Komatsu D85EX-15, D85PX-15 User Manual

EEAM022804

Operation & Maintenance Manual

D85EX

D85PX

BULLDOZER

SERIAL NUMBER

D85EX-15 - 10001 D85PX-15 - 1001

and up

-15

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

FOREWORD FOREWORD

FOREWORD 0.

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most acciden ts are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration and maintenance.

WARNING

Operators and maintenance personnel must always do as follows before beginning operation or maintenance.

Always be sure to read and understand this manual thoroughly before performing operation and

maintenance.

Read the safety messages given in this manual and the safety labels affixed to the machine thor-

oughly and be sure that you understand them fully.

Keep this manual at the storage location for the Operation and M aintenance Manual given below, 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 immediately from Komatsu or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

Location to Keep Operation & Maintenance Manual In Door Pocket Inside of Cab Door

1-2

FOREWORD SAFETY INFORMATION

SAFETY INFORMATION 0.

To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.

Signal words

The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage. In this manual and on machine labels, the following signal words are used to express the potential level of hazard.

DANGER

WARNING

CAUTION

Example of safety message using signal word

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. This word is used also to alert against unsafe practices that may cause property damage.

WARNING

When standing up from the operator's seat, always place the safety lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

Other signal words

In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to protect the machine or to give information that is useful to know.

NOTICE REMARKS

This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine.

This word is used for information that is useful to know.

1-3

SAFETY INFORMATION FOREWORD

Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety pr ocedur es.

Example of safety label using words

Part No.

Safety labels using pictogram

Safety pictograms use a picture to expre ss a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of h azardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.

Part No

Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce. Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual.

The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))

1-4

FOREWORD SAFETY INFORMATION

Noise emission levels 0.

Two labels ind icating the machine noise level a re affixed on the machine. Sound pressure level at the operator's station, measured

according to ISO6396 (Dynamic test method, simulated working cycle)

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 0.

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. 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.

If equipped with mechanical suspension seat The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleratio n value for the body is 0.52 m/s².

These values were determined using a representative machine and measured during the typical operating condition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and ISO 5349.

1-5

SAFETY INFORMATION FOREWORD

Operating condition:

(WHEEL LOADER:) V-shape loading (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

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

Tire pressures (for wheeled machines), tension of crawler (for crawler machines) Brake and steering systems Controls, hydraulic system and linkages

3. Keep the terrain where the machine is working and traveling in good condition

Remove any large rocks or obstacles Fill any ditches and holes Site manager should provide machine operators with machine and schedule time to maintain terrain condi-

tions

4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted

Adjust the seat and suspension for the weight and size of the operator Wear seat belt Inspect and maintain the seat suspension and adju stment 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

When pushing with bucket or blade, avoid sudden loading; load gradually Drive around obstacles and rough terrain conditions Slow down when it is necessary to go over rough terrain Make the curve radius of traveling path as large as possible Travel at low speed when traveling around sharp curves

7. Minimize vibrations for long work cycle or long distance traveling

Reduce speed to prevent bounce Transport machines long distances between worksites

8. The following guidelines can be effective to minimize risks of low back pain

Operate the machine only when you are in good health. Provide breaks to reduce long periods of sitting in the same posture Do not jump down from the cab or machine Do not repeatedly handle and lift loads

1-6

FOREWORD INTRODUCTION

INTRODUCTION 0.

This Komatsu machine is designed to be used mainly for the following work:

Dozing Cutting into hard or frozen ground or ditching Felling trees, removing stumps Pushing Ripping

For further details, see “WORK POSSIBLE USING BULLDOZER ( 3-92 )“.

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 0.

Front

Left

Operator’s seat

Rear

In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when the operator's seat is facing the front and the sprocket is at the rear of the machine.

Right

Sprocket

1-7

NECESSARY INFORMATION FOREWORD

NECESSARY INFORMATION 0.

When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.

MACHINE SERIAL NO. PLATE AND POSITION 0.

Under the front of the console box on the right side of the operator's seat.

ENGINE SERIAL NO. PLATE AND POSITION 0.

This is at the rear of the starting motor on the rights side of the engine. (The EMISSION CONTROL INFORMATION LABEL is at the front surface of the engine oil filler on the left side of the engine.)

