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KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM040203T) – PDF DOWNLOAD
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- KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:SEAM040203T
- SERIAL NUMBER:
D39EX-1201 and up
D39PX-1209 and up
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Description
KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM040203T)
KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM040203T) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM040203T)
- Before beginning operation or maintenance, operators and maintenance personnel must always observe thefoiiowing points.
- Read this manual thoroughly and understand its contents fully.
- Read the safety messages and safety labels given in this rnanuai carefully so that they should be understood 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 rnachlne can consult it periodically.
- In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributorto obtain a new copy.
- When you sell the machine, make sure that this manual should be provided to the new owner togetherwith the machine.
- In this manual, measurements are expressed in international standard units (Si). For the reference purpose, weight units used in the past are also displayed in { }.
TABLE OF CONTENTS:
KOMATSU GALEO D39EX-21 D39PX-21 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM040203T)
COVER............................................................................................... 1 FOREWORD............................................................................................ 2 FOREWORD........................................................................................ 3 SAFETY INFORMATION.............................................................................. 6 INTRODUCTION.................................................................................... 8 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE................................................. 8 NECESSARY INFORMATION........................................................................... 9 MACHINE SERIAL NO.PLATE AND POSITION........................................................ 9 ENGINE SERIAL NO.PLATE AND POSITION......................................................... 9 EMISSION CONTROL INFORMATION LABEL AND POSITION............................................. 10 POSITION OF SERVICE METER................................................................... 10 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN................................................... 11 CONTENTS............................................................................................ 12 SAFETY.............................................................................................. 15 SAFETY.......................................................................................... 16 SAFETY LABELS................................................................................... 18 POSITIONS OF SAFETY PICTOGRAMS.............................................................. 18 GENERAL PRECAUTIONS............................................................................. 22 SAFETY RULES................................................................................ 22 IF ABNORMALITIES ARE FOUND.................................................................. 22 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................... 22 FIRE EXTINGUISHER AND FIRST AID KIT......................................................... 22 SAFETY FEATURES............................................................................. 22 KEEP MACHINE CLEAN.......................................................................... 23 INSIDE OPERATOR'S COMPARTMENT............................................................... 23 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................. 23 HANDRAILS AND STEPS......................................................................... 24 MOUNTING AND DISMOUNTING ................................................................... 24 NO PEOPLE ON ATTACHMENTS.................................................................... 24 CRUSHING OR CUTTING PREVENTION.............................................................. 24 PREVENTION OF BURNS......................................................................... 25 FIRE PREVENTION............................................................................. 25 ACTION IF FIRE OCCURS....................................................................... 26 WINDOW WASHER LIQUID........................................................................ 26 PRECAUTIONS WHEN USING ROPS................................................................. 26 PRECAUTIONS FOR ATTACHMENTS................................................................. 26 UNAUTHORIZED MODIFICATION................................................................... 27 SAFETY AT WORKSITE.......................................................................... 27 WORKING ON LOOSE GROUND..................................................................... 27 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................... 27 ENSURE GOOD VISIBILITY...................................................................... 29 VENTILATION FOR ENCLOSED AREAS.............................................................. 29 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................... 29 EMERGENCY EXIT FROM OPERATOR'S CAB.......................................................... 29 BE CAREFUL ABOUT ASBESTOS DUST.............................................................. 29 PRECAUTIONS FOR OPERATION....................................................................... 30 STARTING ENGINE............................................................................. 30 CHECKS BEFORE STARING ENGINE............................................................ 30 PRECAUTIONS WHEN STARTING............................................................... 30 PRECAUTIONS IN COLD AREAS............................................................... 30 OPERATION................................................................................... 32 CHECKS BEFORE OPERATION................................................................. 32 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................... 32 PRECAUTIONS WHEN TRAVELING.............................................................. 33 TRAVELING ON SLOPES..................................................................... 33 OPERATE CAREFULLY ON SNOW............................................................... 35 PARKING MACHINE......................................................................... 35 TRANSPORTATION.............................................................................. 36 LOADING AND UNLOADING................................................................... 36 SHIPPING................................................................................ 36 BATTERY..................................................................................... 