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D31EX, PX-22

D37EX, PX-22

SERIAL NUMBER

D31EX-22 - 60001 and up

D31PX-22 - 60001 and up

D37EX-22 - 60001 and up

D37PX-22 - 60001 and up

BULLDOZER

Unsafe use of this machine may cause serious injury or

death. Operators and maintenance personnel must read

this manual before operating or maintaining this

machine. This manual should be kept inside the cab for

reference and periodically reviewed by all personnel whowill come into contact with the machine.

Operation &Maintenance Manual

EEAM026805

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

Pocket in the back of the operator's seat (fitted with a lock)

REMARK

If the machine is equipped with an air suspension seat, keep

the Operation and Maintenance Manual in the steel pocket

behind the seat.

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 (1-9).

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

the past are given in ( ).

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FOREWORD BEFORE READING THIS MANUAL

1-3

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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IMPORTANT SAFETY INFORMATION FOREWORD

1-4

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, will

result 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.

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

DANGER

WARNING

CAUTION

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FOREWORD IMPORTANT SAFETY INFORMATION

1-5

NOISE (D37EX-22, D37PX-22) 1

Two labels indicating the machine noise level are affixed on the

machine.

q Sound pressure level at the operators 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 value includes an uncertainty

of 3.0 dB

VIBRATION 1

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

tors 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/s , the uncertainty for this

value is 1 m/s according EN 12096:1997.

The actual acceleration value for the body is less than or equal to 0.5 m/s , the uncertainty for this value is 0.2 m/

s 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.

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IMPORTANT SAFETY INFORMATION FOREWORD

1-6

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 traveling in good condition

qRemove 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 pedalsslowly so that the machine moves smoothly

6. Adjust the machine speed and travel path to minimize the vibration level

q When pushing with bucket or blade, avoid sudden loading; load gradually

q Drive around obstacles and rough terrain conditions

q Slow down when it is necessary to go over rough terrain

q Make the curve radius of traveling path as large as possible

q Travel at low speed when traveling around sharp curves

7. Minimize vibrations for long work cycle or long distance travelingq 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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FOREWORD INTENDED USE

1-7

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 (3-99) for further details.

GENERAL VIEW AND 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) Front (E) Operator's seat

(B) Rear (F) Sprocket

(C) Left

(D) Right

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

1-8

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

This is on the bracket on the rear left side of the engine.

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

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1-10

MACHINE SERIAL PLATE. 1

kg

kW

Model

Seriel Number

Manufacturing year

Weight

Engine power

Product Identification Number

Manufacturer

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

1-11

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

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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1-12

Declaration of conformity (Directive 2006/42/EC)

The manufacturer/Authorized representative

Declares that this machine

D37EX-22

D37PX-22

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 ............................................................................................................... 1-4

NOISE (D37EX-22, D37PX-22) .................................................................................................................. 1-5

VIBRATION................................................................................................................................................. 1-5

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

INTENDED USE ................................................................................................................................................... 1-7

USE OF MACHINE..................................................................................................................................... 1-7

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

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................. 1-8

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ....................................... 1-8

EPA REGULATION, ENGINE SERIAL NO. PLATE................................................................................... 1-8

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

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................................................. 1-9

MACHINE SERIAL PLATE. ...................................................................................................................... 1-10

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.................................................................................................. 2-4

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

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............................................. 2-10

PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-10PREPARATIONS FOR SAFE OPERATION............................................................................................. 2-10

FIRE PREVENTION ................................................................................................................................. 2-12

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE .................................................................... 2-13

DO NOT GET CAUGHT IN WORK EQUIPMENT.................................................................................... 2-16

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-16

UNAUTHORIZED MODIFICATION.......................................................................................................... 2-16

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS........................................................... 2-16

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ............................................................ 2-17

PRECAUTIONS FOR OPERATION ................................................................................................................... 2-18

PRECAUTIONS FOR JOBSITE ............................................................................................................... 2-18

STARTING ENGINE................................................................................................................................. 2-20