EPA: Environmental Protection Agency, U.S.A.

1-8

FOREWORD NECESSARY INFORMATION

BLADE SERIAL NO. PLATE POSITION 0.

This is located at the upper right of blade back surface.

RIPPER SERIAL NO. PLATE POSITION 0.

This is located at the left side surface of ripper beam.

ROPS, FOPS NO. PLATE POSITION 0.

This is located at the top left.

FOPS

ROPS

POSITION OF SERVICE METER 0.

On top of the machine monitor

1-9

NECESSARY INFORMATION FOREWORD

TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 0.

Machine serial No.

Engine serial No.

Product Identification Number Manufacturers name:

Address:

Distributor Address

Phone Service personnel for your

machine:

KOMATSU LTD. 3-6 Akasaka Minato-ku, 101 Tokyo Japan

1-10

FOREWORD NECESSARY INFORMATION

MACHINE SERIAL NUMBER PLATE

Valid until 31 December 2003

Model

Seriel Number

Manufacturing year

Weight

Engine power

Manuafacturer

Valid as of 1 January 2004

Seriel Number

Manufacturing year

Weight

Engine power

Komatsu Ltd. Tokyo, Japan

Produced by Komatsu Tokyo, Japan

Model

Product Identification Number

Manuafacturer

1-11

CONTENTS

FOREWORD

FOREWORD.........................................................................................................................................................1-2

SAFETY INFORMATION...................................................................................................................................... 1-3

Noise emission levels ...................................... ... ... ... ... .... ... ... ... .... ..............................................................1-5

Vibration levels............................................................................................................................................ 1-5

Guide to Reduce Vibration Levels on Machine..................................................................................1-6

INTRODUCTION................................................................................................................................................... 1-7

FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................................... 1-7

NECESSARY INFORMATION .............................................................................................................................1-8

MACHINE SERIAL NO. PLATE AND POSITION ....................................................................................... 1-8

ENGINE SERIAL NO. PLATE AND POSITION............................................................ ... ... .... ... .................1-8

BLADE SERIAL NO. PLATE POSITION .................................................................................................... 1-9

RIPPER SERIAL NO. PLATE POSITION...................................................................................................1-9

ROPS, FOPS NO. PLATE POSITION ........................................................................................................ 1-9

POSITION OF SERVICE METER ..............................................................................................................1-9

TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-10

MACHINE SERIAL NUMBER PLATE . ... ... ... .... ... ... ... ... .......................................... .... ... ... ... .... ... ...............1-11

SAFETY

SAFETY................................................................................................................................................................2-2

SAFETY LABELS.................................................................................................................................................2-4

POSITIONS OF SAFETY PICTOGRAMS ..................................................................................................2-4

SAFETY LABELS ........................ ... .... ... ... ... .... ...................................... .... ... ... ... ... .... .................................2-5

GENERAL PRECAUTIONS .................................................................................................................................2-9

PRECAUTIONS FOR OPERATION................................................................................................................... 2-16

BEFORE STARTING ENGINE ........................................... ... ... .... .......................................... ... ... ............2-16

OPERATION............................................................................................................................................. 2-17

TRANSPORTATION................................................................................................................................. 2-20

BATTERY .................................................................................................................................................2-20

TOWING ................................................................................................................................................... 2-22

PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-23

OPERATION

GENERAL VIEW .................................................................................................................................................. 3-2

1-12

CONTENTS

GENERAL VIEW OF MACHINE............................................................ ... ... ... .... ... ... .................................. 3-2

GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3

EXPLANATION OF COMPONENTS.................................................................................................................... 3-5

FRONT PANEL........................................................................................................................................... 3-5

CHECK MONITOR GROUP............................................... ... .... ... ... .......................................... ........3-7

CAUTION MONITOR GROUP .......................................................................................................... 3-8

EMERGENCY CAUTION ITEMS .................................................................................................... 3-10

METER GROUP....... ... ... .......................................... .......................................... ............................. 3-12

SWITCH........................................................................................................................................... 3-16

LAMP............................................................................................................................................... 3-19

METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-21

SWITCH.................................................................................................................................................... 3-28

CONTROL LEVERS, PEDALS................................................................................................................. 3-31

DUST INDICATOR ................................................................................................................................... 3-36

