Komatsu D65EX-15E0, D65PX-15E0 User Manual
EEAM024400
Operation &
Maintenance Manual
D65EX
D65PX
BULLDOZER
SERIAL NUMBER
D65EX-15E0 - 69001
D65PX-15E0 - 69001
and up
and up
-15E0
-15E0
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
BEFORE READING THIS MANUAL FOREWORD
BEFORE READING THIS MANUAL 1
This manual gives details of the operation and methods of inspection and maintenance for this machine that must
be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this
manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event
should you or others engage in the prohibited uses or actions described in this manual. Improper operation and
maintenance of the machine can be hazardous and could result in serious injury or death.
If you sell the machine, be sure to give this manual to the new owner toge th er with th e ma ch ine .
Always keep this Operation and Maintenance Manu al in the location shown on the r ight so that all relevant person-
nel can read it at any time.
Operation and Maintenance Manual Storing Place
For a machine with a cab, a pocket is provided on the inside of
both right and left doors.
For a machine with a ROPS canopy, a pocket is provided a t the
end of the floor.
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR (1-13)“.
This manual uses the international units (SI) for units of measurement. For reference, unit s th at have been used in
the past are given in ( ).
1-2
FOREWORD BEFORE READING THIS MANUAL
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing imp rovement s in the desig n of this mach ine may le ad to ad ditional changes that are not reflected in this manual. Consult Koma tsu or your Komatsu distributor for the latest
available information concerning your mac hin e or with questions regarding information contai ned in this manual.
q The numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1 → (1))
Komatsu delivers machines that comply with all applicable regulatio ns and st andar ds of the country to which it h as
been shipped. If this machine has been purchased in anoth er country, it may lack certain safety devices and specifications that are necessary for use in you r 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.
1-3
IMPORTANT SAFETY INFORMATION FOREWORD
IMPORTANT SAFETY INFORMATION 1
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The “Safety Alert Symbol“ identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
DANGER
WARNING
CAUTION
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
NOTICE
REMARKS
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury
This signal word indicates a potentially hazardous situation wh ich, if not avo id ed ,
could result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not
avoided, may result in minor or moderate injury.
This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
This word is used for information that is useful to know.
1-4
FOREWORD IMPORTANT SAFETY INFORMATION
Noise emission levels 1
Two labels ind icating the machine noise level a re affixed on the
machine.
q Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
q If equipped with air suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleratio n
value for the body is less than or equal to 0.5 m/s².
q If equipped with mechanical suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s².
D65EX-15 : the actual acceleration value for the body is 0.63 m/s².
D65EXL-15, D65PX-15 : the actual acceleration value for the body is 0.68 m/s².
1-5
IMPORTANT SAFETY INFORMATION FOREWORD
These values were determined using a representative machine and measured during the typical operating condition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
q Tire pressures (for wheeled machines), tension of crawler (fo r crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and ad justed
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 adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
1-6
FOREWORD IMPORTANT SAFETY INFORMATION
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good he alt h.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads.
1-7
INTENDED USE FOREWORD
INTENDED USE 1
USE OF MACHINE 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
q Felling trees, removing stumps
See the section “WORK POSSIBLE USING BULLDOZER (3-88)“ for further details.
GENERAL VIEW AND DIRECTIONS OF MACHINE 1
In this manual, the directions of the machine (front,rear,left,right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
(1) Blade (7) Sprocket
(2) Tilt cylinder (8) Track frame
(3) Lift cylinder (9) Step
(4) Cab (10) Frame
(5) ROPS guard (11) Idler
(6) Track shoe (12) ROPS canopy
(A) Front (C) Left
(B) Rear (D) Right
1-8
FOREWORD INTENDED USE
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The figure bellows shows a front visibility from the machine at a spot 1.0 m away from the side and 1.5 m above
the ground. Shaded area (A) in the figure shows an area whose view is blocked by part of the machine. Operate
the machine, fully aware that the machine has a portion that an operator cannot see.