OPERATION............................................................................................................................................. 2-23

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CONTENTS

1-14

TRANSPORTATION................................................................................................................................. 2-27

TOWING ................................................................................................................................................... 2-28

PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-29

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......................................... 2-29

PRECAUTIONS FOR INSPECTION AND MAINTENANCE..................................................................... 2-32

OPERATION

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

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

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

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

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

CHECK MONITOR SYSTEM ............................................................................................................ 3-5

EMERGENCY CAUTION ITEMS ...................................................................................................... 3-7

CAUTION ITEMS............................................................................................................................... 3-9

METER GROUP.............................................................................................................................. 3-11

METHOD OF USING FAILURE CODE DISPLAY........................................................................... 3-18

LAMPS............................................................................................................................................. 3-19

SWITCHES...................................................................................................................................... 3-21

METHOD OF USING MAINTENANCE MODE................................................................................ 3-25

SWITCHES............................................................................................................................................... 3-31

CONTROL LEVERS AND PEDALS ......................................................................................................... 3-36

BATTERY DISCONNECT SWITCH (if installed)-42

FUSE ........................................................................................................................................................ 3-43

ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................ 3-45

DOOR - OPEN LOCK............................................................................................................................... 3-46

SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-46

COVER, CAP WITH LOCK....................................................................................................................... 3-47

METHOD OF OPENING OR CLOSING HYDRAULIC TANK CAP ................................................. 3-47

METHOD OF OPENING OR CLOSING THE FUEL TANK CAP..................................................... 3-48

METHOD OF OPENING OR CLOSING INSPECTION COVER ..................................................... 3-49

METHOD OF OPENING OR CLOSING COVER WITH LOCK ....................................................... 3-49

OPENING OR CLOSING REAR MASK.................................................................................................... 3-50

DOOR POCKET ....................................................................................................................................... 3-51

ASHTRAY................................................................................................................................................. 3-51

LUNCHBOX HOLDER BELT .................................................................................................................... 3-51

CUP HOLDER .......................................................................................................................................... 3-52

TOOL BOX................................................................................................................................................ 3-52

GREASE PUMP HOLDER........................................................................................................................ 3-52

CAR RADIO, HANDLING ......................................................................................................................... 3-53

EXPLANATION OF COMPONENTS............................................................................................... 3-53

METHOD OF OPERATION............................................................................................................. 3-58

PRECAUTIONS WHEN USING ...................................................................................................... 3-60

AIR CONDITIONER, HANDLING ............................................................................................................. 3-61

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CONTENTS

1-15

EXPLANATION OF PARTS............................................................................................................. 3-61

PREVENTION METHOD OF ENTRY OF DUST............................................................................. 3-62

PRECAUTION WHEN USING AIR CONDITIONER........................................................................ 3-62

INSPECTION DURING OFF-SEASON........................................................................................... 3-62

PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-63

CLEANING AIR FILTER.................................................................................................................. 3-63

OPERATION....................................................................................................................................................... 3-64

CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-64

WALK-AROUND CHECK ................................................................................................................ 3-64

CHECK BEFORE STARTING......................................................................................................... 3-66

ADJUSTMENT................................................................................................................................. 3-76

OPERATION AND CHECK BEFORE STARTING ENGINE............................................................ 3-80

STARTING ENGINE................................................................................................................................. 3-82

NORMAL STARTING...................................................................................................................... 3-82

STARTING IN COLD WEATHER.................................................................................................... 3-83

OPERATIONS AND CHECKS AFTER STARTING ENGINE................................................................... 3-87

BREAKING IN THE NEW MACHINE .............................................................................................. 3-87

WARMING UP OPERATIONS ........................................................................................................ 3-87

STARTING IN COLD WEATHER.................................................................................................... 3-88

STOPPING ENGINE................................................................................................................................. 3-90

MACHINE OPERATION........................................................................................................................... 3-91

MOVING MACHINE......................................................................................................................... 3-91

STOPPING MACHINE..................................................................................................................... 3-93

