKING MACHINE”.
Seat belts -, See “27. USING SEAT BELT”.
these safety precautions.
AWARNING: For reasons of safety, always follow
Improper use of safety features could result in serious bodily injury or death.
CLOTHING AND PERSONAL PROTECTIVE ITEMS
l Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in
moving parts and cause serious injury or death. Also, do not wear oily clothes because
they are flammable.
l Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or main-
taining the machine. Always wear safety goggles, hard hat and heavy gloves if your job
involves scattering metal chips or minute materials - this is so particularly when driving
pins with a hammer, and when cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
Cleaning of air cleaner element
-, See “24.1 WHEN REQUIRED” in service procedure.
l-2
AWARNING: Failure to follow these safety precautions may lead to a
serious accident.
UNAUTHORIZED MODIFICATION
l Any modification made without authorization from Komatsu can create hazards.
l Before making a modification, consult your Komatsu distributor. Komatsu will not be re-
sponsible for any injury or damage caused by any unauthorized modification.
STANDING UP FROM THE SEAT
To avoid hitting unlocked operation levers, before standing up from operator’s seat, do
the following:
Move steering and directional lever to neutral and move PARKING LEVER (located left of
seat) to LOCK position.
Lower equipment to ground and move SAFETY LEVER (located right of seat) to LOCK
position.
Sudden and unwanted machine movement can cause serious injury or death.
6. GENERAL PRECAUTIONS
l-3
6. GENERAL PRECAUTIONS A WARNING: For reasons of safety, always follow these safety precautions.
NEVER jump on or off the machine. NEVER get on or off a moving machine.
When mounting and dismounting, face the machine and use the handholds steps. Maintain three-point contact to be sure that you do not fall from the machine.
Do not hold any control levers when getting on of off the machine.
Repair any damaged handhold or step, and tighten any loose bolts. Handholds and
steps must be free of oil, grease and excessive dirt.
When mounting or dismounting, or when moving along the top of the track, if you hold
the door handle and the door is not properly closed, the door may move and cause you
to fall. Always make sure that the door is properly closed.
When mounting or dismounting, use the points marked with arrow A in the diagram
below.
Use the points marked by arrow B for mounting and dismounting only when the work
equipment is not installed.
Do not use the points marked by arrow C when mounting or dismounting. Use these
points only when moving along the top of the track or when carrying out inspection and
maintenance inside the side cover.
l-4
AWARNING: Failure to
serious accident.
follow these safety precautions may lead to a
6. GENERAL PRECAUTIONS
RE PREVENTION FOR FUEL
Fuel,
oil,
and antifreeze can be ignited by a flame. Fuel is
AND OIL
particularly FLAMMABLE and
can be HAZARDOUS.
Keep a flame away from flammable fluids.
Stop the engine and do not smoke when refueling.
Tighten all fuel and oil caps securely.
Refueling and oiling should be made in well ventilated areas.
Keep oil and fuel in the determined place and do not allow unauthorized persons to
enter.
- BURN HAZARD PREVENTION
l
If the coolant, engine oil, power train oil or hydraulic oil is hot, use a heavy cloth,
gloves, heavy clothing and safety glasses or goggles before checking or touching.
l
To prevent hot water from spurting out:
1) Turn engine off.
2) Allow water to cool.
3) Slowly loosen cap to relieve pressure before removing.
l
To prevent hot oil from spurting out:
1) Turn engine off.
2) Allow oil to cool.
3) Slowly loosen cap to relieve pressure before removing.
l-5
6. GENERAL PRECAUTIONS AWARNING: For reasons of safety, always follow these safety precautions.
ASBESTOS DUST HAZARD PREVENTION 1
l-i
Asbestos dust can be HAZARDOUS to your health if it is inhaled.
If you handle materials containing asbestos fibers, follow these guidelines as given
below:
1) NEVER use compressed air for cleaning.
2) Use water for cleaning to minimize dust cloud.
3) Operate the machine with the wind to your back, whenever possible.