12M CIRCUMFERENCE VISIBILITY 1
The figure below shows a visibility from the machine within a circle of 12 m in radius. Shaded area (B) in the figure
shows an area whose view is blo cked by part of the machine. Operate the machine, fully aware that the machine
has a portion that an operator cannot see.
1-9
INTENDED USE FOREWORD
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, ope rating the machine under full load before bre aking the machine in can adverse ly affect the perf ormance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idle for 15 seconds after star ting it. During this time, do not oper ate the control levers or fuel
control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
1-10
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO.
AND DISTRIBUTOR 1
When ordering replacement parts, please inform your Komatsu distributor of the following.
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 POSITION 1
The engine serial No. plate is located on the side of the engine front cover on the left side of the machine.
1-11
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
ADDITIONAL EPA NAMEPLATE 1
The additional EPA nameplate is located on top of the engine head cover on the left side of the machine.
EPA: Environmental Protection Agency, U.S.A.
SERVICE METER POSITION 1
The service meter is provided at the lower part of the monitor
panel.
1-12
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
(PIN)
Manufacturers name:
Address:
Distributor
Address
Phone
Service personnel for your
machine:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
1-13
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
MACHINE SERIAL NUMBER PLATE 1
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
1-14
CONTENTS
CONTENTS
FOREWORD
BEFORE READING THIS MANUAL.................................................................................................................... 1-2
IMPORTANT SAFETY INFORMATION............................................................................................................... 1-4
Noise emission levels .................................................................................................................................1-5
Vibration levels................................ ... ... .... ... ... .......................................... ... ... .... ... ... ... ............................... 1-5
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-6
INTENDED USE ................................................................................................................................................... 1-8
USE OF MACHINE..................................................................................................................................... 1-8
GENERAL VIEW AND DIRECTIONS OF MACHINE .. ... ... .... ... ... ... .... ... ............................................. ... ... .. 1-8
VISIBILITY FROM OPERATOR'S SEAT.................................................................................................... 1-9
PROXIMITY VISIBILITY.................................................................................................................... 1-9
12M CIRCUMFERENCE VISIBILITY ................................. ... .... ... ... ... ... .... ... ... ... .... ........................... 1-9
BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR........................................... 1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..................................... 1-11
ENGINE SERIAL NO. PLATE POSITION ................................................................................................1-11
ADDITIONAL EPA NAMEPLATE ............................................................................................................. 1-12
SERVICE METER POSITION ........................... ... .... ... ... ... .... ... ... .......................................... ... ... ............. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-13
MACHINE SERIAL NUMBER PLATE....................................................................................................... 1-14
SAFETY
IMPORTANT SAFETY INFORMATION............................................................................................................... 2-2
SAFETY LABELS................................................................................................................................................. 2-4
POSITION FOR ATTACHING SAFETY LABELS.......................................................................................2-5
SAFETY LABELS ....................................................................................................................................... 2-5
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................................... 2-10
PRECAUTIONS DURING OPERATION ............................................................................................................ 2-17
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-23
PRECAUTIONS FOR MACHINE........................................................................................................................ 2-29
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE.. .......................................... ... ... ... .... ... ... ..................................................3-2
1-15
CONTENTS
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-6
FRONT PANEL........................................................................................................................................... 3-6
CHECK MONITOR SYSTEM ............................................................................................................3-7
EMERGENCY CAUTION ITEMS . ... ... .... ... .......................................... ... ... ... .... ... ... ... ........................ 3-8
CAUTION ITEMS...... .... ... ... ... .... ... ... ... .......................................... .... ... ... ... ... .... ... ............................3-10
METER GROUP..............................................................................................................................3-12
LAMPS............................................................................................................................................. 3-16
SWITCHES...................................................................................................................................... 3-18
METHOD OF USING MAINTENANCE MODE................................................................................3-22
SWITCHES............................................................................................................................................... 3-29
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-33
CIRCUIT BREAKER .................................................................................................................................3-41
FUSE ........................................................................................................................................................3-41
FUSIBLE LINK..........................................................................................................................................3-43
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................3-43
MACHINE EQUIPPED WITH CAB..................................................................................................3-43
MACHINE EQUIPPED WITH ROPS CANOPY ............................................................................... 3-44
DOOR - OPEN LOCK...............................................................................................................................3-44
SASH GLASS INTERMEDIATE LOCK.....................................................................................................3-45
DOOR POCKET ....................................................................................................................................... 3-45
OPENING AND CLOSING ENGINE SIDE COVER.................................................................................. 3-46
ASHTRAY................................................................................................................................................. 3-46
