Page 1 Operation & EENAM03522 Maintenance Manual D37EX- D37PX- BULLDOZER SERIAL NUMBER D37EX-24 - 85001 and up D37PX-24 - 85001 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 Operation and Maintenance Manual in the steel box on the back of the seat. 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 FOREWORD READ THIS MANUAL complies with the applicable standards and regulations of your country, consult your Komatsu distributor before operating the machine.
Page 6: 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 7: 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 8: Vibration Levels
ISO 7096. FOR D37EX-24 : The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s , the uncertainty for this value is 0.80 m/s...
Page 9 FOREWORD VIBRATION LEVELS • Transport machines long distances between worksites The following guidelines can be effective to minimize risks of low back pain • Operate the machine only when you are in good health • Provide breaks to reduce long periods of sitting in the same posture •...
Page 10: Introduction
INTRODUCTION FOREWORD INTRODUCTION MAIN USE OF MACHINE This Komatsu machine is designed to be used mainly for the following work: • Dozing work • Leveling work • Cutting into hard or frozen ground or ditching • Works of felling trees and removing stumps For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS”.
Page 11 FOREWORD INTRODUCTION This machine maintains a proximity visibility of a height of 1.5 m and 1.2 m at a point 1 m away from the outside surface of the machine, and a visibility for a radius of 12 m. Height to evaluate the proximity visibility Region of the RB Machine type Mass...
Page 12 INTRODUCTION FOREWORD To assist with job site organisation during use of this machine, a visibility map is provided that shows an approxi- mation of any masking to visibility between the 1 m rectangular boundary and the 12 m test circle. Based upon the information supplied in the visibility map the site operator may wish to provide additional meas- ures where it is felt necessary or provide additional instruction to personnel.
Page 13: Engine Technology To Conform Exhaust Gas Emission
Diesel Exhaust Fluid is the aqueous urea solution for the SCR system. The Komatsu Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the ex- haust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decom- poses the nitrogen oxides into nitrogen and water.
Page 14: Product Information
PRODUCT INFORMATION FOREWORD 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 It is located at front left of the operator's seat.
Page 15: Fluorinated Greenhouse Gases
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 1-13...
Page 16: 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 1-14...
Page 17: 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: D37EX-24 D37PX-24 Fulfils all the relevant provisions of following EC Directives:...
Page 18: Table Of Contents
TABLE OF CONTENTS FOREWORD TABLE OF CONTENTS FOREWORD..............................1-1 READ THIS MANUAL ..........................1-2 SAFETY INFORMATION .......................... 1-4 NOISE............................... 1-5 VIBRATION LEVELS ..........................1-6 VIBRATION - OPERATING CONDITION ................... 1-6 GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ..............1-6 INTRODUCTION ............................1-8 MAIN USE OF MACHINE ........................
Page 19 FOREWORD TABLE OF CONTENTS SWITCHES ............................3-81 CONTROL LEVERS AND PEDALS ....................3-87 OTHER EQUIPMENT ........................3-92 MACHINE OPERATIONS AND CONTROLS ..................3-121 CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ............3-121 METHOD FOR STARTING ENGINE....................3-150 METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ......... 3-155 METHOD FOR STOPPING ENGINE .....................
Page 20 CONSUMABLE PARTS LIST ......................7-3 RECOMMENDED FUEL, COOLANT, AND LUBRICANT ................7-5 LUBRICATION CHART ........................7-5 METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA- TURE ............................. 7-7 RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS ....7-8 INDEX................................8-1 1-18...
Page 21: 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 22 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 ..........2-11 PRECAUTIONS BEFORE STARTING OPERATION................2-11 ENSURE SAFE OPERATION ......................2-11 UNDERSTAND THE MACHINE ......................2-11 PREPARATIONS FOR SAFE OPERATION .....................2-11 PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ..............2-11 INSPECT MACHINE .........................2-11 WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT ..........2-11...
