Page 1 Operation & EENAM03780 Maintenance Manual D155AX -8E0 BULLDOZER SERIAL NUMBER D155AX-8E0 - 100358 and up WARNING Unsafe use of this machine may cause serious injury or ORIGINAL INSTRUCTIONS death. Operators and maintenance personnel must read this manual before operating or maintaining this machine.
Page 3 Komatsu or Ko- matsu approved rebuilt parts or assemblies or others parts of equivalent quality, and that the engine be serviced by an authorized Komatsu distribu- tor. Failure to follow these recommendations could result in ineffective serv- ice, damage to the product or safety risks (including personal injury or death).
Page 4 It is provided on the back side of the operator's seat back. If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine model name and the serial No. immediately to arrange for its replacement.
Page 5: Komatsu Machine Operator Privacy Policy
Belgium, with registered office at 1800 Vilvoorde, Belgium, Mechelsesteenweg 586, registered in Brussels un- der number RPR/CER(0)404.968.268 ("Komatsu Europe", together with the other Komatsu subsidiaries in the EEA referred to as "we" or "us"). Komatsu Europe acts as Komatsu's representative in the EU with respect to MMS.
Page 6 FOREWORD • pictures, videos and sound recordings 4. Why is your personal data processed? When you use Komatsu machines equipped with MMS, your personal data are processed for the following rea- sons: (a) Safety and security (b) Warranty (c) Misuse and theft prevention...
Page 7 (30) days after having received the request. If you have any complaint regarding the processing of your personal data by Komatsu or Komatsu Europe via MMS, you may always contact us via the e-mail address mentioned in the first paragraph of this clause. If you...
Page 8: Safety Information
SAFETY INFORMATION FOREWORD SAFETY INFORMATION To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by- standers, the precautions and warnings included in this manual and the safety signs attached to the machine must always be observed.
Page 9: Noise
FOREWORD NOISE NOISE Two labels indicating the machine noise level are affixed on the machine. • Sound pressure level at the operator’s station, measured according to ISO 6396 (Dynamic test method, simulated working cycle). The maximum value of the standard deviation of the meas- ured time-averaged A-weighted emission sound pressure level at the operator’s position is 2.5dB, in accordance with ISO 11201...
Page 10: Vibration Levels
VIBRATION LEVELS FOREWORD VIBRATION LEVELS When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper- ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO 7096.
Page 11 FOREWORD VIBRATION LEVELS • Do not repeatedly handle and lift loads...
Page 12: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Dozing work • Slot dozing work • Operation on slope • V-shape ditching work • Leveling work • Cutting and ditching of hard or frozen ground •...
Page 13 FOREWORD INTRODUCTION • Evaluation height : 1.2m above the ground • Scale-interval of the circles is 1 m. 1-11...
Page 14: Engine Technology To Conform Exhaust Gas Emission
Catalytic Reduction (SCR) to conform EU Stage V emission regulation in the European Union. • Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process to burn the soot is performed automatically to keep the filtering performance of KDPF high.
Page 15: Product Information
FOREWORD PRODUCT INFORMATION PRODUCT INFORMATION When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items. LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI- AL NO. PLATE This is under the front of the console box on the right side of the operator's seat.
Page 16: Location Of Blade Serial No. Plate
PRODUCT INFORMATION FOREWORD LOCATION OF BLADE SERIAL NO. PLATE This is at the upper right of the blade back face. FLUORINATED GREENHOUSE GASES Product contains fluorinated greenhouse gases. Standard spec. Wide air condensor spec. Product contains fluorinated greenhouse gases HFC-134a 1.57 1430 09971-10111...
Page 17: Location For Rops And Fops Plate
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Manufacturers name: KOMATSU LTD. Address: 2-3-6 Akasaka Minato-ku, Tokyo 107-8414 Japan Authorised representative: KOMATSU EUROPE INT. Address: Mechelsesteenweg 586 B-1800 Vilvoorde Belgium Distributor name Address Service personnel Phone/Fax 1-15...
Page 18: Serial Plate
SERIAL PLATE FOREWORD SERIAL PLATE EI000001 MACHINE DESIGNATION/TYPE ENGINE POWER SERIAL NUMBER PRODUCT IDENTIFICATION NUMBER YEAR OF CONSTRUCTION MANUFACTURER OPERATING MASS AUTHORISED REPRESENTATIVE 1-16...
Page 19: Declaration Of Conformity
FOREWORD DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY The manufacturer/Authorised representative The manufacturer Authorised representative KOMATSU LTD. KOMATSU EUROPE INT. 2-3-6 Akasaka Mechelsesteenweg 586 Minato-ku, Tokyo 107-8414 B-1800 Vilvoorde Japan Belgium Declares that this machine: D155AX-8E0 Fulfils all the relevant provisions of following EC Directives:...
Page 20: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 KOMATSU MACHINE OPERATOR PRIVACY POLICY ................1-3 SAFETY INFORMATION .......................... 1-6 NOISE............................... 1-7 VIBRATION LEVELS ..........................1-8 VIBRATION - OPERATING CONDITION ................... 1-8 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-8 INTRODUCTION ............................
Page 21 FOREWORD TABLE OF CONTENTS MACHINE EQUIPMENT NAME ......................3-2 CONTROLS AND GAUGES NAMES ....................3-3 EXPLANATION OF COMPONENTS ......................3-6 EXPLANATION OF MACHINE MONITOR EQUIPMENT ..............3-6 SWITCHES ............................3-92 CONTROL LEVERS AND PEDALS ....................3-98 OTHER EQUIPMENT ........................3-105 MACHINE OPERATIONS AND CONTROLS ..................
Page 22 OTHER TROUBLE......................... 3-245 MAINTENANCE............................... 4-1 PRECAUTIONS FOR MAINTENANCE ..................... 4-2 CHECK SERVICE METER READING ....................4-2 KOMATSU GENUINE REPLACEMENT PARTS ................4-2 KOMATSU GENUINE LUBRICANTS ....................4-2 ALWAYS USE CLEAN WASHER FLUID .................... 4-2 FRESH AND CLEAN LUBRICANTS ....................4-2 CHECK DRAINED OIL AND USED FILTER..................
Page 23 FOREWORD TABLE OF CONTENTS METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-6 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-21...
Page 25: Safety
SAFETY Please read and make sure that you fully understand the precautions descri- bed in this manual and the safety labels on the machine. When operating or servicing the machine, always follow these precautions strictly.
Page 26 SAFETY SAFETY SAFETY SAFETY LABELS ............................2-4 LOCATION OF SAFETY LABELS......................2-5 CONTENTS OF SAFETY LABELS ......................2-6 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........... 2-12 PRECAUTIONS BEFORE STARTING OPERATION................2-12 ENSURE SAFE OPERATION ......................2-12 UNDERSTAND THE MACHINE ....................... 2-12 PREPARATIONS FOR SAFE OPERATION ....................
Page 27 SAFETY SAFETY PRECAUTIONS FOR TRANSPORTATION..................... 2-26 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-27 TOWING AND BEING TOWED....................... 2-27 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-27 PRECAUTIONS FOR MAINTENANCE ......................2-28 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......... 2-28 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ........2-28 KEEP WORK PLACE CLEAN AND TIDY ..................
Page 28: Safety Labels
If the safety labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part numbers for the safety labels, see this manual or the actual label, and place an order to your Komatsu distributor. •...
Page 29: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS 1. Caution for high-temperature coolant 6. Caution for approaching while moving machine 2. Caution for not getting on engine hood 7. Caution for handling accumulator 3. Caution for handling ROPS/FOPS 8. Caution when leaving operator's seat 4.
Page 30: Contents Of Safety Labels
SAFETY LABELS SAFETY 11. Caution before moving in reverse 16. Caution against high-pressure fuel 12. Caution for operation, inspection and maintenance 17. Prohibition of start by short-circuiting 13. Caution for blast jobsite 18. Caution for handling DEF 14. Caution for not getting on fuel tank 19.
Page 31 SAFETY SAFETY LABELS (4) Caution for adjusting track tension “17A-98-61620” This safety label is attached to the back of the track adjustment window cover. • Sign indicates a hazard of flying plug from track adjuster that could cause injury. • Read the manual and adjusting track for safe and proper handling.
Page 32 SAFETY LABELS SAFETY (8) Caution when leaving the operator's seat “09654-B0641” • Sign indicates a hazard of unexpected moving of stopped machine. • Lower working device to ground, move satety lever to lock position and take engine key with you before leaving ma- chine.
Page 33 SAFETY SAFETY LABELS (11) Caution before moving in reverse “09802-B0640” • Sign indicates a hazard of rear working and advancing be- hind. • Read manual before operation. WARNING To prevent SEVERE INJURY or DEATH, do the following before moving machine or its attachments : •...
Page 34 SAFETY LABELS SAFETY (14) Caution for not getting on fuel tank “09805-C0641” • Sign indicates a hazard of falling. • Do not stand on this place here. (15) Caution for handling cable “09808-A0881” • Sign indicates an electric hazard from handling the cable. •...
Page 35 SAFETY SAFETY LABELS (17) Prohibition of start by short-circuiting “09842-A0481” • Start the engine only after sitting down in the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury of fire.
Page 36: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before per- forming operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 37: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • If water gets into the electrical system, electric devices will cause malfunctions, and the machine will cause error. If the machine cause error, it 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 compo- nents.
Page 38: Prevent Fire
Fire around the machine due to highly heated exhaust gas This machine is equipped with Komatsu Diesel Particulate Filter (hereafter KDPF). 2-14...
Page 39: Precautions When Getting On Or Off Machine
When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regener- ation disable to prevent fire hazards due to highly heated exhaust gas during the aftertreatment devices regen- eration. For setting, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”. Explosion caused by lighting equipment •...
Page 40: Lifting Of Personnel Prohibited
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • Never jump on or off the machine. Never get on or off a moving machine. • 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.
Page 41: Do Not Get Caught In Work Equipment
• 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 consult your Komatsu distributor.
Page 42: Precautions When Running Engine Inside Building
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 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 ma- chine must be operated inside a building or underground, where the ventilation is poor, take steps to ensure that the en- gine exhaust gas is removed and that ample fresh air is...
Page 43: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to serious personal injury or death. Before start- ing operations, always check the following to confirm that there is no danger on the jobsite. •...
Page 44: Ensure Good Visibility
PRECAUTIONS FOR OPERATION SAFETY Voltage of Cables Safety Distance 154000 V Min. 5 m 187000 V Min. 6 m 275000 V Min. 7 m 500000 V Min. 11 m • To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on the opera- tor's seat, and be careful not to touch the chassis with any exposed part of your body.
Page 45: Start Engine
Always observe the regulations for jobsite and environmental standards. This machine does not contain asbestos, but any part which is not the genuine part, it has risk of containing asbestos. Always use Komatsu genuine parts. START ENGINE USE WARNING TAGS If there is a “DANGER! Do NOT operate!”...
Page 46: Precautions When Starting Engine
For adjustment, ask your KOMATSU distributor. • For machines equipped with a rearview camera, adjust the angle so that the operator on the operator's seat can obtain a view of surroundings.
Page 47: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cables. • When connecting a normal machine to a failed machine with the jumper cables, always use the normal machine with the same battery voltage as the failed machine.
Page 48: Precautions When Traveling
PRECAUTIONS FOR OPERATION SAFETY • If there are any persons in the area around the machine, there is danger that they may be hit or caught by the ma- chine, and this may lead to serious personal injury or death. Always observe the following before traveling. •...
Page 49: Precautions When Operating On Slopes
SAFETY PRECAUTIONS FOR OPERATION • Never turn the key in the starting switch to OFF position when the machine is traveling downhill. If the engine stops when the machine is traveling, it may become impossible to operate the steering, and this may cause serious per- sonal injury or death.
Page 50: Precautions For Transportation
PRECAUTIONS FOR OPERATION SAFETY • Do not depress the brake pedal repeatedly more than necessity. • Use the engine brake during downhill travel. PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES • Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the ma- chine, and do not perform abrupt lever operation.
Page 51: Towing And Being Towed
• This machine may need to be divided into components for transportation depending on the regulation. When transporting the machine, consult your Komatsu distributor. PRECAUTIONS WHEN LOADING AND UNLOADING If handling is wrong when loading or unloading the machine, it is dangerous that the machine may tip over or fall.
Page 52: Precautions For Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE During inspection and maintenance, always display the “DAN- GER! Do NOT operate!” warning tag. If there is a “DANGER! Do NOT operate!” warning tag dis- played, it means that someone is performing inspection and maintenance of the machine.
Page 53: Guards
END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE If you are caught or pinched between the work equipment during operation, or exposed to high-temperature or high-pressure liquids, it is dangerous and may cause serious personal injury or death.
Page 54: Precautions When Installing, Removing, Or Storing Attachments
If the automatic active regeneration of KDPF starts during maintenance work, surroundings of KDPF become high temperature. When performing maintenance work, perform the aftertreatment devices regeneration disable according to “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”. • Set work equipment lock lever (1) and parking brake lever (2) to LOCK positions (L) to prevent the work equipment from moving.
Page 55: Precautions For Check And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE • You must walk along the access aisle for checking being paved with non-slip pads. Never climb on the en- gine hood and cover to prevent personal injuries from falling or failing over due to losing your footing. PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT Machine or work equipment may fall, and it is dangerous that serious personal injury or death may occur.
Page 56: Precautions For Welding
PRECAUTIONS FOR MAINTENANCE SAFETY PRECAUTIONS FOR WELDING Welding operations must always be performed by a qualified welder and in a place equipped with proper equip- ment. There is a hazard of gas, fire, or electric shock when performing welding, so never allow any unqualified person to perform welding.
Page 57: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may come out or metal particles may be scattered. It is dangerous and may cause serious personal injury or death. Always observe the following. • When hitting pins or bucket teeth, broken pieces may be scattered, and it may cause personal injury to the people in the surrounding area.
Page 58: Precautions For High-Pressure Fuel
If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 59: High-Pressure Grease When Adjusting Track Tension
If it is disassembled by mistake, the spring may shoot out and cause serious personal injury or death. If it is necessary to disassemble it, ask your Komatsu distributor to perform the work. ACCUMULATOR AND GAS SPRING This machine is equipped with an accumulator.
