Page 1 P092001 P092001 This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
Page 3 Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser.
Page 5 Crawler ............CLT80-1 Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America International Company Parts Inventory Processing System (PIPS).
Page 6 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM ö AND RETURN TO DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME PURCHASE ORDER NO. ö...
Page 7 INTRODUCTION D87E-2 D87P-2...
Page 8: Forward
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from Komatsu or your local distributor. If you sell the machine, be sure to give this manual to the new owner.
Page 9: Intended Use
The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety.
Page 10: Location Of Plates, Table To Enter P.i.n. And Distributor
INTRODUCTION LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR P.I.N. PLATE LOCATION The product identification number (PIN) is stamped on a plate attached to the front of the left console below the transmission controls. It is also stamped into the right rear top of the rear main frame.
Page 11: Engine Serial No. Plate Location
INTRODUCTION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. ENGINE SERIAL NO. PLATE LOCATION The engine serial number is stamped in a plate and mounted on the left side of the air cleaner mounting bracket D87E-2 D87P-2...
Page 12: Table Of Contents
INTRODUCTION TABLE OF CONTENTS INTRODUCTION FORWARD..................0-2 SAFETY INFORMATION.
Page 13 INTRODUCTION PRECAUTIONS FOR MAINTENANCE ............. . . 1-18 BEFORE CARRYING OUT MAINTENANCE .
Page 14 INTRODUCTION ELECTRICAL SYSTEM MASTER SWITCH ........... . 2-16 SEAT, SEAT BELT AND ARM RESTS .
Page 15 INTRODUCTION LOCKING ..................2-69 LEFT SIDE .
Page 16 INTRODUCTION OUTLINE OF OIL, FUEL, COOLANT ............. . 3-4 OIL .
Page 17 INTRODUCTION CHECK OIL LEVEL IN DRIVE TRAIN ............3-30 RADIATOR CORE .
Page 18 INTRODUCTION BLADE CUTTING EDGES AND END BIT BOLT TORQUE ........3-81 TRUNNION HARDWARE .
Page 19 SAFETY Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equipment and attachments. D87E-2 D87P-2...
Page 20: Warning Labels
SAFETY WARNING LABELS Always keep these labels clean. If they are lost or damaged, replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English.
Page 21 SAFETY NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. D87E-2 D87P-2...
Page 22 SAFETY 1. Operating machine 09651-03001 4. Adjusting track tension 09657-03003 2. Door caution 09967-03001 5. Hot oil hazard 09653-03001 3. Leaving operator’s seat 09654-13001 D87E-2 D87P-2...
Page 23 SAFETY 6. Moving in reverse 09802-13000 8. Operation during maintenance 09963-03000 9. Hot water hazard 09668-03001 10. Battery cable 09808-03000 7. Machine moving 09812-13000 11. Hood 09805-13000 D87E-2 D87P-2...
Page 24 SAFETY 12. Fuel tank 17A-98-32920 14. ROPS caution 737 993 C3 13. Seat belt use 195-98-12940 D87E-2 D87P-2...
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Page 26 SAFETY NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT LOCK UNLOCK D87E-2 D87P-2...
Page 27: General Precautions
UNAUTHORIZED MODIFICATION • Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification. CLOTHING AND PERSONAL PROTECTIVE ITEMS •...
Page 28: Mounting And Dismounting
SAFETY MOUNTING AND DISMOUNTING • Never jump on or off the machine. Never get on or off a moving machine. When mounting or dismounting, always face the machine and use the handrail, track shoes and track frame step. • Do not use the machines controls or hoses as hand holds when climbing on or off the machine.
Page 29: Asbestos Dust Hazard Prevention
• Do not use attachments that are not authorized by Komatsu or your local distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 30: Precautions During Operation
SAFETY PRECAUTIONS DURING OPERATION BEFORE STARTING ENGINE SAFETY AT WORK SITE • Before entering the operator's compartment, walk completely around the machine and clear the area of personnel and ob- structions. • Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous.
Page 31: Operating Machine
SAFETY OPERATING MACHINE WHEN STARTING ENGINE • Perform a visual check of the machine before starting the engine. Look for such things as missing protective devices, leaks, improper fluid levels, trash buildup and loose, damaged or missing parts. Do not start the engine until any unsafe conditions are corrected.
Page 32: Operate Carefully On Snow
SAFETY OPERATE CAREFULLY ON SNOW • When working on snow or icy roads, even a slight slope may cause the machine to slip to the side, so always travel at low speed and avoid sudden starting, stopping, or turning. • When there has been heavy snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be seen, so always carry out snow clearing operations carefully.
Page 33: Transportation
SAFETY T RANSPORTATION LOADING AND UNLOADING • Loading and unloading the machine always involves potential hazards. Extreme caution should be used. When loading or unloading the machine, run the engine at low idle and travel at low speed. • Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of a road.
Page 34: Battery
SAFETY BATTERY BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on your- self, immediately flush the area with water. • Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.
Page 35: Towing
SAFETY TOWING When Towing the Machine • Injury or death could result if a disabled machine is towed incorrectly. • If your machine is towed by another machine, always use a wire rope with a sufficient towing capacity. • Before the machine is towed, hydraulically release the secondary brake. •...
Page 36: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE BEFORE CARRYING OUT MAINTENANCE WARNING TAG • If others start the engine or operate the controls while you are performing service and/or lubrication, you could suf- fer serious injury or death. • Always attach the warning tag to the control lever in the operator’s cab to alert others that you are working on the machine.
Page 37 SAFETY NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE LOCK UNLOCK D87E-2 D87P-2 1-19...
Page 38: Periodic Replacement Of Safety Critical Parts
SAFETY PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS • Replace the following fire related components periodically: Fuel system: Fuel hose, spilling hose, and fuel tube cap Hydraulic system: Pump outlet hose, and front and rear pump branch hoses • Replace these components periodically with new ones, regardless of whether or not they appear to be defective. These com- ponents deteriorate over time.
Page 39: During Maintenance
SAFETY DURING MAINTENANCE PERSONNEL • Only authorized personnel can service and repair the machine. Extra precautions should be used when grinding, welding, and using a sledge hammer. ATTACHMENTS • Place attachments that have been removed from the machine in a safe place so that they do not fall. If they fall on you or others, serious injury could result.
Page 40: Precaution With High Pressure Oil
SAFETY PRECAUTION WITH HIGH PRESSURE OIL • Do not forget that the work equipment circuits are always under pressure. • Do not add oil, drain oil, or carry out maintenance or inspection before com- pletely releasing the internal pressure. • If you are hit by a jet of high pressure oil, consult a doctor immediately for med- ical attention.
Page 41 OPERATION D87E-2 D87P-2...
Page 42: General
OPERATION GENERAL VIEW OF MACHINE D87E-2 D87P-2...
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Page 44: Views Of Controls And Gauges
OPERATION VIEWS OF CONTROLS AND GAUGES NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. Instrument Panel Left Side Controls Right Side Controls D87E-2 D87P-2...
Page 45 OPERATION VIEWS OF CONTROLS AND GAUGES Instrument Panel Foot Pedals Left Side Controls Right Side Controls Cab Controls D87E-2 D87P-2...