Page 23 SAFETY SAFETY PRECAUTIONS FOR TRANSPORTATION..................... 2-25 PRECAUTIONS WHEN LOADING AND UNLOADING ..............2-25 TOWING AND BEING TOWED....................... 2-26 PRECAUTIONS FOR TOWING AND BEING TOWED..............2-26 PRECAUTIONS FOR MAINTENANCE ......................2-27 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE .......... 2-27 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ........2-27 KEEP WORK PLACE CLEAN AND TIDY ..................
Page 24: 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 25: Location Of Safety Labels
SAFETY SAFETY LABELS LOCATION OF SAFETY LABELS (1) Caution for operation, inspection and maintenance (9) Stop rotation during inspection and maintenance (2) Caution for safety at rear (10) Caution for approaching while moving machine (3) Caution when leaving operator's seat (11) Prohibition of start by short-circuiting (4) Caution for high-temperature coolant (12) Caution for handling ROPS/FOPS...
Page 26: Contents Of Safety Labels
SAFETY LABELS SAFETY CONTENTS OF SAFETY LABELS (1) Caution for operation, inspection and maintenance (09651- A0481) • Warning ! • Read manual before operation, maintenance, disassembly, assembly and transportation. (2) Caution for safety at rear (09802-B0480) • Sign indicates a hazard of rear working and advancing be- hind.
Page 27 SAFETY SAFETY LABELS (3) Caution when leaving the operator's seat (09654-B0481) • Sign indicates a hazard of unexpected moving of stopped machine. • Lower working device to ground, move safety lever to lock position and take engine key with you before leaving ma- chine.
Page 28 SAFETY LABELS SAFETY (6) Caution for handling accumulator (09659-A057B) • Sign indicates an explosion hazard. • Never drill, cut with gas, hit or disassemble. Also keep open flame away. (7) Caution for adjusting track tension (09657-A0881) This safety label is attached to the back of the cover of the track adjustment window.
Page 29 Do not drill, cut or weld on the ROPS or FOPS structure. Any modification is prohibited. • ROPS or FOPS may provide less protection if it has been structurally damaged or involved roll-over. Con- sult Komatsu Distributor in that case. • Always wear seat belt when moving.
Page 30 SAFETY LABELS SAFETY (14) Caution when traveling in reverse (09833-B0881) (only machine with camera) • When backing up, rear of machine is displayed on monitor. • Before moving, look back and at mirror and monitor to con- firm that no one is rear of machine. Failure to do so can re- sult in serious injury or death.
Page 31: General Precautions Common To Operation And Maintenance
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE 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 32: Precautions To Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- NANCE SAFETY • 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 33: Prevent Fire
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • After a fire, harmful compounds may be left. If it touches your skin, it may have a bad influence on your body. Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).
Page 34: Precautions When Getting On Or Off Machine
In addition, tighten any loose bolt of the handrails and steps. If the handrails and steps are damaged or deformed, they need to be repaired immediately. Ask your Komatsu dis- tributor to perform this work. •...
Page 35: Lifting Of Personnel Prohibited
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE • 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. LIFTING OF PERSONNEL PROHIBITED Under no circumstances should this machine be used for the lifting of personnel.
Page 36: 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 37: Precautions When Running Engine Inside Building
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTE- SAFETY NANCE 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 38: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY 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 39: Ensure Good Visibility
SAFETY PRECAUTIONS FOR OPERATION Voltage of Cables Safety Distance 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 40: 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 41: Precautions When Starting Engine
If the machine is equipped with cameras, adjust the cam- eras to have a good rear view and a good view of sur- rounding area from the operator's seat. For the adjustment, please contact your Komatsu distribu- tor. • Check that there is no person or obstacle above, below, or in the area around the machine.
Page 42: Precautions For Operation
PRECAUTIONS FOR OPERATION SAFETY • When disconnecting the jumper cables, take care not to bring the clips in contact with each other or with the machine. PRECAUTIONS FOR OPERATION CHECKS BEFORE OPERATION If the checks before starting are not performed properly, the machine will be unable to display its full perform- ance.
