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D65EX-16D65PX-16

D65WX-16SERIAL NUMBER

D65EX-16 - 80012 and up

D65PX-16 - 80012 and up

D65WX-16 - 80012 and up

BULLDOZER

Unsafe use of thi s 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 whowill come into contact with the machine.

Operation &Maintenance Manual

EEAM029700

WARNING

ORIGINAL INSTRUCTIONS

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FOREWORD

11

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BEFORE READING THIS MANUAL FOREWORD

1-2

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 possible safety precau-

tions. 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 together with the machine.

Always keep this Operation and Maintenance Manual in the location shown on the right 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 back

side 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 (1-10)“.

This manual uses the international units (SI) for units of measurement. For reference, units that have been used in

the past are given in ( ).

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 improvements in the design of this machine may lead to addi-

tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest

available information concerning your machine or with questions regarding information contained 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 regulations and standards of the country to which it has

been shipped. If this machine has been purchased in another country, it may lack certain safety devices and spec-

ifications 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.

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FOREWORD IMPORTANT SAFETY INFORMATION

1-3

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.

The following signal words are used to alert you to information that must be followed to avoid damage to the

machine.

This signal word indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided,

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.

NOTICEThis precaution is given where the machine may be damaged or the service life reduced if

the precaution is not followed.

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

DANGER

WARNING

CAUTION

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IMPORTANT SAFETY INFORMATION FOREWORD

1-4

Noise emission levels 1

Two labels indicating the machine noise level are affixed on the

machine.

q Sound pressure level at the operator’s station, measured

according to ISO6396 (Dynamic test method, simulatedworking cycle).

The maximum value of the standard deviation of the mea-

sured time-averaged A-weighted emission sound pressure

level at the operator's position is 2.5 dB, in accordance with

ISO 11201

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.

This is the guaranteed value as specified in European

directive 2000/14/EC. This value includes an uncertainty is

mentioned below

Vibration levels 1

When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-

tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO

7096.

The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s² , the uncertainty for this

value is 1.4 m/s² according EN 12096:1997.

The actual acceleration value for the body is less than or equal to 0.5 m/s² , the uncertainty for this value is 0.3 m/

s² according EN 12096:1997

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

ISO 5349.

Model Uncertanties dB (A)

D65EX-16 1.0

D65PX-16 1.3

D65WX-16 1.2

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FOREWORD IMPORTANT SAFETY INFORMATION

1-5

Operating condition:

(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion

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 (for crawler machines)

q Brake and steering systems

q Controls, hydraulic system and linkages

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

q Remove any large rocks or obstacles

q Fill any ditches and holes

q Site manager should provide machine operators with machine and schedule time to maintain terrain con-

ditions

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

q Adjust the seat and suspension for the weight and size of the operator

q Wear seat belt

q Inspect and maintain the seat suspension and 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 travelling path as large as possible

q Travel at low speed when travelling around sharp curves

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

q Reduce speed to prevent bounce

q Transport machines long distances between worksites

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

q Operate the machine only when you are in good health.

q Provide breaks to reduce long periods of sitting in the same posture

q Do not jump down from the cab or machine

q Do not repeatedly handle and lift loads.

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INTENDED USE FOREWORD

1-6

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 (3-128)“ for further details.

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FOREWORD INTENDED USE

1-7

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 theoperator's seat in the direction of travel (front) of the machine.

(1) Blade (7) Track frame

(2) Blade tilt cylinder (8) Step

(3) Blade lift cylinder (9) Frame

(4) ROPS cab (10) Idler

(5) Track shoe (11) Blade angle cylinder

(6) Sprocket

(A) Front (C) Left

(B) Rear (D) Right

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INTENDED USE FOREWORD

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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 blocked by part of the machine. Operate the machine, fully aware that the machine

has a portion that an operator cannot see.

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FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

1-9

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 bottom left at the front of the operator's seat.

The design of the nameplate differs according to the territory.

EPA REGULATION, ENGINE SERIAL NO. PLATE 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.

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LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

1-10

SERVICE METER POSITION 1

The service meter is provided at the center of the machine

monitor.

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1

Machine serial No.

Engine serial No.

Product identification number (PIN)

Manufacturers name: Address:

KOMATSU LTD.2-3-6 Akasaka

Minato-ku, Tokyo 107-8414Japan

Authorised representative: Address: KOMATSU EUROPE INT.Mechelsesteenweg 586B-1800 Vilvoorde

Belgium

Distributor name

Address

Service Personnel

Phone/Fax

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FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

1-11

MACHINE SERIAL NUMBER PLATE 1

MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) 1

Model

Serial Number

Manufacturing year

Weight

Engine power

Product Identification Number

Manufacturer

A

B C

D E

F

G

H

A Machine designation/type E Engine power B Serial Number F Product Identification Number

C Year of construction G Manufacturer

D Operating mass H Authorised representative

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LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD

1-12

Declaration of conformity (Directive 2006/42/EC)

The manufacturer/Authorized representative

Declares that this machine

D65EX-16

D65PX-16

D65WX-16

Fulfills all the relevant provisions of following EC Directives:

The manufacturer Authorized representative

KOMATSU LTD.

