Komatsu Galeo D61EX-15 Manual

D61EX,PX-15
0
KEAM049700T
NOTICE
Komatsu has Operation & Maintenance Manuals written in
some other languages. If a foreign language manual is
necessary, contact your local distributor for availability.
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or maintain-
ing this machine. This manual should be kept near
the machine for reference and periodically reviewed
by all personnel who will come into contact with it.
WARNING
2004
All Right Reserved
Printed in Brazz il 07-04
BULLDOZER
SERIAL NUMBERS
B40001
and up

FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be under-
stood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor
to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference pur-
pose, weight units used in the past are also displayed in { }.
Storage location for the Operation and Maintenance Manual:
If machine is equipped with a cab.
Inside of right and left doors
If machine is not equipped with cab.
Rear face of floor

FOREWORD FOREWORD
1-3

FOREWORD FOREWORD
1-4

FOREWORD SAFETY INFORMATION
1-5
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous 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 mod-
erate injury. This word is used also to alert against unsafe practices that may cause prop-
erty damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the work equipment lock lever in the LOCK posi-
tion.
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 precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
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.

SAFETY INFORMATION FOREWORD
1-6
qSafety 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 procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous 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.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility 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))

FOREWORD INTRODUCTION
1-7
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDozing
qSmoothing
qCutting into hard or frozen ground or ditching
qFelling trees, removing stumps
See the section “WORK POSSIBLE USING BULLDOZER (3-110)“ for further details.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
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.
(A)
(B)
(C)
(D)
Front
Rear
Left
Right
(E)
(F)
Operator's seat
Sprocket

NECESSARY INFORMATION FOREWORD
1-8
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
This is at the front bottom right of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE 1
This is at the front top of the engine on the left side machine.

FOREWORD NECESSARY INFORMATION
1-9
EMISSION CONTROL INFORMATION LABEL 1
This is at the top on the side face of the engine on the left side of the machine.
POSITION OF SERVICE METER 1
The service meter is provided at the lower part of the monitor
panel.
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax

CONTENTS
1-10
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-5
INTRODUCTION................................................................................................................................................... 1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE ....................................................................... 1-7
NECESSARY INFORMATION ............................................................................................................................. 1-8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................................ 1-8
ENGINE SERIAL NO. PLATE..................................................................................................................... 1-8
EMISSION CONTROL INFORMATION LABEL ......................................................................................... 1-9
POSITION OF SERVICE METER .............................................................................................................. 1-9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR .............................................................................. 1-9
CONTENTS ........................................................................................................................................................ 1-10
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 ................................................................................................................... 2-18
STARTING ENGINE ................................................................................................................................. 2-18
OPERATION............................................................................................................................................. 2-20
TRANSPORTATION................................................................................................................................. 2-23
BATTERY ................................................................................................................................................. 2-24
TOWING ................................................................................................................................................... 2-26
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-27
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-6
FRONT PANEL........................................................................................................................................... 3-6