Page 43: Precautions When Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION • When driving the machine on a level ground, keep the work equipment at height (A) of 40 to 50 cm above the ground. If that height is not maintained between the work equipment and the ground, the work equipment may get stuck in the ground and the machine may tip over.
Page 44: Precautions When Operating Machine
PRECAUTIONS FOR OPERATION SAFETY PRECAUTIONS WHEN OPERATING MACHINE • Be careful not to approach too close to the edge of cliffs. When making embankments or landfills, or when dropping soil over a cliff, dump one pile, then use the next pile of soil to push the first pile. •...
Page 45: Precautions For Transportation
• 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 46: Towing And Being Towed
PRECAUTIONS FOR OPERATION SAFETY TOWING AND BEING TOWED PRECAUTIONS FOR TOWING AND BEING TOWED Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or drawbar or the method of towing a disabled machine and being towed may lead to serious personal injury or death.
Page 47: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE 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 48: 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 49: Precautions When Installing, Removing, Or Storing Attachments
SAFETY PRECAUTIONS FOR MAINTENANCE • Rotating parts such as the fan, fan belt are dangerous that they may easily catch a body part or an object someone wears. Be careful not to come close to the rotating part. • Never drop or insert tools or other objects into the fan, fan belt, or other rotating parts.
Page 50: Precautions For Check And Maintenance
PRECAUTIONS FOR MAINTENANCE SAFETY 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. Al- ways observe the following. • Make sure the hoists or hydraulic jacks you use are in good condition and strong enough to handle the weight of the component.
Page 51: Handle Battery
SAFETY PRECAUTIONS FOR MAINTENANCE HANDLE BATTERY Before inspecting or handling the battery, turn the key in the starting switch to OFF position and check that the system operating lamp is off. Then set the battery disconnect switch to OFF position and remove the switch key. Danger of battery exploding When the battery is being charged, flammable hydrogen gas is generated and may explode.
Page 52: Precautions For High-Temperature Coolant
PRECAUTIONS FOR MAINTENANCE SAFETY • If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, pieces might be scattered, and it may cause serious personal injury or death. Always wear protective eyeglasses and gloves. •...
Page 53: 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 54: Precautions For 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. HANDLE ACCUMULATOR This machine is equipped with an accumulator.
Page 55: 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 56 PRECAUTIONS FOR MAINTENANCE SAFETY • 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 57: Precautions For Def
SAFETY PRECAUTIONS FOR DEF PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colorless 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 59: Operation
OPERATION Please read and make sure that you understand the SAFETY section before reading this section.
Page 60: General View
GENERAL VIEW OPERATION GENERAL VIEW MACHINE EQUIPMENT NAME (1) Blade (7) Work equipment frame (2) Front cover (8) Angle cylinder (3) ROPS cab (9) Track frame (4) Sprocket (10) Track (5) Lift cylinder (11) Radiator grille (6) Idler (12) Tilt cylinder (13) DEF pump (15) Battery disconnect switch (14) DEF tank...
Page 61: Controls And Gauges Names
OPERATION GENERAL VIEW (17) Komatsu Closed Crankcase Ventilation (hereafter (19) SCR KCCV) ventilator (18) DEF injector CONTROLS AND GAUGES NAMES (1) Air conditioner switch (10) Starting switch (2) Cigarette lighter (11) Decelerator/brake pedal (3) Fuel control dial (12) Blade control lever...
Page 62 GENERAL VIEW OPERATION MACHINE MONITOR EQUIPMENT NAME AA: Standard screen, BB: Check before starting screen, CC: Maintenance time warning screen (1) Pedal mode selector switch (17) Steering mode display (2) Buzzer cancel switch (18) Preheating pilot lamp (3) Operating mode selector switch (19) Fan reverse rotation pilot lamp (4) Reverse travel speed setting switch (20) FLOAT mode pilot lamp...