Page 60: Precautions For Compressed Air
Do not hit or roll it, or subject it to any impact. • When disposing of the accumulator, the gas must be re- leased. Ask your Komatsu distributor to perform this work. PRECAUTIONS FOR COMPRESSED AIR • When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by flying dust or particles.
Page 61 SAFETY PRECAUTIONS FOR MAINTENANCE • The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious personal injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval.
Page 62: Precautions For Def
PRECAUTIONS FOR DEF SAFETY PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im- mediate action: •...
Page 63: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 64: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Blade (8) Track frame (2) Blade lift cylinder (9) Frame (3) Cab (10) Blade tilt cylinder (4) Ripper tilt cylinder (11) DEF injector (5) Multi-shank ripper (12) Idler (6) Track (13) Ripper lift cylinder (4) Final drive (14) DEF tank...
Page 65: Controls And Gauges Names
OPERATION GENERAL VIEW (15) DEF pump (18) Komatsu Closed Crankcase Ventilation (hereafter KCCV) ventilator (16) SCR (17) Komatsu Diesel Particulate Filter (hereinafter KDPF) CONTROLS AND GAUGES NAMES (1) Cigarette lighter (9) Engine shutdown secondary switch (2) Parking brake lever (10) Brake pedal...
Page 66 GENERAL VIEW OPERATION Machine monitor equipment name AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Air conditioner control switch (20) Dual tilt mode pilot lamp (2) Work equipment automation switch (21) Floating mode pilot lamp (3) Buzzer cancel switch (22) Blade fine control mode pilot lamp (4) Operation mode selector switch...
Page 67 OPERATION GENERAL VIEW REMARK The above figure does not show all of the caution lamp symbols. For details of the caution lamps, see “WARN- ING DISPLAY (3-13)”.
Page 68: Explanation Of Components
EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices necessary to operate the machine. To perform suitable operations correctly and safely, it is important to completely understand methods of operat- ing the equipment, and the meanings of the displays. EXPLANATION OF MACHINE MONITOR EQUIPMENT AA: Standard screen, EE: Warning or Error screen, DD: Guidance screen (1) Warning display...
Page 69 After the opening screen GG is displayed for 2 seconds, the screen switches to the camera image CC. • If the camera image CC is not displayed, there can be a failure. In this case, ask your Komatsu distributor for repair.
Page 70 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE WHILE ENGINE SHUTDOWN SECONDARY SWITCH IS ON While engine shutdown secondary switch (1) is ON (engine is stopped), when the starting switch is turned to ON position, the screen shown in the figure is displayed and engine does not start.
Page 71 EXPLANATION OF COMPONENTS End screen when any message has been received If there is any message from your Komatsu distributor, it is dis- played on the end screen. In this case, turn the starting switch to ON position to re-check the message, and if the message is requesting a response, make a reply to it.
Page 72 Be careful not to use it for the purpose of security enhance- ment. Komatsu cannot accept any responsibility for any loss or damage resulting from the wrong use of ID or unauthorized use of ID by a third person.
Page 73 OPERATION EXPLANATION OF COMPONENTS BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN AB- NORMAL SITUATION • If there is any abnormality when starting the engine, the check before starting screen BB changes to the maintenance time warning screen CC, warning screen FF, or error screen EE. •...
Page 74 EXPLANATION OF COMPONENTS OPERATION If there is any error existing, “！” is displayed on top of switch Press switch F5 to check the detail of the current abnormality. “Current Abnormality” screen is displayed. BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE If any abnormality occurs during operation, the standard screen AA changes to the abnormality screen EE.
Page 75 OPERATION EXPLANATION OF COMPONENTS Press switch F5 to check the detail of the current abnormality. “Current Abnormality” screen is displayed. WARNING DISPLAY NOTICE Appearance of any of action levels “L01” to “L04” on the machine monitor indicates presence of an ab- normality the machine.
Page 76 EXPLANATION OF COMPONENTS OPERATION (*): Displayed items change according to setting of the multi-gauge. For details of the multi-gauge, see “MULTI GAUGE (3-36)”. Standard screen When 1 type of caution is generated, it is displayed on caution lamp (2). When 2 types of caution are generated, they are displayed on caution lamps (2) and (3). When 3 types or more of caution are generated, they are displayed on caution lamps (2) and (3) alternately at intervals of 2 seconds.
Page 77 Sounds inter- Lights up in │ mittently If the condition is not improved, ask your Komatsu distributor ↓ for inspection and maintenance. Some functions may be restricted for use, but the machine Does not Lights up in can operate.
Page 78 EXPLANATION OF COMPONENTS OPERATION Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Fuel level caution lamp Low level Normal Abnormal Abnormal System caution lamp (L04, L03) (L01) Abnormal Abnormal Work equipment system caution lamp (L04, L03) (L01) Abnormal Abnormal...
Page 79 OPERATION EXPLANATION OF COMPONENTS Display color/Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Abnormal Fan control system caution lamp (L04, L03) (L01) Low oil pres- sure Engine oil pressure caution lamp (L03) Overspeed Engine overrun caution lamp (L02) Low coolant Radiator coolant level caution...
Page 80 EXPLANATION OF COMPONENTS OPERATION CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!” is displayed on top of switch F5. While “!” is displayed, press switch F5 to shift the monitor dis- play screen to the Current Abnormality screen. Take appropriate remedies according to the displayed mes- sage.
Page 81 OPERATION EXPLANATION OF COMPONENTS ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature. When abnormal The caution lamp lights up in red and indicates action level “L02”. The engine coolant temperature is abnormally high. While this lamp is lit, the overheat prevention system is auto- matically actuated and the engine speed drops.
Page 82 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation and move the machine to a safe place, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 83 The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 84 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 85 Much soot is accumulated in KDPF, however, the operation can be performed. After the operation is finished, move the machine to a safe place and perform manual stationary regeneration. REMARK For details of the manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”. DEF LEVEL CAUTION LAMP DEF level caution lamp alerts when DEF tank level becomes low.
Page 86 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 87 When action level “L03” is displayed The caution lamp lights up in red and the alarm buzzer sounds intermittently. Stop the work, move the machine to a safe place, and then ask your Komatsu distributor for inspection and maintenance. When action level “L01” is displayed The caution lamp lights up in yellow.
Page 88 Charging is not be performed normally while the engine is run- ning. Stop the engine and check the alternator belt and air condition- er compressor belt for damage, then ask your Komatsu distrib- utor for inspection and maintenance. AIR CLEANER CLOGGING CAUTION LAMP Air cleaner clogging caution lamp warns about clogging of the air cleaner.
Page 89 The caution lamp lights up in yellow and indicates action level “L01”. The air conditioner system has abnormality. Ask your Komatsu distributor for inspection and maintenance as soon as possible. MAINTENANCE TIME CAUTION LAMP Maintenance time caution lamp displays notices and alarms concerning maintenance time.
Page 90 EXPLANATION OF COMPONENTS OPERATION SEATBELT CAUTION LAMP The seat belt caution lamp lights up in red when the seat belt is not fastened. It goes out when the seat belt is fastened. For details of the seat belt, see “CHECK SEATBELT (3-163)”. PILOT DISPLAY AND METER DISPLAY Pilot display 1.
Page 91 Pilot lamp goes out: Air conditioner OFF MESSAGE DISPLAY The User Message is displayed when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY (3-90)”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply is made.
Page 92 When there are thatched houses, dry leaves or pieces of paper near the job site, set the system to the regeneration disable to prevent fire hazards due to highly heated exhaust gas during the after- treatment devices regeneration. For details of the setting method, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”.
Page 93 For the procedures of cancellation of the regeneration disable setting, and setting of manual stationary regeneration, see “HANDLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”. WORK EQUIPMENT LOCK PILOT LAMP The work equipment lock pilot lamp lights up when the work equipment lock lever is in LOCK position.
Page 94 EXPLANATION OF COMPONENTS OPERATION ECO GUIDANCE The guidance for energy saving operation to reduce the fuel consumption may be displayed during operation. The details of the guidance are as follows: Idling Stop Guidance If no operation is performed for more than 5 minutes, and the engine is idling, the idling stop message is displayed on the machine monitor.
Page 95 OPERATION EXPLANATION OF COMPONENTS Overload Prevention Guidance If the machine is overloaded during work, overload prevention message is displayed. Fuel consumption can be reduced by avoiding shoe slip or op- erating the machine in the green zone of ECO gauge. Overload prevention guidance goes out more than 5 seconds later or when switch F5 is pressed.
Page 96 EXPLANATION OF COMPONENTS OPERATION Engine stop operation during the aftertreatment devices regeneration guidance Immediately after starting the aftertreatment devices regeneration, the information about engine stop operation during the aftertreatment devices regeneration is displayed. When stopping the engine during Aftertreatment Devices Re- generation, stop the regeneration first according to “PROCE- DURE FOR AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING (3-119)”, then stop the engine after run-...
Page 97 OPERATION EXPLANATION OF COMPONENTS BLADE FINE CONTROL MODE PILOT LAMP The blade fine control mode pilot lamp lights up when the blade fine control mode is set. In the blade fine control mode, the work equipment starts rising and lowering smoothly. Select the blade fine control mode in the customize mode.
Page 98 EXPLANATION OF COMPONENTS OPERATION SPEED RANGE DISPLAY The gear speed display section indicates the following informa- tion. The travel gear speed of the machine (F1 for FORWARD 1st, R2 for REVERSE 2nd) is displayed in top left area (a). The gear shift mode is displayed in top right area (b). The preset mode is displayed in bottom area (c).
Page 99 OPERATION EXPLANATION OF COMPONENTS When the engine is started, if the indicator is in position (D), perform the warm-up operation. For details, see “METHOD FOR ENGINE WARM-UP OPERATION (3-174)”. Display (H) when temperature is proper: Back ground (K) of en- gine coolant temperature caution lamp lights up in blue.
Page 100 EXPLANATION OF COMPONENTS OPERATION HYDRAULIC OIL TEMPERATURE GAUGE Hydraulic oil temperature gauge shows the hydraulic oil tem- perature. If the indicator is in green range during operations, it is normal. If the indicator goes beyond red range (A) during operations, the overheat prevention system operates.
Page 101 OPERATION EXPLANATION OF COMPONENTS SERVICE METER / CLOCK The service meter/clock shows the total hours of operation of the machine or the present time. When the engine is running, the service meter advances even when the machine is not moving. The service meter advances 0.1 every 6 operation minutes, regardless of the engine speed.
Page 102 EXPLANATION OF COMPONENTS OPERATION ECO GAUGE / DRAWBAR PULL GAUGE The ECO gauge/ drawbar pull gauge displays ECO gauge (in- stantaneous fuel consumption) (C) or drawbar pull gauge (work load) (D). The instantaneous fuel consumption means the fuel consump- tion rate at each moment, which varies with the work load and engine speed.
Page 103 OPERATION EXPLANATION OF COMPONENTS REMARK • Immediately after turning the starting switch to ON position and during the engine is running, DEF level cau- tion lamp (1) lights up in white. However, this does not indicate abnormality. • In cold weather, DEF level cannot be detected and DEF level caution lamp (1) lights up in white for approxi- mately 1 hour.
Page 104 EXPLANATION OF COMPONENTS OPERATION When the monitor display shows the standard screen, the types of guidance icons and functions of function switches are as follows: For the details of each function, see the detailed explanation of each item. (A) Switch F1: Dual tilt mode switch (Only machines equipped with dual tilt function) (B) Switch F2: Multi-gauge selector switch (C) Switch F3: Camera image selector switch...
Page 105 OPERATION EXPLANATION OF COMPONENTS (H) Switch F1 or F3: Moves to the left item. (When on the left end, it moves to the right end.) (I) Switch F2 or F4: Moves to the right item. (When on the right end, it moves to the left end.) (J) Switch F3: Moves to the item below (forward).
Page 106 EXPLANATION OF COMPONENTS OPERATION AIR CONDITIONER SWITCH The air conditioner switch consists of 9 switches. For explanation of each switch, see “HANDLE AIR CONDI- TIONER”. OPERATING MODE SELECTOR SWITCH The operating mode selector switch is used for switching the working mode of the engine. Normally, it is possible to perform all operations in E mode, and this mode reduces fuel consumption.
Page 107 OPERATION EXPLANATION OF COMPONENTS Setting and saving each item Press switch F3 or F4 on the customize mode select screen to set the yellow cursor to the target item of setting change and press F6 key. The setting change screen for the selected item is dis- played.
Page 108 EXPLANATION OF COMPONENTS OPERATION Press switch F3 or F4 to move the yellow cursor to a mem- ory number (M1 to M5) to call up. As the cursor is set to the number, the setting stored in the memory is displayed in the right side of the screen. Press switch F6 to call up the selected setting.
Page 109 OPERATION EXPLANATION OF COMPONENTS WORK EQUIPMENT AUTOMATION SWITCH The work equipment automation switch is used for turning ON/OFF the functions of auto-pitch and ripper auto-return. When this switch is turned ON, the auto-pitch and ripper auto- return functions can be used in the mode set on the Mode Se- lect screen.
Page 110 EXPLANATION OF COMPONENTS OPERATION • While the auto-pitch function is in operation, Auto-pitch pilot lamp lights up in yellow. • While the auto-pitch function is interrupted, Auto-pitch pilot lamp flashes. Auto-pitch mode • While the machine is traveling forward, each time the auto- pitch button (P) of the work equipment control lever is pressed, the blade pitch angle is set automatically for dig- ging and hauling position (Q) or dumping position (R) alter-...
Page 111 OPERATION EXPLANATION OF COMPONENTS Each operation while auto-pitch mode is ON Reverse Gear Machine operation when auto-pitch interlock Blade button is pressed position Steering Blade lift Blade tilt Ripper setting pitch Neutral Pitches back fully to digging or doz- ing (Q) position Pitches back fully automatically to digging or dozing (Q) position 2 seconds after joystick is set in RE-...
Page 112 EXPLANATION OF COMPONENTS OPERATION Each operation while auto-pitch mode is ON Reverse Gear Machine operation when auto-pitch interlock Blade button is pressed position Steering Blade lift Blade tilt Ripper setting pitch Forward Auto-pitch function does not work Neutral Pitches back fully to digging or doz- ing (Q) position Pitches back fully automatically to digging or dozing (Q) position 2 sec-...