Page 46: Universal Symbols
OPERATION UNIVERSAL SYMBOLS Universal symbols are used to pictorially identify various instruments and controls. These symbols are an effort to overcome language differences for all operators in a positive way, thus enhancing their safety through quicker recognition of the instru- ments and controls while operating the equipment.
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Page 48 OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. GAUGES AND WARNING LIGHTS Fuel Gauge 7. Converter Temperature Warning Light 13. Engine Oil Pressure Gauge Engine Coolant Warning Light 8. Drive Train Oil Pressure Warning Light 14.
Page 49: Explanations Of Components
OPERATION EXPLANATIONS OF COMPONENTS GENERAL This area of the section covers the location and function of the various instruments and controls of this machine. In the case of controls, more detailed information regarding operation can be found in the following text within this section. Regardless of previous experience as an operator, you must be thoroughly familiar with the location and use of all instruments and controls before operating this machine.
Page 50: Fuel Gauge
OPERATION FUEL GAUGE The fuel gauge (1) indicates the amount of fuel in the fuel tank. After each days operation, be sure to fill the fuel tank. F. Indicates that the tank is full. E. Indicates there is less than 17 L (4.5 gal) of fuel remaining in the tank, so add fuel.
Page 51: Equipment Filter Warning Light
OPERATION EQUIPMENT FILTER WARNING LIGHT The equipment filter warning light (9) will glow amber when the oil fil- ter element reaches the maximum allowable restriction. When this hap- pens, filter element service is required. ENGINE COOLANT TEMPERATURE GAUGE This gauge (10) registers the temperature of the coolant circulating thru the engine.
Page 52: Engine Oil Pressure Gauge
OPERATION ENGINE OIL PRESSURE GAUGE The gauge (13) registers the pressure at which the lube oil is circulated through the engine. The pointer must register in green area immediately upon engine starting and when the engine is operated at full load speeds. HOURMETER The hourmeter (14) electrically records the actual hours of engine oper- ation.
Page 53: Gear Indicator
OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. GEAR INDICATOR The gear indicator (17) indicates the transmission range in the left hand vertical row of three (3) green lights. One (1) of the three (3) lights will always be on.
Page 54: Switches
OPERATION SWITCHES KEY START SWITCH This switch (1) is used to start or stop the engine. It has four key posi- tions. R1 position This position is used to check bulbs, warning lights and the audible alarm. OFF position The key can be inserted or removed. The switches for the electric system, except the lighting circuits, are all turned off and the engine is stopped.
Page 55: Work Light Switch
OPERATION WORK LIGHT SWITCH The work light switch is a rocker type switch. Activation of the switch turn on the work lights. Left switch (3) Cab front and rear lights Right switch (2) Hood level and rear fuel tank light Remark The lighting circuits can be operated with the starting key switch in OFF position and master disconnect switch in the...
Page 56: Electrical System Master Switch
OPERATION ELECTRICAL SYSTEM MASTER SWITCH Turn the key clockwise to connect the battery ground circuit. Turn the key counterclockwise to disconnect the battery ground circuit. Remark Keep the switch on while the engine is running. 2-16 D87E-2 D87P-2...
Page 57 OPERATION CAB SWITCHES Control Panel The control panel is located below the left window rearward of the left entry door. Door Wiper and Washer Switch This three position push in switch is used to activate the door wiper and washer systems. Push the switch knob in to employ the washer system.
Page 58 OPERATION Operator Environment Switch This seven position switch is used to control the amount of heated or cooled air delivered in the cab. OFF -When in this position the blower fans are off. Heater Positions HI When in this position, a maximum amount of heated air is cir- culated through the cab.
Page 59 OPERATION Cab Interior Light Switch The interior light incorporates a push type switch for on/off operation. To turn the light on push in the switch, to turn the light off push in the switch. D87E-2 D87P-2 2-19...
Page 60: Seat, Seat Belt And Arm Rests
OPERATION SEAT, SEAT BELT AND ARM RESTS SEAT This seat can be adjusted using the following seven functions. • Adjust the seat position at the beginning of each shift or when opera- tors change and fasten the seat belt. • Adjust the seat so that the brake pedal can be depressed all the way with the operator’s back against the seat back rest.
Page 61: Seat Belt
OPERATION SEAT BELT • Before driving the machine, adjust the seat and fasten the seat belt. Adjust the seat belt to fit snugly and low around the hips to lessen the chance and severity of injury in the event of an accident. Never wear the seat belt across the abdomen.
Page 62: Fuel Control Lever
OPERATION CONTROL LEVERS NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. Left Side Controls Right Side Controls Fuel Control Lever Transmission/Steering Lever Blade Control Lever Safety Lock Lever Not used Ripper Control Lever FUEL CONTROL LEVER This lever (1) is used to control the engine speed and output.
Page 63: Control Levers
OPERATION CONTROL LEVERS Left Side Controls Right Side Controls Fuel Control Lever Transmission Lever Blade Control Lever Safety Lock Lever Steering Levers Ripper Control Lever FUEL CONTROL LEVER This lever (1) is used to control the engine speed and output. Engine Shut Off (First notch forward) Low Idle (Second notch forward) Mid Range Idle (4th or 5th notch)
Page 64: Transmission Lever
OPERATION TRANSMISSION LEVER The lever (3) is used to select the transmission direction and various gear ranges. Remark When the shift lever is put in any one of the reverse posi- tions, the back up alarm will automatically sound STEERING LEVERS These levers (4) steer the machine by supplying an additional speed range to either track for gradual turns with power to both tracks.
Page 65: Transmission/Steering Lever
OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. TRANSMISSION/STEERING LEVER The transmission/steering lever (3) is used to select direction, range gear, and high or low steering clutches. Center position of the transmission/steering lever (3) is neutral. Move the safety lock lever to the UNLOCK position.
Page 66: High Or Low Steering Range And Power Turns
OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. High or Low Steering Range and Power Turns The four (4) buttons on the transmission/steering lever control the two- speed steering clutches in the steering drive. Move the transmission/steering lever from neutral (center) to a drive position for steering range and power turn functions.
Page 67: Ripper Control Lever
OPERATION RIPPER CONTROL LEVER This lever (6) controls all operation of the ripper; raise, hold, lower, pitch forward and pitch aft. Remark Holding the lever in any position except HOLD for an ex- tended period of time after the cylinder rod has reached its limit of travel will produce excessive heat in the hydraulic sys- may affect equipment performance.
Page 68: Cab Controls
OPERATION CAB CONTROLS Outer Door Handle Insert key and unlock the door. Depress the handle button and rotate the door rearward to secure with the door hold open latch. Door Hold Open Latch This latch will catch and hold the door open when the door is rotated rearward and contact is made.
Page 69: Locking Cap
OPERATION LOCKING CAP The fuel (1) and hydraulic (2) tank filler ports are each equipped with a locking cap. Use the start switch key to lock and unlock the cap. OPENING Move lock cover back and insert key into the cap. Ensure that the key is fully inserted up to its shoulder before turning.
Page 70: Operation
OPERATION OPERATION CHECKS BEFORE STARTING ENGINE GROUND LEVEL INSPECTION Dirt, oil or fuel around parts of the engine which reach high tempera- tures may cause fire and damage to machine. Check carefully, and if any abnormality is found, always repair it or contact your distributor. Before starting the engine, look around the machine and under the ma- chine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
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Page 72 OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-32 D87E-2 D87P-2...