FUSE BOX.. .... ... ... ... ... .... .......................................... .......................................... ...................................... 3-37

CIRCUIT BREAKER........................................................................................................................ 3-38

FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-38

FUSIBLE LINK...... ... ... .... ... ... .......................................... .......................................... ................................ 3-39

DOOR OPEN LOCK................................................................................................................................. 3-40

SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-40

DOOR POCKET ....................................................................................................................................... 3-41

ASHTRAY................................................................................................................................................. 3-41

CAR STEREO, HANDLING...................................................................................................................... 3-42

EXPLANATION OF COMPONENTS............................................................................................... 3-42

METHOD OF OPERATION.............................................................................................................3-47

PRECAUTION WHEN USING................................................................... ... ... ... .... ... ... ................... 3-49

AIR CONDITIONER.................................................................................................................................. 3-50

GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL .......... ... ... ... .... ... ... ... ... .... ... ... ... 3-50

METHOD OF OPERATION.............................................................................................................3-52

PRECAUTIONS WHEN USING ...................................................................................................... 3-53

SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......... 3-53

CHECKS DURING OFF-SEASON.................................................................................................. 3-53

PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-53

CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-54

CLEANING AIR FILTER.................................................................................................................. 3-54

ACCUMULATOR, HANDLING.................................................................................................................. 3-54

METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH

ACCUMULATOR............................................................................................................................. 3-54

OPERATION....................................................................................................................................................... 3-55

CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-55

WALK-AROUND CHECK ................................................................................................................ 3-55

CHECK BEFORE STARTING...................................................................... ... ... .... ... ... ... ................ 3-56

ADJUSTMENT................................................................................................................................. 3-65

OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-69

STARTING ENGINE....... ... ... ... .... ... .......................................... ... ... .......................................................... 3-71

NORMAL STARTING................................................................................................................

...... 3-71

1-13

CONTENTS

STARTING IN COLD WEATHER.................................................................................................... 3-72

OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-75

BREAKING IN THE MACHINE........................................................................................................ 3-75

NORMAL OPERATION ... ... ... .... ... ... ... .......................................... .......................................... .........3-75

IN COLD AREAS................................................ .... ... ... .......................................... ... .... ... ...............3-77

STOPPING ENGINE . ... ... ... ................................................................................. ...................................... 3-78

CHECK AFTER STOPPING ENGINE ......................................................................................................3-78

MOVING MACHINE OFF.......................................................................................................................... 3-79

STOPPING MACHINE. ... ... .... ... ... .......................................... .......................................... .........................3-81

SHIFTING GEAR......................................................................................................................................3-82

SHIFTING BETWEEN FOEWARD AND REVERSE ................................................................................3-84

STEERING MACHINE.............................................................................................................................. 3-86

NORMAL TURNING............................... ... ... ... ... .... ...................................... .... ... ... ... .... ... ... ............3-86

TURNING WHILE DESCENDING A SLOPE............................. ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... ......3-87

PRECAUTIONS FOR OPERATION .........................................................................................................3-88

PAY ATTENTION TO GAUGES...................................................................................................... 3-88

PERMISSIBLE WATER DEPTH...................................................................................................... 3-88

PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..........................................................3-88

PRECAUTIONS ON SLOPE ...........................................................................................................3-88

METHOD OF USING BRAKES ........................................................................................... ............ 3-88

PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS ...........................................3-89

IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW

3-89

PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY.......................3-89

PARKING MACHINE ............................................................................. .... ... ... ... ... .... ...............................3-89

CHECK AFTER FINISHING WORK ... .......................................... ... ... ... .... ... ... ......................................... 3-91

LOCKING.................................................................................................................................................. 3-91

WORK POSSIBLE USING BULLDOZER ................................................................................................. 3-92

DOZING........................................................................................................................................... 3-92

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING....................................................3-92

FELLING TREES, REMOVING STUMPS .......................................................................................3-92

PUSHER OPERATIONS .................................................................................................................3-92

SMOOTHING...................................................................................................................................3-93

ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-94

BLADE ADJUSTMENT....................................................................................................................3-94

However, the more the digging angle is changed, the more the chang e become s in the am oun t of tilt on th e

left and right sides provided by the tilt cylinder. .. ... ... ... .... ... ... ... .... .......................................... ... ...............3-95

ADJUSTING RIPPER......................................................................................................................3-96

TIPS FOR LONGER UNDERCARRIAGE LIFE ........................................................................................ 3-98

OPERATION METHOD...............................................................................................................