Page 113 OPERATION EXPLANATION OF COMPONENTS This function is used for storing the ripper automatically when the machine travels in reverse after ripping opera- tion. • Since the ripper does not need to be controlled manually, the operator's work load is decreased. •...
Page 114 EXPLANATION OF COMPONENTS OPERATION Each operation while ripper auto-return function is Gear Ripper raise Ripper tilt back operation Blade shifting operation Steering Ripper lift Ripper tilt operation FORWARD Auto-return does not operate. (Normal manual operation is possible.) NEUTRAL Automatic full tilt back oper- Normal Normal Auto-raise opera-...
Page 115 OPERATION EXPLANATION OF COMPONENTS Each operation while ripper auto-return function is Gear Ripper raise Ripper tilt back operation Blade shifting operation Steering Ripper lift Ripper tilt operation FORWARD Auto-return does not operate. (Normal manual operation is possible.) NEUTRAL Normal Normal Auto-raise opera- Automatic full tilt back oper- Operation...
Page 116 EXPLANATION OF COMPONENTS OPERATION Each operation while ripper auto-return function is Gear Ripper raise Ripper tilt back operation Blade shifting operation Steering Ripper lift Ripper tilt operation FORWARD Auto-return does not operate. Auto-return does not oper- (Normal manual NEUTRAL ate. operation is pos- (Normal manual operation is sible.)
Page 117 OPERATION EXPLANATION OF COMPONENTS Other mode operations while camera image is displayed Even during the camera image is displayed, it is possible to op- erate following modes. • The air conditioner can be operated. When the air conditioner switch is operated, the screen switches to the air conditioner control screen.
Page 118 EXPLANATION OF COMPONENTS OPERATION • It is possible to change the customize setting by pressing the customize switch. For the customize switch, see “CUSTOMIZE SWITCH (3-44)”. After the customize setting is finished, the screen automat- ically returns to the standard screen. •...
Page 119 OPERATION EXPLANATION OF COMPONENTS Actions against warning during camera image display • If any abnormality is generated on the machine while the camera image is displayed, the caution lamp flashes at the top left of the screen. • If the caution lamp is displayed, press switch F6 to return to the standard screen, and check the content of the ab- normality or warning display.
Page 120 EXPLANATION OF COMPONENTS OPERATION SERVICE METER / CLOCK DISPLAY SELECTOR SWITCH By pressing switch F4, you can switch the service meter and clock display on the standard screen. • When the clock is being displayed, press switch F4 to switch to the service meter display. When the service meter is being displayed, press switch F4 to switch to the clock display.
Page 121 OPERATION EXPLANATION OF COMPONENTS Multi gauge selection item Remarks Engine speed With caution lamp Travel speed Work equipment pump pres- sure Engine oil pressure With caution lamp Battery voltage With caution lamp Drawbar pull Load graph Pitch graph Clock display Approximate values indicated by the multi gauge are as follows.
Page 122 EXPLANATION OF COMPONENTS OPERATION Engine oil pressure (1) 0.0 MPa (2) 0.2 MPa (3) 0.3 MPa (4) 0.4 MPa (5) 0.5 MPa (6) 0.7 MPa Battery voltage (1) 0 V (2) 15 V (3) 20 V (4) 25 V (5) 30 V (6) 31 V Drawbar pull (1) 0 W (2) 0.2 W (3) 0.4 W (4) 0.6 W (5) 0.8 W...
Page 123 OPERATION EXPLANATION OF COMPONENTS Clock display USER MENU DISPLAY SWITCH On the standard screen, press switch F6 to display the user menu screen on which you can make various settings for the machine in the monitor display. USER MENU The user menu consists of the following kinds. Press switches F1 and F2 to move to right and left for selecting menu screens.
Page 124 EXPLANATION OF COMPONENTS OPERATION (a) “Energy Saving Guidance” • Check of “Operation Records” • Check of “ECO Guidance Records” • Check and reset of “Average Fuel Consumption Record” • “Configurations” (b) “Machine Setting” • “Fan Reverse Mode” • “Auto Idle Stop Timer Setting” (c) “Aftertreatment Devices Regeneration”...
Page 125 OPERATION EXPLANATION OF COMPONENTS (f) “Monitor Setting” • “Screen Adjustment” • “Screen Adjustment (camera)” • “Clock Adjustment” • “Language” • “ID key information” • “Operator ID” (g) Mail Check • Check of mail contents and reply to mail Operation on user menu screen On the user menu screen, it is possible to perform the following operations with switches F1 to F6.
Page 126 EXPLANATION OF COMPONENTS OPERATION F5: Returns the screen to the standard screen. F6: Displays the setting screen for selected item. • If no switch is operated for 30 seconds on the user menu screen, the screen automatically returns to the previous screen.
Page 127 OPERATION EXPLANATION OF COMPONENTS Operation on the Operation Records screen On “Operation Records” screen, you can perform the following operations by pressing switch F3 to F5. F3: Displays the next page. When on the last page, it displays the first page. F4: Displays the previous page.
Page 128 EXPLANATION OF COMPONENTS OPERATION CHECK FUEL CONSUMPTION RECORD Select the Average Fuel Consumption Record (3) from the En- ergy Saving Guidance menu screen, then press switch F6. On the Average Fuel Consumption Record menu, display the graph of hourly average fuel consumption during the last 12 hours or the graph of daily fuel consumption during the last 1 week.
Page 129 OPERATION EXPLANATION OF COMPONENTS Switching of displayed graph Press F2 on the Average Fuel Consumption Record screen to change the currently displayed graph to another. REMARK There are 2 types of graphs. One shows hourly average fuel consumption during the last 12 hours and the other is daily average fuel consumption during the last 1 week.
Page 130 EXPLANATION OF COMPONENTS OPERATION CHANGE DISPLAY SETTING Select Configurations (4) from the Energy Saving Guidance menu screen, then press switch F6. On the Configurations menu, following operations are availa- ble. • Setting the Average Fuel Consumption Display • Switching ON/OFF of the ECO Gauge Display •...
Page 131 OPERATION EXPLANATION OF COMPONENTS Select Average Fuel Consumption Display (6) from the Configurations screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6. F3: Moves to the next item (1 line below). When on the last line, it moves to the first line.
Page 132 EXPLANATION OF COMPONENTS OPERATION REMARK When you select the split measurement, the measurement stop switch (STOP) is displayed on the Operation Records screen and the ECO Guidance Records screen. When you stop the measurement, move from Energy Saving Guidance menu (a) screen to the Operation Records (1) screen or ECO Guidance Records (2) screen, then press the measure- ment stop switch F1 (STOP).
Page 133 OPERATION EXPLANATION OF COMPONENTS Select the ECO Gauge Display (8) from the Configurations screen, then press switch F6. ECO Gauge Display setting screen appears. Traction: Displays drawbar pull gauge (A) on the standard screen. Fuel Consump: Displays ECO gauge (B) on the standard screen.
Page 134 EXPLANATION OF COMPONENTS OPERATION SWITCH DISPLAY/NON-DISPLAY OF ECO GUIDANCE It is possible to change the setting of Display/Non-display of ECO guidance (10). Select ECO Guidance Display (11) from the Configurations screen, then press switch F6. ECO Guidance Display setting screen appears. ON: Displays ECO Guidance (10) on the standard screen.
Page 135 OPERATION EXPLANATION OF COMPONENTS Select ECO Guidance Display at Key OFF (13) from the Configurations screen, then press switch F6. The setting screen for ECO Guidance Display at Key OFF screen appears. ON: Displays ECO Guidance (12) on the end screen. OFF: Does not display ECO Guidance (12) on the end screen.
Page 136 EXPLANATION OF COMPONENTS OPERATION REVERSE HYDRAULIC FAN NOTICE • After stopping the engine, check around the engine for sticking dry leaves or dirt. In particular, carefully check around the exhaust mani- fold and turbocharger for sticking dirt which can cause a fire. •...
Page 137 OPERATION EXPLANATION OF COMPONENTS If the parking brake lever or work equipment lock lever is in FREE position or the engine is running, the screen shown in the figure is displayed and the fan rotation is not re- versed. Press switch F5 to return to the previous screen. Press switch F6 when the fan reversing confirmation screen is displayed.
Page 138 EXPLANATION OF COMPONENTS OPERATION 11. After finishing the work, press switch F5 and stop the fan reverse rotation. 12. Turn the fuel control dial to Low idle (MIN) position. 13. Turn the starting switch key to OFF position, and stop the engine.
Page 139 For details of aftertreatment devices regeneration, see “HAN- DLE Komatsu Diesel Particulate Filter (KDPF) (3-113)”. The operation methods and the contents of the display of KDPF regeneration and urea SCR regeneration are common.
Page 140 EXPLANATION OF COMPONENTS OPERATION SCR INFORMATION Each item of “SCR information” menu (d) is for displaying infor- mation related to SCR and DEF. For details of SCR information, see “HANDLE UREA SCR SYSTEM WARNING (3-123)”. MAINTENANCE SCREEN SETTING Each item of setting menu (e) on “Maintenance” screen is used for displaying and setting the notification relevant to mainte- nance.
Page 141 • If you want to change the setting for the maintenance time or maintenance notice time (initial setting: 30 hours), consult your Komatsu distributor. Operations on the “Maintenance Due Time Reset” screen On the “Maintenance” menu screen, if switch F6 is kept pressed for at least 1.5 seconds, the screen changes to the “Maintenance Due Time Reset”...
Page 142 EXPLANATION OF COMPONENTS OPERATION MONITOR SETTINGS Each item of “Monitor Setting”menu (f) is to make settings for the monitor. SCREEN ADJUSTMENT Use the “Screen Adjustment” menu to adjust brightness of the monitor screen. Select “Screen Adjustment” (1) on the “Monitor Setting” menu screen, then press switch F6.
Page 143 The guide lines indicate blade width lines and a line 5 m away from the rear of the machine. When changing the blade, ask your Komatsu distributor for adjustment of the camera screen. Select camera screen adjustment on the monitor setting menu screen.
Page 144 EXPLANATION OF COMPONENTS OPERATION Use switches F2 to F6 to adjust brightness of the screen. F2: Resets an adjusted value to default value. F3: Moves the indicator to the left by one notch. F4: Moves the indicator to the right by one notch. F5: Cancels the change and returns the screen to “Screen Adjustment (Camera)”...
Page 145 OPERATION EXPLANATION OF COMPONENTS SET GUIDE LINE DISPLAY MODE Select the “Guide Line” on the “Screen Adjustment (Cam- era)” screen. Press switch F6. The “Guide Line” setting screen is displayed. • OFF: Guide lines (Outline (A), Center Line (B)) are not displayed.
Page 146 EXPLANATION OF COMPONENTS OPERATION The screen switches to the “Clock Adjustment” screen for selecting a menu. The following 5 items can be changed. (a): “GPS Synchronization” (b): “Calendar” (c): “Time” (d): “12h/24h Mode” (e): “Daylight Saving Time” REMARK • (b) Calendar and (c) Time need to be readjusted since they are reset after a long-term storage.
Page 147 OPERATION EXPLANATION OF COMPONENTS The “Calendar” screen is displayed. When year display (A) is highlighted in yellow, operate the switches as follows to change year display (A). If it is not necessary to change the year setting, press switch F6. F3: Calendar goes back 1 year.
Page 148 EXPLANATION OF COMPONENTS OPERATION The “Time” screen is displayed. When the hour display (D) is highlighted in yellow, operate the switches as follows to change hour display (D). If it is not necessary to change the hour setting, press switch F6. F3: The time goes back 1 hour.
Page 149 OPERATION EXPLANATION OF COMPONENTS Select “Daylight Saving Time” (e) on “Clock Adjustment” screen, then press switch F6. The “Daylight Saving Time” screen is displayed. F3: Moves to the next item (1 line below). Moves to the top line when on the bottom line. F4: Moves to the previous item (1 line above).
Page 150 The “Operator ID” menu is not displayed when the operator identification function is disabled. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or cancelling the operator identi- fication function. WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITH SKIP When the starting switch is ON and ID is inputted, the identified ID is displayed in the column of “Operator ID”...
Page 151 OPERATION EXPLANATION OF COMPONENTS • Input the already registered ID on the “Operator ID Change” screen and press F6. Then, the identified ID can be changed. A message is displayed below and the screen returns to the “Monitor Setting” menu screen. On the “Monitor Setting”...
Page 152 MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this mail confirmation menu (g). When there is any message, the User Message at the left end of the standard screen lights up.
Page 153 When the message display lights up in blue (B), it means that no reply has been made yet to any read message to your Komatsu distributor. Please reply to the message ac- cording to the replying method mentioned below: •...
Page 154: Switches
EXPLANATION OF COMPONENTS OPERATION REPLY TO MESSAGE Input the selected item number in the Numeric Input box (1) on the screen of mail confirmation menu (g). The selected item number is written in place (2) of the message text. • Input the number by using the monitor panel switch.
Page 155 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electri- cal system (except room lamp) are all turned off, and the en- gine is stopped.
Page 156 EXPLANATION OF COMPONENTS OPERATION WIPER SWITCH The wiper switch operates the windshield wiper. The wiper switches are as follows. (LH) Left door (FF) Front window (RH) Right door (RR) Rear window (INT) Wiper intermittent operation switch REMARK If the wiper blade is locked for some reason, the wiper stops automatically.
Page 157 OPERATION EXPLANATION OF COMPONENTS REMARK When washer tank and window washer hoses are removed, connect them correctly according to their colors. (A) For left (blue) (B) For right (red) (C) For rear (black) (D) For front (colorless) (E) Washer tube (tank side) (F) Washer tube (cab side) (G) Left door (blue) (H) Right door (red)
Page 158 EXPLANATION OF COMPONENTS OPERATION HEAD LAMP SWITCH The headlamp switch is used to light up the head lamp and monitor illumination. (A) Night position Lamps light up and monitor illumination is set to night mode. (B) Day position Lamps light up and monitor illumination is set to day mode. (C) OFF position Lamps go out.
Page 159 • Use the engine shutdown secondary switch only in an emergency. Immediately ask your Komatsu distributor for repair of the problem. • If this switch is set to the “STOP ENGINE” position by mistake while the machine is operating nor- mally, “Engine Shutdown Secondary SW In Operation”...