CONTENTS
1-11
CHECK MONITOR SYSTEM ............................................................................................................3-7
EMERGENCY CAUTION ITEMS ...................................................................................................... 3-8
CAUTION ITEMS............................................................................................................................. 3-10
METER GROUP .............................................................................................................................. 3-12
LAMPS............................................................................................................................................. 3-17
SWITCHES...................................................................................................................................... 3-19
METHOD OF USING MAINTENANCE MODE................................................................................ 3-24
SWITCHES ............................................................................................................................................... 3-33
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-37
CIRCUIT BREAKER ................................................................................................................................. 3-44
FUSE ........................................................................................................................................................ 3-45
FUSIBLE LINK .......................................................................................................................................... 3-47
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-48
MACHINE EQUIPPED WITH CAB .................................................................................................. 3-48
MACHINE EQUIPPED WITH CANOPY .......................................................................................... 3-48
DOOR - OPEN LOCK ............................................................................................................................... 3-49
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-49
CAP, COVER WITH LOCK....................................................................................................................... 3-50
METHOD OF OPENING AND CLOSING CAP WITH LOCK .......................................................... 3-50
METHOD OF OPENING AND CLOSING COVER WITH LOCK ..................................................... 3-51
DOOR POCKET ....................................................................................................................................... 3-52
OPENING AND CLOSING ENGINE SIDE COVER.................................................................................. 3-52
ASHTRAY ................................................................................................................................................. 3-53
TOOL BOX................................................................................................................................................ 3-53
CAR STEREO, HANDLING ...................................................................................................................... 3-54
EXPLANATION OF COMPONENTS............................................................................................... 3-54
METHOD OF OPERATION .............................................................................................................3-60
PRECAUTION WHEN USING......................................................................................................... 3-62
AIR CONDITIONER, HANDLING ............................................................................................................. 3-63
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................ 3-63
METHOD OF OPERATION .............................................................................................................3-66
PRECAUTION WHEN USING AIR CONDITIONER........................................................................ 3-67
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE .......... 3-67
INSPECTION DURING OFF-SEASON ........................................................................................... 3-67
PROCEDURE FOR REPLACING RECEIVER ................................................................................ 3-67
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-67
CLEANING AIR FILTER .................................................................................................................. 3-68
ACCUMULATOR, HANDLING.................................................................................................................. 3-69
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR ............................................................................................................................. 3-69
OPERATION....................................................................................................................................................... 3-72
CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-72
WALK-AROUND CHECK ................................................................................................................ 3-72
CHECK BEFORE STARTING ......................................................................................................... 3-74

CONTENTS
1-12
ADJUSTMENT................................................................................................................................. 3-82
OPERATION AND CHECK BEFORE STARTING ENGINE............................................................ 3-87
STARTING ENGINE ................................................................................................................................. 3-89
NORMAL STARTING ...................................................................................................................... 3-89
STARTING IN COLD WEATHER .................................................................................................... 3-91
OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................................................... 3-94
BREAKING IN THE NEW MACHINE .............................................................................................. 3-94
WARMING UP OPERATIONS ........................................................................................................ 3-94
STARTING IN COLD WEATHER .................................................................................................... 3-95
STOPPING ENGINE................................................................................................................................. 3-97
MACHINE OPERATION ........................................................................................................................... 3-98
MOVING MACHINE......................................................................................................................... 3-98
STOPPING MACHINE................................................................................................................... 3-100
SHIFTING GEARS.................................................................................................................................. 3-101
GEARSHIFTING OPERATION...................................................................................................... 3-101
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION........................................... 3-102
AUTO DOWN SHIFT OPERATION............................................................................................... 3-103
SHIFTING BETWEEN FORWARD AND REVERSE .............................................................................. 3-104
STEERING MACHINE ............................................................................................................................ 3-106
NORMAL TURNING ...................................................................................................................... 3-106
PRECAUTIONS FOR OPERATION .......................................................................................................3-108
PAY ATTENTION TO GAUGES .................................................................................................... 3-108
PERMISSIBLE WATER DEPTH.................................................................................................... 3-108
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS........................................................ 3-108
PRECAUTIONS ON SLOPES ....................................................................................................... 3-108
METHOD OF USING BRAKES ..................................................................................................... 3-109
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................. 3-109
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-109
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES ................ 3-109
WORK POSSIBLE USING BULLDOZER ............................................................................................... 3-110
DOZING......................................................................................................................................... 3-110
SMOOTHING................................................................................................................................. 3-110
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING .................................................. 3-111
FELLING TREES, REMOVING STUMPS ..................................................................................... 3-111
ADUSTING POSTURE OF WORK EQUIPMENT .................................................................................. 3-112
ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-112
ADJUST AMOUNT OF TILT POWER TILT ................................................................................... 3-113
PARKING MACHINE .............................................................................................................................. 3-114
CHECK AFTER FINISHING WORK ....................................................................................................... 3-115
BEFORE STARTING ENGINE ...................................................................................................... 3-115
AFTER STARTING ENGINE ......................................................................................................... 3-115
LOCKING................................................................................................................................................ 3-116
TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-117
OPERATION METHOD ................................................................................................................. 3-117
TRANSPORTATION......................................................................................................................................... 3-118
TRANSPORTATION MEANS ................................................................................................................. 3-118