4) Use an approved respirator if necessary.
CRUSHING OR CUTTING PREVENTION
l Do not enter, or put your hand or arm or any other part of your body between movable
parts such as between the work equipment and cylinders, or between the machine and
the blade or ripper or any other attachment.
If the work equipment is operated, the clearance will change and this may lead to seri-
ous damage or personal injury.
FIRE EXTINGUISHER AND FIRST AID KIT
l Be sure fire extinguishers have been provided and know how to use them.
l Know where a first aid kit is located.
l Know what to do in the event of a fire.
l Be sure you know the phone numbers of persons you should contact in case of an
emergency.
1-6
AWARNING: Failure to follow these safety precautions may lead to a
serious accident.
PRECAUTIONS FOR ROPS 1
r-i
I ’
Do not operate machine with ROPS removed if equipped.
The ROPS is installed to protect the operator if the machine should overturn. It is designed not only to take the load when the machine overturns, but also to absorb the
impact energy.
The Komatsu ROPS fulfills all worldwide regulations and standards, but if any unauthorized modification is carried out on it, or if it is damaged when the machine overturns,
its strength will be reduced and it will not be able to provide its original capacity. It will
be able to provide this capacity only if modifications and repairs are carried out in the
specified way.
When carrying out modification or repairs, always consult your Komatsu distributor first.
Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot
protect you properly. Always fasten your seat belt when operating the machine.
Seat belts -f See “27. USING SEAT BELT.”
,
6. GENERAL PRECAUTIONS
1
PRECAUTIONS FOR ATTACHMENTS
-r--
l When installing and using an optional attachment, read the instruction manual for the at-
tachment and the information related to attachments in this manual.
l Do not use attachments that are not authorized by Komatsu or your Komatsu distributor.
Use of unauthorized attachments could create a safety problem and adversely affect the
proper operation and useful life of the machine.
l Any injuries, accidents, product failures resulting from the use of unauthorized attach-
ments will not be the responsibility of Komatsu.
1-7
6. GENERAL PRECAUTIONS
MACHINES WITH ACCUMULATOR
AWARNING: For reasons of safety, always follow these safety precautions.
On machines equipped with an accumulator,
for a short time after the engine is
stopped, if the work equipment control lever is moved to the LOWER position, the work
equipment will move down under its own weight.
After stopping the engine, always place the safety lock lever in the LOCK position.
When releasing the pressure inside the work equipment circuit on machines equipped
with an accumulator, follow the procedure given in the inspection and maintenance section.
Method of releasing pressure + See “29. HANDLING ACCUMULATOR”.
The accumulator is filled with high-pressure nitrogen gas, and it is extremely dangerous
if it is handled in the wrong way. Always observe the following precautions.
l Never make any hole in the accumulator or expose it to flame or fire.
l Do not weld any boss to the accumulator.
l When carrying out disassembly or maintenance of the accumulator, or when disposing
of the accumulator, it is necessary to release the gas from the accumulator. A special
air bleed valve is necessary for this operation,
so please contact your Komatsu
distributor.
Gas in accumulator -+ See “29. HANDLING ACCUMULATOR”.
1-8
7. PRECAUTIONS DURING
OPERATION
AWARNING: Failure to follow these safety precautions may
lead to a serious accident.
7.1 BEFORE STARTING ENGINE
SAFETY AT WORKSITE
4
Before starting the engine, thoroughly check the area
for any unusual conditions that could be dangerous.
Before starting the engine, examine the terrain and soil
conditions of the worksite. Determine the best and safest method of operation.
If you need to operate on a street, protect pedestrians
and cars by designating a person for worksite traffic
duty or by installing fences around the worksite.
If water lines, gas lines, and high-voltage electrical lines
may be buried under the worksite, contact each utility
and identify their locations. Be careful not to sever or
cut any of these lines.
Check the depth and flow of water before operating in
water or crossing a river. NEVER be in water which is
in excess of the permissible water depth.