Page 73: Check Before Starting
OPERATION CHECK BEFORE STARTING Check and Refill Coolant Do not remove cap while coolant is hot. Hot coolant may spurt out. When removing cap, wait until the coolant temperature goes down and release radiator pressure little by little by loosening slowly, then remove the cap.
Page 74 OPERATION After completing work, fill the fuel tank through the filler port. • For details of locking cap, see “LOCKING CAP” on page 2-29. • For details of the fuel to use, see “USE OF FUEL, COOLANT AND LUBRICANTS” on page 3-7. After adding fuel, tighten the cap securely.
Page 75 OPERATION Check Oil Level in Drive Train, Add Oil Open the rear access door. Unscrew the T handle of the oil level gauge, remove the gauge and wipe it clean. Insert the gauge fully into the filler sleeve. Do not tighten. Remove gauge and check the lubricant level.
Page 76 OPERATION Check Decelerator Pedal Travel Measure the distance (A) from pedal full height to stop bolt posi- tion, at center of pedal, 53 mm (2.1 in) at 850 ± 50 rpm at stop bolt. If not within these criteria consult your distributor. Check Oil Level in Hydraulic Tank, Add Oil Pressurized Reservoir.
Page 77 OPERATION Please contact your distributor for investigation and correction of the cause. Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fire, so always check and remove such material. When performing walk around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material.
Page 78: Operations And Checks Before Starting Engine
OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE If any of the control levers are touched by accident, the work equip- ment or the machine may move suddenly. When leaving the operator’s compartment, always set the safety lever securely to the LOCK posi- tion.
Page 79 OPERATION OPERATIONS AND CHECKS BEFORE STARTING ENGINE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. D87E-2 D87P-2 2-39...
Page 80 OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-40 D87E-2 D87P-2...
Page 81 OPERATION Insert the key in the starting switch and turn to the R1 position. Check all warning lights for illumination and audible alarm for sound when the key in the start switch is in the R1 position. If warning light does not illuminate or alarm does not sound, check for abnormality.
Page 82 OPERATION 10. Press the horn switch and check that the horn sounds. 11. Clutch pressure light, oil pressure light, and visual warning light re- main illuminated and audible alarm will sound in this key-on and engine-off condition. NOTE: his added illustration shows the differ- ences for machines equipped with Single Lever Transmission/Steering Control.
Page 83: Starting Engine
OPERATION STARTING ENGINE Remark This engine cannot be started by towing, pushing or coasting the machine. Before entering the operator’s area walk completely around the ma- chine and clear the area of personnel and obstructions. • Understand all control functions before starting the engine. Sound the horn.
Page 84: Cold Weather Starting
OPERATION Turn the start switch key to the START position and release the key the instant the engine starts. The key will automatically return to the ON position. COLD WEATHER STARTING Never use starting aid fluids as they may cause explosions. Move the fuel control lever to the full speed position (A).
Page 85 OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. COLD WEATHER STARTING D87E-2 D87P-2 2-45...
Page 86 OPERATION Carry out preheating. There are the following two ways of carrying out preheating. First use the convenient automatic preheating system. Automatic Preheating Turn grid heater timer switch (4) to the AUTO position. When the switch is turned to the AUTO position, preheating is automatically car- ried out according to the ambient temperature.
Page 87 OPERATION When the preheating is completed, turn the start switch key to the START position to start the engine. When the engine starts, release the start switch key. The key will re- turn automatically to the ON position. Remark To prevent damage to the starter motor and avoid low battery output, do not continuously crank the engine for more than 30 second intervals.
Page 88: Operations And Checks After Engine Starts
OPERATION OPERATIONS AND CHECKS AFTER ENGINE STARTS After starting the engine, do not immediately start any operations. First, carry out the following operations and checks. Remark Avoid abrupt acceleration until warm up run is completed. Do not run the engine at low idle or high idle for more than 20 minutes.
Page 89 OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. NORMAL OPERATION D87E-2 D87P-2 2-49...
Page 90: Cold Operation
OPERATION COLD OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-50 D87E-2 D87P-2...
Page 91 OPERATION COLD OPERATION Pull throttle lever to the center position between low and high idle and run the engine at medium speed for about 10 minutes with no load. Operate blade control lever to the full raise position, then keep the blade raised to the maximum height and continue to relieve the cir- cuit for 10 minutes.
Page 92: Moving The Machine
OPERATION MOVING THE MACHINE • When moving the machine, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Clear all obstacles from the path of the machine.
Page 93 OPERATION MOVING THE MACHINE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. Rotate (twist) the transmission/steering control lever to one of three rotary detent (mechanical) positions for transmission range gear se- lection. • Counter-clockwise rotation to the 1st gear detent;...
Page 94: Shifting The Transmission
OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. SHIFTING THE TRANSMISSION Center position of the transmission/steering lever is neutral. Move the safety lock lever to the UNLOCK position. This action sup- plies oil to the transmission/steering lever control valve making it oper- ational.
Page 95 OPERATION SHIFTING THE TRANSMISSION The three speeds of the transmission, controlled by lever (1) and the high and low speed ranges of the steering drive, controlled by levers (2), provide six speeds for both forward and reverse travel. With the steering levers in low range and the transmission shift lever in the (1-2) speed position, the machine can be put into second speed by moving the steer- ing levers into high range.
Page 96: Downgrade Operation
OPERATION DOWNGRADE OPERATION When operating down hill, always put the transmission in the low range position. Use the brake pedal to slow the machine. Never go down hill with the transmission controls in neutral. Failure to do so could result in losing control of the machine and a rollover could result.
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Page 98: Stopping The Machine
OPERATION STOPPING THE MACHINE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-58 D87E-2 D87P-2...
Page 99 OPERATION STOPPING THE MACHINE • Avoid stopping suddenly. Give yourself ample room when stopping. • When stopping the machine, select flat hard ground and avoid dan- gerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground.
Page 100: Precautions For Operation
OPERATION PRECAUTIONS FOR OPERATION PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of the carrier roller above the surface of the water. Also, be careful that the engine cooling fan will not come in contact with water. The fan can be damaged. WHEN TRAVELING UP OR DOWN HILLS Use Engine as a Brake When going downhill, shift the transmission lever into 1st speed to run...
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Page 102: Parking The Machine
OPERATION PARKING THE MACHINE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-62 D87E-2 D87P-2...
Page 103 OPERATION PARKING THE MACHINE • Avoid stopping suddenly. Give yourself ample room when stopping. • When stopping the machine, select flat hard ground and avoid dan- gerous places. If it is unavoidably necessary to park the machine on a slope, insert blocks underneath the track shoes. As an additional safety measure, thrust the blade into the ground.
Page 104: Check After Finishing Work
OPERATION CHECK AFTER FINISHING WORK Check all the gauges for proper operation. Check all the warning lights so that none are illuminated 2-64 D87E-2 D87P-2...
Page 105 OPERATION CHECK AFTER FINISHING WORK NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. D87E-2 D87P-2 2-65...
Page 106: Stopping The Engine
OPERATION STOPPING THE ENGINE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 2-66 D87E-2 D87P-2...