Page 63: Explanation Of Components
OPERATION EXPLANATION OF COMPONENTS 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 64 EXPLANATION OF COMPONENTS OPERATION BASIC OPERATION OF MACHINE MONITOR BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NOR- MAL SITUATION • When the starting switch is turned to ON position, opening screen GG is displayed. • After opening screen GG is displayed for 2 seconds, the screen switches to camera image FF. •...
Page 65 End screen when any message has been re- ceived 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 66 F1, and the screen changes to the Check Before Starting screen BB without inputting ID number. REMARK • Contact your Komatsu distributor for details of the method of setting, changing, or canceling the operator identifica- tion function. • Depending on the set value of ID holding time, even if in-...
Page 67 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 68 EXPLANATION OF COMPONENTS OPERATION If there is any abnormality currently generated, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality. The “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 69 OPERATION EXPLANATION OF COMPONENTS If there is any error existing, “!” is displayed on top of switch F5. Press switch F5 to check the detail of the current abnormality. The “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 of the machine.
Page 70 EXPLANATION OF COMPONENTS OPERATION (1) Action level display (6) Engine speed caution lamp (*) (2) Caution lamp (7) DEF level caution lamp (3) Caution lamp (8) Fuel level caution lamp (4) Hydraulic oil temperature caution lamp (9) Caution lamp (5) Engine coolant temperature caution lamp (*): Displayed items change according to setting of the multi-gauge.
Page 71 │ no load or stop it. 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 from use, but the machine ↓...
Page 72 EXPLANATION OF COMPONENTS OPERATION CAUTION LAMP LIST NOTICE • These caution lamps do not guarantee the condition of the machine. Do not simply rely on the caution lamp when performing checks before starting (start-up inspec- tion). Always get off the machine and check each item directly. •...
Page 73 OPERATION EXPLANATION OF COMPONENTS Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Abnormal Abnormal Regeneration performance cau- tion lamp (L03) (L01) Abnormal Sensing is DEF level caution lamp Normal disabled (L04, L03) Abnormal Abnormal DEF system caution lamp (L04, L03) (L01)
Page 74 EXPLANATION OF COMPONENTS OPERATION Display color/ Machine condition (Action level) Symbol Type of caution lamp Yellow Blue White Due time is Maintenance time caution lamp Notice over Seat belt is Seat belt caution lamp not fastened For the meaning of each caution lamp and the action to take for it, see the section of each caution lamp. CURRENT ABNORMALITY DISPLAY SWITCH If there is any abnormality currently generated, “!”...
Page 75 OPERATION EXPLANATION OF COMPONENTS F1: Displays the next page. When on the last page, it displays the first page. F2: Displays the previous page. When on the first page, it dis- plays the last page. F5: Returns the screen to the standard screen. ENGINE COOLANT TEMPERATURE CAUTION LAMP Engine coolant temperature caution lamp warns about states caused by engine coolant temperature.
Page 76 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 77 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 78 EXPLANATION OF COMPONENTS OPERATION 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. Some functions may be restricted from use, but the machine can operate.
Page 79 It is not necessary to stop the machine immediately. However, it is recommended to inspect the machine for maintenance after you finish operations. Ask your Komatsu distributor for inspection and maintenance as necessary. REGENERATION PERFORMANCE CAUTION LAMP This warns about the deterioration of regeneration performance of aftertreatment devices.
Page 80 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 81 OPERATION EXPLANATION OF COMPONENTS Move the machine to a safe area and stop the machine, then ask your Komatsu distributor for inspection and maintenance. When action level “L01” appears on screen. The caution lamp comes on in yellow. It is not necessary to stop the machine immediately.
Page 82 The alarm buzzer sounds intermittently. Charging is not performed normally while the engine is running. Stop the engine and check the alternator drive belt for damage, and then ask your Komatsu distributor for inspection and main- tenance. AIR CLEANER CLOGGING CAUTION LAMP Air cleaner clogging caution lamp warns about clogging of the air cleaner.