Permissible water depth -, See “12.9.2 PERMISSIBLE WATER
DEPTH”.
FIRE PREVENTION
Thoroughly remove wood chips, leaves, paper and other flammable things accumulated
on the engine compartment. They could cause a fire.
Check fuel, lubrication, and hydraulic systems for leaks. Have any leaks repaired. Wipe
up any excess oil, fuel or other flammable fluids.
Check points + See “12.1 .I WALK-AROUND CHECK”.
Be sure a fire extinguisher is present and working.
l-9
7. PRECAUTIONS DURING OPERATION
..:.::i::.:..
..:..::..:.
:.>:.:.>:.:
IN OPERATOR’S CAB
Do not leave tools or spare parts lying around in the operator’s compartment. They may
damage or break the control levers or switches. Always put them in the tool box on the
left side of the machine.
Keep the cab floor, controls, steps and handholds free of oil, grease, snow, and excess
dirt.
Check the seat belt, buckle and hardware for damage or wear. Replace any worn or
damaged parts. Always use seat belts when operating your machine.
Seat belts + See “27.USING SEAT BELT”.
l If it is necessary to start the engine within an enclosed area, provide adequate ventila-
tion. Exhaust fumes from the engine can KILL.
A WARNING: For reasons of safety, always follow these safety precautions.
..:.>:.. ..>:::_.
.-...........-........ ..c.
::........::..:
.‘.....‘.‘.5’...’ ..::::::.
pa: J$$$ii:
:::::.:::::::: . . . . . . :. .._. :.:.:::y
. . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . .
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A
:::.
PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS
l Remove all dirt from the surface of the windows and lights to ensure that you can see
well.
l Adjust the rear view mirror so that you can see clearly from the operator’s seat, and always
keep the surface of the mirror clean. If any glass is broken, replace it with a new part.
l Check that the head lamps and rear lamps are installed to match the operating con-
ditions. Check also that they light up properly.
I-IO
AWARNING: Failure to follow these safety precautions may lead to a
serious accident.
7. PRECAUTIONS DURING OPERATION
7.2 OPERATING MACHINE
WHEN STARTING ENGINE
Walk around your machine again just before mounting it, checking for people and objects that might be in the way.
NEVER start the engine if a warning tag has been attached to the control.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Do not allow anyone other than the operator to ride in the cab or on the machine body.
For machines equipped with a reverse warning
device operates correctly.
PRECAUTIONS WHEN MOVING FORWARD OR BACKWARD
Before moving machine or its attachments:
Honk horn to alert people nearby.
Be sure no one is around machine, particularly behind machine.
Use spotter if necessary, particularly if you are moving in reverse.
When operating in areas that may be hazardous or have poor visibility, designate a per-
son to direct worksite traffic.
Prevent people from entering the line of travel of the machine.
Follow above even if equipped with back-up alarm and mirrors.
buzzer, check that the warning
1-11
7. PRECAUTIONS DURING OPERATION
AWARNING: For reasons of safety, always follow these safety precautions.
TRAVELING ON SLOPES
Traveling on hills, banks or slopes that are steep could result in the machine tipping
over or slipping.
On hills, banks or slopes, carry the work equipment closer to the ground, approximately
20 to 30 cm above the ground. In case of emergency, quickly lower the
work equipment
to the ground to help the machine stop and prevent it from tipping over.
Do not change direction on slopes. Avoid sideways travel whenever
possible: rather
travel up and down the slopes.
Do not travel up and down on grass, fallen leaves, and wet steel plates.
These materials
may allow the machine to slip, if it is traveling sideways. Keep travel speed very low.
When traveling downhill, drive slowly and use the engine as a brake.
When traveling downhill with the machine being pushed by its own weight, the machine
may steer in the opposite direction, so be careful when steering.
Reverse steering when traveling downhill
+ see “12.7.2 TURNING WHEN DESCENDING A
SLOPE (D65E, P)“.