Page 107 OPERATION STOPPING THE ENGINE Remark If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from a emergency. In particu- lar, if the engine has overheated, do not abruptly stop it but run it at medium speed (1/2 throttle) to allow it to cool gradu- ally, then stop it.
Page 108 OPERATION Turn the key switch to the off position and remove. Remove the key from the master switch. 2-68 D87E-2 D87P-2...
Page 109: Checks After Stopping Engine
OPERATION CHECKS AFTER STOPPING ENGINE Walk around the machine and check the work equipment and un- dercarriage, and check also for leakage of oil or water. If any abnor- malities are found, repair them. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 110: Work Possible Using Mounted Equipment
OPERATION WORK POSSIBLE USING MOUNTED EQUIPMENT In addition to the following, it is possible to further increase the range of applications by using various attachments. DOZING A dozer digs and transports dirt in a forward direction. Slope excavation can always be most effectively carried out by proceeding from the top downward.
Page 111: Mounted Equipment
OPERATION MOUNTED EQUIPMENT SEMI U DOZER - D87E-2 GENERAL In addition to raising or lowering, the blade can be hydraulically tilted or manually pitched. BLADE TILT Equal Tilt 1. Right Tilt 2. Left Tilt Remark Equal tilt is accomplished in the normal blade position, when the back of the blade is perpendicular (90°) to the ground and the blade cutting edge is 52°...
Page 112: Straight Angle Dozer - D87E-2
OPERATION STRAIGHT ANGLE DOZER - D87E-2 ANGLING BLADE • When adjusting the angle, it is dangerous if the work equipment is moved by mistake. Set the work equipment in a safe condition, then stop the engine. • Be careful when removing the upper/lower strut. After the 2nd up- per/lower strut is removed the blade can move freely on its center hinge.
Page 113: Tilting The Blade
OPERATION Angle to Straight Raise blade 400 to 500 mm (15.8 to 19.7 in) above ground, then put blocking under the C frame. Make sure that all of the load is off of the upper struts before the lower strut is removed from the C frame bracket. Remove the pin securing the forward upper/lower strut to C frame and remove strut from mounting bracket swing out all the way.
Page 114: Levelling Blade
OPERATION Mechanical Tilt Raise blade 400 to 500 mm (15.8 to 19.7 in) above ground, then put blocking under the C frame. Make sure that all of the load is off of the upper struts before the lower strut is removed from the C frame bracket. Remove the strut trunnion from its bracket on the side to be raised, and position strut close to the C frame.
Page 115 OPERATION Remove the locking pins and adjust both upper struts so that the gap between the shoulder of the eyebolt and strut body is 39 mm (1.53 in) on each end. This will position the blade in its neutral tilt position.
Page 116: Straight Dozer - D87P-2
OPERATION STRAIGHT DOZER - D87P-2 GENERAL In addition to raising or lowering, the blade can be hydraulically tilted or manually pitched. BLADE TILT Equal Tilt 1. Right Tilt 2. Left Tilt Remark Equal tilt is accomplished in the normal blade position, when the back of the blade is perpendicular (90°) to the ground and the blade cutting edge is 52°...
Page 117: Ripper
OPERATION RIPPER • The optimum digging angle for the shank is when the shank is per- pendicular to the ground. • In comparatively soft rock, it is also possible to carry out ripping with the shank tilted to the rear. •...
Page 118: Tips For Longer Undercarriage Life
OPERATION TIPS FOR LONGER UNDERCARRIAGE LIFE Undercarriage life varies greatly depending on operation method, in- spection and maintenance. Track components have a certain dimension when new. As wear occurs dimensions will decrease (or increase in case of track pitch and front idler flange height) until a decision must be made wheth- er to rebuild or recondition components, replace them or run them to de- struction.
Page 119: Inspection And Adjustment
OPERATION INSPECTION AND ADJUSTMENT Properly adjust track tension. Tension should be measured at clearance shown in the diagram - usually 50 to 63 mm (2 to 2.5 in) at this point. For rocky terrain, tighten tracks slightly. In clay or sandy areas, slightly loosen them.
Page 120 OPERATION Measuring Height of Grouser Clean off all materials on the shoe plate and grouser tops. Lay a squeeze bar across grousers approximately 1/4 of way in from the end of the shoe. Insert a 305 mm (12 in) scale in the squeeze bar so that the scale is against the top of the track plate and take a reading.
Page 121: Utility Box
OPERATION UTILITY BOX An utility box is located at the right side of the machine utilized as an operator’s compartment step. It can be used to hold a variety of useful things and can be pad locked when not in use. To open, remove pad lock, pull down on the handle (1) and lift up on the deck plate (2).
Page 122: Transportation
When raising the machine, if the rope is not fixed properly, the machine may slip and cause a serious accident or injury. The weight table given below shows the weights of the machine manu- factured by Komatsu when it is shipped from the factory. D87E-2 Semi U Dozer D87E-2 Angle Dozer D87P-2...
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Page 124: Securing The Machine
OPERATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. SECURING THE MACHINE 2-84 D87E-2 D87P-2...
Page 125 OPERATION Method of fitting rope. After fitting the rope, raise the machine 100 to 200 mm (4 to 8 in) and check that there is no slack in the wire cable and that the ma- chine is being raised horizontally. If any points are unclear, please contact your local distributor for advice.
Page 126: Precautions
OPERATION Turn the starting switch key to the OFF position to stop the engine. Remove the key. Turn the master disconnect switch to OFF and remove key. To avoid machine slippage, secure it tightly as follows. A. Put blocks in front and behind the track shoes of both sides. B.
Page 127: Cold Weather Operations
OPERATION COLD WEATHER OPERATIONS PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows: FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. •...
Page 128: After Completion Of Work
OPERATION Measure the specific gravity and calculate the rate of charge from the following conversion table. Fluid temp 20°C 0°C -10°C -20°C Charge rate (68°F) (32°F) (14°F) (-4°F) 100% 1.28 1.29 1.30 1.31 1.26 1.27 1.28 1.29 1.24 1.25 1.26 1.27 1.23 1.24...
Page 129: Long Term Storage
OPERATION LONG TERM STORAGE BEFORE STORAGE If possible, prepare the machine for long term storage outdoors. If this must be done indoors, open doors and windows for ventilation to pre- vent carbon monoxide poisoning. When putting the machine in storage for a long time, do as follows: •...
Page 130: Troubleshooting
OPERATION TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting after running out of fuel, fill with fuel, then fill the fuel filter cartridge with clean fuel and bleed the air from the fuel system be- fore starting. For details of bleeding the air, see “REPLACE FUEL FIL- TER CARTRIDGE”...
Page 131 OPERATION Disconnect the negative cable (1) from rear battery. Disconnect the positive cable (2) from the front battery. Disconnect and re- move cross over cable (3) from each battery. Remove front long bolts (4) then single rear bolt and retainer plate (5). Remove batteries from compartment.
Page 132 OPERATION Connecting With Booster Cables Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 133: Other Trouble
OPERATION OTHER TROUBLE Always contact your distributor when handling these items. • In cases of abnormalities or causes which are not listed below, please contact your distributor for repairs. ELECTRICAL SYSTEM PROBLEM MAIN CAUSE REMEDY • Defective wiring ....{Check, repair loose terminals, discon- Voltmeter does not register charge when nections}...