SHIFTING GEARS.................................................................................................................................... 3-94

SHIFTING BETWEEN FORWARD AND REVERSE................................................................................ 3-95

STEERING MACHINE.............................................................................................................................. 3-96

NORMAL TURNING........................................................................................................................ 3-96

TURNING WHILE DESCENDING A SLOPE................................................................................... 3-97

PRECAUTIONS FOR OPERATION......................................................................................................... 3-98

PAY ATTENTION TO GAUGES...................................................................................................... 3-98

PERMISSIBLE WATER DEPTH...................................................................................................... 3-98

PRECAUTIONS WHEN TRAVELING DOWNHILL ......................................................................... 3-98

PRECAUTIONS ON SLOPES......................................................................................................... 3-98

IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-98

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

WILL OBSTRUCT THE VIEW ........................................................................................................ 3-99

PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY..................................................... 3-99

WORK POSSIBLE USING BULLDOZER................................................................................................. 3-99

DOZING........................................................................................................................................... 3-99

SMOOTHING................................................................................................................................. 3-100

CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................. 3-100

FELLING TREES, REMOVING STUMPS ..................................................................................... 3-100

SIDE-CUTTING OPERATIONS..................................................................................................... 3-101

ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................. 3-101

ADJUST ANGLE OF BLADE EDGE.............................................................................................. 3-101

PARKING MACHINE.............................................................................................................................. 3-103

CHECK AFTER FINISHING WORK ....................................................................................................... 3-104

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CONTENTS

1-16

BEFORE STOPPING ENGINE...................................................................................................... 3-104

AFTER STOPPING ENGINE......................................................................................................... 3-104

LOCKING................................................................................................................................................ 3-105

TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................... 3-106

OPERATION METHOD................................................................................................................. 3-106

INSPECTION AND ADJUSTMENT............................................................................................... 3-107

INSPECTION AND REPAIR.......................................................................................................... 3-107

TRANSPORTATION......................................................................................................................................... 3-109

TRANSPORTATION MEANS................................................................................................................. 3-109

REMOVING CAB.................................................................................................................................... 3-109

PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-109

LOADING, UNLOADING WORK ............................................................................................................ 3-110

METHOD OF LIFTING MACHINE.......................................................................................................... 3-113

COLD WEATHER OPERATION ...................................................................................................................... 3-115PRECAUTIONS FOR LOW TEMPERATURE ........................................................................................ 3-115

AFTER COMPLETION OF WORK ......................................................................................................... 3-116

AFTER COLD WEATHER ...................................................................................................................... 3-116

LONG-TERM STORAGE.................................................................................................................................. 3-117

BEFORE STORAGE............................................................................................................................... 3-117

DURING STORAGE ............................................................................................................................... 3-117

AFTER STORAGE.................................................................................................................................. 3-118

TROUBLESHOOTING...................................................................................................................................... 3-119

AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-119

METHOD OF TOWING MACHINE......................................................................................................... 3-119

IF BATTERY IS DISCHARGED.............................................................................................................. 3-120

REMOVE AND INSTALL BATTERY ............................................................................................. 3-121

PRECAUTIONS FOR BATTERY CHARGING .............................................................................. 3-121

STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-122

OTHER TROUBLE ................................................................................................................................. 3-125

ELECTRICAL SYSTEM................................................................................................................. 3-125

MONITOR PANEL......................................................................................................................... 3-126

CHASSIS....................................................................................................................................... 3-127ENGINE......................................................................................................................................... 3-128

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

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CONTENTS

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CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-7

STORING OIL AND FUEL................................................................................................................. 4-8

FILTERS............................................................................................................................................ 4-8

RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-9

HANDLING HYDRAULIC SYSTEM............................................................................................................ 4-9

WEAR PARTS LIST ........................................................................................................................................... 4-10

WEAR PARTS LIST.................................................................................................................................. 4-11

RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................................................................................. 4-13

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ............ 4-14

RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS

OTHER THAN KOMATSU GENUINE OIL............................................................................................... 4-15