CUP HOLDER .......................................................................................................................................... 3-47
TOOL BOX................................................................................................................................................3-47
SHOVEL HOLDER ............ .... .......................................... ... ... ... .......................................... .... ..................3-47
AIR CONDITIONER, HANDLING ............................................................................................................. 3-48
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................ 3-48
METHOD OF OPERATION................ .... ... ... ... ... .... ... ... ... .......................................... .... ... ... ... ... .... ..3-50
PRECAUTIONS WHEN USING ......................................................................................................3-51
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE ..........3-51
INSPECTION DURING OFF-SEASON ...........................................................................................3-51
PROCEDURE FOR REPLACING RECEIVER ................................................................................ 3-51
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-52
CLEANING AIR FILTER..................................................................................................................3-52
OPERATION....................................................................................................................................................... 3-53
CHECK BEFORE STARTING ENGINE, ADJUST..................................... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 3-53
WALK-AROUND CHECK ................................................................................................................ 3-53
CHECK BEFORE STARTING ......................................................................................................... 3-54
ADJUSTMENT................................................................................................................................. 3-62
OPERATION AND CHECK BEFORE STARTING ENGINE............................................................3-66
STARTING ENGINE.................................................................................................................................3-68
NORMAL STARTING ................................... ... ... .... ... ... ... .... ... .......................................... ... ... ......... 3-68
STARTING IN COLD WEATHER....................................................................................................3-70
OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................... 3-73
WARMING UP OPERATIONS ........... .......................................... .... ... ... ... ... .... ... ... ... .... ... ... ............3-73
1-16
CONTENTS
STARTING IN COLD WEATHER.................................................................................................... 3-74
STOPPING ENGINE................................................................................................................................. 3-75
MACHINE OPERATION.............. ... ... ... .... ... ... ... .......................................... ... .... ... ... ... .... ... ...................... 3-77
MOVING MACHINE......................................................................................................................... 3-77
STOPPING MACHINE........................................................ ... .... ... .......................................... ......... 3-79
SHIFTING GEARS.................................................................................................................................... 3-79
GEARSHIFTING OPERATION........................................................................................................ 3-80
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION ............................................ 3-80
AUTO DOWN SHIFT OPERATION................................................................................................. 3-82
SHIFTING BETWEEN FORWARD AND REVERSE................................................................................ 3-83
STEERING MACHINE.............................................................................................................................. 3-85
NORMAL TURNING........................................................................................................................ 3-85
PRECAUTIONS FOR OPERATION..... .... ... ... ... ... .... ... ... ... .......................................... .... ... ... ... ... .... ... ...... 3-86
PAY ATTENTION TO GAUGES...................................................................................................... 3-86
PERMISSIBLE WATER DEPTH...................... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ............................. 3-86
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................... 3-86
PRECAUTIONS ON SLOPES......................................................................................................... 3-87
METHOD OF USING BRAKES ....................................................................................................... 3-87
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-87
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-87
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES.................. 3-88
WORK POSSIBLE USING BULLDOZER................................................................................................. 3-88
DOZING........................................................................................................................................... 3-88
SMOOTHING................................................................................................................................... 3-89
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................... 3-89
FELLING TREES, REMOVING STUMPS....................................................................................... 3-89
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-90
ADJUST ANGLE OF BLADE EDGE................................................................................................ 3-90
ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT ........................................................ 3-91
ADJUSTING TENSION OF CENTER BRACE ................................................................................ 3-91
ADJUST AMOUNT OF TILT............................................................................................................3-92
METHOD OF ANGLING BLADE ..................................................................................................... 3-93
PARKING MACHINE................................................................................................................................ 3-94
CHECK AFTER FINISHING WORK .........................................................................................................3-95
BEFORE STOPPING ENGINE.............. ... ... .... ... ... ... .... .......................................... ... ... ... ... .... ... ... ... 3-95
AFTER STOPPING ENGINE....................... .... ... ... ... .......................................... .... ... ... ... ... .... ... ... ...3-95
LOCKING.................................................................................................................................................. 3-96
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................... ... .... ... ... ... .... ... ... ... ... .... ... ...... 3-96
OPERATION METHOD................................................................................................................... 3-96
INSPECTION AND ADJUSTMENT....... .......................................................................................... 3-97
INSPECTION AND REPAIR ..........................................................................................................