Page 160: Control Levers And Pedals
EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS AND PEDALS (1) Parking brake lever (5) Blade control lever (2) Joystick (steering, directional and gear shift lever) (6) Work equipment lock lever (3) Brake pedal (7) Ripper control lever (4) Decelerator pedal BLADE CONTROL LEVER The blade control lever is used to control the blade.
Page 161 OPERATION EXPLANATION OF COMPONENTS Tilting control (A) RIGHT tilt (B) Tilt LEFT Machine with dual tilt Press function switch F1, and the dual tilt mode is selected. This mode is used for lifting, tilting, and pitching the blade. • While dual tilt mode pilot lamp (M) is lit, the machine is set in the dual tilt mode.
Page 162 EXPLANATION OF COMPONENTS OPERATION Tilting control (A) RIGHT tilt (B) Tilt LEFT REMARK • In the dual tilt mode, the blade is tilted more than in the single tilt mode. • The dual tilt operation can be done in RAISE, HOLD or LOWER position.
Page 163 OPERATION EXPLANATION OF COMPONENTS Blade operation in each mode • Blade fine control mode (See “BLADE FINE CONTROL MODE PILOT LAMP (3-35)”.) ON: Fine control performance is higher than when OFF. OFF: Normal mode • Blade slow down mode (See “BLADE SLOW DOWN PILOT LAMP (3-34)”). ON: Blade lowers slowly to stroke end.
Page 164 EXPLANATION OF COMPONENTS OPERATION REMARK • When setting the parking brake lever to LOCK position, return the joystick (steering, directional and gear shift lever) to N (NEUTRAL) position. • When starting the engine, set the parking brake lever to LOCK position. When the parking brake lever is not in LOCK position, the limit switch operates, and the engine does not start.
Page 165 OPERATION EXPLANATION OF COMPONENTS Forward/reverse switching operation Position (a): Forward travel Position (b): Reverse travel Position N: Neutral When the lever is tilted forward, the machine travels forward. When the lever is tilted backward, the machine travel in re- verse. Steering operation Position (L): Left turn Position (R): Right turn...
Page 166 EXPLANATION OF COMPONENTS OPERATION REMARK • When the gear is shifted, the current gear speed is displayed in the gear speed display section of the ma- chine monitor. (Example) Neutral: "N" is displayed in the display section. Forward 2nd: "F2" is displayed in the display section. Reverse 3rd: "R3"...
Page 167: Other Equipment
OPERATION EXPLANATION OF COMPONENTS RIPPER CONTROL LEVER The ripper control lever is used for operating the ripper. (a) RAISE (b) HOLD: Ripper is stopped and held in this position. (c) LOWER Toggle switch (A) Decrease cutting angle: Cutting angle (α) is decreased. (B) Increase cutting angle: Cutting angle (α) is increased.
Page 168 EXPLANATION OF COMPONENTS OPERATION Push the door against the door catch (1). The door is fixed to the catch. When releasing the door, move lever (2) in the cab toward the front inside the cab. The catch releases. NOTICE • When keeping the door open, fix it securely to the catch.
Page 169 OPERATION EXPLANATION OF COMPONENTS Insert the key as far as it will go to the shoulder (A) and turn it. If the key is turned when it is not inserted all the way to the end, it may break. DOOR POCKET They are installed to the inside of the right and left doors.
Page 170 EXPLANATION OF COMPONENTS OPERATION 12V power supply The capacity of the accessory socket (2 places) is 144W (12V x 12A). • When it is used at one place: 144W (12V x 12A) • When it is used at 2 places: 144W in total REMARK Use this power source while engine is running.
Page 171 OPERATION EXPLANATION OF COMPONENTS Fuse capacities and circuit names Fuse box (1) Fuse ca- Name of circuit pacity 5 A Pedal brake switch 20 A Continuous power supply (cab) 20 A Continuous power supply (air conditioner) 10 A Horn power supply 5 A Parking Brake 20 A Seat, preheater, pin puller 20 A...
Page 172 EXPLANATION OF COMPONENTS OPERATION CIRCUIT BREAKER • If the starting switch does not operate when it is turned to ON position, remove the inspection cover under the front of the console box on the left side of the operator's seat and check the circuit breakers (A) and (B).
Page 173 Do not hold down the reset button of the circuit breaker for a long time. • If the starting motor does not operated after the circuit breaker is restored, contact your Komatsu distributor. REMARK The capacities of circuit breakers (A) and (B) are as follows.
Page 174 EXPLANATION OF COMPONENTS OPERATION NOTICE • Keep battery disconnect switch in ON position except the following cases. • When the machine is stored for a long time (more than a month) • When repairing the electrical system • When performing electric welding •...
Page 175 • After the starting switch has been turned off, the system operating lamp may stay lit for a long time. In such case, consult your Komatsu distributor. • The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon.
Page 176 “PROCEDURE FOR MANUAL STA- TIONARY REGENERATION (3-117)”. If soot accumulated in the KDPF exceed the defined level without performing “PROCEDURE FOR MANUAL STATIONARY REGENERATION (3-117)”, the Action level “L04” lights up in red. Stop the machine immediately and ask your Komatsu distributor. 3-114...
Page 177 • Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF fil- ters, adversely affect the engine such as deteriorated oil may reduce lubricating function, and it may cause failure.
Page 178 EXPLANATION OF COMPONENTS OPERATION When the degree of emergency is low • If KDPF soot accumulation caution lamp (2) lights up in yellow (action level (3): L01), screen (A) is displayed first. • The action level goes out 2 seconds after and the screen changes to standard screen (B).
Page 179 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION CAUTION Exhaust gas temperature may increase higher than the previous models during Aftertreatment Devices Regenera- tion. Avoid getting near the exhaust pipe outlet and around the aftertreatment device to prevent being burnt. Also, keep combustible materials away from the exhaust pipe outlet and around the aftertreatment device to prevent a fire.
Page 180 EXPLANATION OF COMPONENTS OPERATION REMARK After function switch F6 is pressed in step 6, the screen shown in the figure may be displayed. This indicates that the operations in steps 1 to 4 were not performed correctly or there is trouble other than KDPF soot accumulation ab- normality.
Page 181 OPERATION EXPLANATION OF COMPONENTS This screen is displayed during the manual stationary re- generation. It may take more than 40 minutes to complete the manual stationary regeneration. Do not touch any switch on the screen or operate fuel control dial until the regeneration is completed and the standard screen ap- pears again.
Page 182 EXPLANATION OF COMPONENTS OPERATION NOTICE Even if the regeneration is disabled, KDPF soot accumula- tion caution lamp (1) lights up if soot is accumulated and the manual stationary regeneration is required. If KDPF soot accumulation caution lamp lights up, move the ma- chine to a safe place and perform manual stationary regen- eration.
Page 183 OPERATION EXPLANATION OF COMPONENTS REMARK • When the regeneration is disabled, the aftertreatment devi- ces regeneration disable pilot lamp (2) is lit on the stand- ard screen. • The setting of the regeneration disable is canceled by turn- ing starting switch to OFF position. When the automatic re- generation needs to be kept disabled, perform the above procedure each time you start the engine.
Page 184 EXPLANATION OF COMPONENTS OPERATION Select the regeneration disable, press function switch F6, and the regeneration stops. REMARK The regeneration performed to protect the system may not be stopped, but this is not a failure. PROCEDURE FOR CANCEL OF AFTERTREATMENT DEVICES REGENERATION DISABLE SETTING CAUTION When canceling the regeneration disable, move the machine to a safe place and check that there is no...
Page 185 The Komatsu Urea System also monitors recurrences of abnormalities of the system. Inducement in the recur- rences is activated when another abnormality occurs within 40 hours after the first abnormality is fixed. The Komatsu’s Urea is composed of two major systems, which are the DEF system and the SCR catalyst Ass’y. 3-123...
Page 186 In addition, it may cause fail- ures in the engine system. If DEF out of the standard is filled or used by mistake, contact your Komatsu dis- tributor. About the operation of Urea SCR system The Urea SCR System automatically starts operating as soon as the engine is started.
Page 187 OPERATION EXPLANATION OF COMPONENTS and injection while heating continues. Once the ambient temperature rises above a temperature where DEF system becomes functional, it resumes operation automatically. Short duration of white plume given off from the tail pipe may be visible at and shortly after engine start-up in cold weather, but this is not malfunction.
Page 188 EXPLANATION OF COMPONENTS OPERATION • Warning: 2 gradations of the DEF level gauge light up in the red range. The DEF level caution lamp (1) lights up in red. No audible alert. No Action level is displayed. Press F6 to display the “SCR Information” screen. Inducement status (4): “1 DEF low level warning appears.”...
Page 189 “L04 (Severe Inducement)” is displayed. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 190 EXPLANATION OF COMPONENTS OPERATION Perform the following procedure. Press F6 on the standard screen to display the “SCR Informa- tion” screen of the user menu. If either the parking brake lever and work equipment lock lever are set to LOCK position or the joystick (steering, directional and gear shift lever) is in NEUTRAL position for over 3 sec- onds, “SCR Information”...
Page 191 OPERATION EXPLANATION OF COMPONENTS “SCR Information” screen message (4): “2 Without treat- ment, engine power will be derated.” Move the machine to the safe place and contact your Ko- matsu Distributor. The duration of “Continuous Warning” is 5 hours. The re- maining time (Hours and Minutes) to “Low level Induce- ment”...
Page 192 Komatsu distributor. This engine power restoration works only when the Inducement status is “Severe Inducement” and relieves back temporarily to the power deration of “Low level Inducement”.
Page 193 OPERATION EXPLANATION OF COMPONENTS • Warning: The audible alert sounds in short and sharp beeps. The KDPF system caution lamp (1) lights up in red. The action level “L03” lights up in red at action level dis- play (3). Press F6 to display the “SCR Information” screen. “SCR Information”...
Page 194 Komatsu distributor. Inducement strategy when abnormality is found in the EGR Valve System by the...
Page 195 “Severe Inducement”, the engine power will be further derated. If “L03” is displayed, move the machine to a safe place and contact your Komatsu distributor. The content of the warning can be checked on the “SCR Information” screen of the user menu.
Page 196 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen message (5): “1 Please inspect and maintain SCR system.” Engine power is derated. Move the machine to the safe place and contact your Ko- matsu Distributor. If operation continues for 5 hours after “Warning” started without taking any actions instructed by the Action Level table, Inducement advances to “Continuous Warning”.
Page 197 “Temporary Restoration from Inducement” in this manual. If Inducement advances to “Severe In- ducement” and it becomes necessary to restore engine power, use the engine power restoration function to move the machine to a safe place and contact your Komatsu distributor. Temporary Restoration from Inducement Temporary Restoration from Inducement is the one of the Inducement strategies allowed to be included in Urea SCR systems.
Page 198 EXPLANATION OF COMPONENTS OPERATION Press F6 to display the menu windows popping up in the bottom half of the “SCR Information”. The menu windows popping up in the bottom half of the “SCR Information” screen alternate every 15 seconds as shown in the graphics A and B.
Page 199 Inducement. If this occurs, utilize “Temporary Restoration from Inducement” and move to the machine to a safe place, and contact your Komatsu distributor. The maximum duration of power restoration is 30 minutes and 3 operations are allowed.
Page 200 It can be useful for you to perform the machine management by yourself. Your Komatsu distributor uses the above ma- chine information for supply of service to the customers, improvement of our products and service, etc.
Page 201 In other cases that Komatsu or Komatsu distributor judges that it is necessary to suspend KOMTRAX com- munication. If you do not observe the above rules, neither Komatsu nor your Komatsu distributor shall be held liable for any resulting impacts or damages.
Page 202: Machine Operations And Controls
Remove dirt and check DEF line for leakage. Check for dirt accumulated around the DEF tank and clean blue DEF tank filler cap and surrounding area. Check DEF tank, pump, injector, hoses, and joints for leakage. If any problem is found, ask your Komatsu distributor for repair.
Page 203 12. Check the seat belt and mounting hardware. Check the seat belt and mounting hardware for any abnormality. If any damage is found, ask your Komatsu distributor to replace it with new one. 13. Check and clean the rearview camera (if equipped) Check the rearview camera for any abnormality.
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION Turn drain valve (1) to OPEN position to drain all the sedi- ment and water accumulated at the bottom together with fuel to the container to receive. When only the clean fuel flows out, turn drain valve (1) to CLOSE position.
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS Stop the machine on a level place. If the machine is inclining, make it level before checking. Set the machine in the posture shown below for checking the oil level, and stop the engine. (SIGMA dozer) Lower blade (a) so that the tilt cylinder length is the value in the table below.
Page 206 MACHINE OPERATIONS AND CONTROLS OPERATION (Semi-U dozer, U-dozer) Lower blade (a) so that the tilt cylinder length is the value in the table below. Lower ripper (b) to the ground with the pin at the bottom so that the length of each cylinder is the value in the table below.
Page 207 OPERATION MACHINE OPERATIONS AND CONTROLS If the level is below level L, add through filler port (F). METHOD FOR CHECKING COOLANT LEVEL, ADDING COOLANT WARNING • Do not open the radiator cap unless necessary. When checking the coolant level, check the reser- voir tank when the engine is cold.
Page 208 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN ENGINE OIL PAN, ADDING OIL WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they have cooled down before starting the work. •...
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS Remove drain plug (3) from the taking-off opening. Loosen drain valve (4) and drain excessive oil, and then check the oil level again. If the oil level is proper, tighten the oil filler cap securely. Close the engine side cover.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION Remove drain plug (2) through the taking-off opening, and loosen drain valve (3) and drain excessive oil. When draining the engine oil, put a container to re- ceive the oil under the drain plug. Tighten drain valve (3). Check the oil level again.
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS Open inspection cover (2) at the center of the power train case bottom. Drain excessive oil through drain plug (P) of the en- gine damper at the front of the machine which is seen through the inspection window. When draining the engine oil, put a container to re- ceive the oil under the drain plug.
Page 212 • If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause of it and to perform the repair. • Keep the top surface of the battery clean and check the vent hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap with water to clear the vent hole.
Page 213 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the audible alert sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and for inspection. DEF injector and/or DEF pump may need to be replaced.