INCORRECT
VISIBILITY
Turn ON the head lamps and rear lamp, when working at night or at dark sites. Provide
additional lights for the worksite if necessary.
If visibility is diminished by fog, snow or rain, stop operation. Wait until there is adequate visibility for safe operation.
WORKING ON SNOWY SITE 1
l Snow-covered and frozen ground may allow the machine to slip sideways, even if the
grade is not steep. Slow down the machine when traveling on such ground. Avoid rapid
starts, stops, and steering.
l In snow removal work, pay special attention to the edge of the road and to objects
under the snow.
1-12
AWARNING: Failure to follow these safety precautions may lead to a
serious accident.
WORKING ON LOOSE GROUND
Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse, your machine could fall or tip over and result in serious in-
jury or death. Remember that the soil after heavy rain or blasting is weakened in these
areas.
Earth laid on the ground and the soil near ditches are loose. They can collapse under
the weight or vibration of your machine.
Install the HEAD GUARD or FOPS if working in areas where there is danger of falling
rocks and dirt.
When working in places where there is danger of falling rocks or danger of the machine
turning over, install ROPS and a seat belt.
PARKING THE MACHINE 1
-I
Park on level ground whenever possible. If not possible, block the tracks, lower the
blade to the ground and thrust the edge of the blade in the ground.
7. PRECAUTIONS DURING OPERATION
When parking on public roads, provide fences and signs, such as flags or lights, on the
machine to warn passersby to be careful. Be sure that the machine, flags or lights do
not obstruct traffic.
Parking procedure + See “12.12 PARKING MACHINE”.
Before leaving the machine, lower the work equipment to the ground, move the SAFETY
LEVER to LOCK position, stop the engine, and lock all the doors, windows, and covers
and remove the key(s).
Work equipment posture -, See “12.12 PARKING MACHINE”.
Locks + See “12.16 LOCKING”.
1-13
7. PRECAUTIONS DURING OPERATION
AWARNING: For reasons of safety, always follow these safety precautions.
7.3 TRANSPORTATION
LOADING AND UNLOADING
-I
Loading and unloading the machine always involves potential hazards. EXTREME CAUTION
SHOULD BE USED.
Perform loading and unloading on firm, level ground only. Maintain a safe distance from the
edge of a road.
ALWAYS block the wheels of the hauling vehicle and place blocks under both ramps before
loading and unloading.
ALWAYS use ramps of adequate strength. Be sure the ramps are wide and long enough to
provide a safe loading slope.
Be sure that the ramps are securely positioned and fastened, and that the two sides are at
the same level as one another.
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove
dirt from the machine tracks.
NEVER correct your steering on the ramps. If necessary, drive away from the ramps and
climb again.
After loading, block the machine tracks and secure the machine with tie-downs.
Loading and unloading -f See “13. TRANSPORTATION.”
Tie-downs + See “13. TRANSPORTATION.”
CORRECT
Distance between ramps
SHIPPING
l When shipping the machine on a hauling vehicle, obey all state and local laws governing the
weight, width, and length of a load. Also obey all applicable traffic regulations.
l Determine the shipping route while taking into account the width, height and weight of the
load.
1-14
AWARNING: Failure to follow these safety precautions may lead to a
serious accident.
7.4 BATTERY
7. PRECAUTIONS DURING OPERATION
BATTERY HAZARD PREVENTION
0
Battery electrolite contains sulfuric acid and can quickly burn the skin and eat holes in
clothing. If you spill acid on yourself, immediately flush the area with water.
l
Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes,
flush them immediately with large quantities of water and see a doctor at once.
l
If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or ve-
getable oil. Call a doctor or poison prevention center immediately.
l
When working with batteries. ALWAYS wear safety glasses or goggles.
0
Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited
with a small spark or flame.
l
Before working with batteries, stop the engine and turn the starting switch to the OFF
position.
l
Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.
l
Tighten the battery terminals securely. Loosened terminals can generate sparks and lead
to an explosion.
l
When removing or installing, check which is the positive (+) terminal and negative (-) terminal.
l
Tighten the battery cap.