2-3-6 Akasaka

Minato-ku, Tokyo 107-8414Japan

KOMATSU EUROPE INT.

Mechelsesteenweg 586

B-1800 VilvoordeBelgium

Machinery Directive 2006/42/EC

Electro Magnetic Compatibility Directive 2004/108/EC

Outdoor noise Directive 2000/14/EC amended by 2005/88/EC

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CONTENTS

1-13

CONTENTS

FOREWORD

BEFORE READING THIS MANUAL .................................................................................................................... 1-2

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

Noise emission levels ................................................................................................................................. 1-4

Vibration levels............................................................................................................................................ 1-4

Guide to Reduce Vibration Levels on Machine.................................................................................. 1-5

INTENDED USE ................................................................................................................................................... 1-6

USE OF MACHINE..................................................................................................................................... 1-6

GENERAL VIEW AND DIRECTIONS OF MACHINE................................................................................. 1-7

VISIBILITY FROM OPERATOR'S SEAT.................................................................................................... 1-8

PROXIMITY VISIBILITY .................................................................................................................... 1-8

12M CIRCUMFERENCE VISIBILITY ................................................................................................ 1-8

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................. 1-9

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ....................................... 1-9

EPA REGULATION, ENGINE SERIAL NO. PLATE................................................................................... 1-9

SERVICE METER POSITION .................................................................................................................. 1-10

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

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

MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC) ................................................. 1-11

Declaration of conformity (Directive 2006/42/EC)..................................................................................... 1-12

SAFETY

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

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

POSITIONS OF SAFETY PICTOGRAMS.................................................................................................. 2-5

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

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............................................. 2-12

PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-12

PREPARATIONS FOR SAFE OPERATION............................................................................................. 2-12

FIRE PREVENTION ................................................................................................................................. 2-14

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE .................................................................... 2-15

DO NOT GET CAUGHT IN WORK EQUIPMENT.................................................................................... 2-17

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-18

UNAUTHORIZED MODIFICATION.......................................................................................................... 2-18

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS........................................................... 2-18PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................................................ 2-19

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CONTENTS

1-14

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-20

PRECAUTIONS FOR JOBSITE ............................................................................................................... 2-20

STARTING ENGINE................................................................................................................................. 2-23

OPERATION............................................................................................................................................. 2-26

TRANSPORTATION................................................................................................................................. 2-30

TOWING ................................................................................................................................................... 2-31

PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-32

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-32

PRECAUTIONS FOR INSPECTION AND MAINTENANCE..................................................................... 2-36

OPERATION

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

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

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

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

MACHINE MONITOR ................................................................................................................................. 3-5

BASIC OPERATION OF MACHINE MONITOR ................................................................................ 3-6

EMERGENCY MONITORS ............................................................................................................. 3-10

CAUTION MONITORS .................................................................................................................... 3-12

BASIC CHECK MONITORS............................................................................................................ 3-14

METER DISPLAY PORTION........................................................................................................... 3-15

SPEED RANGE DISPLAY............................................................................................................... 3-21

MONITOR SWITCHES PORTION .................................................................................................. 3-22

HANDLING FUNCTION SWITCHES............................................................................................... 3-26

SWITCHES............................................................................................................................................... 3-46

CONTROL LEVERS AND PEDALS ......................................................................................................... 3-51

DUST INDICATOR ................................................................................................................................... 3-59

BATTERY DISCONNECT SWITCH ......................................................................................................... 3-60

FUSE ........................................................................................................................................................ 3-61

FUSIBLE LINK.......................................................................................................................................... 3-63

ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-64

OIL FILLER CAP....................................................................................................................................... 3-65

METHOD OF OPENING AND CLOSING HYDRAULIC TANK FILLER CAP.................................. 3-65

METHOD OF OPENING AND CLOSING FUEL TANK CAP........................................................... 3-66

DOOR - OPEN LOCK............................................................................................................................... 3-67

SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-67

DOOR POCKET ....................................................................................................................................... 3-68

ASHTRAY................................................................................................................................................. 3-68

SHOVEL HOLDER ................................................................................................................................... 3-68

CAR RADIO, HANDLING ......................................................................................................................... 3-69

EXPLANATION OF COMPONENTS............................................................................................... 3-69

METHOD OF OPERATION............................................................................................................. 3-70

PRECAUTIONS WHEN USING ...................................................................................................... 3-72

AIR CONDITIONER, HANDLING ............................................................................................................. 3-73

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CONTENTS

1-15

GENERAL LOCATIONS OF CONTROL PANEL ............................................................................ 3-73

METHOD OF OPERATION............................................................................................................. 3-78