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-16

TORQUE LIST.......................................................................................................................................... 4-16

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-17

SAFETY CRITICAL PARTS...................................................................................................................... 4-18

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-20

MAINTENANCE SCHEDULE CHART...................................................................................................... 4-20

INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) .................................... 4-20

INITIAL 500 HOURS SERVICE (ONLY AFTER THE FIRST 500 HOURS) .................................... 4-20

WHEN REQUIRED.......................................................................................................................... 4-20

CHECK BEFORE STARTING......................................................................................................... 4-20

EVERY 50 HOURS SERVICE......................................................................................................... 4-20

EVERY 250 HOURS SERVICE....................................................................................................... 4-20

EVERY 500 HOURS SERVICE....................................................................................................... 4-20

EVERY 1000 HOURS SERVICE..................................................................................................... 4-21




SERVICE PROCEDURE .................................................................................................................................... 4-22

WHEN REQUIRED................................................................................................................................... 4-22

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-22CHECK ADDITIONAL WATER SEPARATOR, CLEAN INSIDE OF CASE

(ONLY POOR FUEL ARRANGEMENT SPECIFICATION) ............................................................ 4-25

CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-26

CHECK TRACK SHOE TENSION, ADJUST................................................................................... 4-29

CHECK AND TIGHTEN TRACK SHOE BOLTS.............................................................................. 4-31

REVERSE AND REPLACE END BITS AND CUTTING EDGES .................................................... 4-32

CLEAN, CHECK RADIATOR FINS ................................................................................................. 4-33

CHECK, ADJUST AIR CONDITIONER........................................................................................... 4-37

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

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

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

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

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CONTENTS

1-18

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

CHECK IDLER OIL LEVEL.............................................................................................................. 4-42

ADJUST IDLER CLEARANCE ........................................................................................................ 4-42

ADJUST PLAY IN CENTER BALL .................................................................................................. 4-43

PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM..................................................... 4-44

PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM................. 4-45

CHECK BEFORE STARTING .................................................................................................................. 4-46

EVERY 50 HOURS SERVICE.................................................................................................................. 4-47

LUBRICATING................................................................................................................................. 4-47

DRAIN WATER, SEDIMENT FROM FUEL TANK (ONLY STANDARD SPECIFICATION) ............ 4-48

EVERY 250 HOURS SERVICE................................................................................................................ 4-49

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-49

CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-50

CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST-52

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.................................... 8.-54

CHECK BRAKE PERFORMANCE.................................................................................................. 4-56

CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)............................................ 4-57

EVERY 500 HOURS SERVICE................................................................................................................ 4-58

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................... 4-58

REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-60

CHECK ELECTRIC WIRING AROUND STARTING MOTOR, ALTERNATOR............................... 4-62

EVERY 1000 HOURS SERVICE.............................................................................................................. 4-63

REPLACE FUEL MAIN FILTER CARTRIDGE (STANDARD SPECIFICATION)............................. 4-63

REPLACE FUEL MAIN FILTER CARTRIDGE

(POOR FUEL ARRANGEMENT SPECIFICATION)........................................................................ 4-65

REPLACE FUEL TANK BREATHER ELEMENT............................................................................. 4-67

REPLACE HYDRAULIC TANK BREATHER ELEMENT................................................................. 4-68

CHANGE OIL IN FINAL DRIVE CASE ............................................................................................ 4-68

CHECK CLAMP TIGHTENING PORTIONS FOR MACHINE INTAKE/EXHAUST PIPING]............ 4-69

CHECK FOR LOOSE ROPS MOUNT BOLTS................................................................................ 4-69

CHECK, CLEAN FAN ...................................................................................................................... 4-71


CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL

FILTER ELEMENT AND CLEAN HYDRAULIC TANK STRAINER ................................................ 4-73

CHECK ACCUMULATOR (FOR CONTROL CIRCUIT) .................................................................. 4-75

CHECK ALTERNATOR................................................................................................................... 4-77