Page 134: Chassis
OPERATION CHASSIS PROBLEM MAIN CAUSE REMEDY • Oil pressure of drive train is not raised When transmission lever is moved to the Insufficient oil in system Add oil to specified level, see “CHECK desired position, machine does not start OIL LEVEL IN DRIVE TRAIN” on or traveling speed is low page 3-30 When transmission steering lever is...
Page 135: Engine
OPERATION ENGINE PROBLEM MAIN CAUSE REMEDY • Engine oil pan level is low ..Add oil to specified level, see “CHECK ENGINE CRANKCASE OIL LEVEL” on page 3-23 Engine oil pressure warning light • Clogged oil filter element ..Replace element, see “DRIVE TRAIN PRES- remains lit when engine speed is SURE FILTER”...
Page 136: Methods Of Towing Machine
OPERATION METHODS OF TOWING MACHINE • When using a chain or cable, be sure it is strong enough for the ex- pected load and it is properly secured to the drawbar pins, ripper toolbeam or tow hook. • When pulling with a chain or cable, take up the slack slowly to avoid jerking.
Page 137: Maintenance
MAINTENANCE D87E-2 D87P-2...
Page 138: Guides To Maintenance
Use Komatsu genuine parts specified in the Parts Book list as replacement parts. Komatsu genuine oils: • Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. • For details of the fluid to use, see “USE OF FUEL, COOLANT AND LUBRICANTS” on page 3-7 Clean oil and grease: •...
Page 139 MAINTENANCE Welding instructions: • Turn off the engine starting switch and master switch. • Do not apply more than 200 V continuously. • Connect the ground cable within 1 m (3.28 ft) from the area to be welded. • Avoid seals or bearings from being between the area to be welded and the position of grounding point. Fire prevention: •...
Page 140: Outlines Of Service
MAINTENANCE OUTLINES OF SERVICE • Use Komatsu genuine parts for replacement. • When changing or adding oil, do not use a different type of oil. • Unless otherwise specified, the oil and coolant used at the time of shipment from the factory are as shown in the table below.
Page 141: Coolant
Never remove or disassemble any electric components installed in the machine. Never install any electric components other than these specified by Komatsu. Be careful to keep the electric system free of water when washing the machine or when it rains. When working on the seashore, carefully clean the electric system to prevent corrosion. Never connect any optional power source to the fuse, starting switch, battery relay, etc.
Page 142: Wear Parts List
MAINTENANCE WEAR PARTS LIST Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits. The wear parts should be changed correctly in order to use the machine economically. For part change, Komat- su genuine parts of excellent quality should be used.
Page 143: Use Of Fuel, Coolant And Lubricants
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS It is not our policy to approve lubricants or to guarantee oil performance in service. The responsibility of quality of the lubri- cant must remain with the supplier of the lubricant. When in doubt consult your distributor. The lubricants specified for this machine are shown below.
Page 144: Abbreviations
Komatsu gear lube or multi purpose gear lube, see “FINAL DRIVE OIL OR PIVOT SHAFT HOUSING SPEC- IFICATIONS” on page 3-9. Komatsu super grease or multi purpose grease 251 HEPM or NLGI grade #2 multi purpose lithium grease with 3 to 5% MoS (molybdenum disulfide).
Page 145: Arctic Operation
For service only of the track front idlers, track rollers and top idlers, optionally use Komatsu Hydraulic Fluid or engine oil with an API classification of CD/CC, CD or MIL-L-2104D or E and meeting C-3 and TO-2 and containing 0.10% zinc minimum.
Page 146: Cooling System
MAINTENANCE COOLING SYSTEM GENERAL The cooling system operates under pressure which is controlled by the pressure relief valve in the radiator cap. The belt driven water pump circulates the coolant through the engine block, cylinder heads, radiator, and engine oil cooler. Circulation is con- trolled by the thermostat which by passes coolant flow around the radiator until the engine reaches operating temperature.
Page 147: Inhibitors/Conditioners
MAINTENANCE Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and goggles and keep face away from the filler neck. Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection against freezing.
Page 148: Fuel System
MAINTENANCE FUEL SYSTEM GENERAL Cleanliness of diesel fuel determines the service life of the fuel injection components. Water and contaminants, allowed to reach precision injection components, cause rapid wear and poor performance. Clean fuel and regular servicing of the fuel tank and fuel filtering components are necessary for long service life.
Page 149: Standard Tightening Torques
MAINTENANCE STANDARD TIGHTENING TORQUES INTRODUCTION OF NECESSARY TOOLS The following tools are needed when carrying out maintenance. Name of tool Part No. Description Width across flats - S Open end wrench - 8x10 mm Open end wrench - 12x14 mm 1.
Page 150: Bolt Identification Chart
MAINTENANCE BOLT IDENTIFICATION CHART TYPE/CLASS DESCRIPTION HEAD MARK Type 5 Three radial lines on top and none on side of head. Medium carbon steel quenched Inch Thread and tempered. Type 5.2 Three radial lines on top and none on side of head. Low carbon boron steel Inch Thread quenched and tempered.
Page 151: Grade 5 And 8 Non-Phosphate Coated Hardware
MAINTENANCE GRADE 5 AND 8 NON-PHOSPHATE COATED HARDWARE Recommended torque for all standard application nuts and bolts, provided; all thread surfaces are clean and lubricated with SAE-30 engine oil or joints are rigid, that is, no gaskets or compressible materials are used. When reusing nuts or bolts, use minimum torque values.
Page 152: Grade 8 Phosphate Coated Hardware
MAINTENANCE GRADE 8 PHOSPHATE COATED HARDWARE STANDARD TORQUE ± 10% This chart provides tightening torque for general purpose NOMINAL applications using original equipment standard hardware as THREAD lbf ft • listed in the Parts Books for the machine involved. 5/16 DO NOT SUBSTITUTE.
Page 153: Hydraulic Tubes And Fittings
MAINTENANCE HYDRAULIC TUBES AND FITTINGS The torque figures are recommended for plain, cadmium or zinc plated fittings, dry or wet installations. Swivel nuts either swaged or brazed. Figures are for tube nuts used with 37° flared fittings and JIC - 37° seat o-ring boss plugs and swivel nuts. Tube Nuts O-ring Boss Plugs And Swivel Nuts For 37°...
Page 154: Periodic Replacement Of Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of the parts given in the table on the next page.
Page 155: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE INITIAL 10 HOURS SERVICE 1. Check torque of blade cutting edge and end bit hardware ..........3-22 2.
Page 156 MAINTENANCE EVERY 250 HOURS SERVICE SERVICE ITEM PAGE EVERY 250 HOURS SERVICE 1. Check alternator and engine fan belt tension ............3-44 2.
Page 157 MAINTENANCE SERVICE ITEM PAGE WHEN REQUIRED 1. Clean or replace air cleaner elements (per indicator) ........... . 3-65 2.
Page 158: Service Procedure
MAINTENANCE SERVICE PROCEDURE INITIAL 10 HOURS SERVICE BLADE CUTTING EDGE HARDWARE Check the torque of the blade cutting edge and end bit hardware. Plow bolt nuts 725 N•m (535 lbf ft) TRACK SHOE BOLT TORQUE The bolts used for attaching the track shoes to the tracks are heat treated alloy bolts and will stand a considerable tightening strain.