INSPECTION AND ADJUSTING.....................................................................................................3-98

INSPECTION AND REPAIR............................................................................................................3-99

....3-98

TRANSPORTATION.........................................................................................................................................3-100

TRANSPORTATION PROCEDURE.......................................................................................................3-100

LOADING, UNLOADING WORK ............................................................................................................3-100

PRECAUTIONS FOR LOADING ............................................................................................................3-100

METHOD OF LIFTING MACHINE.......................................................................................................... 3-101

1-14

CONTENTS

PRECAUTIONS FOR TRANSPORTATION ................... ... .... .......................................... ... ... ... ... .... ... ... . 3-102

TRAVELING ON ROADS .................................................. .... ... ... ... .... ... ... ... ... .... .................................... 3-102

REMOVAL OF CAB................................................................................................................................ 3-102

INSTALLATION OF CAB........................................................................................................................ 3-103

INSTALLATION OF ROPS..................................................................................................................... 3-103

COLD WEATHER OPERATION...................................................................................................................... 3-104

PRECAUTIONS FOR LOW TEMPERATURE.................................................... ... ... ... .... ... ... ... ... .... ... ... . 3-104

FUEL AND LUBRICANTS .............................................................................................................3-104

COOLANT ..................................................................................................................................... 3-104

BATTERY...................................................................................................................................... 3-104

AFTER COMPLETION OF WORK......................................................................................................... 3-105

AFTER COLD WEATHER...................................................................................................................... 3-105

LONG-TERM STORAGE.................................................................................................................................. 3-106

BEFORE STORAGE............................................................................................................................... 3-106

DURING STORAGE............................................................................................................................... 3-106

AFTER STORAGE.................................................................................................................................. 3-106

TROUBLESHOOTING...................................................................................................................................... 3-107

AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-107

PROCEDURE FOR BLEEDING AIR............................................................................................. 3-107

METHOD OF TOWING MACHINE.........................................................................................................3-108

IF BATTERY IS DISCHARGED.............................................................................................................. 3-109

STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-109

OTHER TROUBLE ................................................................................................................................. 3-112

ELECTRICAL SYSTEM................................................................................................................. 3-112

MONITOR PANEL......................................................................................................................... 3-113

CHASSIS....................................................................................................................................... 3-114

ENGINE......................................................................................................................................... 3-116

MAINTENANCE

GUIDES TO MAINTENANCE............................................................................................................................... 4-2

OUTLINES OF SERVICE..................................................................................................................................... 4-5

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ............................................. ... ... .. 4-5

OIL..................................................................................................................................................... 4-5

FUEL.................................................................................................................................................. 4-5

COOLANT ......................................................................................................................................... 4-5

GREASE............................................................................................................................................ 4-6

CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-6

STORING OIL AND FUEL................................................................................................................. 4-7

FILTERS............................................................................................................................................ 4-7

OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-7

WEAR PARTS LIST............................................................................................................................................. 4-8

WEAR PARTS LIST.................................................................................................................................... 4-8

1-15

CONTENTS

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................... 4-9

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ...........................................................4-9

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................................................4-13

TORQUE LIST..........................................................................................................................................4-13

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-14

SAFETY CRITICAL PARTS................................... ... ... .... ... ... ... .... ... ... ... ................................................... 4-15

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-17

MAINTENANCE SCHEDULE CHART......................................................................................................4-17

INTIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) ...................................... 4-17

WHEN REQUIRED.......................................................................................................................... 4-17

CHECK BEFORE STARTING .........................................................................................................4-17

EVERY 250 HOURS SERVICE....................................................................................................... 4-17

EVERY 500 HOURS SERVICE....................................................................................................... 4-17

EVERY 1000 HOURS SERVICE............................ .........................................................................4-18

EVERY 2000 HOURS SERVICE............................ .........................................................................4-18

EVERY 4000 HOURS SERVICE............................ .........................................................................4-18

EVERY 8000 HOURS SERVICE............................ .........................................................................4-18

SERVICE PROCEDURE ....................................................................................................................................4-19

INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)...............................................4-19

WHEN REQUIRED............................................................................. ......................................................4-19

CHECK BEFORE STARTING ......................................................................... ... ... .... ... ... ... ......................4-37

EVERY 250 HOURS SERVICE................................................................................................................ 4-38

EVERY 500 HOURS SERVICE................................................................................................................ 4-45

EVERY 1000 HOURS SERVICE.............................................................................................................. 4-49

EVERY 2000 HOURS SERVICE.............................................................................................................. 4-53

EVERY 4000 HOURS SERVICE.............................................................................................................. 4-58

EVERY 8000 HOURS SERVICE.............................................................................................................. 4-61

SPECIFICATIONS

SPECIFICATIONS................................................................................................................................................5-2

ATTACHMENTS, OPTIONS

GENERAL PRECAURIONS.................................................................................................................................6-2

PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2

SELECTION OF TRACK SHOE........................................................................................................................... 6-3

SELECTION OF TRACK SHOES...............................................................................................................6-3

PROCEDURE FOR SELECTING RIPPER POINT...............................................................................................6-4

PROCEDURE FOR SELECTING RIPPER POINT..................................................................................... 6-4

1-16

CONTENTS

CAP WITH LOCK, HANDLING............................................................................................................................ 6-5

METHOD OF OPENING AND CLOSING CAP WITH LOCK...................................................................... 6-5

INDEX

COLOPHON

1-17

CONTENTS

1-18

SAFETY

WARNING

Please be sure that you fully underst an d this manual an d the precautions discribed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precaustions strictly.

SAFETY SAFETY

SAFETY 0.

Safety Labels ............................................ .... ... ... ... .... .......................................... ... ... ... ........................................ 2-4

Positions of Safety Pictograms ...................................................................................................................... 2-4

Safety Labels .................................................................................................................................................2-5

General Precautions

Safety Rules................................................................................................................................................... 2-9

If Abnormalities Are Found.............................. .... ... ... ... ... .... ... ... ... .... ..............................................................2-9

Clothing and Personal Protective Items......................................................................................................... 2-9

Fire Extinguisher and First Aid Kit..................................................................................................................2-9

Fafety Features.............................................................................................................................................. 2-9

Keep Machine Clean......................................................................................................................................2-9

Inside Operator's Compartment................................................................................................................... 2-10

Always Apply Lock When Leaving Operator's Seat................................................................... ... ... ... .........2-10

Handrails and Steps........................................ .... ... ... .......................................... ... ... ................................... 2-11

Mounting and Dismounting .......................................................................................................................... 2-11

No People on Attachments .......................................................................................................................... 2-11

Prevention of Burns...................................................................................................................................... 2-12

Fire Prevention.............................................................................................................................................2-12

Action If Fire Occurs..................................................................................................................................... 2-13

Window Washer Liquid ................................................................................................................................ 2-13

Pecautions for ROPS...................................................................................................................................2-13

Precautions for Attachments........... ... .... .......................................... ... ... ... .... ... ... ... ... .... ... ... .........................2-13

Cab Window Glasses............................................................................. ... .... ............................................... 2-13

Unauthorized Modification............................................................................................................................2-13

Safety at Worksite........................................................................................................................................ 2-14

Working on Loose Ground........................................... ... .... ... ... ... .......................................... ......................2-14

Do Not Go Close to High-Voltage Cables....................................................................................................2-14

Ensure Good Visivility..................................................................................................................................2-15

Ventilation for Enclosed Areas..................................................................................................................... 2-15

Checking Signalman's Signals and Signs.................................................................................................... 2-15

Be Careful About Asbestos Dust..................................................................................................................2-15

Precautions for Operation ................................................................................................................................... 2-16

Before Starting Engine................................................................................................................................. 2-16

Checks Before Starting Engine.............................................................................................................2-16

Precautions When Starting...................... .... ... ... ... ... .... .......................................... ... ... ... .... ..................2-16

Precautions in Cold Areas ....................................................................................................................2-17

Operation .....................................................................................................................................................2-17

Checks Before Operation...................................................................................................................... 2-17

Precautions When Moving Machine Forward or in Reverse........................................................................2-17

Precautions When Traveling........................... ... ... ... .... ... ... ... .... ... ... ... .... ............................................... 2-18

Traveling on Slopes .............................................................................................................................. 2-18

Prohibited Operations ........................................................................................................................... 2-19

Useing Brakes.......................................................................................................................................2-19

Operate Carefully on Snow...................................................................................................................2-19

Parking Machine............................. ... ... ... .... ... ... ... .......................................... ... .... ... .....