.. 3-97
TRANSPORTATION......................................................................................................................................... 3-100
TRANSPORTATION MEANS................................................................................................................. 3-100
REMOVING CAB.................................................................................................................................... 3-100
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-100
PRECAUTIONS WHEN REMOVING ROPS .......................................................................................... 3-101
1-17
CONTENTS
LOADING, UNLOADING WORK ............................................................................................................ 3-102
LIFTING MACHINE................................................................................................................................. 3-105
TRAVELING ON ROADS ....................................................................................................................... 3-107
COLD WEATHER OPERATION ...................................................................................................................... 3-108
PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-108
AFTER COMPLETION OF WORK .................................. ... ... ... .... ... ... ... .... ... .......................................... 3-109
AFTER COLD WEATHER ........................................... .... ... ... ... .......................................... .... ... ... .......... 3-109
LONG-TERM STORAGE..................................................................................................................................3-110
BEFORE STORAGE . ... ... ... .... .......................................... ... ... ... .......................................... .... ................3-110
DURING STORAGE ........................................ ... ... ... ... .... .......................................... ... ... ... .... ................3-110
AFTER STORAGE.... ... ... ... .... ... .......................................... ... ... .... ... ... ... .... ............................................. 3-110
TROUBLESHOOTING...................................................................................................................................... 3-111
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-111
PROCEDURE FOR BLEEDING AIR............................................................................................. 3-111
METHOD OF TOWING MACHINE.........................................................................................................3-112
IF BATTERY IS DISCHARGED..............................................................................................................3-113
REMOVE AND INSTALL BATTERY ............................................................................................. 3-114
PRECAUTIONS FOR BATTERY CHARGING ..............................................................................3-114
STARTING ENGINE WITH BOOSTER CABLE ............................................................................3-115
OTHER TROUBLE ............ .......................................... .... ... ... ... .......................................... .... ................3-117
ELECTRICAL SYSTEM.................................................................................................................3-117
MONITOR PANEL..................... ... ... ... .... .......................................... ... ... ... ... .................................3-118
CHASSIS....................................................................................................................................... 3-119
ENGINE.........................................................................................................................................3-121
MAINTENANCE
GUIDE TO MAINTENANCE .................................................................................................................................4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-5
OIL..................................................................................................................................................... 4-5
FUEL..................................................................................................................................................4-6
COOLANT AND WATER FOR DILUTION......................................................................................... 4-6
GREASE............................................................................................................................................ 4-7
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ....................................................................4-7
STORING OIL AND FUEL......... ... .......................................... ... ... .... ......................................... ........ 4-8
FILTERS............................................................................................................................................ 4-8
RELATING TO ELECTRIC SYSTEM .........................................................................................................4-8
HANDLING HYDRAULIC SYSTEM............................................................................................................ 4-9