Page 214 MACHINE OPERATIONS AND CONTROLS OPERATION After checking, turn the starting switch back to OFF posi- tion (A). Check that the engine is stopped. Open up cover (1) at the left side of the machine, clean blue DEF tank filler cap (2) and surrounding area. Turn the cap (2) counterclockwise.
Page 215 If the lamps do not light up, a broken bulb or disconnected wire are the possible causes. Ask your Komatsu distributor for repairs. After finishing the check, turn the head lamp to OFF posi- tion (c) and turn the rear lamp to OFF position (e).
Page 216 Do not perform the check before starting only on the monitor. Always perform other checks before start- ing. Turn starting switch (1) to ON position (B). Check that KOMATSU mark is displayed first and then the camera screen and the basic monitor screen is displayed in order, and the buzzer sounds for approximately 2 sec- onds.
Page 217 MACHINE OPERATIONS AND CONTROLS If the horn does not sound or its volume is extremely low, it may be broken or may have an open circuit. Ask you Komatsu distributor for repair. METHOD FOR CHECKING BACKUP ALARM OPERATION STATUS Turn the starting switch to ON position (B).
Page 218 MACHINE OPERATIONS AND CONTROLS OPERATION MECHANICAL SUSPENSION SEAT METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, set the seat to the de- sired position. Fore-and-aft adjustment: 160 mm (16 stages) After adjusting, release the lever. METHOD FOR RECLINING SEAT The reclining of the seat becomes large when the seat is moved forward, and it becomes smaller as the seat is moved backward.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING WEIGHT AND HEIGHT OF SEAT Pull out the crank of knob (1) under the seat and turn it so that weight indicator (2) reads the green range. You can adjust the height by turning knob (1) in the green range. X: When crank is stored Y: When crank is pulled out (for adjusting weight) Adjust the weight according to the following procedure.
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING LUMBAR SUPPORT Turn the adjustment knob to the right or left, and give proper tension to the waist part. The back cushion tension is increased by turning the adjust- ment knob to the right. The tension of the back cushion can be adjusted to 5 steps.
Page 221 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When the seat surface temperature is above approximately 20 °C, the heater does not operated even if switch (8) is turned ON. AIR SUSPENSION SEAT (if equipped) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, set the seat to the de- sired position.
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION The seat height can be adjusted by fully pressing down or pull- ing up lever (2). When it is adjusted to the desired position, you can release the lever. When raising, pull up the lever until it clicks. If the lever is pulled up and held, the seat stops at the maxi- mum height.
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR HEATING SEAT Turn the seat heater switch ON. (a): OFF position (b): ON position The backrest and seat surface are heated. When the seat heater switch is turned ON, the heater in the seat operates. When the seat surface temperature exceeds approximately 20 °C, the heater is turned OFF automatically.
Page 224 MACHINE OPERATIONS AND CONTROLS OPERATION Pull up lock lever (1) at the rear of case (2) on the left side of the operator's seat, and set it to FREE position (F). While pulling up lock lever (1) with one hand, hold the front part of case (2) with the other hand, and move in the for- ward and backward directions with both hands.
Page 225 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING • Before fastening the seat belt, check that there is no problem in the belt mounting bracket or belt. If it is worn or damaged, replace it. •...
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR UNFASTENING SEAT BELT Press button (5) in buckle (4) and remove tongue (3) from buckle (4). The belt is automatically wound in, hold grip (2) and return the belt slowly to retractable device (1). METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE WARNING •...
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS Check that joystick (steering, directional and gear shift lev- er) (2) is in N (neutral) position. When joystick (steering, directional and gear shift lever) (2) is in FORWARD or REVERSE, the letter P on speed range display (A) will flash.
Page 228 If a password is set, the input display screen will be indi- cated on the monitor screen. REMARK Contact your Komatsu distributor for details of the method of setting, changing, or canceling the password. 10. Perform the following inspection on the machine monitor.
Page 229: Method For Starting Engine
OPERATION MACHINE OPERATIONS AND CONTROLS After approximately 2 seconds, the screen will change to the preset (speed range to start) display screen. Then, it will switch to the standard screen. • Engine coolant temperature caution lamp (9) • Engine coolant temperature gauge (10) •...
Page 230 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not turn the starting motor continuously for more than 20 seconds. If the engine does not start, wait for approximately 2 minutes, and then repeat the opera- tion from step 2. • Before starting, check that the fuel control dial is in Low idle (MIN) position.
Page 231 OPERATION MACHINE OPERATIONS AND CONTROLS Turn starting switch key (2) to START position (C). The engine will start. When the engine starts, release the starting switch key (2). The key will return automatically to ON position (B). REMARK • White smoke may be discharged for a short time im- mediately after the engine is started or during the Af- tertreatment Devices Regeneration in the cold season, but this is not a failure.
Page 232 MACHINE OPERATIONS AND CONTROLS OPERATION When the ambient temperature is low, start the engine according to the following procedure. Check that the parking brake lever is in LOCK position (L). If parking brake lever is not set to LOCK position (L), the engine cannot be started.
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS Check if preheating pilot lamp on the monitor panel (3) is lighting up. If a password has been set, the input display screen will be indicated on the monitor screen, but the preheating pilot lamp operates as in the standard screen. Leave this condition until preheating pilot lamp goes out.
Page 234 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • If the key of starting switch (2) is turned counterclockwise from OFF position, preheating pilot lamp lights up and preheating is performed, regardless of the ambient temperature. (Preheating continues while starting switch (2) is held counterclockwise.) For the preheating time, see the table in step 7.
Page 235: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 236 (A) to (C). • (A) to (B): Red range • (A) to (C): Green range • (C) to (D): White range Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. 3-174...
Page 237 (C) to (D): White range REMARK If the power train oil temperature is not sufficiently high, it takes longer to reach the maximum speed. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distributor. 3-175...
Page 238: Method For Stopping Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING ENGINE WARNING Keep away from the exhaust pipe immediately after stopping the engine. NOTICE If the engine is stopped before it is cooled down, the serv- ice lives of component parts of the engine may be consid- erably reduced.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK • When the key in starting switch (2) is turned to OFF position, the engine stops but the power supply to the machine is not turned OFF immediately. During this period, the power is supplied to the con- troller to save the operating condition and then finish the system.
Page 240: Method For Starting Machine (Travel Forward And Reverse) And Stopping Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MACHINE METHOD FOR MOVING MACHINE WARNING • Check that the area around the machine is safe, and sound the horn before starting the machine. • Keep people away from the machine.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Set blade control lever (3) to RAISE (a) position and raise the blade to 40 to 50 cm above the ground. Set ripper control lever (4) to RAISE (a) position and raise the ripper to the upper limit. Turn fuel control dial (5) to High idle (MAX) position and in- crease the engine speed.
Page 242: Shift Gears
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STOPPING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Do not park the machine on a slope. If it is unavoida- bly necessary to park the machine on a slope, place parking brake lever (1) in LOCK position and insert blocks underneath the track shoes to prevent the ma- chine from moving.
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS Move joystick (steering, directional and gear shift lever) (1) to the desired speed range to shift gears. METHOD FOR SHIFTING GEARS Shift the gear by pressing switches (a) and (b). Up switch (a): The gear is shifted up by 1 step each time this switch is pressed.
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHANGING GEARSHIFT MODE The automatic shift mode and manual shift mode are changed over to each other by pressing the gear shift mode selector switch while the speed range is in neutral. DISPLAY OF GEAR SHIFT MODE The gear shift mode is displayed in the gear shift mode display section of the monitor panel as shown below.
Page 245 OPERATION MACHINE OPERATIONS AND CONTROLS Manual shift mode Set the starting speed range. METHOD FOR GEARSHIFTING OPERATION USING PRESET MODE FUNCTION The preset mode selection is the function to set the maximum travel speed range (automatic shift mode) or starting speed range (manual shift mode). You can select a shift mode by pressing up switch (a) or down switch (b) while the joystick (steering, directional and gear shift lever) is in N (Neutral) position.
Page 246 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK Even while you are setting the preset mode, you can perform gear shift operation by operating the up switch and down switch. For detail, see “METHOD FOR CHANGING GEAR SPEED WITH SHIFT SWITCH OPERA- TION WHILE TRAVELING (3-184)”.
Page 247: Method For Switching Between Forward And Reverse
OPERATION MACHINE OPERATIONS AND CONTROLS (Manual shift mode) Changing maximum speed range used when traveling • When traveling forward: Possible to change speed range used from F1 through F3 • When traveling in reverse: Possible to change speed range used from R1 to R3 Up switch (a): Each time it is pressed, speed range used goes up one range.
Page 248: Method For Steering Machine
MACHINE OPERATIONS AND CONTROLS OPERATION Depress decelerator pedal (1) to decrease the engine speed, and stop the machine. Set joystick (steering, directional and gear shift lever) (2) to a desired position. Release decelerator pedal (1) gradually, and increase the engine speed to start the machine. REMARK •...
Page 249 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR TURNING THE MACHINE WHILE TRAVELING FORWARD When gradually turning to the left, tilt the joystick (steering, di- rectional and gear shift lever) forward and tilt it to left (L) half- way. REMARK When gradually turning to the right, tilt the joystick (steering, di- rectional and gear shift lever) forward and tilt it to right halfway.
Page 250: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR TURNING WHILE TRAVELING ON DOWNHILL METHOD FOR TURNING THE MACHINE GRADUALLY WHILE TRAVELING FOR- WARD When gradually turning to the left, tilt joystick (steering, direc- tional and gear shift lever) forward and tilt it to left (L) halfway. Cross steering does not occur.
Page 251: Precautions When Operating On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PRECAUTIONS WHEN TRAVELING ON SLOPES USE DECELERATOR PEDAL When stepping on the decelerator pedal while going uphill, climbing ability will be reduced and the machine will stop. Furthermore, the engine may stall. USE ENGINE BRAKE When traveling downhill, move joystick (steering, directional and gear shift lever) into low speed to run engine at slow speed and travel down slope using the engine brake.
Page 252: Do Not Open Door While Operating Machine
MACHINE OPERATIONS AND CONTROLS OPERATION • Apply the brake sharply during travel at high idle. • Operate the brake while the engine is running at high idle in the 1st speed range (F1 or R1). (Machine is stalled) DO NOT OPEN DOOR WHILE OPERATING MACHINE Always keep the door closed when traveling or performing operations.
Page 253 OPERATION MACHINE OPERATIONS AND CONTROLS SLOT DOZING WORK You can carry more soil by dozing in the slot. Do not perform dozing deeper than blade tip. Work efficiency is better when starting the excavation work of the slot from the place near the dumping place. When you dig the two slots in parallel, keep the soil wide enough between them so that it does not collapse.
Page 254 MACHINE OPERATIONS AND CONTROLS OPERATION To finish the ground to a flat surface after digging or piling soil, put a full load of soil on the front face of the blade and operate the blade up and down in small movements while traveling for- ward.
Page 255: Effective Use Of Ripper
OPERATION MACHINE OPERATIONS AND CONTROLS EFFECTIVE USE OF RIPPER • The optimum shank angle to the ground is approximately 90 ° (the cutting edge angle is 45 to 50 °). • The ripper can dig rocks even if the shank is tilted out (rip- per point tip angle is large), if they are relatively soft (elas- tic wave 1200 m/s or less).
Page 256 MACHINE OPERATIONS AND CONTROLS OPERATION Slope: Face of bank, etc. METHOD FOR OPERATING PIN PULLER (Only machine equipped with giant ripper) Stop the machine on a safe place. Lower the shank to the ground. Turn the pin puller switch at the rear of the ripper control lever to PULL position (1).
Page 257: Operating Method For Ripping Work
OPERATION MACHINE OPERATIONS AND CONTROLS Turn the pin puller switch to PUSH position (2). Insert the mounting pin. If the shank hole position does not match to the pin, turn pin puller switch to PUSH position (2). In this state, move the ripper up and down slowly. REMARK When raising the pin position and digging deep, use the long protector to prevent wear of the shank.
Page 258 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • If the ripper is applied while the rear of the machine is raised from the ground, length of track on ground (A) decreases. Accordingly, the drawbar pull decreases and the ripping efficiency lowers. •...
Page 259 OPERATION MACHINE OPERATIONS AND CONTROLS • If there is a hard rock-bed during the ripping operation, ap- ply the second ripping in the opposite direction to the first ripping. If you still cannot break the rock-bed, break it little by little from its periphery.
Page 260 MACHINE OPERATIONS AND CONTROLS OPERATION If you cannot break or dig up the boulder by repeating step 3, perform the following operation. Move back approximately 10 cm, and then raise the shank. Move forward around rocks and boulders you cannot rip, and restart ripping. PRECAUTIONS WHEN RIPPING •...
Page 261: Method For Adjusting Work Equipment
OPERATION MACHINE OPERATIONS AND CONTROLS • Do not rip rock-beds with the shank length at the maxi- mum. The shank may not penetrate sufficiently and may be over- loaded, and accordingly the shank may be broken. METHOD FOR ADJUSTING WORK EQUIPMENT METHOD FOR ADJUSTING BLADE WARNING It is dangerous if the work equipment moves by mistake when the blade is adjusted.
Page 262 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SHIM AT BLADE LIFT CYLINDER CAP Set standard shim thickness (A) of the blade lift cylinder cap to 4 mm. Remove some shims, according to the wear of the cap and cyl- inder mounting ball. Proper clearance: 0.2 to 1.2 mm METHOD FOR ADJUSTING BRACE WARNING...
Page 263 OPERATION MACHINE OPERATIONS AND CONTROLS WARNING It is dangerous if the work equipment moves by mistake when the angle of blade edge is adjusted. Set the work equipment in a stable condition, stop the engine and set the work equipment lock lever secure- ly to LOCK position.
Page 264 MACHINE OPERATIONS AND CONTROLS OPERATION ADJUST DIGGING DEPTH There are mounting pin holes on the shank. Use either of them according to the digging depth. Use the lower hole for the ordinary digging, and use the upper one for deep digging. Change the digging depth according to the following procedure.
Page 265: Tips For Longer Undercarriage Life
OPERATION METHOD • Use a track shoe suitable for soil condition. For selection of the shoe, consult your Komatsu distributor. • Do not let the shoe slip during operation. If the shoe starts slipping, decrease the load to prevent slipping.