CONTENTS
1-13
REMOVING CAB .................................................................................................................................... 3-118
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-118
POWER ANGLE, POWER TILTDOZER ....................................................................................... 3-118
POWER TILTDOZER .................................................................................................................... 3-118
PRECAUTIONS WHEN REMOVING ROPS .......................................................................................... 3-119
LOADING, UNLOADING WORK ............................................................................................................ 3-120
LIFTING MACHINE................................................................................................................................. 3-124
COLD WEATHER OPERATION ...................................................................................................................... 3-128
PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-128
AFTER COMPLETION OF WORK ......................................................................................................... 3-130
AFTER COLD WEATHER ...................................................................................................................... 3-130
LONG-TERM STORAGE.................................................................................................................................. 3-131
BEFORE STORAGE............................................................................................................................... 3-131
DURING STORAGE ............................................................................................................................... 3-131
AFTER STORAGE.................................................................................................................................. 3-131
TROUBLESHOOTING...................................................................................................................................... 3-132
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-132
MACHINE TOWING METHOD ............................................................................................................... 3-132
WHEN IT IS POSSIBLE TO START ENGINE............................................................................... 3-133
WHEN ENGINE DOES NOT START ............................................................................................ 3-134
IF BATTERY IS DISCHARGED.............................................................................................................. 3-138
REMOVE AND INSTALL BATTERY ............................................................................................. 3-138
PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-139
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-139
OTHER TROUBLE ................................................................................................................................. 3-142
ELECTRICAL SYSTEM................................................................................................................. 3-142
MONITOR PANEL ......................................................................................................................... 3-143
CHASSIS ....................................................................................................................................... 3-144
ENGINE ......................................................................................................................................... 3-145
MAINTENANCE
GUIDE TO MAINTENANCE ................................................................................................................................. 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-5
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
OIL ..................................................................................................................................................... 4-5
FUEL.................................................................................................................................................. 4-5
COOLANT ......................................................................................................................................... 4-6
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-6
STORING OIL AND FUEL................................................................................................................. 4-7
FILTERS ............................................................................................................................................ 4-7
RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-8

CONTENTS
1-14
WEAR PARTS LIST ............................................................................................................................................. 4-9
WEAR PARTS LIST.................................................................................................................................... 4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..................... 4-10
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ......................................................... 4-10
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-14
TORQUE LIST .......................................................................................................................................... 4-14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-15
SAFETY CRITICAL PARTS...................................................................................................................... 4-15
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-17
MAINTENANCE SCHEDULE CHART......................................................................................................4-17
WHEN REQUIRED.......................................................................................................................... 4-17
CHECK BEFORE STARTING ......................................................................................................... 4-17
EVERY 50 HOURS SERVICE......................................................................................................... 4-17
EVERY 250 HOURS SERVICE....................................................................................................... 4-17
EVERY 500 HOURS SERVICE....................................................................................................... 4-17
EVERY 1000 HOURS SERVICE ..................................................................................................... 4-18
EVERY 2000 HOURS SERVICE ..................................................................................................... 4-18
EVERY 4000 HOURS SERVICE ..................................................................................................... 4-18
SERVICE PROCEDURE .................................................................................................................................... 4-19
WHEN REQUIRED ................................................................................................................................... 4-19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ......................................................... 4-19
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-23
CHECK TRACK SHOE TENSION, ADJUST ................................................................................... 4-26
CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-28
CHECK ELECTRICAL INTAKE AIR HEATER ................................................................................ 4-28
REVERSE AND REPLACE END BITS AND CUTTING EDGES..................................................... 4-29
CLEAN, CHECK RADIATOR FINS ................................................................................................. 4-31
CHECK, ADJUST AIR CONDITIONER ........................................................................................... 4-33
GREASE DOOR HINGE.................................................................................................................. 4-34
CHECK DOOR LOCK STRIKER ..................................................................................................... 4-34
REPLACE DOOR DAMPER ............................................................................................................ 4-34
CHECK DOOR LATCH.................................................................................................................... 4-35
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID .............................................................. 4-35
REPLACE WIPER BLADE .............................................................................................................. 4-36
CHECK IDLER OIL LEVEL, ADD OIL ............................................................................................. 4-37
ADJUST IDLER CLEARANCE ........................................................................................................ 4-38
CHECK LINK PITCH ....................................................................................................................... 4-38
CHECK OUTSIDE DIAMETER OF TRACK ROLLER ..................................................................... 4-39
CHECK HEIGHT OF GROUSER .................................................................................................... 4-39
ADJUST PLAY IN CENTER BALL .................................................................................................. 4-40
LUBRICATING UNIVERSAL JOINT ................................................................................................ 4-41
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM ..................................................... 4-42
PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM................. 4-42
CHECK BEFORE STARTING .................................................................................................................. 4-43