WEAR PARTS LIST ...........................................................................................................................................4-10
WEAR PARTS LIST.................................................................................................................................. 4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-12
1-18
CONTENTS
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ............ 4-13
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........................................................................................................................................... 4-15
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-16
TORQUE LIST.......................................................................................................................................... 4-16
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-17
SAFETY CRITICAL PARTS...................................................................................................................... 4-17
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-19
MAINTENANCE SCHEDULE CHART......................................................................................................4-19
WHEN REQUIRED.................................................................... ... ... ... ............................................. 4-19
CHECK BEFORE STARTING............ ... ... ... .... ... ... ... .... ... .......................................... ... ... ... .... ... ... ... 4-19
EVERY 50 HOURS SERVICE......................................................................................................... 4-19
EVERY 250 HOURS SERVICE....................................................................................................... 4-19
EVERY 500 HOURS SERVICE....................................................................................................... 4-19
EVERY 1000 HOURS SERVICE..................................................................................................... 4-19
EVERY 2000 HOURS SERVICE..................................................................................................... 4-20
EVERY 4000 HOURS SERVICE..................................................................................................... 4-20
EVERY 8000 HOURS SERVICE..................................................................................................... 4-20
SERVICE PROCEDURE .................................................................................................................................... 4-21
WHEN REQUIRED................................................................................................................................... 4-21
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................ .... ... ... ... ... .... ... ... ... 4-21
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-24
CHECK TRACK SHOE TENSION, ADJUST...................... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ...... 4-27
CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-29
REVERSE AND REPLACE END BITS AND CUTTING EDGES .................................................... 4-30
CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND AFTER-
COOLER.......................................................................................................................................... 4-32
CHECK, ADJUST AIR CONDITIONER........................................................................................... 4-35
GREASE DOOR HINGE.................................................................................................................. 4-36
CHECK DOOR LOCK STRIKER........................................ ... .... ... ... .......................................... ... ... 4-37
REPLACE DOOR DAMPER............................................................................................................ 4-37
CHECK DOOR LATCH.................... ... ... ... ... .... .......................................... ... ... ... .... ... ... ... ................ 4-37
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID.............................................................. 4-38
REPLACE WIPER BLADE ..............................................................................................................4-39
CHECK IDLER OIL LEVEL, ADD OIL............................................................................................. 4-40
ADJUST IDLER CLEARANCE........................................................................................................ 4-40
LUBRICATING UNIVERSAL JOINT......................... .............................................. ... ...................... 4-41
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM........... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-42
CHECK BEFORE STARTING .................................................................................................................. 4-43
EVERY 50 HOURS SERVICE.................................................................................................................. 4-43
DRAIN WATER, SEDIMENT FROM FUEL TANK........................................................................... 4-43
EVERY 250 HOURS SERVICE........................................................................................................