Transportation.............................................................................................................................................. 2-20

Shipping................................................................................................................................................2-20

Battery.......................................................................................................................................................... 2-20

Battery Hazard Prevention........................................................................ ... ... ... .... ... ... ... ......................2-20

Starting with Booster Cable .................................................................................................................. 2-21

Towing.......................................................................................................................................................... 2-22

When Towing........................................................................................................................................2-22

Precautions for Maintenance ..............................................................................................................................2-23

Warning Tag................................................................................................................................................. 2-23

Keep Work Place Clean and Tidy................................................................................................................ 2-23

....................... 2-19

2-2

SAFETY SAFETY

Appoint Leader When Working with Others.......................... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... ............. 2-23

Stop Engine Before Carrrying Out Inspection and Maintenance ................................................................. 2-24

Two Workers for Maintenance when Engine is Running ............................................................................. 2-24

Proper Tools .. .......................................... .......................................... .......................................................... 2-25

Handling Accumulator.................................................................................................................................. 2-25

Personnel..................................................................................................................................................... 2-25

Attachments................................................................................................................................................. 2-25

Work Under the Machine ............................................................................................................................. 2-26

Noise............................................................................................................................................................ 2-26

Precautions When Using Hammer............................................................................................................... 2-26

Repair Welding ............................................................................................................................................ 2-26

Removing Battery Terminal ...................................................... ... ... ... .... ...................................................... 2-26

Precautions When Using High-Pressure Grease to Adjust Track Tension.. ... ... .......................................... 2-27

Do Not Disassemble Recoil Spring.............................................................................................................. 2-27

Precaution with High-Pressure Oil............................................................................................................... 2-27

Handing High-Pressure Hoses .................................................................................................................... 2-27

Waste Material............................................................................................................................................. 2-28

Maintenance for Air Conditioner .................................................................................................................. 2-28

Compressed Air........................................................................................................................................... 2-28

Periodic Replacement of Safety Critical Parts ............................................................................................. 2-28

2-3

SAFETY LABELS SAFETY

SAFETY LABELS 0.

The following warning signes and safety labels are used on this machine.

Be sure that you fully understand the correct position and content of labels. To ensure that the content of labels can be read properly, be sure that they are in the correct place and always

keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the lab els to peel off.

There are also other labels in addition to the warning signes and safety labels. Han dle those labels in the same

way.

If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part

numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITIONS OF SAFETY PICTOGRAMS 0.

2-4

SAFETY SAFETY LABELS



SAFETY LABELS 0.

(1) Precautions for operation, inspection and maintenance (09651-A0641)

Warning!

Read manual before operation, maintaince, disassembly,

assembly and transportation.

(2) Precautions when traveling in reverse (09802-13000)

Warning To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments:

Honk horn to alert people nearby. Be sure no one is on or near the machine. Use spotter if view is obstructed.

Follow above even if the machine is equipped with back-up alarm and mirrors.

(3) Precautions for leaving operator's seat (09654-B0641)

To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments . Honk horn to alert people nearby. . Be sure no one is on or near the machine. . Use spotter if view is ob- structed. Follow above even if the machine is equipped with back-up alarm and mirrors.

09802-13000

Sign indicates a hazard of unexpected moving of stopped

machine.

Lower working device to ground, move safety lever to lock

position and take engine key with you before leaving machine.

2-5

SAFETY LABELS SAFETY

(4) Precautions for high-temperature cooling water (09653-A0481)

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.

Never remove the radiator or hydraulic tank oil filler when

cooling water or hydraulic oil is at high temperatures.

5. Precautions when adjusting track tension (09657-A0881)

Safety label is attached on the back side of the inspection cover of the track frame Plug coming from track shoe tension adjustment device

causing injury.

Read the operation and maintenance manual and carrying

out the correct method when looseing track tension.

(6) Precautions for handling electric wires (09808-A0881)

There is the hazard to electric shock when handling electric

wires.