PRECAUTION WHEN USING AIR CONDITIONER........................................................................ 3-84

INSPECTION AND MAINTENANCE OF AIR CONDITIONER EQUIPPED MACHINE................... 3-84

OPERATION....................................................................................................................................................... 3-85

CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-85

WALK-AROUND CHECK ................................................................................................................ 3-85

CHECK BEFORE STARTING......................................................................................................... 3-86

ADJUSTMENT................................................................................................................................. 3-95

OPERATION AND CHECK BEFORE STARTING ENGINE.......................................................... 3-101

STARTING ENGINE............................................................................................................................... 3-103

NORMAL STARTING.................................................................................................................... 3-103

STARTING IN COLD WEATHER.................................................................................................. 3-105

BREAKING IN THE NEW MACHINE ............................................................................................ 3-108

OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................. 3-108

CHECKING OF ENGINE STARTABILITY AND NOISE................................................................ 3-108

CHECKING OF ENGINE ACCELERATION AND DECELERATION ............................................ 3-108

WARMING UP OPERATIONS ...................................................................................................... 3-109

STARTING IN COLD WEATHER.................................................................................................. 3-110

STOPPING ENGINE............................................................................................................................... 3-112

MACHINE OPERATION......................................................................................................................... 3-113

MOVING MACHINE....................................................................................................................... 3-113

STOPPING MACHINE................................................................................................................... 3-115

SHIFTING GEARS.................................................................................................................................. 3-116

GEARSHIFTING OPERATION...................................................................................................... 3-116

SHIFTING BETWEEN FORWARD AND REVERSE.............................................................................. 3-122

STEERING MACHINE............................................................................................................................ 3-123

NORMAL TURNING...................................................................................................................... 3-123

TURNING WHILE DESCENDING A SLOPE................................................................................. 3-124

PRECAUTIONS FOR OPERATION....................................................................................................... 3-125

PAY ATTENTION TO GAUGES.................................................................................................... 3-125

PERMISSIBLE WATER DEPTH.................................................................................................... 3-125

PRECAUTIONS WHEN TRAVELING FOR A LONG TIME........................................................... 3-125

PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................ 3-125

PRECAUTIONS ON SLOPES....................................................................................................... 3-126

PRECAUTIONS FOR USING BRAKE........................................................................................... 3-126

IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................. 3-126

IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY

THAT WILL OBSTRUCT THE VIEW............................................................................................. 3-126

PRECAUTIONS FOR FLOATING BLADE .................................................................................... 3-127

PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY................................................... 3-127

WORK POSSIBLE USING BULLDOZER............................................................................................... 3-128

DOZING......................................................................................................................................... 3-128

SMOOTHING................................................................................................................................. 3-128

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................. 3-129

FELLING TREES, REMOVING STUMPS ..................................................................................... 3-129

RECOMMENDED MODE FOR EACH TYPE OF OPERATION............................................................. 3-130

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CONTENTS

1-16

ADVANTAGES OF EACH MODE ................................................................................................. 3-130

TABLE OF RECOMMENDED MODES ......................................................................................... 3-131

ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................. 3-132

ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-132

ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT....................................................... 3-135

ADJUSTING TENSION OF CENTER BRACE .............................................................................. 3-136

ADJUST AMOUNT OF TILT.......................................................................................................... 3-137

METHOD OF ANGLING BLADE ................................................................................................... 3-138

PARKING MACHINE .............................................................................................................................. 3-139

CHECK AFTER FINISHING WORK ....................................................................................................... 3-141

BEFORE STOPPING ENGINE...................................................................................................... 3-141

AFTER STOPPING ENGINE......................................................................................................... 3-141

LOCKING................................................................................................................................................ 3-142

TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-143

OPERATION METHOD................................................................................................................. 3-143

INSPECTION AND ADJUSTMENT............................................................................................... 3-143

INSPECTION AND REPAIR.......................................................................................................... 3-144

TRANSPORTATION......................................................................................................................................... 3-146

TRANSPORTATION MEANS................................................................................................................. 3-146

PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-146

LOADING, UNLOADING WORK ............................................................................................................ 3-147

LIFTING MACHINE................................................................................................................................. 3-151

TRAVELING ON ROADS ....................................................................................................................... 3-153

COLD WEATHER OPERATION ...................................................................................................................... 3-154

PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-154

AFTER COMPLETION OF WORK ......................................................................................................... 3-155

AFTER COLD WEATHER ...................................................................................................................... 3-155

LONG-TERM STORAGE.................................................................................................................................. 3-156

BEFORE STORAGE............................................................................................................................... 3-156

DURING STORAGE ............................................................................................................................... 3-156

AFTER STORAGE.................................................................................................................................. 3-156

STARTING MACHINE AFTER LONG-TERM STORAGE ...................................................................... 3-157

TROUBLESHOOTING...................................................................................................................................... 3-158

AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-158

PROCEDURE FOR BLEEDING AIR ............................................................................................. 3-158

METHOD OF TOWING MACHINE......................................................................................................... 3-159

IF BATTERY IS DISCHARGED.............................................................................................................. 3-160

REMOVE AND INSTALL BATTERY ............................................................................................. 3-160

PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-161

STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-162

OTHER TROUBLE ................................................................................................................................. 3-164

ELECTRICAL SYSTEM................................................................................................................. 3-164ELECTRONIC CONTROL SYSTEM ............................................................................................. 3-165

CHASSIS....................................................................................................................................... 3-166

ENGINE......................................................................................................................................... 3-167

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CONTENTS

1-17

POINT OF CONTACT TO TELEPHONE WHEN ERROR OCCURS............................................ 3-168

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

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ............ 4-13

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS

OTHER THAN KOMATSU GENUINE OIL................................................................................................ 4-14

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-15

TORQUE LIST.......................................................................................................................................... 4-15

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16

SAFETY CRITICAL PARTS...................................................................................................................... 4-16

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-18

MAINTENANCE SCHEDULE CHART...................................................................................................... 4-18

WHEN REQUIRED.......................................................................................................................... 4-18

CHECK BEFORE STARTING......................................................................................................... 4-18EVERY 50 HOURS SERVICE......................................................................................................... 4-18

EVERY 250 HOURS SERVICE....................................................................................................... 4-18

EVERY 500 HOURS SERVICE....................................................................................................... 4-18

EVERY 1000 HOURS SERVICE..................................................................................................... 4-19




SERVICE PROCEDURE .................................................................................................................................... 4-20

WHEN REQUIRED................................................................................................................................... 4-20CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-20

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-24

CHECK TRACK SHOE TENSION, ADJUST................................................................................... 4-27

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CONTENTS

1-18

CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-28

REVERSE AND REPLACE END BITS AND CUTTING EDGES..................................................... 4-29

CLEAN AND CHECK RADIATOR FINS AND OIL COOLER FINS................................................. 4-32

CLEAN HYDRAULIC TANK BREATHER........................................................................................ 4-35

CLEAN FUEL TANK BREATHER ................................................................................................... 4-35

REPLACE FUEL TANK BREATHER ELEMENT............................................................................. 4-36

CHECK, ADJUST AIR CONDITIONER........................................................................................... 4-36

REPLACE AIR CONDITIONER BELT............................................................................................. 4-37

GREASE DOOR HINGE.................................................................................................................. 4-38

CHECK DOOR LOCK STRIKER..................................................................................................... 4-38

REPLACE DOOR DAMPER............................................................................................................ 4-38

CHECK DOOR LATCH.................................................................................................................... 4-39

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............................................................. 4-39

REPLACE WIPER BLADE .............................................................................................................. 4-40

CHECK IDLER OIL LEVEL.............................................................................................................. 4-41

ADJUST IDLER CLEARANCE ........................................................................................................ 4-41

LUBRICATING UNIVERSAL JOINT................................................................................................ 4-42

PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM..................................................... 4-43

INSTALLATION OF TRUNNION CAP............................................................................................. 4-43

ADJUSTING SHIMS, ADJUSTING TENSION AT WORK EQUIPMENT LINKS ............................. 4-44

CHECK BEFORE STARTING .................................................................................................................. 4-51

EVERY 50 HOURS SERVICE.................................................................................................................. 4-52

DRAIN WATER, SEDIMENT FROM FUEL TANK........................................................................... 4-52

LUBRICATING................................................................................................................................. 4-52

EVERY 250 HOURS SERVICE................................................................................................................ 4-54

LUBRICATING................................................................................................................................. 4-54

GREASE EQUALIZER BAR SIDE PIN............................................................................................ 4-56

GREASE EQUALIZER BAR CENTER PIN ..................................................................................... 4-56

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-57

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.................................................................... 4-57

CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-58

CHECK, CLEAN ADDITIONAL FUEL STRAINER .......................................................................... 4-60

CHECK BRAKE PERFORMANCE .................................................................................................. 4-61

EVERY 500 HOURS SERVICE................................................................................................................ 4-62

REPLACE AIR CONDITIONER FRESH/RECIRC FILTERS........................................................... 4-62CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE .................... 4-64

REPLACE POWER TRAIN OIL FILTER ELEMENT........................................................................ 4-65

REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-66

EVERY 1000 HOURS SERVICE.............................................................................................................. 4-69

REPLACE FUEL MAIN FILTER CARTRIDGE ................................................................................ 4-69

CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS

(POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)...................................... 4-72

REPLACE HYDRAULIC TANK BREATHER ELEMENT................................................................. 4-74

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ......................................................................... 4-75

CHANGE OIL IN FINAL DRIVE CASE............................................................................................ 4-76

CLEAN BREATHER ........................................................................................................................ 4-77

CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS................................ 4-77

CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................ 4-78

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CONTENTS

1-19

INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS.................. 4-78


CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL

FILTER ELEMENT AND CLEAN HYDRAULIC TANK STRAINER ................................................. 4-79

CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR

(FOR CONTROL CIRCUIT)............................................................................................................. 4-80CHANGE OIL IN DAMPER CASE................................................................................................... 4-84

CHECK VIBRATION DAMPER ....................................................................................................... 4-85

CHECK ALTERNATOR................................................................................................................... 4-85

CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................... 4-85


REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).............................................................. 4-86

CHECK WATER PUMP................................................................................................................... 4-86

CHECK STARTING MOTOR........................................................................................................... 4-86

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...... 4-87

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ....... 4-88


REPLACE HIGH-PRESSURE PIPING CLAMP .............................................................................. 4-89

REPLACE FUEL SPLAY PREVENTION CAPS.............................................................................. 4-89

SPECIFICATIONS

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

ATTACHMENTS, OPTIONS

GENERAL PRECAUTIONS ................................................................................................................................. 6-2

AUTHORIZED OPTIONAL EQUIPMENT................................................................................................... 6-2

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

PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT.................................................... 6-3

HANDLING HYDRAULIC RIPPER....................................................................................................................... 6-4

GENERAL VIEW......................................................................................................................................... 6-4

EXPLANATION OF COMPONENTS.......................................................................................................... 6-5

OPERATION............................................................................................................................................... 6-6

CHECK BEFORE STARTING ENGINE, ADJUST ............................................................................ 6-6

PRECAUTIONS WHEN OPERATING............................................................................................... 6-6

ADJUSTING POSTURE OF WORK EQUIPMENT ........................................................................... 6-6

TROUBLESHOOTING................................................................................................................................ 6-8

OTHER TROUBLE ............................................................................................................................ 6-8

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CONTENTS

1-20

HANDLING 3 M WIDE BLADE ............................................................................................................................ 6-9

GENERAL VIEW......................................................................................................................................... 6-9

OPERATION............................................................................................................................................. 6-10

WORK POSSIBLE USING BULLDOZER........................................................................................ 6-10

TRANSPORTATION................................................................................................................................. 6-11

TRANSPORTATION MEANS.......................................................................................................... 6-11

FOLDING OF BLADE...................................................................................................................... 6-11

UNFOLDING OF BLADE................................................................................................................. 6-13

MAINTENANCE........................................................................................................................................ 6-14

WHEN REQUIRED.......................................................................................................................... 6-14

SPECIFICATIONS.................................................................................................................................... 6-15

HANDLING MACHINES EQUIPPED WITH KOMTRAX .................................................................................... 6-16

BASIC PRECAUTIONS ............................................................................................................................ 6-16

INDEX

COLOPHON

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SAFETY

12

WARNINGPlease read and make sure that you full y und erstand the

precautions described in this manual and the safety labels

on the machine. When operating o r servicing the machine,

always follow these precautions strictly.

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SAFETY SAFETY

2-2

SAFETY 2

SAFETY LABELS................................................................................................................................................ 2-42

POSITIONS OF SAFETY PICTOGRAMS ................................................................................................... 2-52

SAFETY LABELS......................................................................................................................................... 2-52

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................ 2-122

PRECAUTIONS BEFORE STARTING OPERATION................................................................................ 2-122

ENSURING SAFE OPERATION ........................................................................................................ 2-122

UNDERSTANDING THE MACHINE................................................................................................... 2-122

PREPARATIONS FOR SAFE OPERATION.............................................................................................. 2-122

PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT.................................................... 2-122

INSPECTING MACHINE .................................................................................................................... 2-122

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT .............................................. 2-122

KEEP MACHINE CLEAN.................................................................................................................... 2-132

PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT................................................................ 2-132

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ..................................................................... 2-132 IF ANY PROBLEM IS FOUND............................................................................................................ 2-132

FIRE PREVENTION................................................................................................................................... 2-142

ACTION IF FIRE OCCURS ................................................................................................................ 2-142

PRECAUTIONS TO PREVENT FIRE................................................................................................. 2-142

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...................................................................... 2-152

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE...................................... 2-152

NO JUMPING ON OR OFF MACHINE............................................................................................... 2-162

LIFTING OF PERSONNEL PROHIBITED.......................................................................................... 2-16

NO PEOPLE ON ATTACHMENTS...................................................................................................... 2-162

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT .............................................. 2-172

PRECAUTIONS WHEN LEAVING MACHINE.................................................................................... 2-172

EMERGENCY EXIT FROM OPERATOR'S CAB................................................................................ 2-172

DO NOT GET CAUGHT IN WORK EQUIPMENT ..................................................................................... 2-172

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................................................................ 2-182

UNAUTHORIZED MODIFICATION ........................................................................................................... 2-182

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS............................................................ 2-182