37 BATTERY HAZARD PREVENTION............................................................... 37 STARTING WITH BOOSTER CABLE............................................................. 38 TOWING...................................................................................... 39 WHEN TOWING............................................................................. 39 PRECAUTIONS FOR MAINTENANCE..................................................................... 40 WARNING TAG................................................................................. 40 KEEP WORK PLACE CLEAN AND TIDY.............................................................. 40 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................... 40 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................................. 40 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................... 41 PROPER TOOLS................................................................................ 42 NO UNAUTHORIZED PERSONNEL INTO AREA......................................................... 42 ATTACHMENTS................................................................................. 42 WORK UNDER THE MACHINE...................................................................... 42 NOISE....................................................................................... 42 PRECAUTIONS WHEN USING HAMMER............................................................... 43 REPAIR WELDING.............................................................................. 43 REMOVING BATTERY TERMINAL................................................................... 43 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................... 43 DO NOT DISASSEMBLE RECOIL SPRING............................................................ 43 PRECAUTION WITH HIGH-PRESSURE OIL........................................................... 44 HANDLING HIGH-PRESSURE HOSES................................................................ 44 WASTE MATERIAL.............................................................................. 44 MAINTENANCE OF AIR CONDITIONER.............................................................. 44 COMPRESSED AIR.............................................................................. 45 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................... 45 OPERATION........................................................................................... 46 GENERAL VIEW.................................................................................... 47 GENERAL VIEW OF MACHINE..................................................................... 47 GENERAL VIEW OF CONTROLS AND GAUGES......................................................... 48 EXPLANATION OF COMPONENTS....................................................................... 49 MONITOR PANEL............................................................................... 49 SWITCHES.................................................................................... 52 CONTROL LEVERS AND PEDALS................................................................... 56 FUSE........................................................................................ 62 ELECTRIC POWER TAKE-OUT ADAPTER............................................................. 63 DOOR-OPEN LOCK.............................................................................. 64 SASH GLASS INTERMEDIATE LOCK................................................................ 64 CAP,COVER WITH LOCK......................................................................... 65 DOOR POCKET................................................................................. 66 ASHTRAY..................................................................................... 67 LUNCHBOX HOLDER BELT........................................................................ 67 CUP HOLDER.................................................................................. 67 TOOL BOX.................................................................................... 68 GREASE PUMP HOLDER.......................................................................... 68 CAR STEREO,HANDLING......................................................................... 69 AIR CONDITIONER,HANDLING.................................................................... 77 OPERATION....................................................................................... 81 CHECK BEFORE STARTING ENGINE,ADJUST......................................................... 81 STARTING ENGINE............................................................................. 98 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................101 STOPPING ENGINE.............................................................................104 CHECK AFTER STOPPING ENGINE.................................................................104 MACHINE OPERATION...........................................................................105 SHIFTING GEAR...............................................................................109 SHIFTING BETWEEN FORWARD AND REVERSE........................................................110 STEERING MACHINE............................................................................111 PRECAUTIONS FOR OPERATION...................................................................114 WORK POSSIBLE USING BULLDOZER...............................................................116 PARKING MACHINE.............................................................................118 CHECK AFTER FINISHING WORK..................................................................120 LOCKING.....................................................................................120 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................121 TRANSPORTATION..................................................................................124 TRANSPORTATION MEANS........................................................................124 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT....................................................124 REMOVING CAB................................................................................124 LOADING,UNLOADING WORK......................................................................125 LIFTING MACHINE.............................................................................128 COLD WEATHER OPERATION..........................................................................129 PRECAUTIONS FOR LOW TEMPERATURE.............................................................129 AFTER COMPLETION OF WORK....................................................................131 AFTER COLD WEATHER..........................................................................131 LONG-TERM STORAGE...............................................................................132 BEFORE STORAGE..............................................................................132 DURING STORAGE..............................................................................132 AFTER STORAGE...............................................................................132 