CHECK ENGINE VALVE CLEARANCE, ADJUST.......................................................................... 4-77


REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) .............................................................. 4-78

CHECK WATER PUMP................................................................................................................... 4-78

CHECK STARTING MOTOR........................................................................................................... 4-78

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER ...... 4-79

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ....... 4-79


REPLACE HIGH-PRESSURE PIPING CLAMPS............................................................................ 4-80

REPLACE FUEL SPLAY PREVENTION CAPS .............................................................................. 4-80

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CONTENTS

1-19

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

AIR SUSPENSION SEAT..................................................................................................................................... 6-4

EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT................................................................................... 6-7

HANDLING MACHINES EQUIPPED WITH KOMTRAX ...................................................................................... 6-8

BASIC PRECAUTIONS.............................................................................................................................. 6-8

INDEX

COLOPHON

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CONTENTS

1-20

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SAFETY

12

WARNINGPlease be sure that you fully understand this manual and the

precautions discribed in this m anual and t he safety labels

on the machine. When operating or servicing the machine,

always follow these precaustions strictly.

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SAFETY SAFETY

2-2

SAFETY 2

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

POSITIONS OF SAFETY PICTOGRAMS ................................................................................................... 2-42

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

GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................ 2-102

PRECAUTIONS BEFORE STARTING OPERATION................................................................................ 2-102

ENSURING SAFE OPERATION ........................................................................................................ 2-102

UNDERSTANDING THE MACHINE................................................................................................... 2-102

PREPARATIONS FOR SAFE OPERATION.............................................................................................. 2-102

PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT.................................................... 2-102

INSPECTING MACHINE .................................................................................................................... 2-102

WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT .............................................. 2-102

KEEP MACHINE CLEAN.................................................................................................................... 2-112

PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT................................................................ 2-112

PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ..................................................................... 2-112 IF ANY PROBLEM IS FOUND............................................................................................................ 2-112

FIRE PREVENTION................................................................................................................................... 2-122

ACTION IF FIRE OCCURS ................................................................................................................ 2-122

PRECAUTIONS TO PREVENT FIRE................................................................................................. 2-122

PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...................................................................... 2-132

USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE...................................... 2-132

NO JUMPING ON OR OFF MACHINE............................................................................................... 2-152

LIFTING OF PERSONNEL PROHIBITED.......................................................................................... 2-152

NO PEOPLE ON ATTACHMENTS..................................................................................................... 2-152

PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT .............................................. 2-152

PRECAUTIONS WHEN LEAVING MACHINE.................................................................................... 2-152

EMERGENCY EXIT FROM OPERATOR'S CAB................................................................................ 2-162

DO NOT GET CAUGHT IN WORK EQUIPMENT ..................................................................................... 2-162

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES................................................................ 2-162

UNAUTHORIZED MODIFICATION ........................................................................................................... 2-162

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS............................................................ 2-162

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.............................................................. 2-172

PRECAUTIONS FOR OPERATION ................................................................................................................. 2-182

PRECAUTIONS FOR JOBSITE................................................................................................................. 2-182

INVESTIGATE AND CONFIRM JOBSITE CONDITIONS .................................................................. 2-182

WORKING ON LOOSE GROUND...................................................................................................... 2-182

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES......................................................................... 2-192

ENSURE GOOD VISIBILITY .............................................................................................................. 2-192 CHECKING SIGNS AND SIGNALMAN'S SIGNALS .......................................................................... 2-202

BEWARE OF ASBESTOS DUST ....................................................................................................... 2-202

STARTING ENGINE .................................................................................................................................. 2-202

USE WARNING TAGS ....................................................................................................................... 2-202

CHECKS BEFORE STARTING ENGINE ........................................................................................... 2-212

PRECAUTIONS WHEN STARTING................................................................................................... 2-212

PRECAUTIONS IN COLD AREAS ..................................................................................................... 2-212

STARTING WITH BOOSTER CABLES.............................................................................................. 2-222