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.............................................................. 2-192

PRECAUTIONS FOR OPERATION ................................................................................................................. 2-202

PRECAUTIONS FOR JOBSITE................................................................................................................. 2-202

INVESTIGATE AND CONFIRM JOBSITE CONDITIONS .................................................................. 2-202

WORKING ON LOOSE GROUND...................................................................................................... 2-202

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES......................................................................... 2-212

ENSURE GOOD VISIBILITY .............................................................................................................. 2-212 CHECKING SIGNS AND SIGNALMAN'S SIGNALS .......................................................................... 2-212

BEWARE OF ASBESTOS DUST ....................................................................................................... 2-222

STARTING ENGINE .................................................................................................................................. 2-232

USE WARNING TAGS ....................................................................................................................... 2-232

CHECKS BEFORE STARTING ENGINE ........................................................................................... 2-232

PRECAUTIONS WHEN STARTING................................................................................................... 2-242

PRECAUTIONS IN COLD AREAS ..................................................................................................... 2-242

STARTING WITH BOOSTER CABLES.............................................................................................. 2-252

OPERATION.............................................................................................................................................. 2-262

CHECKS BEFORE OPERATION....................................................................................................... 2-262

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................................ 2-262

PRECAUTIONS WHEN TRAVELING................................................................................................. 2-272

TRAVELING ON SLOPES.................................................................................................................. 2-282

PRECAUTIONS WHEN OPERATING................................................................................................ 2-282

METHOD OF USING BRAKES .......................................................................................................... 2-282

TRAVELING ON SNOW-COVERED OR FROZEN SURFACES ....................................................... 2-222

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SAFETY SAFETY

2-3

PARKING MACHINE.......................................................................................................................... 2-292

TRANSPORTATION.................................................................................................................................. 2-302

LOADING AND UNLOADING............................................................................................................. 2-302

TOWING .................................................................................................................................................... 2-312

PRECAUTIONS WHEN TOWING ...................................................................................................... 2-312

PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-322

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ........................................... 2-322 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE........................................ 2-322

KEEP WORKPLACE CLEAN AND TIDY............................................................................................ 2-322

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ........................................... 2-322

STABILITY.......................................................................................................................................... 2-32

GUARDS............................................................................................................................................. 2-32

ONLY AUTHORIZED PERSONNEL................................................................................................... 2-322

APPOINT LEADER WHEN WORKING WITH OTHERS.................................................................... 2-322

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................ 2-332

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ........................................... 2-332

INSTALLING, REMOVING, OR STORING ATTACHMENTS............................................................. 2-342

PRECAUTIONS WHEN WORKING AT HIGH PLACES..................................................................... 2-342

PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT........................... 2-342 PROPER TOOLS................................................................................................................................ 2-352

PRECAUTIONS FOR INSPECTION AND MAINTENANCE...................................................................... 2-362

PRECAUTIONS WHEN WELDING.................................................................................................... 2-362

HANDLING BATTERY........................................................................................................................ 2-362

PRECAUTIONS WHEN USING HAMMER......................................................................................... 2-372

PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT............................................................... 2-372

PRECAUTIONS WITH HIGH-TEMPERATURE OIL........................................................................... 2-382

PRECAUTIONS WITH HIGH-PRESSURE OIL.................................................................................. 2-382

PRECAUTIONS WITH HIGH-PRESSURE FUEL............................................................................... 2-382

HANDLING HIGH-PRESSURE HOSES AND PIPING....................................................................... 2-392

NOISE................................................................................................................................................. 2-392

PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION ......... 2-392

DO NOT DISASSEMBLE RECOIL SPRING ...................................................................................... 2-402

HANDLING ACCUMULATOR AND GAS SPRING............................................................................. 2-402

PRECAUTIONS WITH COMPRESSED AIR ...................................................................................... 2-402

CHEMICAL HAZARD.......................................................................................................................... 2-402

MAINTENANCE OF AIR CONDITIONER........................................................................................... 2-402

DISPOSING OF WASTE MATERIALS............................................................................................... 2-412

METHOD OF SELECTING WINDOW WASHER FLUID.................................................................... 2-412

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................... 2-412

DISMANTLING THE MACHINE END OF SERVICE LIVE ................................................................. 2-41

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SAFETY LABELS SAFETY

2-4

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.

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SAFETY SAFETY LABELS

2-5

POSITIONS OF SAFETY PICTOGRAMS 2

SAFETY LABELS 2

(1) Caution before operating or maintaining machine

(09651-A0641)

q Warning!

q Read manual before operation, maintenance, disassembly,

assembly and transportation.

T

R

Q

Q

R

S

S

9JH10667

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2-6

(2) Caution before moving in reverse (09802-13000)

WARNINGTo 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) 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 cap or hydraulic tank oil filler

when cooling water or hydraulic oil is at high temperatures.