Page 266 Extremely low track tension can cause abnormal vibration or abnormal wear of sprocket teeth. In addition, whenever jobsite or ground condition is changed, Komatsu recommend customer to adjust track tension. For an inspection and maintenance method, see “METH- OD FOR CHECKING AND ADJUSTING TRACK TENSION (4-23)”, and perform an inspection and adjust- ment of track tension..
Page 267 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR MEASURE GROUSER HEIGHT Eliminate the sag of the track, and measure at the center of the track. Standard dimension (h): 80 mm Repairable limit: 30 mm METHOD FOR MEASURING TRACK ROLLER DIAMETER Measure the link tread (dimension C) as shown in the fig- ure.
Page 268: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR PARKING MACHINE WARNING • Avoid a sudden stop. Stop the machine gradually. • Park the machine on a firm and level place. Do not park the machine on a slope. If you have to park on a slope, set parking brake lever (4) to LOCK position, block the track, and thrust the work equipment into the ground to prevent movement of the machine.
Page 269: Method For Checking After Finishing Work
Perform walk-around check for oil or coolant leakage and for abnormality in work equipment, exterior parts, and undercarriage. If oil or coolant leakage or any abnormality is detected, repair it. Check DEF tank, pump, injector, hose, and joint for leakage. If any abnormality is found, ask your Komatsu distributor for repair. 3-207...
Page 270: Lock
MACHINE OPERATIONS AND CONTROLS OPERATION Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. Remove any mud affixed to the undercarriage. LOCK To prevent vandalism, there are locks in the following places. Places that can be locked with the starting switch key.
Page 271 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key counterclockwise. Align the rotor groove with match mark (2) of the cap. Turn the cap slowly. If a “click” is heard, the cap is unlocked and can be re- moved. PROCEDURE FOR CLOSING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot.
Page 272 MACHINE OPERATIONS AND CONTROLS OPERATION • Cab door opener Position (A): OPEN Position (B): CLOSE (LOCK) • R.H. and L.H. engine side covers, battery inspection cover, reservoir tank inspection cover, tool box storage cover, DEF tank inspection cover, and water separator inspection cover Position (A): OPEN Position (B): CLOSE (LOCK)
Page 273: Handle Air Conditioner
If any abnormality is detected in any equipment or sensor used on the air conditioner, the air conditioner system caution lamp lights up on the monitor screen. If the air conditioner system caution lamp lights up, ask your Komatsu distributor for inspection and repair. Ventilation •...
Page 274: Explanation Of Air Conditioner Equipment
HANDLE AIR CONDITIONER OPERATION EXPLANATION OF AIR CONDITIONER EQUIPMENT (1) Sunlight sensor (6) Vent selector switch (2) Display monitor (7) FRESH/RECIRC air selector switch (3) Auto switch (8) Fan switch (4) Air conditioner switch (9) Temperature control switch (5) OFF switch OFF SWITCH This switch is used for stopping the fan and air conditioner.
Page 275 OPERATION HANDLE AIR CONDITIONER Monitor display and air flow Monitor display Air flow rate Air flow "low" Air flow "medium 1" Air flow "medium 2" Air flow "medium 3" Air flow "medium 4" Air flow "high" TEMPERATURE SET SWITCH Use the temperature set switch to adjust the temperature inside the cab.
Page 276 HANDLE AIR CONDITIONER OPERATION (A1): Face vent (right and left 1 place) (A2): Rear vent (2 places) (A3): Front vent (2 place) (B): Foot vent (2 place) (C1): Door glass vent (right and left 1 places) (C2): Front window glass vent (1 place) Air blows out from the vents marked with ○.
Page 277 OPERATION HANDLE AIR CONDITIONER AUTO SWITCH Use the auto switch for automatic selection of the air flow, vents, and air source (FRESH/RECIRC) according to the set temperature. • Press this switch, then use temperature control switch (1) to set the temperature, and run the air conditioner under automatic control.
Page 278: Method For Operating Air Conditioner
HANDLE AIR CONDITIONER OPERATION When OFF switch (1) is pressed, the display of temperature setting (a) and air flow (b) goes out, and operation stops. AIR CONDITIONER SWITCH Use air conditioner switch for turning the air conditioner (cool- ing, dry heating) ON or OFF. •...
Page 279 OPERATION HANDLE AIR CONDITIONER Set temperature (a) and air flow (b) are displayed. Use temperature control switch (2) to set to the desired temperature. The air flow, combination of vents, and selection of fresh or recirculated air is automatically selected according to the set temperature, and the air conditioner is operated auto- matically to provide the set temperature.
Page 280 HANDLE AIR CONDITIONER OPERATION METHOD FOR MANUAL OPERATION Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. Turn air conditioner switch (2) ON. Use temperature control switch (3) to set to the desired temperature.
Page 281 OPERATION HANDLE AIR CONDITIONER Press vent selector switch (4) and select the desired vents. When this is done, the display for vent (c) of the monitor changes according to the selection. Press FRESH/RECIRC selector switch (5) and select recir- culation of the air inside the cab (RECIRC) or intake of fresh air from outside (FRESH).
Page 282 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING WITH COLD AIR TO FACE AND WARM AIR TO FEET To operate with cold air blowing to the face and warm air blow- ing to the feet, set as follows. Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor.
Page 283 OPERATION HANDLE AIR CONDITIONER Turn air conditioner switch (2) ON. Adjust fan switch (1), temperature control switch (3) and FRESH/RECIRC selector switch (5) to the desired posi- tions. 3-221...
Page 284 HANDLE AIR CONDITIONER OPERATION METHOD FOR OPERATING DEFROSTER Press fan switch (1) and adjust the air flow. When doing this, check that temperature setting (a) and air flow (b) are displayed on the monitor. Press vent selector switch and set vent display on the dis- play monitor to (f) or (g) as shown in the figure.
Page 285 OPERATION HANDLE AIR CONDITIONER Press FRESH/RECIRC selector switch (5) and set it to FRESH mode. Press temperature control switch (1) and set temperature on the monitor to 32.0 of maximum heating. When operating in the rainy season or when it is desired to remove the mist from the window glass or to dehumidify the air, turn air conditioner switch (2) ON.
Page 286: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the sound to a level where it is possible to hear extraneous sound during operation. • If water gets into the speaker case or radio, it may lead to failure. Take care that no water fall on them. •...
Page 287 OPERATION HANDLE RADIO It is possible to preset 6 stations each for both AM and FM. DISPLAY SELECTOR BUTTON Use the display selector button to change frequency and clock shown on the display. Each time you press this button, frequency, clock and band are shown on the display in this order. If 1.5 seconds passes while a band is shown, a frequency will be displayed.
Page 288: Method For Controlling Radio
HANDLE RADIO OPERATION Open cap (a). Connect a portable audio equipment by using an commer- cially available audio cable. Press the band/AUX selector button and select AUX. METHOD FOR CONTROLLING RADIO METHOD FOR ADJUSTING FREQUENCY Press band/AUX selector button (1) and select FM or AM. Press tuning/time adjustment button (2) to adjust the fre- quency.
Page 289 OPERATION HANDLE RADIO METHOD FOR CALLING PRESET Press band/AUX selector button (1) and select FM or AM. Press one of 1 to 6 of preset button (2). The frequency registered in the preset number of the pressed button is called up and received. “Example”...
Page 290: Antenna
HANDLE RADIO OPERATION METHOD FOR ADJUSTING HIGH REGISTER RANGE (TREBLE) Press sound control button (1) to light up “TRE” on the dis- play. You can adjust the high register range (treble) of the sound. Press tuning/time adjustment button (2) to adjust the high register range (treble).
Page 291: Transportation
Select the transportation route taking into consideration of the width of the road as well as the height and weight of the machine. Since the transportation-related specified values are set forth in the applicable laws and regulations, contact your Komatsu dealer before performing the planned transportation. Transportation method TRAVEL ON ROAD When traveling on paved roads, use flat shoes to protect their surface.
Page 292: Loading And Unloading With Trailer
TRANSPORTATION OPERATION LOADING AND UNLOADING WITH TRAILER WARNING • Since loading and unloading of the machine is dangerous, be extremely careful. • When loading or unloading the machine, lower the engine speed, set the speed range to the 1st, and operate slowly.
Page 293 OPERATION TRANSPORTATION METHOD FOR SECURING MACHINE NOTICE Be sure to keep the radio antenna tilted into the storage position. After loading the machine onto a trailer, secure the machine as follows. Lower the work equipment slowly. (When transporting with work equipment installed) Set the work equipment lock lever securely to LOCK posi- tion (L).
Page 294: Method For Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs depending on the attachments and options installed. For details of the procedure for machines that are not the standard specification, consult your Komatsu distributor. For the weight, see “SPECIFICATIONS (5-2)”.
Page 295 OPERATION TRANSPORTATION When lifting the machine, stop the machine on a level place, and perform the following procedure. Stop the engine. Set the parking brake lever securely to LOCK position (L). Set the work equipment lock lever securely to LOCK posi- tion (L).
Page 296: Cold Weather Operation
If DEF or the machine equipped with DEF system cannot be stored at the outside temperature is lower than –11 °C, DEF in the tank may freeze. Ask your Komatsu distributor for discharging of DEF, and keep it in the condition free from freezing.
Page 297: Precautions After Daily Work Completion In Cold Weather
OPERATION COLD WEATHER OPERATION When the ambient temperature drops, the capacity of the battery will also drop. Maintain the battery charging rate as close as possible to 100%. Insulate it against cold temperature to ensure that the machine can be started easily in the next morning.
Page 298 COLD WEATHER OPERATION OPERATION If the machine is parked for long time in the cold weather condition, quality of DEF may be affected by repeated freeze, ask your Komatsu distributor to inspect. 3-236...
Page 299: Precautions For Long-Term Storage
STARTING MACHINE AFTER LONG-TERM STORAGE NOTICE If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor before using it. When using the machine after long-term storage, perform the following items before using it. •...
Page 300 If SCR system still has abnormality after the engine is restarted, contact your Komatsu distributor. • If DEF is kept in DEF tank for more than 1 year, ask your Komatsu distributor for replacement. Dispose of drained DEF according to the local regulations and rules.
Page 301: Troubles And Actions
If the engine stops or the oil pressure in the brake circuit lowers because of a trouble in the hydraulic sys- tem, the brake works and the machine cannot move. To move the machine in this case, the oil pressure in the brake circuit must be heightened to the specified level with a special device. Contact your Komatsu dis- tributor.
Page 302 TROUBLES AND ACTIONS OPERATION • If the machine gets stuck in the mud or a heavy thing needs to be towed, install a towing wire rope to the towing hook as shown in the figure on the right. If the machine is equipped with the counterweight, install the wire rope to the towing hook of the counterweight.
Page 303: Precautions For Discharged Battery
OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR DISCHARGED BATTERY WARNING • It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charg- ing. • When checking or handling the battery, stop the en- gine and turn the starting switch and battery discon- nect switch keys to OFF positions.
Page 304 TROUBLES AND ACTIONS OPERATION Turn the battery disconnect switch to OFF position (O). Remove battery cover (2) by using a small crane, etc. Remove bolt (3). Remove plastic sheet (4). When removing the battery cables, first remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive (+) terminal and the chassis, there is a hazard of sparks being generated.
Page 305 OPERATION TROUBLES AND ACTIONS PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, it is dangerous that the battery may explode. Al- ways follow the instruction manual accompanying the charger, and observe the following. •...
Page 306 TROUBLES AND ACTIONS OPERATION START ENGINE WITH JUMPER CABLES WARNING • When connecting the cables, never contact the posi- tive (+) and negative (-) terminals. • Always wear protective eyeglasses and rubber gloves when starting the engine by using the jumper cable. •...
Page 307: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 308 PHENOMENA AND ACTIONS FOR CHASSIS • For the remedies indicated with (*) in the remedy column, always contact your Komatsu distributor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs. Problem Main causes Remedy...
Page 309 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • As for the corrective actions indicated with (*) in the remedy column, always contact your Komatsu distribu- tor. • In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
Page 310 TROUBLES AND ACTIONS OPERATION Problem Main causes Remedy Steam spurts out from top of radiator. Lowered coolant level, leakage of Check, add coolant, repair. See (pressure valve) coolant CHECK BEFORE STARTING. Dirt or scale accumulated in cooling Change coolant, flush inside of cool- system ing system.
Page 311 If CA2249 or CA559 does not disappear even after the re- placement, ask your Komatsu distributor for an inspection immediately, even though the machine can per- form normal operation. Telephone number for the point of contact if an error occurs...
Page 313: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 314: Precautions For Maintenance
Komatsu recommends using Komatsu genuine parts specified in Parts Book as replacement parts. KOMATSU GENUINE LUBRICANTS For lubrication of the machine, Komatsu recommends using Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. ALWAYS USE CLEAN WASHER FLUID Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 315: Precautions For Kdpf
MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR KDPF When performing inspection and maintenance during or just after regeneration, take care of the high tempera- ture parts. Even after the engine stops the parts around KDPF may be at high temperature. PRECAUTIONS FOR SCR ASSEMBLY Be careful for the high temperature parts when performing inspection and maintenance.
Page 316 PRECAUTIONS FOR MAINTENANCE MAINTENANCE Checks after operation (with engine stopped) • Have any inspection and maintenance points been forgotten? • Have all inspection and maintenance items been performed correctly? • Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism.
Page 317: Outline Of Maintenance
Oil remaining in the piping and cylinders may be mixed in. NOTICE Komatsu recommends using Komatsu genuine engine oil for KDPF. If engine oil other than Komatsu genuine oil for KDPF is used, it may shorten cleaning interval of KDPF filters, adversely affect the en- gine such as deteriorated oil may reduce lubricating function, and it may cause failure, shortening of the machine life, lowering of performance and increase of fuel consumption.
Page 318 (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 319 Grease is used to prevent seizure and noises at the joints. • This construction equipment is used under heavy-duty conditions. Komatsu recommends using the recom- mended grease and follow the replacement intervals and recommended ambient temperatures given in this Operation and Maintenance Manual.
Page 320 Perform sampling at regular fixed intervals. • Do not perform sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, contact your Komatsu distributor. STORE OIL AND FUEL • Keep oil and fuel indoors to prevent any water, dirt, or other impurities from getting in.