CONTENTS
1-15
EVERY 50 HOURS SERVICE .................................................................................................................. 4-44
DRAIN WATER, SEDIMENT FROM FUEL TANK........................................................................... 4-44
LUBRICATING................................................................................................................................. 4-44
EVERY 250 HOURS SERVICE ................................................................................................................ 4-45
LUBRICATING................................................................................................................................. 4-45
GREASE EQUALIZER BAR SIDE PIN............................................................................................ 4-47
GREASE EQUALIZER BAR CENTER PIN ..................................................................................... 4-47
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-48
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.................................................................... 4-48
CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-49
CLEAN WATER SEPARATOR STRAINER .................................................................................... 4-51
CHECK BRAKE PERFORMANCE .................................................................................................. 4-52
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ..................................... 4-53
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) ........................................... 4-54
EVERY 500 HOURS SERVICE ................................................................................................................ 4-55
REPLACE FUEL FILTER CARTRIDGE .......................................................................................... 4-55
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE .................... 4-56
REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-57
REPLACE POWER TRAIN OIL FILTER ELEMENT ....................................................................... 4-57
EVERY 1000 HOURS SERVICE .............................................................................................................. 4-58
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER,
SCAVENGING PUMP STRAINER) ................................................................................................. 4-58
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ......................................................................... 4-60
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................ 4-61
CLEAN BREATHER ........................................................................................................................ 4-61
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER ........................................................... 4-62
CHECK PLAY OF TURBOCHARGER ROTOR .............................................................................. 4-62
CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................ 4-62
EVERY 2000 HOURS SERVICE .............................................................................................................. 4-63
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT..................................... 4-63
REPLACE HYDRAULIC TANK BREATHER ELEMENT ................................................................. 4-64
CHANGE OIL IN DAMPER CASE................................................................................................... 4-65
CLEAN, CHECK TURBOCHARGER............................................................................................... 4-66
CHECK VIBRATION DAMPER ....................................................................................................... 4-66
CHECK ALTERNATOR, STARTING MOTOR ................................................................................ 4-66
CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................... 4-66
EVERY 4000 HOURS SERVICE .............................................................................................................. 4-67
CHECK WATER PUMP................................................................................................................... 4-67
SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ................................................................................................................................. 6-2

CONTENTS
1-16
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
HANDLING HYDRAULIC RIPPER....................................................................................................................... 6-3
GENERAL VIEW......................................................................................................................................... 6-3
EXPLANATION OF COMPONENTS .......................................................................................................... 6-4
OPERATION............................................................................................................................................... 6-5
CHECK BEFORE STARTING ENGINE, ADJUST............................................................................. 6-5
PRECAUTIONS WHEN OPERATING............................................................................................... 6-5
ADJUSTING POSTURE OF WORK EQUIPMENT............................................................................ 6-5
TROUBLESHOOTING................................................................................................................................ 6-7
OTHER TROUBLE ............................................................................................................................ 6-7
MAINTENANCE.......................................................................................................................................... 6-8
EVERY 250 HOURS SERVICE.........................................................................................................6-8
SPECIFICATIONS ...................................................................................................................................... 6-8
AIR SUSPENSION SEAT..................................................................................................................................... 6-9
DELUXE SEAT ................................................................................................................................................... 6-12
HEADREST ........................................................................................................................................................ 6-14
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................. 6-15
INDEX
COLOPHON