TROUBLESHOOTING.................................................................................133 AFTER RUNNING OUT OF FUEL...................................................................133 MACHINE TOWING METHOD.......................................................................133 IF BATTERY IS DISCHARGED....................................................................138 WHEN ENGINE DOES NOT STOP...................................................................142 OTHER TROUBLE...............................................................................143 MAINTENANCE.........................................................................................147 GUIDE TO MAINTENANCE............................................................................148 OUTLINE OF SERVICE..............................................................................151 OUTLINE OF OIL,FUEL,COOLANT.................................................................151 RELATING TO ELECTRIC SYSTEM.................................................................153 WEAR PARTS LIST.................................................................................154 WEAR PARTS LIST.............................................................................154 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................155 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS.............................................155 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................159 TORQUE LIST.................................................................................159 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................160 SAFETY CRITICAL PARTS.......................................................................161 MAINTENANCE SCHEDULE CHART......................................................................162 MAINTENANCE SCHEDULE CHART..................................................................162 SERVICE PROCEDURE...............................................................................164 WHEN REQUIRED...............................................................................164 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................164 CLEAN INSIDE OF COOLING SYSTEM..........................................................167 CHECK TRACK TENSION.....................................................................169 CHECK AND TIGHTEN TRACK SHOE BELT.......................................................171 CHECK ELECTRICAL INTAKE AIR HEATER......................................................171 REVERSE AND REPLACE END BITS AND CUTTING EDGES..........................................172 CHECK IDLER OIL LEVEL,ADD OIL...........................................................173 ADJUST IDLER CLEARANCE..................................................................174 ADJUST PLAY IN CENTER BALL..............................................................174 GREASE DOOR HINGE.......................................................................175 CHECK DOOR LOCK STRIKER.................................................................175 CHECK,ADJUST AIR CONDITIONER............................................................176 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID...............................................177 REPLACE WIPER BLADE.....................................................................177 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM..........................................179 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM...........................180 CHECK BEFORE STARTING.......................................................................181 EVERY 50 HOURS SERVICE......................................................................182 DRAIN WATER,SEDIMENT FROM FUEL TANK.....................................................182 EVERY 250 HOURS SERVICE.....................................................................183 LUBRICATING.............................................................................183 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL.............................................184 CHECK LEVEL OF BATTRY ELECTROLYTE.......................................................185 CHECK BRAKE PERFORMANCE.................................................................187 CLEAN AIR CONDITIONER AIE FILTER(FRESH/RECIRC FILTER)...................................188 EVERY 500 HOURS SERVICE.....................................................................189 REPLACE FUEL FILTER CARTRIDGE...........................................................189 CHANGE OIL ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE...........................192 REPLACE CORROSION RESISTER CARTRIDGE....................................................194 CLEAN,CHECK RADIATOR FINS AND OIL COOLER FINS...........................................194 EVERY 1000 HOURS SERVICE....................................................................196 CHANGE OIL IN FINAL DRIVE CASE..........................................................196 CHECK FAN BELT TENSION,ADJUST...........................................................197 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..............................................197 CHECK PLAY OF TURBOCHARGER ROTOR........................................................197 CHECK FOR LOOSE ROPS MOUNT BOLTS........................................................197 EVERY 2000 HOURS SERVICE....................................................................198 CHANGE OIL IN HYDRAULIC TANK,REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER....198 CLEAN,CHECK TURBOCHARGER................................................................199 CHECK VIBRATION DAMPER..................................................................199 CHECK ALTERNATOR,STARTING MOTOR.........................................................199 CHECK ENGINE VALVE CLEARANCE,ADJUST.....................................................199 EVERY 4000 HOURS SERVICE....................................................................200 CHECK WATER PUMP........................................................................200 SPECIFICATIONS......................................................................................201 SPECIFICATIONS..................................................................................202 ATTACHMENTS,OPTIONS.................................................................................203 GENERAL PRECAUTIONS.............................................................................204 PRECAUTIONS RELATED TO SAFETY...............................................................204 DELUXE SEAT.....................................................................................205 HEADREST........................................................................................206 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT...................................................207 INDEX...............................................................................................208
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