OPERATION.............................................................................................................................................. 2-232

CHECKS BEFORE OPERATION....................................................................................................... 2-232

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................................ 2-232

PRECAUTIONS WHEN TRAVELING................................................................................................. 2-242

TRAVELING ON SLOPES.................................................................................................................. 2-252

PRECAUTIONS WHEN OPERATING................................................................................................ 2-252

TRAVELING ON SNOW-COVERED OR FROZEN SURFACES ....................................................... 2-252

PARKING MACHINE .......................................................................................................................... 2-262

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SAFETY SAFETY

2-3

TRANSPORTATION.................................................................................................................................. 2-272

LOADING AND UNLOADING............................................................................................................. 2-272

TOWING .................................................................................................................................................... 2-282

PRECAUTIONS WHEN TOWING ...................................................................................................... 2-282

PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-292

PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ........................................... 2-292

DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE........................................ 2-292 KEEP WORKPLACE CLEAN AND TIDY............................................................................................ 2-292

SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE ........................................... 2-292

STABILITY.......................................................................................................................................... 2-29

GUARDS............................................................................................................................................. 2-292

ONLY AUTHORIZED PERSONNE..................................................................................................... 2-292

ONLY AUTHORIZED PERSONNEL................................................................................................... 2-292

APPOINT LEADER WHEN WORKING WITH OTHERS.................................................................... 2-302

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............................ 2-302

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING ........................................... 2-302

INSTALLING, REMOVING, OR STORING ATTACHMENTS............................................................. 2-312

PRECAUTIONS WHEN WORKING AT HIGH PLACES..................................................................... 2-312

PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT........................... 2-312 PROPER TOOLS................................................................................................................................ 2-322

PRECAUTIONS FOR INSPECTION AND MAINTENANCE...................................................................... 2-322

PRECAUTIONS WHEN WELDING .................................................................................................... 2-322

HANDLING BATTERY........................................................................................................................ 2-322

PRECAUTIONS WHEN USING HAMMER......................................................................................... 2-342

PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT............................................................... 2-342

PRECAUTIONS WITH HIGH-TEMPERATURE OIL........................................................................... 2-342

PRECAUTIONS WITH HIGH-PRESSURE OIL.................................................................................. 2-352

PRECAUTIONS WITH HIGH-PRESSURE FUEL............................................................................... 2-352

HANDLING HIGH-PRESSURE HOSES AND PIPING....................................................................... 2-352

NOISE................................................................................................................................................. 2-352

PRECAUTIONS WITH HIGH-PRESSURE GREASE WHEN ADJUSTING TRACK TENSION ......... 2-362

DO NOT DISASSEMBLE RECOIL SPRING ...................................................................................... 2-362

HANDLING ACCUMULATOR AND GAS SPRING............................................................................. 2-362

PRECAUTIONS WITH COMPRESSED AIR ...................................................................................... 2-372

MAINTENANCE OF AIR CONDITIONER........................................................................................... 2-372

HEMICAL HAZARD............................................................................................................................ 2-372

DISPOSING OF WASTE MATERIALS.............................................................................................. 2-372

METHOD OF SELECTING WINDOW WASHER FLUID.................................................................... 2-372

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................... 2-382

DISMANTLING THE MACHINE END OF SERVICE LIVE ................................................................. 2-38

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SAFETY LABELS SAFETY

2-4

SAFETY LABELS 2

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

q Be sure that you fully understand the correct position and content of labels.

q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always

keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels

to peel off.

q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same

way.

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

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

POSITIONS OF SAFETY PICTOGRAMS 2

Z

Z

YX

X

Y

9JR07058B

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SAFETY SAFETY LABELS

2-5

SAFETY LABELS 2

(1) Caution for operation, inspection and maintenance

(09651-A0481)

q Warning!

q Read manual before operation, maintenance, disassembly,

assembly and transportation.

(2) Caution before moving in reverse (09802-B0640)

WARNINGTo prevents SEVERE INJURY or DEATH, do the fo llowing

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-B0481)

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.