SAFETY
12

SAFETY SAFETY
2-2
SAFETY 2
SAFETY LABELS................................................................................................................................................ 2-42
POSITIONS OF SAFETY PICTOGRAMS ................................................................................................... 2-42
SAFETY LABELS......................................................................................................................................... 2-52
GENERAL PRECAUTIONS
Safety rules .................................................................................................................................................. 2-92
If abnormalities are found............................................................................................................................. 2-92
Clothing and personal protective items ........................................................................................................ 2-92
Fire extinguisher and first aid kit .................................................................................................................. 2-92
Safety features ........................................................................................................................................... 2-102
Keep machine clean................................................................................................................................... 2-102
Inside operator's compartment................................................................................................................... 2-102
Always apply lock when leaving operator's seat ........................................................................................ 2-102
Handrails and steps ................................................................................................................................... 2-112
Mounting and dismounting ......................................................................................................................... 2-112
No people on attachments ......................................................................................................................... 2-122
Crushing or cutting prevention ................................................................................................................... 2-122
Prevention of burns .................................................................................................................................... 2-122
Fire prevention ........................................................................................................................................... 2-132
Action if fire occurs..................................................................................................................................... 2-142
Window washer liquid ................................................................................................................................ 2-142
Precautions when using ROPS (Roll Over Protective Structure)............................................................... 2-142
Precautions for attachments ...................................................................................................................... 2-142
Unauthorized modification.......................................................................................................................... 2-142
Safety at worksite....................................................................................................................................... 2-152
Working on loose ground ........................................................................................................................... 2-152
Do not go close to high-voltage cables ...................................................................................................... 2-152
Ensure good visibility ................................................................................................................................. 2-162
Ventilation for enclosed areas.................................................................................................................... 2-162
Checking signalman's signals and signs.................................................................................................... 2-162
Emergency exit from operator's cab .......................................................................................................... 2-162
Be careful about asbestos dust.................................................................................................................. 2-172
PRECAUTIONS FOR OPERATION ................................................................................................................. 2-182
STARTING ENGINE .................................................................................................................................. 2-182
Checks before starting engine ............................................................................................................ 2-182
Precautions when starting................................................................................................................... 2-182
Precautions in cold areas.................................................................................................................... 2-192
OPERATION .............................................................................................................................................. 2-202
Checks before operation..................................................................................................................... 2-202
Precautions for moving machine forward or in reverse....................................................................... 2-202
Precautions when traveling ................................................................................................................. 2-202
Traveling on slopes ............................................................................................................................. 2-212
Using brakes ....................................................................................................................................... 2-212
Operate carefully on snow .................................................................................................................. 2-222
Parking machine ................................................................................................................................. 2-222
TRANSPORTATION .................................................................................................................................. 2-232
Loading and unloading........................................................................................................................ 2-232
Shipping .............................................................................................................................................. 2-232
BATTERY................................................................................................................................................... 2-242
Battery hazard prevention................................................................................................................... 2-242
Starting with booster cable.................................................................................................................. 2-252
TOWING .................................................................................................................................................... 2-262
When towing ....................................................................................................................................... 2-262

SAFETY SAFETY
2-3
PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-272
Warning tag................................................................................................................................................ 2-272
Keep work place clean and tidy ................................................................................................................. 2-272
Appoint leader when working with others .................................................................................................. 2-272
Stop engine before carrying out inspection and maintenance ................................................................... 2-272
Two workers for maintenance when engine is running.............................................................................. 2-282
Proper tools................................................................................................................................................ 2-292
No unauthorized personnel into area......................................................................................................... 2-292
Attachments ............................................................................................................................................... 2-292
Work under the machine............................................................................................................................ 2-302
Noise.......................................................................................................................................................... 2-302
Precautions when using hammer............................................................................................................... 2-302
Repair welding ........................................................................................................................................... 2-302
Removing battery terminal ......................................................................................................................... 2-302
Precautions when using high-pressure grease to adjust track tension...................................................... 2-312
Do not disassemble recoil spring ............................................................................................................... 2-312
Precaution with high-pressure oil............................................................................................................... 2-312
Handling high-pressure hoses ................................................................................................................... 2-322
Waste material ........................................................................................................................................... 2-322
Maintenance for air conditioner.................................................................................................................. 2-322
Compressed air.......................................................................................................................................... 2-322
Periodic replacement of safety critical parts .............................................................................................. 2-322