1
STARTING WITH BOOSTER CABLES 11
-I
ALWAYS wear safety glasses or goggles when starting the machine with booster cables.
When starting from another machine, do not allow the two machines to touch.
Be sure to connect the positive (+) cable first when installing the booster cables. Dis-
connect the ground or negative (-) cable first when removing them.
Connect the batteries in parallel: positive to positive and negative to negative.
When connecting the ground cable to the frame of the machine to be started, be sure
to connect it as far as possible from the battery.
Starting with booster cables -, See “16.2 IF BATTERY IS DISCHARGED”.
INCORRECT
1-15
7. PRECAUTIONS DURING OPERATION
AWARNING: For reasons of safety, always follow these safety precautions.
7.5 TOWING
WHEN TOWING THE MACHINE, FIX THE WIRE
TO THE REAR HITCH PIN OR RIPPER.
Injury or death could result if a disabled machine is towed incorrectly.
If your machine is towed by another machine, ALWAYS use a wire rope with a sufficient
towing capacity.
When the machine is towed, always set the steering and directional lever to the N (neutral)
position.
NEVER allow a disabled machine to be towed on a slope.
Do not use a kinked or frayed wire rope.
Do not straddle the towing cable or wire rope.
When connecting up a towing machine, do not let anyone enter the area between the
ing machine and the equipment being towed.
Set the towing machine and the towing connection of the equipment being towed
straight line when connecting it.
Take up the slack in the wire rope and tow the machine.
tow-
in a
1-16
8. PRECAUTIONS FOR MAINTENANCE
AWARNING: Failure to follow these safety precautions may
lead to a serious accident.
8.1 BEFORE CARRYING OUT MAINTENANCE
WARNING TAG 1
-1
If others start the engine or operate the controls while you are performing service or lu-
brication, you could suffer serious injury or death.
ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert
others that you are working on the machine. Attach additional warning tags around the
machine, if necessary.
These tags are available from your Komatsu distributor. (Part No. 09963-03000)
PROPER TOOLS
l Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools
could cause personal injury.
Tools + See “21 .I INTRODUCTION OF NECESSARY TOOLS”.
-9
PERIODIC REPLACE
Replace the following fire-related components periodically:
Fuel system:
Hydraulic system: Pump outlet hose, and front and rear pump branch hoses
Replace these components periodically with new ones, regardless of whether or not they
appear to be defective. These components deteriorate over time.
Replace or repair any such components if any defect is found, even though they have
not reached the time specified.
Fuel hose, spilling hose, and fuel tube cap
0
4
Replacement of safety critical components -, See “22. PERIODIC REPLACEMENT OF
SAFETY CRITICAL PARTS”.
1-17
AWARNING: For reasons of safety, always follow these safety
8. PRECAUTIONS FOR MAINTENANCE
OUT INSPECTION AND MAINTENANCE
Always stop the machine on firm flat ground and stop the engine before carrying out inspection and maintenance.
If it is necessary to run the engine when carrying out maintenance, such as when cleaning
the inside of the radiator, place the safety lock lever at the LOCK position and carry out the
operation with two workers.
One worker should sit in the operator’s seat so that he can stop the engine immediately if
necessary. He should also be extremely careful not to touch any lever by mistake. Touch the
levers only when they have to be operated.
precautions.
The worker carrying out the maintenance should be extremely careful not to
caught in the moving parts.
If maintenance is carried out with the work equipment raised, always support it
blocks.
OFF
touch or get
securely with
START
1-18
AWARNING: Failure to follow these safety precautions may
lead to a serious accident.
8. PRECAUTIONS FOR MAINTENANCE
8.2 DURING MAINTENANCE
l Only authorized personnel can service and repair the machine. Extra precaution should be
used when grinding, welding, and using a sledge-hammer.