Read the operation and maintenance manual and carrying

out the correct method when handling.

(7) Caution for engine running (09667-A0481)

Sign indicates a hazard of rotating parts, such as belt. Turn off before inspection and maintenance.

2-6

SAFETY SAFETY LABELS

(8) Precautions for handling accumulator (09659-A057B)

There is the hazard of explotion causing injury. Do not disassemble the accumulator, make holes in it, weld

it, cut it, hit it, roll it or bring it near flame.

(9) Caution for approach when machine moving (09806-B1683)

Sign indicates a hazard of being run over by moving equip-

ment.

Keep a safe distance from equipment when it is moving.

(10) ROPS (09620-B2000)

ROPS CERTIFICATION This protective structure complies with the standard provided that us properly equipped on the machine which mass is less than the specified maximum mass.

1. MODEL 3. FOPS LEVEL No. 5. MAX. MASS kg (Lb)

2. MACHINE MODEL 4. SERIAL NO.

WARNING If some modification is applied to the ROPS. It might not enough strength and might not be complied with the

standard. Consult Komatsu Distributor before altering.

ROPS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu

Distributor in that case.

Always wear seat belt when moving.

2-7

SAFETY LABELS SAFETY

(11) FOPS (09620-C2000)

FOPS CERTIFICATION This protective structure was provided to comply with the following standard.

1. MODEL 2. MACHINE MODEL

3. SERIAL NO. 4. FOPS LEVEL No.

If some modification is applied to the FOBS. It might not enough strength and might not be complied with the

standard. Consult Komatsu Distributor before altering.

FOBS may provide less protection if it has been structurally damaged or involved roll-over. Consult Komatsu

Distributor in that case.

Always wear seat belt when moving. (12) Precaution for avoiding falling down (09805-C0881)

Sign indicates a hazard of falling Do not stand on this place here

(13) Jump start prohibited (09842-A0481) Start the engine only after sitting down in the operator’s

seat.

Do not attempt to start the engine by short-circuiting the

engine starting circuit. Such an act may cause a serious bodily injury or fire.

2-8

SAFETY GENERAL PRECAUTIONS

GENERAL PRECAUTIONS 0.

SAFETY RULES 0.

Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the

machine.

If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may

be severly impaired putting yourself and everyone else on your jobsite in danger.

When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-

stand all hand signals that are to be used.

IF ABNORMALITIES ARE FOUND 0.

If you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor ), rep ort to the pe rson in charge and have the necessary action taken. Do not operate the machine until the abnormality has been corrected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS 0.

Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other

protruding parts.

If you have long hair and it hangs out from your hard hat,

there is a hazard that it may get caugh t up in the machin e, so tie your hair up and be careful not to let it get caught.

Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine.

Check that all protective equipment functions properly

before using it.

FIRE EXTINGUISHER AND FIRST AID KIT 0.

Always follow the precautions below to prepare for action if any injury or fire should occur. Be sure that fire extinguishers have been provide d and rea d

the labels to ensure that you know how to use them in emergencies.

Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.

Provide a first aid kit at the storage point. Carry out p eriodic

checks and add to the contents if necessary.

SAFETY FEATURES 0.

Be sure that all guards and covers are in their proper position. Have guards and cover s repaired immediately if

they are damaged.

Understand the method of use of safety features and use them properly. Never remove any safety features. Always keep them in good operating condition.

KEEP MACHINE CLEAN 0.

If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not

use water or steam to wash the electrical system (sensors, connectors).

2-9

GENERAL PRECAUTIONS SAFETY

If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.

INSIDE OPERATOR'S COMPARTMENT 0.

When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.

If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious accident.

Do not leave parts or tools lying around the operator's compartment. Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire. Do not use cellular telephones inside the operator's compartment when driving or operating the machine. Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 0.

Before standing up from the operator's seat, lower the work

equipment completely to the ground, set safety lock lever and parking lever securely to the LOCK position, then stop the engine. If you accidentally touch the levers when they are not locked, there is a hazard that the machine may suddenly move and cause serious injury or property damage.

Free

Lock

When leaving the machine, always lower the work equip-

ment completely to the ground, set safety lock lever and Parking lever securely to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place.

Free

Lock

2-10

+ 210 hidden pages