........ 4-44
LUBRICATING................................................................................................................................. 4-44
GREASE EQUALIZER BAR SIDE PIN............................................................................................ 4-45
GREASE EQUALIZER BAR CENTER PIN ..................................................................................... 4-46
1-19
CONTENTS
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ..................................................................4-46
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................................................4-47
CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-48
CHECK, CLEAN ADDITIONAL FUEL STRAINER ..........................................................................4-49
CHECK BRAKE PERFORMANCE.................................................................................................. 4-50
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................4-51
EVERY 500 HOURS SERVICE................................................................................................................4-52
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................... 4-52
REPLACE POWER TRAIN OIL FILTER ELEMENT........................................................................ 4-54
REPLACE FUEL PRE-FILTER CARTRIDGE..................................................................................4-54
EVERY 1000 HOURS SERVICE..............................................................................................................4-57
REPLACE FUEL MAIN FILTER CARTRIDGE ....................................... ... ... .... ... ... ... .... ... ... ... ... .... .. 4-57
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER,
SCAVENGING PUMP STRAINER)................................................................................................. 4-60
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.........................................................................4-62
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................4-63
CLEAN BREATHER ........................................................................................................................ 4-63
REPLACE CORROSION RESISTOR CARTRIDGE .......................................................................4-64
CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................ 4-64
INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS .................. 4-64
EVERY 2000 HOURS SERVICE..............................................................................................................4-65
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT.....................................4-65
REPLACE HYDRAULIC TANK BREATHER ELEMENT .................................................................4-66
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT).........................................................................................................................................4-66
CHANGE OIL IN DAMPER CASE...................................................................................................4-69
CHECK VIBRATION DAMPER .......................................................................................................4-70
CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................... 4-70
EVERY 4000 HOURS SERVICE..............................................................................................................4-71
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).............................................................. 4-71
CHECK WATER PUMP...................................................................................................................4-71
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER ......4-72
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER .......4-73
EVERY 8000 HOURS SERVICE..............................................................................................................4-74
REPLACE HIGH-PRESSURE PIPING CLAMP .............................................................................. 4-74
REPLACE FUEL SPLAY PREVENTION CAPS............................................................ ... ... ... ... .... .. 4-74
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS .................................................................................................................................6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
1-20
CONTENTS
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
ADJUSTING POSTURE OF WORK EQUIPMENT ........................................................................... 6-5
TROUBLESHOOTING................................................................................................................................ 6-7
OTHER TROUBLE...... ... .... ... ... .......................................... ... .......................................... ... ............... 6-7
MAINTENANCE.......................................................................................................................................... 6-7
EVERY 250 HOURS SERVICE.........................................................................................................6-7
SPECIFICATIONS...................................................................................................................................... 6-8
AIR SUSPENSION SEAT..................................................................................................................................... 6-9
DELUXE SEAT................................................................................................................................................... 6-12
HEADREST ........................................................................................................................................................ 6-14
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................. 6-15
INDEX
COLOPHON
1-21
CONTENTS
1-22
SAFETY
12
WARNING
Please read and make sure that you fully understand the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
IMPORTANT SAFETY INFORMATION SAFETY
IMPORTANT SAFETY INFORMATION 2
SAFETY LABELS................................................................................................................................................2-42
POSITION FOR ATTACHING SAFETY LABELS . .......................................... .... ... ... ......................................... 2-52
SAFETY LABELS...............................................................................................................................................2-52
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...............................................................2-102
FOR SAFE OPERATION.................................................................................................................................2-102
KNOW YOUR EQUIPMENT ............................................................................................................................ 2-102
PREPARE FOR SAFE OPERATION............................................................................................................... 2-102
CLOTHING AND PERSONAL PROTECTIVE ITEMS .....................................................................................2-112
FIRE EXTINGUISHER AND FIRST AID KIT ...................................................................................................2-112
KEEP THE MACHINE CLEAN.........................................................................................................................2-112
IF ABNORMALITIES ARE FOUND.................................................................................................................. 2-112
HANDRAILS AND STEPS ............................................................................................................................... 2-122
MOUNTING AND DISMOUNTING ..................................................................................................................2-122
INSIDE OPERATOR'S COMPARTMENT........................................................................................................ 2-122