ATTACHMENTS
0
Place attachments that have been removed from the machine in a safe place so that they do
not fall. If they fall on you or others, serious injury could result.
l Always lower all movable work equipment to the ground or to their lowest position before
performing service or repairs under the machine.
l Always block the tracks of the machine securely.
l Never work under the machine if the machine is poorly supported.
KEEP THE MACHINE CLEAN
4
Spilled oil or grease, or scattered tools or broken pieces are dangerous because they may
cause you to slip or trip.
Always keep your machine clean and tidy.
If water gets into the electrical system, there is danger that the machine may not move or
may move unexpectedly.
Do not use water or steam to clean the sensors, connectors, or the inside of the operator’s
compartment.
1-19
AWARNING: For reasons of safety, always follow these safety
8. PRECAUTIONS FOR MAINTENANCE
l Spilled fuel and oil may cause you to slip, so always wipe it up immediately.
l Always tighten the cap of the fuel and oil fillers securely.
l Never use fuel for washing any parts.
l Always add fuel and oil in a well-ventilated place.
RADIATOR WATER LEVEL
mecautions.
l If it is necessary to add water to the radiator, stop the engine and allow the engine and
radiator to cool down before adding the water.
l Slowly loosen the caps to relieve pressure before removing the caps.
USE OF LIGHTING
-I
l When checking fuel, oil, coolant, or battery electrolyte, always use lighting with anti-
explosion specifications.
If such lighting equipment is not used, there is danger of explosion.,
I-20
&k&F---
AWARNING: Failure to follow these safety precautions may
lead to a serious accident.
PRECAUTIONS WITH BATTERY
-I
l When repairing the electrical system or when carrying out electrical welding, remove the ne-
gative (-) terminal of the battery to stop the flow of current.
HANDLING HIGH-PRESSURE HOSES
4
l Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or
cracked piping, tubes or hoses. They may burst during use.
l Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a
fire.
8. PRECAUTIONS FOR MAINTENANCE
l Avoid torching, soldering, or welding on pipes, tubes and equipment that contain fuel or oils.
If heated, they can generate flammable fumes or mist and could cause a fire or explosion.
PRECAUTIONS WITH HIGH PRESSURE OIL
-I--
l Do not forget that the work equipment circuits are always under pressure.
l Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing
the internal pressure.
l If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-press-
ure oil hits your skin or enters your eyes. Always wear safety glasses and thick gloves, and
use a piece of cardboard or a sheet of wood to check for oil leakage.
l If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical atten-
tion.
1-21
8. PRECAUTIONS FOR MAINTENANCE
AZ;~;NJG~FO~ reasons of safety, always follow these safety
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR
HIGH PRESSURE
l Immediately after stopping operations, the engine cooling water and oil at all parts is at high
temperature and under high pressure.
In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, this may result in burns or other injury. Wait for the temperature to go down, then
carry out the inspection and maintenance in accordance with the procedures given in this
manual.
Cleaning inside or cooling system + see “24.1 WHEN REQUIRED”.
Checking cooling water level, lubricating oil level
Checking oil level in hydraulic tank, final drive case
Changing oil, replacing filters
+ see “24.5 - 7 PERIODIC MAINTENANCE”.
+ see “24.2 CHECK BEFORE STARTING”.
+ see “24.4 PERIODIC MAINTENANCE”.
PRE>
GREASE TO ADJUST TRACK TENSION
Grease is pumped into the track tension adjustment system under high pressure.
If the specified procedure for maintenance is not followed when making adjustments, the plug
or grease fitting may fly out and cause damage or personal injury.
When loosening the grease drain plug, never loosen it more than one turn.
Never put your face, hands, feet, or any other part of your body directly in front of any
grease drain plug or valve.
Adjusting track tension + see “24.1 WHEN REQUIRED”.
ROTATING FAN AND BELT
l Keep away from rotating parts and be careful not to let anything get caught in them.
l If your body or tools touch the fan blades or fan belt, they may be cut off or sent flying, so
never touch any rotating parts.
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