09802-B0640

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2-8

(9) Caution for approach when machine moving

(09806-B1683)

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

ment.

q Keep a safe distance from equipment when it is moving.

(10) Prohibition of jump start (09842-A0481)

q Start the engine only after sitting down in the operator’s

seat.

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

engine starting circuit. Such an act may cause a serious

bodily injury or fire.

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2-9

(11) Caution for ROPS/FOPS (09620-A3000)

ROPS/FOBS CERTIFICATION

This protective structure complies with the standard provided

that it is properly equipped on the machine which mass is less

than the specified maximum mass.

q If some modification is applied to the ROPS or FOPS, it may effect the strength and may not be comply with

the standard. Consult Komatsu Distributor before altering.

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

Komatsu Distributor in that case.

q Always wear seat belt when moving.

(12) Caution of fuel filter (6271-71-6860)

Sign indicates a caution of fuel filter.

q Read manual for fuel filter.

q Only use specified fuel filter for high pressure fuel injection

system

(13) Caution of pre fuel filter (6271-71-6860)

q Sign indicates a caution of fuel pre filter.

q Read manual and replacing fuel pre filter for safe and

proper handling.

6271-71-6860

6271-71-6860

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2-10

(14)Caution of exchanging air cleaner (09637-A0640)

q Sign indicates a caution of exchanging air cleaner

q Read manual for exchanging air cleaner

NOTICE

Don’t put oil in to this cleaner.

Use only genuine Komatsu elements

When service indicator tu rns to red (if there is no indi -

cator, every 250 hours ) clean outer element.

One year after exchange or after us ing cleaned outer

element for six times, renew inner and outer element.

If service indicator turns to red soon or color of

exhaust gas is not clean and also in case of lacking

power after cleaning outer element, inner and outer

elements shall be replaced.

in th is case, however, do not clean inner element.

Element must be kept free of cracks and oil. If element has

a cracks, it must be replaced.

(15) Caution of add coolant (09642-A0480)

q Sign indicates a caution of exchanging air cleaner

q Read manual for add coolant

(16)Drawbar (09823-00001)

Read manual for drawbar

(1): Indicate the maximum pulling load.

(2): Indicate the maximum vertical load.

NAC AF

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2-11

(17) (Where fitted in cabin) Warning of an explosion hazard

caused by active radio transmitter at a blast zone

(09845-00480).

Keep machine at a safe distance from blast zone and a detona-

tor.

17

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

2-12

GENERAL PRECAUTIONS COMMON TO OPERATION ANDMAINTENANCE 2

Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying

out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefullyand obey the warnings.

PRECAUTIONS BEFORE STARTING OPERATION 2

ENSURING SAFE OPERATION

q Only trained and authorized personnel can operate and maintain the machine.

q Follow all safety, precautions, and instructions in this manual when operating or performing inspection or

maintenance on the machine.

qIf you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely oper-ate or repair your machine may be severely impaired, putting yourself and everyone else on your job site in

danger.

q When working with another operator or with the person on the worksite traffic duty, discuss the content of the

operation beforehand and use the determined signals when carrying out the operation.

UNDERSTANDING THE MACHINE

Before operating the machine, read this manual thoroughly. If there are any places in this manual that you do not

understand, ask the person in charge of safety to give an explanation.

PREPARATIONS FOR SAFE OPERATION 2

PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT

q Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired

immediately if they are damaged.

q Understand the method of use of safety features and use them properly.

q Never remove any safety features. Always keep them in good operating condition.

INSPECTING MACHINE

Check the machine before starting operations. If any abnormality is found, do not operate the machine until

repairs of the problem location have been completed.

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT

q Do not wear loose clothes or any accessories. If these

catch on the control levers or protruding parts, there is dan-

ger that it may cause the machine to move unexpectedly.

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

the work requires it, wear safety glasses, mask, gloves, ear

plugs, and safety belt when operating or maintaining the

machine.

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

there is a hazard that it may get caught up in the machine,

so tie your hair up and be careful not to let it get caught.

q Check that all protective equipment functions properly

before using it.

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SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE

2-13

KEEP MACHINE CLEAN

q If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or

oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the

machine clean.

qIf water gets into the electrical system, there is a hazardthat it will cause malfunctions or misoperation. If there is

any misoperation, there is danger that the machine may

move unexpectedly and cause serious personal injury or

death. When washing the machine with water or steam, do

not allow the water or steam to come into direct contact

with electrical components.

PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT

q 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.

q Do not leave tools or a machine parts lying around inside the operator's compartment. If tools or parts get into

the control devices, it may obstruct operation and cause the machine to move unexpectedly, resulting in seri-

ous personal injury or death.

q Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.

q Do not use a cell phone when driving or operating the machine. This may lead to mistakes in operation, which

could cause serious personal injury or death.

q Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.

q Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use them in

emergencies.

q Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.

q Provide a first aid kit in the storage point. Carry out peri-odic checks and add to the contents if necessary.