Page 83 • The lighting time of maintenance due time notice (yellow) has been initially set to 30 hours, but it can be changed. To change the setting, ask your Komatsu distributor. • For operations on the “Maintenance” screen, see “MAIN- TENANCE SCREEN SETTING”.
Page 84 ON position. MESSAGE DISPLAY The User Message is displayed when there is a message from Komatsu. To read the message, see “MESSAGE DISPLAY”. Lights up in green (A): There is unread message. Lights up in blue (B): There is any read message to which no reply has been made.
Page 85 OPERATION EXPLANATION OF COMPONENTS OPERATING MODE DISPLAY The currently set operating mode is displayed on the operating mode display. The display of the operating mode is as follows. (P): For heavy-duty operations Lights up when the mode is set to power mode. (E): For operations with emphasis on fuel consumption Lights up when the mode is set to economy mode.
Page 86 EXPLANATION OF COMPONENTS OPERATION PARKING BRAKE PILOT LAMP The parking brake pilot lamp lights up when the parking brake lever is in LOCK position. It goes out when the parking brake lever is set to FREE posi- tion. When the parking brake lever needs to be set to LOCK posi- tion, the parking brake pilot lamp flashes.
Page 87 OPERATION EXPLANATION OF COMPONENTS GUIDANCE DISPLAY 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 88 EXPLANATION OF COMPONENTS OPERATION Overload prevention guidance If the machine is overloaded during work, overload prevention message is displayed on the machine monitor. 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 89 OPERATION EXPLANATION OF COMPONENTS Guidance for engine stop operation during the aftertreatment devices regenera- tion Immediately after starting aftertreatment devices regeneration, the information about engine stop operation during the after- treatment devices regeneration is displayed on the machine monitor. The guidance for engine stop operation during regeneration of the aftertreatment devices goes out 10 seconds later or when switch F5 is pressed.
Page 90 EXPLANATION OF COMPONENTS OPERATION METER DISPLAY MULTI GAUGE The multi gauge can display various items. As an example, dis- play of the engine tachometer is explained below. If the indicator is in green range during operations, it is normal. When the indicator goes beyond (A) of red range during opera- tions, the engine speed is too high.
Page 91 OPERATION EXPLANATION OF COMPONENTS Red range (A) position: Hydraulic oil temperature caution lamp (E) shows abnormality display. Red range (B) position: Engine speed changes to a middle level, hydraulic oil temperature caution lamp (E) shows abnormality display, and alarm buzzer sounds at the same time. The overheat prevention system continues to operate until the indicator enters the green range.
Page 92 EXPLANATION OF COMPONENTS OPERATION REMARK • If the battery is disconnected for a long period for storage etc., the time information may be lost. • 12-hour or 24-hour system is available for clock display. • For details of setting and correction of time, see “CLOCK ADJUSTMENT”. Service meter display Clock display (12-hour display) Clock display (24-hour display)
Page 93 OPERATION EXPLANATION OF COMPONENTS FUEL CONSUMPTION GAUGE Fuel consumption gauge shows the average fuel consumption of the machine. (A): Shows the average fuel consumption of a day (from 0:00 a.m. of the day to 0:00 a.m. of the next day). (B): Shows the split fuel consumption under measurement.
Page 94 EXPLANATION OF COMPONENTS OPERATION MONITOR SWITCHES (1) Function switch (4) Pedal mode selector switch (2) Buzzer cancel switch (5) Gear shift mode selector switch (3) Operating mode selector switch (6) Reverse travel speed setting switch FUNCTION SWITCHES AND GUIDANCE ICONS •...