Page 321: Handle Electrical Components
Komatsu recommends installing electric components specified by Komatsu. • External electro-magnetic interference may cause malfunction of the control system controller. Accordingly, consult your Komatsu distributor before installing a radio receiver or other wireless equipment to the ma- chine. • When working on the seashore, carefully clean the electric system to prevent corrosion.
Page 322 OUTLINE OF MAINTENANCE MAINTENANCE • When the hydraulic oil filter element or strainer is replaced or cleaned, or when a hydraulic component is repaired, replaced, or its piping is removed, air in the circuit must be bled. • The accumulator is charged with high-pressure nitrogen gas, and it is extremely dangerous if it is handled incorrectly.
Page 323: Standard Tightening Torque For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, Komatsu recom- mends using Komatsu genuine part of the same size as the part that is removed.
Page 324 STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS MAINTENANCE Taper seal Tightening torque Nominal Thread size “a” Width across flats Target value Allowable range No. of hose (mm) “b” (mm) Nm kgm Nm kgm 34 to 63 3.5 to 6.5 59 to 98 6.0 to 10.0 10.5 84 to 132...
Page 325: Maintenance Schedule
MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE If the currently used diesel fuel which does not include the bio-fuel is changed to the one mixed with the bio-fuel, the replacement interval of the fuel filter is changed as well. See “MAINTENANCE INTERVAL WHEN DIESEL FUEL MIXED WITH BIO-FUEL IS USED”.
Page 326 MAINTENANCE SCHEDULE MAINTENANCE METHOD FOR REPLACING FUEL TANK BREATHER ELEMENT............4-62 METHOD FOR REPLACING PILOT FILTER ELEMENT................. 4-62 METHOD FOR CHECKING AND CLEANING FUEL STRAINER ............4-64 METHOD FOR REPLACING HYDRAULIC TANK BREATHER ELEMENT ..........4-65 METHOD FOR REPLACING DEF TANK BREATHER ELEMENT............4-65 METHOD FOR CHECKING DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR AND AIR CONDITIONER COMPRESSOR......................
Page 327: Maintenance Procedure
MAINTENANCE MAINTENANCE PROCEDURE MAINTENANCE PROCEDURE INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) As the 1st maintenance of a new machine, perform the following maintenance after operating initial 250 hours. • Replacement of power train oil filter element (500 hours maintenance) •...
Page 328 MAINTENANCE PROCEDURE MAINTENANCE Check dust indicator (1). Open the engine side cover at the left of the machine, and you see dust indicator (1). If the inside yellow piston of dust indicator (1) laps over the peripheral red zone (A), clean the air cleaner element. After cleaning, press reset button (2) to reset.
Page 329 MAINTENANCE MAINTENANCE PROCEDURE Wipe off or brush off the dirt stuck to the inside of the air cleaner body (6) and cover (3). Blow dry compressed air (Max. 0.2 MPa{2.1 kg/cm }) from the inside of the outer element along the pleats. Blow along the pleats from the outside, then blow again from the inside.
Page 330 MAINTENANCE PROCEDURE MAINTENANCE NOTICE When inserting the element into the body, if the rubber at the tip is swollen or the outer element (4) is not pushed in straight, and cover (3) is installed by force with hook (2), there is a danger that the hook and air cleaner body may be damaged, so be careful when installing.
Page 331 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR REPLACING ELEMENT Open the engine side cover on the left side of the ma- chine. Undo latches (2) (6 places) and remove cover (3). Hold the outer element (4), rock it lightly up and down and to the right and left, and pull the element out.
Page 332 MAINTENANCE PROCEDURE MAINTENANCE Replace O-ring (7) of cover (3) with a new one. Install cover (3) according to the following procedure. Align cover (3) with the element. Lock the tip of hook (2) on the protrusion of the air cleaner body. Lock hooks (2) diagonally, (top and bottom, right and left) in the same way as when tightening bolts.
Page 333: Method For Cleaning Inside Of Cooling System
NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
Page 334 When handling the cooling water containing coolant that has been drained during changing the coolant or repair of radiator, contact your Komatsu distributor or request a qualified company to perform the operation. Coolant is toxic, so never pour it into drainage ditches or drain it onto the ground surface.
Page 335: Method For Checking And Adjusting Track Tension
MAINTENANCE MAINTENANCE PROCEDURE 11. Drain the coolant in reservoir tank (3). 12. Add Non-Amine Engine Coolant (AF-NAC) up to the mid- dle between FULL and LOW of reservoir tank (3). NOTICE After replacing Non-Amine Engine Coolant (AF-NAC), the coolant level of the reservoir tank may largely de- crease as time passes.
Page 336 Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). If the track tension cannot be loosened by the above pro- cedure, ask your Komatsu distributor for repair. METHOD FOR INCREASING TRACK TENSION NOTICE •...
Page 337 Separating the track may be very dangerous. Before separating the track, perform the adjustment shown in “METHOD FOR DECREASING TRACK TENSION (4-25)”. If the track shoe is still not loosened after this adjustment, ask your Komatsu distribu- tor for repair.
Page 338: Method For Checking Looseness And Tightening Track Shoe Bolts
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING LOOSENESS AND TIGHTENING TRACK SHOE BOLTS If shoe bolts (1) are used while they are loose, they are broken. Tighten them immediately whenever you find they are loose. METHOD FOR RETIGHTENING SHOE BOLT Tighten the shoe bolts in the order shown in the figure. Tightening torque for shoe bolt: 530 to 650 Nm {54 to 66 kgm} Check that the nut and shoe are in close contact with the...
Page 339: Method For Inverting And Replacing Cutting Edge And End Bit
(4 places on the right and left, and inside and out- side). If clearance (A) is 3 mm or more, adjust shim (E). Ask your Komatsu distributor for adjustment of shim (E). METHOD FOR INVERTING AND REPLACING CUTTING EDGE AND END BIT WARNING It is dangerous if the work equipment moves by mistake when the cutting edge or end bit is being re- placed.
Page 340 MAINTENANCE PROCEDURE MAINTENANCE Wear standards (SIGMA dozer) Item Criteria Standard Measuring point Repair limit dimension Outside height of end bit 300 mm 235 mm Width of end bit 640 mm 560 mm Inside height of end bit 330 mm 270 mm Height of cutting edge 105 mm 165 mm (From center of bolt mounting 115 mm...
Page 341: Method For Cleaning And Checking Radiator Fin, Oil Cooler Fin, And Aftercooler Fin
MAINTENANCE MAINTENANCE PROCEDURE REMARK • If both sides of the cutting edge and end bit are worn, replace them with new ones. • If the mounting face of seat (1) is worn as well, repair it before inverting or replacing. Remove the cutting edge and end bit.
Page 342 MAINTENANCE PROCEDURE MAINTENANCE Turn starting switch (1) to OFF position and stop the en- gine. Fully open the right and left engine side covers and lock them. Turn starting switch (1) to ON position. On the user menu, set Fan Reverse Mode. For setting of Fan Reverse Mode, see “REVERSE HY- DRAULIC FAN (3-74)”.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE Turn starting switch (1) to OFF position and stop the en- gine. Close the right and left engine side covers. REMARK • If dirt is caught in the radiator fins, blow with compressed air to clean. • In a cold circumstance, perform the cleaning by Fan Reverse Mode within less than 5 minutes.
Page 344 MAINTENANCE PROCEDURE MAINTENANCE Steam or water may be used instead of the compressed air. However, when performing powerful steam cleaning (high-pressure machine washing) of the heat exchang- er (radiator), maintain sufficient distance from the machine. If steam cleaning (high-pressure machine wash) is performed at close distance, there is a danger that the internal fins of the heat exchange equipment may be deformed, and this will cause early clogging and breakage of the equipment.
Page 345: Check And Clean Air Conditioner Condenser Intake Port
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CLEANING AFTERCOOLER FIN Open engine side covers (1) on both sides of the machine. Clean them through the oil cooler fins (2) from both sides of the machine. Blow off mud, dirt, leaves, etc. in aftercooler fins (3) with compressed air.
Page 346: Clean Power Train Case Breather
MAINTENANCE PROCEDURE MAINTENANCE CLEAN POWER TRAIN CASE BREATHER Remove exterior cover (1) at the right of the cab. Remove breather (2). Breather (2) is installed on the rear side of the machine. Rinse the breather in clean diesel fuel or cleaning oil, and remove dirt from inside.
Page 347: Method For Checking And Adjusting Alternator And Air Conditioner Compressor Belt Tension
MAINTENANCE MAINTENANCE PROCEDURE Remove nut (2) of breather assembly (1) on the top of the fuel tank. Remove cover (3). Remove dirt sticking to breather element (4). Clean in clean diesel fuel or flushing oil. Install cover (3) and nut (2). In order not to damage the threaded portion of nut, tighten nut (2) by hand until it is seated, then tighten it 15 to 30°...
Page 348: Method For Replacing Door Damper
Seal bolt (1) of the idler is not seen until the outside side cover is removed. Remove seal bolt (1). If no oil oozes, the oil level is low. Ask your Komatsu dis- tributor for repair. METHOD FOR REPLACING DOOR DAMPER Measure groove depth (A) of door damper rubber (1).
Page 349: Method For Lubricating Door Hinge
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR LUBRICATING DOOR HINGE If the door creaks when it opens or closes, spray lubricant through the bushing slit of the hinge. If the bushing is worn, replace the hinge. METHOD FOR CHECKING DOOR LATCH WARNING It is dangerous if the machine moves by mistake during in- spection.
Page 350: Method For Replacing Wiper Blade
MAINTENANCE PROCEDURE MAINTENANCE Open the inspection cover on the side of the battery cover at the rear left of the machine. Check the fluid level in window washer tank (1). If the fluid level is low, remove cap (2) and add window washer fluid for automobile through the filler port.
Page 351: Method For Checking And Maintenance Air Conditioner
REMARK When there are bubbles, the refrigerant gas is insufficient. In this case, ask your Komatsu distributor to add re- frigerant. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor.
Page 352: Method For Cleaning Air Conditioner Air Filters (Fresh/Recirc)
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING DURING OFF SEASON Even during the off-season, operate the air conditioner for 3 to 5 minutes once a month to maintain the oil film at all parts of the compressor. METHOD FOR CLEANING AIR CONDITIONER AIR FILTERS (FRESH/RECIRC) When the air conditioner air filter is clogged and the air conditioner does not work well, clean the air filter.
Page 353 MAINTENANCE MAINTENANCE PROCEDURE Since the engine needs to be started and the work equipment needs to be operated, see OPERATION, “METH- OD FOR STARTING ENGINE (3-167)”, “BLADE CONTROL LEVER (3-98)”, and “RIPPER CONTROL LEVER (3-105)”. NOTICE • If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.
Page 354: Method For Bleeding Air From Fuel Circuit
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR BLEEDING AIR FROM FUEL CIRCUIT This machine is equipped with the fuel feed pump to bleed air from the fuel circuit. In the following cases, bleed air according to the following procedure. • When the fuel filter is replaced. •...
Page 355: Method For Lubricating
After greasing, wipe off any old grease that is pushed out. METHOD FOR CHECKING ELECTRICAL INTAKE AIR HEATER Check before starting in the cold weather (once a year). Ask your Komatsu distributor for check of the electrical intake air heater. METHOD FOR CHECKING AND REPLACING RIPPER SHANK NOTICE If the wear of the contact face with inside of ripper point at the tip of the ripper shank advances, the point fixing pin may break due to the load on the ripper point.
Page 356: Checks Before Starting
If the minimum clearance (L) is 0 mm and the ripper point contacts the point fixing pin, replace the ripper shank. Ask your Komatsu distributor for replacement of the ripper shank. REMARK When assembling the new ripper shank and the ripper point, default value of the clearance is 2.6 mm.
Page 357 MAINTENANCE MAINTENANCE PROCEDURE 1) Remove all soil and sand from the top of the track frame and top of cover (1). 2) Stand on the straight frame, and remove the cover (1) through the track frame and track shoe (A). 3) Supply grease from above the track shoe.
Page 358: Method For Checking Oil Level In Final Drive Case, Adding Oil
MAINTENANCE PROCEDURE MAINTENANCE ・Sigma dozer (1) Lift cylinder support yoke (4 places) (2) Lift cylinder support shaft (2 places) (3) Blade arm (1 place) (4) Tilt cylinder ball joint (1 place) (5) Pitch cylinder ball joint (1 place) ・Ripper (1) Tilt cylinder bottom pin (1 place) (2) Lift cylinder bottom pin (1 place) (3) Tilt cylinder rod end pin (1 place) (4) Lift cylinder rod end pin (1 place)
Page 359: Method For Checking Battery Electrolyte Level
MAINTENANCE MAINTENANCE PROCEDURE Stop the machine so that drain plug (1) is directly at the bottom. Remove oil level plug (2). If the oil level is near the lower edge of the hole of plug (P), the oil amount is proper. If the oil is insufficient, remove oil filler plug (3) and add en- gine oil until it spills over oil level plug (2).
Page 360 If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed electrolyte with baking soda (sodium bicarbon- ate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 361 If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed electrolyte with baking soda (sodium bicarbon- ate), then flush it away with a large amount of water. If necessary, consult your Komatsu distributor or a battery manufacturer.
Page 362: Method For Checking And Adjusting Alternator And Air Conditioner Compressor Belt Tension
METHOD FOR CHECKING BRAKE PERFORMANCE WARNING If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme- diately. NOTICE Never set the joy stick (steering, directional and gear shift lever) to the 1st speed range. This will cause damage to the machine.
Page 363: Every 500 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Check that the machine does not move off. This indicates that brake performance is normal. EVERY 500 HOURS MAINTENANCE Maintenance for every 250 hours service should be performed out at the same time. METHOD FOR CHANGING OIL IN ENGINE OIL PAN, REPLACING ENGINE OIL FILTER CARTRIDGE WARNING Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Page 364 Take care not to deform the stopper pin in drain valve (2) by loosening the valve too much. Check the drained oil. If it contains much metallic powder or foreign material, contact your Komatsu distributor. Tighten drain valve (2) and drain plug (P). •...
Page 365: Method For Replacing Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 366 MAINTENANCE PROCEDURE MAINTENANCE Clean the filter head, fill the new filter cartridge with clean fuel, thinly apply oil to the packing surface, then install it to the filter head. NOTICE • When filling the filter cartridge with fuel, do not re- move cap (B).