Page 159: Every 10 Hours Service
MAINTENANCE EVERY 10 HOURS SERVICE CHECK RADIATOR COOLANT LEVEL • Hot, scalding coolant can spray out if the radiator cap is removed suddenly. Relieve system pressure by slowly turning the cap to the first notch or lifting the safety lever (if equipped). Remove the cap only after the pressure is relieved.
Page 160: Check Oil Level In Hydraulic Tank
MAINTENANCE Check the oil level. For an accurate reading wait for the oil to drain into the crankcase pan. Open hood access door. Remove the oil level gauge (1) and wipe it clean. Reinsert the gauge completely. Remove the gauge and check the oil level. If the level is at or below the L mark, add oil through the filler opening (2) to bring the level up to the H mark on the gauge.
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Page 162: Fill Fuel Tank
MAINTENANCE FILL FUEL TANK NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 3-26 D87E-2 D87P-2...
Page 163: Cab Glass
MAINTENANCE FILL FUEL TANK When adding fuel, never let the fuel overflow. This may cause a fire. If spilling fuel, thoroughly clean up any spillage. Check the fuel level using fuel gauge. After completing work, fill the fuel tank through the filler port. •...
Page 164: Instrument Panel
MAINTENANCE INSTRUMENT PANEL Thoroughly clean the faces of the gauges and warning lights. WINDOW WASHER RESERVOIR Open the left engine access door. Remove cap and fill washer fluid. In- stall cap when filled. AIR CLEANER CAP The dome of the air cleaner cap serves as a rain shield and prevents chaff and course dirt from getting into the air cleaner.
Page 165 MAINTENANCE INSTRUMENT PANEL NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. D87E-2 D87P-2 3-29...
Page 166: Every 50 Hours Service
MAINTENANCE EVERY 50 HOURS SERVICE • Perform maintenance for every 10 hours of service at this time. CHECK OIL LEVEL IN DRIVE TRAIN Open the rear access door. Unscrew the T handle of the oil level gauge, remove the gauge and wipe it clean. Insert the gauge fully into the filler sleeve.
Page 167 MAINTENANCE Adjusting Tension The track chains are adjusted by hydraulic pressure. When lubricant is introduced into the front idler fork through the lubrication fitting, it acts upon the piston within the front idler fork forcing the front idler fork and front idler forward for track adjustment. To avoid possible injury, always stand to the side of the bleeder plug when making track adjustment.
Page 168: Lubrication
MAINTENANCE LUBRICATION Blade Equipment 10 FITTINGS Apply grease until clean lubricant is visible. Always use a clean lubrica- tor and wipe dirt from fittings before fresh grease is applied. If grease fails to go through the fitting, determine the cause and correct it. After greasing, wipe off any old grease that was purged.
Page 169: Initial 250 Hours Service
MAINTENANCE INITIAL 250 HOURS SERVICE DRIVE TRAIN PRESSURE FILTER Remark If the pressure filter indicator light on the instrument panel, remains on at operating oil temperature with the engine run- ning, the pressure filter must be changed. With the engine stopped, operate the transmission and steering le- vers several times to relieve any pressure.
Page 170: Change Drive Train System Oil
MAINTENANCE CHANGE DRIVE TRAIN SYSTEM OIL When working under the machine, turn off the electrical system master switch and tag the controls to warn against starting the machine. Remove the drain plug immediately after operation while the lubri- cant is still warm. Drain into a suitable container. After the system has been completely drained, reinstall and tighten the drain plug.
Page 171 MAINTENANCE Remove the four hex nuts and separate the housing (7) from the base (1). Pull out the element (4) with o-ring (3) from the housing (7). Remove the ceramic magnets (8) and clean the magnets with a clean soft cloth, do not rap the magnets. Wash the element (4), spring (5) and housing (7) in a nonflammable commercial cleaning solvent.
Page 172: Equipment System Pilot Filter
MAINTENANCE EQUIPMENT SYSTEM PILOT FILTER Remark If the filter indicator light on the instrument panel, remains on at operating oil temperature with the engine running, the filter cartridge must be changed. With the engine stopped, operate the equipment levers several times to relieve any pressure.
Page 173: Equipment System Return Filter
MAINTENANCE EQUIPMENT SYSTEM RETURN FILTER Remark If the filter indicator light on the instrument panel, remains on at operating oil temperature with the engine running, the filter cartridge must be changed. With the engine stopped, operate the equipment levers several times to relieve any pressure.
Page 174: Change Equipment System Oil
MAINTENANCE CHANGE EQUIPMENT SYSTEM OIL Start the engine and operate the blade to warm the oil for easy draining. Park the machine on level ground, lower blade and ripper equipment to the ground. Stop the engine. Shift to neutral and apply the lock lever.
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Page 176 MAINTENANCE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 3-40 D87E-2 D87P-2...
Page 177: Replace Fuel Filter Cartridge
MAINTENANCE Clean the strainer with a nonflammable commercial cleaning sol- vent. Install the strainer in the reservoir and mount reservoir top cover with new o-ring to reservoir. Remark The strainer does not have to be disassembled for cleaning. Fire hazard - do not use kerosene, diesel fuel or flammable liquids to clean parts.
Page 178 MAINTENANCE With the engine stopped, open the left engine side door. Position a catch container under the fuel filter cartridges (1). Loosen the plug (2) at the bottom of cartridge and drain fuel. Before loosening the filter, clean the filter head to prevent dirt or foreign material from entering the system.
Page 179: Engine Valve Clearance
MAINTENANCE 10. After replacing the fuel filter cartridge, loosen the air bleed plug (3). 11. Loosen the knob of fuel feed pump (4), then operate it up and down until no more bubbles come out with the fuel from air bleed plug. Tighten air bleed plug (3), then push in the knob of feed pump and tighten it.
Page 180: Every 250 Hours Service
MAINTENANCE EVERY 250 HOURS SERVICE • Perform maintenance for every 10 and 50 hours of service at this time. ENGINE FAN AND ALTERNATOR BELT Check The belt should normally deflect by 6 to 10 mm (0.24 to 0.39 in) when pressed with the finger, with ≈...
Page 181: Reversible Fan
MAINTENANCE Diagonal Strut Joints 1 FITTING Apply grease until clean lubricant is visible. Always use a clean lubrica- tor and wipe dirt from fittings before fresh grease is applied. If grease fails to go through the fitting, determine the cause and correct it. After greasing, wipe off any old grease that was purged.
Page 182 MAINTENANCE After all the oil is drained, close the drain valve (4), remove hose (3) and install drain plug (2). Drain valve ....58 to 78 N•m (43 to 57 lbf ft) Drain plug .
Page 183 MAINTENANCE Add engine oil through oil filler (1) until the oil level is between the H and L marks on the dipstick (2). • For details of the oil to use, see “USE OF FUEL, COOLANT AND LUBRICANTS” on page 3-7. Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H and L marks on the dip- stick.
Page 184: Every 500 Hours Service
MAINTENANCE EVERY 500 HOURS SERVICE • Perform maintenance for every 10, 50 and 250 hours of service at this time. REPLACE FUEL FILTER CARTRIDGE • Park the machine on level ground, stop the engine, lower all mounted equipment to the ground, apply the safety lock, apply the brake pedal lock, turn off the electrical system master switch.
Page 185 MAINTENANCE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. D87E-2 D87P-2 3-49...