09802-B0640

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2-6

(4) Caution with high-temperature coolant, hydraulic oil

(09653-A0481)

q Never remove the cap when the engine is at operating

(high) temperature. Stream or high temperature oil blowing

up from the radiator or hydraulic tank, will cause personal

injury and or burns.

q Never remove the radiator or hydraulic tank oil filler when

cooling water or hydraulic oil is at high temperatures.

(5) Caution for accumulator (09659-A057B)

q There is the hazard of explotion causing injury.

q Do not disassemble the accumulator, make holes in it, cut

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

(6) Caution for adjusting track tension (09657-A0881)

The safety label is attached to the rear side of the track adjust-

ment window cover.

q Sign indicates a hazard or flining plug from track adjuster

that could cause injury.

q Read the manual and adjusting track for safe and proper

handling.

(7) Caution for battery cable (09808-A0881)

q Sing indicates an electric hazard from handling the cable.

q Read the manual for save and proper handling.

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2-7

(8) Stop rotation during inspection and maintenance

(09667-A0481)

q Sign indicates a hazard of rotating parts, such as belt.

qTurn off before inspection and maintenance.

(9) Caution for approach when machine moving

(09806-B1201)

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 operators

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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2-8

(11) Caution for ROPS/FOPS (09620-A2000)

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 exchanging air cleaner (09637-A0640)

q Sign indicates a caution of exchanging air cleaner

q Read manual for exchanging air cleaner

NOTICE

Dont put oil in to this cleaner.

Use only genuine Komatsu elements

When service indicator turns 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 o il. If element

has a cracks, it must be replaced.

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2-9

(13) Caution adding coolant

q Sign indicates a caution of exchanging air cleaner.

q Read manual for add coolant

(14)Drawbar (09823-00001)

Read manual for drawbar

(1): Indicate the maximum pulling load.

(2): Indicate the maximum vertical load.

q

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

caused by active radio transmitter at a blast zone

(09845-00480).

q Keep machine at a safe distance from blast zone and a

detonator.

NACAF

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GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE SAFETY

2-10

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.

q If 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

2-11

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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2-12

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.

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 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.

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2-13

q Fire coming from pip ing

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.

WHEN GETTING ON OR OFF FROM OPERATOR'S SEAT (D31EX, D31PX, D37EX, D37PX)

q Get on or off the operator's seat from the front of the

machine and use the handrails and steps marked by the

arrow in the diagram on the right.

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2-14

WHEN ADDING FUEL, COOLANT, HYDRAULIC OIL (D31EX, D37EX)

q Use the handrails and steps marked by arrows in the dia-

gram on the right when adding fuel, coolant, or hydraulic

oil, and get on or off from the side of the machine.

WHEN ADDING FUEL, COOLANT, HYDRAULIC OIL (D31PX, D37PX)

q Use the handrails and steps marked by arrows in the dia-

gram on the right when adding fuel, coolant, or hydraulic

oil, and get on or off from the front of the machine.

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.

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2-15

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.

q Do 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.

L IFTING 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.

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 personalinjury.

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.

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2-16

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.

PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2

The operator's compartment is equipped with a structure

(ROPS, FOPS) to protect the operator by absorbing the impact

energy. If the machine weight (mass) exceeds the certified

value (shown on the ROLL-OVER PROTECTIVE STRUC-TURE (ROPS) CERTIFICATION plate), ROPS will not be able

to fulfill its function. Do not increase machine weight beyond

the certified value by modifying the machine or by installing

attachments to the machine. Also, if the function of the protec-

tive equipment is impeded, the protective equipment will not be

able to protect the operator, and the operator may suffer injury

or death. Always observe the following.

q If the machine is equipped with a protective structure, do

not remove the protective structure and carry out opera-

tions without it.

q If the protective structure is welded, or holes are drilled in it, or it is modified in any other way, its strength maydrop. Consult your Komatsu distributor before carrying out any modifications.

q If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be

reduced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu dis-

tributor for advice on the method of repair.

q Even if the protective structure is installed, always fasten your seat belt properly when operating the machine.