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT ........................................................... 2-132
PRECAUTIONS WHEN LEAVING THE MACHINE.........................................................................................2-132
EMERGENCY ESCAPE FROM OPERATOR'S CAB ......................................................................................2-132
FIRE PREVENTION.........................................................................................................................................2-142
ACTION IF FIRE OCCURS..............................................................................................................................2-152
BATTERY HAZARD PREVENTION ................................................................................................................2-152
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS .............................................................. 2-162
BE CAREFUL ABOUT ASBESTOS DUST...................................................................................................... 2-162
PRECAUTIONS DURING OPERATION...........................................................................................................2-172
EXAMINATION AND CONFIRMATION OF WORKSITE.................................................................................2-172
WORKING ON LOOSE GROUND................................................................................................................... 2-172
DO NOT GO NEAR HIGH-VOLTAGE CABLES ..............................................................................................2-172
ENSURE GOOD VISIBILTY ............................................................................................................................2-182
CONFIRMATION OF MARK............................................................................................................................ 2-182
PRECAUTION FOR WARNING TAG ....................................... ... ... ... .... ... ... ... .... ............................................. 2-182
CHECK BEFORE STARTING ENGINE,ADJUST............................................................................................2-182
PRECAUTIONS WHEN STARTING................................................................................................................2-192
STARTING WITH BOOSTER CABLES....................... ... ... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... .............................2-192
CHECK BEFORE STARTING OPERATION ...................................................................................................2-202
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE .............................................................2-202
PRECAUTIONS WHEN TRAVELING..............................................................................................................2-212
PRECAUTIONS FOR ACCUMULATED SNOW, AND ICE.................... ... ... ... .... ... ... ... ... ................................. 2-212
SHIPPING........................................................................................................................................................ 2-212
WHEN TOWING .............................................................................................................................................. 2-222
PRECAUTIONS FOR MAINTENANCE ............................................................................................................2-232
UNAUTHORIZED MODIFICATION .................................................................................................................2-232
WARNING TAG ...............................................................................................................................................2-232
KEEP WORK PLACE FOR MAINTENANCE CLEAN AND TIDY.................................................................... 2-232
REPAIR WELDING..........................................................................................................................................2-232
USE CAUTION WHEN FUELING....................................................................................................................2-232
PERSONAL MAINTENANCE .......................................................................................................................... 2-232
PROPER TOOLS............................................................................................................................................. 2-242
SELECTION WORK PLACE FOR MAINTENANCE........................................................................................ 2-242
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.......................................... 2-242
TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING.........................2-252
WORK UNDER THE MACHINE ......................................................................................................................2-252
PRECAUTIONS WHEN USING HAMMER.................................................................................................
.....2-262
2-2
SAFETY IMPORTANT SAFETY INFORMATION
PREVENTION BURNS FROM HOT WATER.................................................................................................. 2-262
PREVENTION BURNS FROM HOT OIL ......................................................................................................... 2-262
COMPRESSED AIR......................................................................................................................................... 2-262
HANDLING HIGH-PRESSURE HOSES, PIPING............................................................................................ 2-262
PRECAUTIONS WITH HIGH-PRESSURE OIL...............................................................................................2-272
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION..................... 2-272
DO NOT DISASSEMBLE RECOIL SPRING.................................................................................................... 2-272
ACCUMULATOR ............................................................................................................................................. 2-282
MAINTENANCE OF AIR CONDITIONER........................................................................................................2-282
WASTE MATERIALS.......................................................................................................................................2-282
PRECAUTIONS FOR MACHINE...................................................................................................................... 2-292
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)......................................................... 2-292
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
The following safety labels are used on this machine.
q Make sure that you fully understand the location and content of each safety label, together with the means of
avoiding the danger shown.
q To ensure that the contents of safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning the labels, do not use organic solvents or gasoline. They may cause
the labels to peel off.
q If the labels are damaged, lost, or cannot be read properly, contact your Komatsu distributor immediately
regarding their replacement. For details concerning the part numbers for the labels, see this manual or the
actual label.
q There are also other labels on the machine in addition to the safety labels. Handle those labels in the same
way.
2-4
SAFETY SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS 2
SAFETY LABELS 2
(1) Caution before operating or maintaining machine
(09651-A0641)
q Warning!
q Read manual before operation, maintaince, disassembly,
assembly and transportation.
2-5
SAFETY LABELS SAFETY
(2) Caution before moving in reverse (09802-B0750)
(3) Caution for leaving operator's seat (09654-B0641)
q Sign indicates a hazard of unexpected moving of stopped
machine.
q Lower working device to ground, move safety lever to lock
position and take engine key with you before leaving
machine.
(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.
2-6
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