Page 186: Pivot Shaft Housing Oil Level
MAINTENANCE Fill fuel filters with clean fuel. Apply a light coating of clean engine oil or chassis grease to the seal surface on the new filter. Install, but do not spin, the new filter, turning it until the seal just contacts the filter head.
Page 187: Drive Train Suction Strainer
MAINTENANCE DRIVE TRAIN SUCTION STRAINER Open the left access side door. Remove all outside dirt from the suction strainer. Remove the four hex nuts and separate the housing (7) from the base (1). Pull out the element (4) with o-ring (3) from the housing (7).
Page 188: Transmission Scavenger Suction Strainer
MAINTENANCE When finished, lift up on door stay and close door. TRANSMISSION SCAVENGER SUCTION STRAINER To gain access to the oil strainer first remove the center cover in floor of cab. Disconnect the transmission scavenger hose (1) from the intake pipe (2). Remove the strainer from the hose. Clean the strainer with a nonflammable commercial cleaning sol- vent.
Page 189: Every 1000 Hours Service
MAINTENANCE EVERY 1000 HOURS SERVICE • Perform maintenance for every 10, 50, 250 and 500 hours of ser- vice at this time. BATTERIES AND TERMINALS General • A battery gives off highly flammable gas. Never allow sparks, open flame or lighted smoking material near the battery. Avoid spilling any electrolyte on hands or clothing.
Page 190: Change Drive Train System Oil
MAINTENANCE CHANGE DRIVE TRAIN SYSTEM OIL When working under the machine, turn off the electrical system master switch and tag the controls to warn against starting the machine. Remove the drain plug immediately after operation while the lubri- cant is still warm. Drain into a suitable container. After the system has been completely drained, reinstall and tighten the drain plug.
Page 191: Replace Drive Train System Breather
MAINTENANCE Using a filter wrench remove the spin on filter. Wipe the filter base, removing all of the old oil from the seal area. Fill the new filter with clean oil, then coat the filter seal with clean oil. Install the filter by threading (do not spin) it onto the filter base (3) until the seal contacts the base, turn the filter by hand an additional 1/4 to 1/2 turn.
Page 192: Drain, Flush And Refill Final Drive Oil
MAINTENANCE The breather is located on a stand pipe at the right rear top of the rear main frame cover. Unscrew the breather from the reducer nip- ple and discard. Install the new breather on the nipple. DRAIN, FLUSH AND REFILL FINAL DRIVE OIL •...
Page 193: Equipment System Return Filter
MAINTENANCE Move the machine so that the OIL LEVEL filler/check plug is par- allel to the track frame. Remove the check/filler plug. Fill the hous- ing with fresh lubricant up to the bottom of the check/ filler plug opening. Reinstall and tighten the filler and level plug. •...
Page 194: Clean Hydraulic Reservoir Relief Valve
MAINTENANCE Install the filter by threading (do not spin) it onto the filter base (3) until the seal contacts the base, turn the filter by hand an additional 1/4 to 1/2 turn. Remark Do not over tighten the filter or use any tools for installation because this can damage the gasket and filter.
Page 195: Lubricate Gimbal Tube
MAINTENANCE LUBRICATE GIMBAL TUBE Park the machine on level ground, stop the engine, lower all mounted equipment to the ground, apply the safety lock, apply the brake pedal lock, turn off the electrical system master switch. With the engine stopped, open the right engine side door. 1.
Page 196 MAINTENANCE Clean the filter holder, coat the thread and the seal surface of the new cartridge thinly with engine oil, then install the cartridge. Install the filter by threading (do not spin) it onto the filter base un- til the seal contacts the base, turn the filter by hand an additional 2/ 3 turn.
Page 197: Every 2000 Hours Service
MAINTENANCE EVERY 2000 HOURS SERVICE • Perform maintenance for every 10, 50, 250, 500 and 1000 hours of service at this time. EQUIPMENT SYSTEM PILOT FILTER Remark If the filter indicator light on the instrument panel, remains on at operating oil temperature with the engine running, the filter cartridge must be changed.
Page 198: Change Equipment System Oil
MAINTENANCE CHANGE EQUIPMENT SYSTEM OIL Start the engine and operate the blade to warm the oil for easy draining. Park the machine on level ground, lower blade and ripper equipment to the ground. Stop the engine. Shift to neutral and apply the lock lever.
Page 199: Clean Engine Breather Element
MAINTENANCE Clean the strainer with a nonflammable commercial cleaning sol- vent. Install the strainer in the reservoir and mount reservoir top cover with new o-ring to reservoir. Remark The strainer does not have to be disassembled for cleaning. Fire hazard - do not use kerosene, diesel fuel or flammable liquids to clean parts.
Page 200: Every 4000 Hours Service
MAINTENANCE EVERY 4000 HOURS SERVICE • Perform maintenance for every 10, 50, 250, 500, 1000 and 2000 hours of service at this time. CHECK WATER PUMP Check that there is oil leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your distributor for disassem- bly and repair or replacement.
Page 201: When Required
MAINTENANCE WHEN REQUIRED CLEAN AIR CLEANER ELEMENTS Remark Whenever the service light comes on, check the air cleaner elements. The audio alarm will not sound. General This machine is equipped with a dry type air cleaner with replaceable filter elements. The air cleaner has two filter elements, a outer and a in- ner.
Page 202 MAINTENANCE REMOVAL • Never clean or replace the air cleaner filter element with the engine running. • When using compressed air to clean the filter element, wear safety glasses or goggles to protect your eyes and limit the air pressure to less than 7 kg/cm²...
Page 203 MAINTENANCE Carefully tap the side or end of the element against the palm of your hand to remove loose dust. Direct clean dry compressed air up and down the pleats on the inside of the element, then direct it from outside along its folds and again from inside.
Page 204: Fuel Tank Filler Strainer
MAINTENANCE Inner Filter Element Remove the cover and the outer element, and then remove the inner element (2). To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side) Clean the air cleaner body interior, then remove the cloth cover. Fit a new inner element to the connector and tighten it with nuts.
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Page 206 MAINTENANCE NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. 3-70 D87E-2 D87P-2...
Page 207: Drain Fuel Tank Sediment Bowl
MAINTENANCE Remove the filter from the box. Clean inside of the filter box. Clean filter with compressed air. If it is extremely dirty, wash it in a neutral agent. After washing, dry completely before installing again. Remark If clogging of the filter cannot be removed by washing or us- ing compressed air, replace the filter with a new one.
Page 208: Linkage Lubrication
MAINTENANCE LINKAGE LUBRICATION Front Lower Throttle Lever (1) 1 FITTING Apply grease until clean lubricant is visible. Always use a clean lubrica- tor and wipe dirt from fittings before fresh grease is applied. If grease fails to go through the fitting, determine the cause and correct it. After greasing, wipe off any old grease that was purged.
Page 209 MAINTENANCE LINKAGE LUBRICATION NOTE: This added page shows the differences for machines equipped with Single Lever Transmission/Steering Control. Front Lower Throttle Lever (1) 1 FITTING Apply grease until clean lubricant is visible. Always use a clean lubrica- tor and wipe dirt from fittings before fresh grease is applied. If grease fails to go through the fitting, determine the cause and correct it.