IF ANY PROBLEM IS FOUND

If you find any problems 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), report to the person in

charge and have the necessary action taken. Do not operate the machine until the problem has been corrected.

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2-14

FIRE PREVENTION 2

ACTION IF FIRE OCCURS

q Turn the start switch OFF to stop the engine.

q Use the handrails and steps to get off the machine.

q Do not jump off the machine. There is the danger of falling and suffering serious injury.

PRECAUTIONS TO PREVENT FIRE

q Fire caused by fuel, oil, antifreeze, or window washer

fluid

Do not bring any flame or fire close to flammable sub-

stances such as fuel, oil, antifreeze, or window washer

fluid. There is danger that they may catch fire. To prevent

fire, always observe the following:

q Do not smoke or use any flame near fuel or other flam-

mable substances.

q Stop the engine before adding fuel.

q Do not leave the machine when adding fuel or oil.

q Tighten all fuel and oil caps securely.

q Be careful not to spill fuel on overheated surfaces or on

parts of the electrical system.

q After adding fuel or oil, wipe up any spilled fuel or oil.

q Put greasy rags and other flammable materials into asafe container to maintain safety at the workplace.

q When washing parts with oil, use a non-flammable oil.

Do not use diesel oil or gasoline. There is danger that

they may catch fire.

q Do not weld or use a cutting torch to cut any pipes or

tubes that contain flammable liquids.

q Determine well-ventilated areas for storing oil and fuel.

Keep the oil and fuel in the determined place and do

not allow unauthorized persons to enter.

q When carrying out grinding or welding work on the

machine, move any flammable materials to a safe

place before starting.

q Fire caused by accumulation o f flammable material.

q Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated

or affixed around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.

q To prevent fires spreading from sparks or burning particles from other fires, remove any flammable materi-

als such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated

around the cooling system (radiator, oil cooler) or inside the undercover.

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2-15

q Fire coming from electric wiring

Short circuits in the electrical system can cause fire. To prevent fire, always observe the following.

q Keep all electric wiring connections clean and securely tightened.

q Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps.

Repair or replace any damaged wiring.

q Fire coming from pipi ng

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.

If they are loose, they may vibrate during operation and rub against other parts. There is danger that this may

lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire, serious personal injury or

death.

q Explosion caused by lighting equipment

q When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifica-

tions.

q When taking the electrical power for the lighting from the machine itself, follow the instructions in this man-

ual.

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE

To prevent personal injury caused by slipping or falling off the machine, always do as follows.

q Use the parts marked by arrow A in the diagrams when

getting on or off the machine.

Never use the parts marked by arrow B when getting on or

off the machine. Use them only when moving along the top

of the track or when checking or carrying out maintenance

inside the side cover, or when filling the tank with oil.

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2-16

(Power angle power tilt dozer)

q Always face the machine and maintain at least three-point

contact (both feet and one hand, or both hands and one

foot) with the handrail and steps to ensure that you support

yourself.

q Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on

them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts.

q Do not grip the control levers and work equipment lock lever when getting on or off the machine.

q Never climb on the engine hood or covers where there are no non-slip pads.

qDo not get on or off the machine while holding tools in your hand.

NO JUMPING ON OR OFF MACHINE

q Never jump on or off the machine. Never get on or off a moving machine.

q If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try

to stop it.

LIFTING OF PERSONNEL PROHIBITED

Under no circumstances should this machine be used for the lifting of personnel.

NO PEOPLE ON ATTACHMENTS

Never let anyone ride on the work equipment or other attachments. There is a hazard of falling and suffering seri-

ous personal injury or death.

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2-17

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT

When standing up from the operator's seat to adjust the opera-

tor's seat, always lower the work equipment completely to the

ground, set work equipment lock lever (1) and parking brake

lever (2) to the LOCK position (L), and stop the engine.

If the control lever is touched by accident, there is danger that

the machine may suddenly move and cause serious personal

injury.

PRECAUTIONS WHEN LEAVING MACHINE

If the proper procedures are not taken when parking the

machine, the machine may suddenly move off by itself, and this

may lead to serious personal injury or death. Always do the fol-

lowing.

q When leaving the machine, always lower the work equip-

ment completely to the ground, set work equipment lock

lever (1) and parking brake lever (2) to the LOCK position

(L), and stop the engine.

Always lock all parts, take the key with you and leave it in

the specified place.

EMERGENCY EXIT FROM OPERATOR'S CAB

Machines equipped with a cab have doors on the left and right sides. If the door on the one side does not open,

escape from the door on the other side.

DO NOT GET CAUGHT IN WORK EQUIPMENT 2

The clearance in the area around the work equipment changes according to the movement of the link. If you get

caught, you may suffer serious personal injury or death. Do not allow anyone to come close to any rotating or

extending/retracting portion.

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O&M D65EX-16 80012-UP EEAM029700.pdf