If you do not fasten your seatbelt properly, it cannot display its effect.

UNAUTHORIZED MODIFICATION 2

q Komatsu will not be responsible for any injuries, accidents, product failures or other property damages result-ing from modifications made without authorization from Komatsu.

q Any modification made without authorization from Komatsu can create hazards. Before making a modification,

consult your Komatsu distributor.

PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2

q Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized

attachments or parts will not be the responsibility of Komatsu.

q When installing optional parts or attachments, there may be problems with safety or legal restrictions. There-

fore contact your Komatsu distributor for advice.

q When installing and using optional attachments, read the instruction manual for the attachment, and the gen-

eral information related to attachments in this manual.

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2-17

PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2

The engine exhaust gas contains substances that may damage

your health or even cause death. Start or operate the engine in

a place where there is good ventilation. If the engine or

machine must be operated inside a building or under ground,

where the ventilation is poor, take steps to ensure that the

engine exhaust gas is removed and that ample fresh air is

brought in.

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PRECAUTIONS FOR OPERATION SAFETY

2-18

PRECAUTIONS FOR OPERATION 2

PRECAUTIONS FOR JOBSITE 2

INVESTIGATE AND CONFIRM JOBSITE CONDITIONS

On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting opera-

tions, always check the following to confirm that there is no danger on the jobsite.

q When carrying out operations near combustible materials such as thatched roofs, dry leaves or dry grass,

there is a hazard of fire, so be careful when operating.

q Check the terrain and condition of the ground at the worksite, and determine the safest method of operation.

Do not operate where there is a hazard of landslides or falling rocks.

q If water lines, gas lines, or high-voltage electrical lines may

be buried under the worksite, contact each utility and iden-

tify their locations. Be careful not to sever or damage anyof these lines.

q Take necessary measures to prevent any unauthorized

person from entering the operating area.

q In particular, if you need to operate on a road, protect

pedestrian and cars by designating a person for worksite

traffic duty or by installing fences around the worksite.

q When traveling or operating in water or on soft ground,

check the water depth, speed of the current, bedrock, and

shape of the ground beforehand and avoid any place that

will obstruct travel.

WORKING ON LOOSE GROUND

q Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The

ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,

there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or

after earthquakes is weak in these areas.

q When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of

the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is

safe and to prevent the machine from rolling over or falling.

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SAFETY PRECAUTIONS FOR OPERATION

2-19

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause

serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as fol-

lows.

qBefore starting work near electric cables, inform the local power company of the work to be performed, andask them to take the necessary action.

q Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.

Always maintain a safe distance (see the table on the right)

between the machine and the electric cable. Check with

the local power company about safe operating procedure

before starting operations.

q To prepare for any possible emergencies, wear rubber

shoes and gloves. Lay a rubber sheet on top of the seat,

and be careful not to touch the chassis with any exposed

part of your body.q Use a signalman to give warning if the machine

approaches too close to the electric cables.

q When carrying out operations near high voltage cables, do

not let anyone near the machine.

q If the machine should come too close or touch the electric

cable, to prevent electric shock, the operator should not

leave the operator's compartment until it has been con-

firmed that the electricity has been shut off.

Also, do not let anyone near the machine.

ENSURE GOOD VISIBILITY

This machine is equipped with mirrors to ensure good visibility, but even then there are places that cannot be seen

from the operator's seat, so be careful when operating.

Before travelling or operating the machine, the operator should sound the horn to warn people in the area.

When traveling or carrying out operations in places with poor visibility, it is impossible to check for obstacles in the

area around the machine and to check the condition of the jobsite. This leads to danger of serious personal injury

or death. When traveling or carrying out operations in places with poor visibility, always observe the following.

q Position a signalman if there are areas where the visibility is not good.

q Only one signalman should give signals.

q When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up

additional lighting in the work area if necessary.

q Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.

q When checking the

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