Page 367: Method For Replacing Element On Power Train Oil Filter
(5). Remove the element. Clean the inside of the case and the removed parts, then install the new element. Komatsu recommends using Komatsu genuine elements. Install cover (2). Tighten bolt (1). METHOD FOR REPLACING AIR CONDITIONER FRESH/RECIRC FILTERS Since the filtering ability of the filters decreases as they are aged, replace them every 500 operating hours or every year.
Page 368: Every 1000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING FRESH AIR FILTER Loosen knobs (1) at the rear left of the machine, and re- move upper cover (2). Remove fresh air filter covers (3), and remove fresh air fil- ters (4). Remove soil and sand from the sealing surface of fresh air filter covers (3) and inside of the filter cases.
Page 369 MAINTENANCE MAINTENANCE PROCEDURE Remove cover (1) on the left side of the power train case bottom. Remove drain plug (2). Loosen drain valve (P1) and drain the oil. After draining the oil, tighten drain valve (P1). Do not remove drain valve (P1). Remove inspection cover (3) of the undercover at the rear of the machine bottom according to the following procedure.
Page 370: Method For Replacing Power Train Case Breather
MAINTENANCE PROCEDURE MAINTENANCE Remove drain plug (P2) on the strainer cover and drain the oil (approximately 4 ℓ) staying in the internal piping. Loosen mounting bolts (6) of the power train pump strain- er, and remove cover (7). Take out spring (8) and then take out strainer (9). Remove all dirt from strainer (9), then wash it in clean die- sel fuel or flushing oil.
Page 371: Method For Changing Oil In Final Drive Case
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN FINAL DRIVE CASE WARNING • Immediately after operation is stopped, the parts and oil are still very hot and may cause burn in- jury. Accordingly, wait until they have cooled down before starting the work. •...
Page 372: Method For Replacing Fuel Main Filter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genu- ine filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Page 373 MAINTENANCE MAINTENANCE PROCEDURE Turn fuel supply valve (1) at the bottom of the fuel tank to “CLOSE” position (S). Open the engine side cover on the left side of the ma- chine. Remove mudguards (A) and (B) on the front side. Place a container to receive the fuel under filter cartridge (2).
Page 374 MAINTENANCE PROCEDURE MAINTENANCE Turn valve (1) at the bottom of the fuel tank to “OPEN” po- sition (O). 10. Bleed the air from the fuel circuit. See “METHOD FOR BLEEDING AIR FROM FUEL CIR- CUIT (4-42)”. 11. After bleeding air from the fuel circuit, start the engine and run it at low idle for approximately 10 minutes.
Page 375 MAINTENANCE MAINTENANCE PROCEDURE Loosen oil filler cap (F) slowly on the top of the hydraulic tank to release the internal pressure in the hydraulic tank. Open the L.H. side cover and remove cover (1). Remove bolts (2), and remove cover (3). Place a container to catch drained oil under the filter ele- ment.
Page 376 MAINTENANCE PROCEDURE MAINTENANCE After checking that the hydraulic oil temperature has drop- ped, turn filter case (4) counterclockwise, remove it, then take out element (5). Clean the removed parts, then install new element (5). • Element (5) must be installed facing in the correct di- rection.
Page 377 If the machine is operated without DEF tank breather element attached, or with the element other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine. Never operate the machine in such condition.
Page 378: Every 2000 Hours Maintenance
TERNATOR AND AIR CONDITIONER COMPRESSOR METHOD OF CHECKING Check the pulley for play and grease leakage. If any abnormality is found, ask your Komatsu distributor for re- pair or replacement. METHOD FOR LUBRICATING By using a grease pump, pump in grease through the grease fittings shown by arrows.
Page 379 MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHANGING OIL IN DAMPER CASE AND CLEANING DAMPER BREATHER WARNING • Immediately after the machine is stopped, its parts and oil are still very hot and may cause burn in- jury. Accordingly, wait until they have cooled down before starting the work. •...
Page 380 MAINTENANCE PROCEDURE MAINTENANCE Drain plug (P) is seen at the upper position. Pull out dipstick (G). Remove drain plug (9) and drain the oil. After draining the oil, tighten drain plug (P). Add oil through the insertion hole of dipstick (G). After adding oil, insert dipstick (G) Remove all dirt from breather (6), then wash it in clean die- sel fuel or flushing oil.
Page 381 MAINTENANCE MAINTENANCE PROCEDURE (Semi-U dozer, U-dozer) Lower blade (a) so that the tilt cylinder length is the value in the table below. Lower ripper (b) to the ground with the pin at the bottom so that the length of each cylinder is the value in the table below.
Page 382 MAINTENANCE PROCEDURE MAINTENANCE 16. Loosen cover (7) mounting bolts (6 pieces). 17. Remove cover (7) and pull out inside strainer (8). 18. Clean the strainer in clean diesel fuel or flushing oil. 19. Install strainer (8) to its original position. 20.
Page 383 • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. NOTICE If the nitrogen gas charge pressure in the accumulator is low and operations are continued, it becomes impossible to release the remaining pressure inside the hydraulic circuit if a failure occurs on the ma- chine.
Page 384 MAINTENANCE PROCEDURE MAINTENANCE Raise the work equipment (blade) to the upper limit. Perform the procedure 4 to 6 within 15 seconds. Since the accumulator pressure decreases gradually after the engine stops, you can release only just after the engine stops. With the work equipment at the upper limit, turn the start- ing switch to OFF position (A), and stop the engine.
Page 385 Set the work equipment lock lever to LOCK position, then turn the starting switch to OFF position (A). METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE Special tools are necessary for inspection and maintenance. Ask your Komatsu distributor to perform this work. METHOD FOR REPLACING KCCV FILTER ELEMENT WARNING After the engine has been operated, all of parts are still very hot.
Page 386 MAINTENANCE NOTICE • Komatsu recommends using Komatsu genuine parts for replacement parts. • If the engine is operated without the filter element, the turbocharger and aftercooler become dirty and their performance will lower and that can cause engine problems such as overrun caused by suction of oil.
Page 387 MAINTENANCE MAINTENANCE PROCEDURE After ring (3) comes off, remove case (4) from body (2) and remove element (5). Oil may be accumulated in or sticking to the case and ele- ment. When replacing the element, take care that the oil will not spill out.
Page 388 MAINTENANCE PROCEDURE MAINTENANCE Align the position of ◇ mark (8) on the case with that of ◇ mark (11) of the filter body label, then install the case to the filter body. The element can be installed only when its teeth (12) and case's teeth (13) are correctly inserted in grooves (14) of the filter body.
Page 389 Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without DEF filter attached, or with the filter other than Komatsu genuine parts, foreign materials may enter into DEF pump and DEF injector which will cause failure of the machine.
Page 390 MAINTENANCE PROCEDURE MAINTENANCE Insert filter removal tool (3) into the bottom of the DEF pump and thrust in with hand. Check that filter removal tool (3) is fully inserted to the end. Insert the filter removal tool (3) to the end where you can- not thrust it in any further.
Page 391: Every 4000 Hours Maintenance
Width across flats: 27 mm METHOD FOR CHECKING ALL TIGHTENING POINTS OF ENGINE INTAKE PIPE CLAMPS Ask your Komatsu distributor for checking the tightening of the clamps between the air cleaner - turbocharger - aftercooler - engine. EVERY 4000 HOURS MAINTENANCE Maintenance for every 250, 500, 1000, and 2000 hours services should be performed out at the same time.
Page 392 Do not perform drilling, welding or flame-cutting. • Do not hit or roll it, or subject it to any impact. • When disposing of it, the gas must be released. Ask your Komatsu distributor to have this work per- formed. 4-80...
Page 393 Replace the accumulator every 2 years or every 4000 hours, whichever comes sooner. Ask your Komatsu distributor for re- placement. The accumulator is installed to the position shown in the figure.
Page 394 MAINTENANCE PROCEDURE MAINTENANCE If there are any problems, the related parts must be replaced. Ask your Komatsu distributor for replacement. 4-82...
Page 395 MAINTENANCE MAINTENANCE PROCEDURE NOTICE If the engine operation is continued while any bolt is loosened or any rubber is hardened or removed, the contact portions of the high-pressure piping may be worn and may be broken by vibration. Be sure to check that the specified high-pressure piping clamps are installed correctly.
Page 396: Every 4500 Hours Maintenance
Special techniques and tools are required for this work. Ask your Komatsu distributor for replacement of the fuel spray prevention cap on fuel doser. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-84...
Page 397: Specifications
SPECIFICATIONS...
Page 398: Specifications : D155Ax-8E0
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS : D155AX-8E0 Item Unit D155AX-8E0 Operating weight (excluding operator) *1 kg 42200 Blade unit weight (including cylinder) kg 5400 Ripper unit weight kg 3760 Engine model Komatsu SAA6D140E-7 diesel engine SAE J1995 268 / 1900 Rated...
Page 399: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 400: General Precautions
GENERAL PRECAUTIONS PRECAUTIONS FOR 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 and Maintenance Manual, contact your Komatsu distrib- utor first.
Page 401: Attachments And Options
660 mm wide Track shoe Wide shoe 710 mm wide Heavy duty shoe 610 mm wide Heavy duty shoe 660 mm wide Ripper point Cab with lock Headrest There are many other options in addition to the above. Ask your Komatsu distributor about them.
Page 402: Selection Procedure Of Ripper Point
SELECTION PROCEDURE OF RIPPER POINT ATTACHMENTS AND OPTIONS SELECTION PROCEDURE OF RIPPER POINT REMARK • When the tip of a symmetrical point is worn and its penetration performance decreases, the penetration performance can be restored by turning it. Accordingly, it is suitable for ripping of hard-rock beds. •...
Page 403: Handle Headrest
ATTACHMENTS AND OPTIONS HANDLE HEADREST HANDLE HEADREST Keep the headrest inserted to the end.
Page 405: Replacement Parts
REPLACEMENT PARTS...
Page 406: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Retighten all loose hoses and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time. Have your Komatsu distributor replace the defined life parts. DEFINED LIFE PARTS LIST Periodical replacement parts...
Page 407: Consumable Parts
The consumable parts should be replaced correctly in order to ensure more economic use of the machine. When replacing parts, Komatsu recommends using Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change. Inform your Ko- matsu distributor of the machine serial number and check the latest part number when ordering parts.
Page 408 CONSUMABLE PARTS REPLACEMENT PARTS Weight Item Part No. Part name Q'ty Replacement interval 17A-71-46680 Cutting edge (L.H.) 32.7 17A-71-46670 Cutting edge (R.H.) 32.7 17A-71-45210 Cutting edge 78.5 SIGMA dozer 17A-71-46611 End bit (L.H.) 51.6 (Cemented car- bide bit edge 17A-71-46621 End bit (R.H.) 51.6 specification)
Page 409: Recommended Fuel, Coolant, And Lubricant
Failure to follow these recommendations may result in shortened life or excessive wear of the en- gine, power train, cooling system, and/or other components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recommend any commercially available lubricant additive. •...
Page 410 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS Symbols used in the lubrication standard chart Symbol Meaning of symbol Symbol Meaning of symbol Read Operation and Maintenance Manual Supply grease Change engine oil Check engine oil level Change hydraulic oil Check hydraulic oil level Change power train oil Check power train oil level Replace engine oil filter...
Page 411 250 hours. For changing maintenance time of machine monitor, ask your Komatsu distributor to perform. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils.
Page 412 Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu recommends the use of Non-Amine Engine Coolant (AF-NAC). If you use another coolant, it may cause serious problems in the cooling system, including the engine.
Page 413 INDEX INDEX Symbols Automatic operation - Start......... 3-216 Automatic operation - Stop......... 3-217 12H/24H display mode - Switch......3-86 AUX..............3-225 Avoid mixing oil............4-3 Accumulator - Function......... 4-71 Accumulator - Handle........... 2-35 Backup alarm operation - Check......3-155 Accumulator for control circuit - Check / Release ni- Band/AUX selector button........3-224 trogen gas charge pressure......4-71 Basic operation of machine monitor......3-7...
Page 414 INDEX Checks after stopping engine......3-207 Display monitor........... 3-215 Checks and adjustment before starting engine...3-140 Display selector button........3-225 Checks before starting.......... 2-23 Display setting - Change........3-68 Checks before starting - Perform......4-44 Display warning tag during inspection and mainte- Checks before stopping engine......3-207 nance.............
Page 415 INDEX Engine coolant temperature caution lamp.... 3-19 Fuel consumption gauge - Set display....3-68 Engine coolant temperature gauge.......3-36 Fuel consumption record - Check......3-66 Engine high-pressure piping - Replace....4-84 Fuel control dial.............3-93 Engine high-pressure piping clamp - Check for loose- Fuel doser - Clean..........4-84 ness and hardening of rubber......4-81 Fuel filler port cap - Open........
Page 416 Machine - Turn during forward travel....3-187 Komatsu Closed Crankcase Ventilation (KCCV) 3-123 Machine - Turn gradually during forward travel on Komatsu Diesel Particulate Fillter (KDPF) - Handle..downhill slope..........3-188 ..............3-113 Machine - Turn on downhill slope....... 3-188 Komatsu genuine lubricants........4-2...
Page 417 Parking brake pilot lamp........3-31 Maintenance during long-term storage....3-237 Parking brake system caution lamp...... 3-24 Maintenance of air conditioner......2-36 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Maintenance procedure........4-15 Periodic replacement of defined life parts..2-36,7-2 Maintenance schedule.......... 4-13 Pilot display............3-29 Maintenance schedule table.........
Page 418 INDEX Precautions for high-pressure grease when adjusting Prevent fire............2-14 track tension..........2-35 Product information..........1-13 Precautions for high-pressure oil......2-33 Provide fire extinguisher and first aid kit....2-13 Precautions for high-temperature coolant.....2-33 Precautions for high-temperature oil.....2-33 Precautions for high-temperature parts....2-33 R.H.
Page 419 Sound control button...........3-225 Vent selector switch - Select....... 3-213 Specifications............5-2 Vibration levels............1-8 Specifications: D155AX-8E0........5-2 Visibility from operator's seat........ 1-10 Speed range - Change with shift switch....3-184 Volume control button......... 3-224 Speed range - Operate / Preset by shift switch in neu- tral..............3-182...

Komatsu D155AX-8E0 Operation & Maintenance Manual

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