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Page 211: Wear Of Undercarriage Components
MAINTENANCE Steering Lever Pivot (5) 2 FITTINGS Apply grease until clean lubricant is visible. Always use a clean lubrica- tor and wipe dirt from fittings before fresh grease is applied. If grease fails to go through the fitting, determine the cause and correct it. After greasing, wipe off any old grease that was purged.
Page 212: Sockets And Diagonal Strut
MAINTENANCE Front Idler Guides Periodically check the thickness of the front idler guides (1). Consult your local distributor. A (minimum thickness)16 mm (0.63 in) SOCKETS AND DIAGONAL STRUT Upper Strut And Tilt Cylinder The upper strut and tilt cylinder sockets must be checked occasion- ally to ensure that excessive movement does not occur between the cap (1) and the blade socket (2).
Page 213: Electrical System
MAINTENANCE Diagonal Strut The diagonal strut adjustment must be checked occasionally and if it is found that the strut presses on the blade, it has to be adjusted. Adjust as follows: A. With the blade on the ground and stopped engine, remove the pin (1) at the push arm bracket connection.
Page 214 MAINTENANCE Alternator The alternator requires no lubrication since its bearings are factory lu- bricated for life and require attention only at time of major overhaul. The alternator is equipped with an integral, transistorized voltage regu- lator. If the alternator fails to operate properly, consult your distributor. Remark The unit electrical system is negative ground.
Page 215 MAINTENANCE The upper working lights (cab or canopy mounted) and the lower work- ing lights (hood and fuel tank mounted) are each protected by an auto- matic reset circuit breaker. A 15 amp circuit breaker is mounted on the underside of the instrument panel. In the event of a short circuit or ground, the circuit breaker will open and close until the trouble clears or is corrected.
Page 216 MAINTENANCE CLEANING THE BATTERIES Battery acid causes severe burns. Avoid contact with eyes, skin, or clothing. Wear goggles, rubber gloves, and apron. If eye contact occurs, flush with water for 15 minutes and get prompt medical attention. If skin contact occurs, flush with soap and water. If the top of the batteries are dirty, they may be cleaned with a brush dipped in ammonia or soda solution.
Page 217: Seat Belt
MAINTENANCE SEAT BELT Seat Belt - Do not clean with solvents or bleach or redye color of the webbing as this may cause a severe loss of strength. This could cause the webbing to break and result in personal injury. Wash in warm wa- ter with a mild detergent.
Page 218: Trunnion Hardware
MAINTENANCE TRUNNION HARDWARE Check the torque of the trunnion cap bolts (1), qty. 4, and trunnion plate mounting bolts (2), qty.16. Trunnion hardware 1050 N•m (775 lbf ft) CUTTING EDGE AND END BIT WEAR It is dangerous if the work equipment moves by mistake when the cut- ting edges and end bits are being reversed or replaced.
Page 219: Ripper Points For Wear
MAINTENANCE Loosen nut (2) and remove bolt (1), then replace or turn over cut- ting edge. • Install the cutting edge to the blade and tighten temporarily, then push the blade against the ground surface to remove any play in the bolt and tighten to the specified torque. •...
Page 220 MAINTENANCE The filler screens the oil entering the tank and eases the job of the filter. Remove and clean the screen with a nonflammable commer- cial cleaning solvent. Install the screen in the reservoir and mount locking cap. Fire hazard - do not use kerosene, diesel fuel or flammable liquids to clean parts.
Page 221: Drain, Flush And Refill Cooling System
MAINTENANCE DRAIN, FLUSH AND REFILL COOLING SYSTEM • Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine cool before draining the cool- ant. • Never remove the radiator cap when the engine is at operating tem- perature.
Page 222: Transmission Scavenger Screen
MAINTENANCE Open the radiator drain valve. Allow the system to completely drain into a suitable container. Do not let drain outlets plug up during draining. Close the radiator drain valve and engine oil cooler drain valve. Flushing the System Be sure the radiator drain valve and engine oil cooler drain valve are closed and tightened.
Page 223: Electric Intake Air Heater
MAINTENANCE ELECTRIC INTAKE AIR HEATER Before the start of the cold season (once a year), contact your distributor to have the electrical air intake heater checked or repaired for dirt or dis- connections. When inspecting or replacing the electrical air heater, replace the gas- kets with new ones.
Page 224 MAINTENANCE MEMORANDA 3-88 D87E-2 D87P-2...
Page 225: Specifications
SPECIFICATIONS D87E-2 D87P-2...
Page 226 SPECIFICATIONS SPECIFICATIONS AND DIMENSIONS SPECIFICATIONS D87E-2 D87P-2 Semi U Blade Angle Blade Straight Blade WEIGHT - Includes blade equipment, ROPS, cab, standard equipment and full capacity of lubricants, coolant and fuel. • Operating weight w/o operator kg (lbs) 23998 (52885) 24326 (53630) 25909 (57120) BLADE...
Page 227 D87E-2 D87P-2 Semi U Blade Angle Blade Straight Blade ENGINE • Model Komatsu S6D125E-2 Diesel Engine • Flywheel horse kW (hp) 172 (230) @ 2100 RPM • Maximum torque N•m (lbf ft) 999 (737) @ 1400 RPM • Starting motor •...
Page 228: D87E-2 Dimensions
SPECIFICATIONS D87E-2 DIMENSIONS SEMI U DOZER On machine height dimensions, 66.55 mm (2.62 in) has been added. This represents the track shoe grouser height. Description Height, ground to top of ROPS 3569 Height, top of cab to top of ROPS Height, fuel tank refill 2322 Height, exhaust stack...
Page 229 SPECIFICATIONS D87E-2 D87P-2...
Page 230: Straight Angle Dozer
SPECIFICATIONS STRAIGHT ANGLE DOZER On machine height dimensions, 66.55 mm (2.62 in) has been added. This represents the track shoe grouser height. Description Height, ground to top of ROPS 3569 Height, top of cab to top of ROPS Height, fuel tank refill 2322 Height, exhaust stack 3372...
Page 231 SPECIFICATIONS D87E-2 D87P-2...
Page 232: D87P-2 Dimensions
SPECIFICATIONS D87P-2 DIMENSIONS STRAIGHT DOZER On machine height dimensions, 66.55 mm (2.62 in) has been added. This represents the track shoe grouser height. Description Height, ground to top of ROPS 3569 Height, top of cab to top of ROPS Height, fuel tank refill 2322 Height, exhaust stack 3372...
Page 233 SPECIFICATIONS D87E-2 D87P-2...
Page 234 SPECIFICATIONS MEMORANDA 4-10 D87E-2 D87P-2...
Page 235: Options, Attachments
OPTIONS, ATTACHMENTS D87E-2 D87P-2...
Page 236: Precautions Related To Safety
OPTIONS, ATTACHMENTS PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorized by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation &...
Page 237 DataKom Publishing Corporation 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. PROPOSAL FOR MANUAL OR CSS REVISION Attn: Service Publications Fax No. (847) 970-4186 DATE: FOR INTERNAL USE ONLY -- No. PMR NAME OF COMPANY: CITY: STATE OR PROVINCE:: DEPARTMENT: COUNTRY: NAME:...

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Boss d87p-2 P090001 P092001

Komatsu Boss D87E-2 Operation & Maintenance Manual

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