Page 95 OPERATION EXPLANATION OF COMPONENTS (B) Switch F3: Camera image selector switch. (C) Switch F4: Service meter / clock display selector switch (D) Switch F5: Current Abnormality display switch (Only while caution lamp is lit) (E) Switch F5: Energy saving (ECO) guidance erase switch (While ECO guidance is displayed) (F) Switch F6: User menu display switch Guidance icons and their functions differ with the contents of the displayed screen, but representative guidance...
Page 96 EXPLANATION OF COMPONENTS OPERATION (K) Switch F5: Cancels any change and returns to the previous screen. (L) Switch F6: Decides any selection and changes contents and advances to the next screen. REMARK • Even if some guidance icons look the same, their display positions and corresponding function switches may differ in accordance with the screens to be displayed.
Page 97 OPERATION EXPLANATION OF COMPONENTS When the starting switch is turned to ON position, the decelerator mode is selected. The selected mode is displayed at the top of the screen. GEAR SHIFT MODE SELECTOR SWITCH The gear shift mode selector switch is used to switch the gear shift mode between quick shift mode and variable shift mode.
Page 98 EXPLANATION OF COMPONENTS OPERATION Item Contents of setting 2nd Speed Set- -2/-1/0/+1/+2 (5 levels) ting 3rd Speed Set- -2/-1/0 (3 levels) ting OPERATING MODE Select “Operating Mode” on “Mode Select” screen, and press switch F6. Operating mode of engine can be switched in accordance with the operation.
Page 99 OPERATION EXPLANATION OF COMPONENTS LOAD DISPLAY Select “Load Display” on “Mode Select” screen, and press switch F6. Display/Non-display of load graph can be switched. Horizontal axis (X) indicates the time, and vertical axis (Y) indi- cates the drawbar pull in the load graph. Similarly to the ECO gauge, it is recommended to use in green range (G).
Page 100 EXPLANATION OF COMPONENTS OPERATION 1ST TRAVEL SPEED SETTING Select “1st Travel Speed Setting” on “Mode Select” screen, and press switch F6. 1st travel speed in quick shift mode can be selected out of 5 levels according to the operation. By setting the travel speed according to the operation in ad- vance, gear shifting is not necessary when operating the joy- stick (steering, directional and gear shift lever).
Page 101 OPERATION EXPLANATION OF COMPONENTS 2ND TRAVEL SPEED SETTING Select “2nd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 2nd travel speed in quick shift mode can be selected out of 5 levels according to the operation. You can increase or decrease the speed in 2 levels each. +2: Increases 2 levels from preset 2nd travel speed +1: Increases 1 level from preset 2nd travel speed 0: Preset 2nd travel speed...
Page 102 EXPLANATION OF COMPONENTS OPERATION 3RD TRAVEL SPEED SETTING Select “3rd Travel Speed Setting” on “Mode Select” screen, and press switch F6. 3rd travel speed in quick shift mode can be selected out of 3 levels according to the operation. You can increase or decrease the speed in 1 level each. 0: Increases 1 level from preset 3rd travel speed -1: Preset 3rd travel speed -2: Decreases 1 level from preset 3rd travel speed...
Page 103 OPERATION EXPLANATION OF COMPONENTS Check the setting of each item (on the left of the screen). Press the switch F3 or F4 to move the yellow cursor to a memory number (“M1” to “M5”) to save, and press the switch F6. The setting is saved by the above operation.
Page 104 EXPLANATION OF COMPONENTS OPERATION Other mode operations while camera image is displayed Even when the camera image is displayed, it is possible to operate following modes. • It is possible to change the operating mode by pressing the operating mode selector switch. When the operating mode is changed, the screen returns automatically to the standard screen.
Page 105 OPERATION EXPLANATION OF COMPONENTS • Press the pedal mode selector switch to change the pedal mode. Actions against warning during camera image display If any error or warning occurs on the machine while the camera image is displayed, the caution lamp flashes at the top left of the screen.
Page 106 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. If you press switch F4 while the clock is displayed, the service meter is displayed instead of the clock. If you press switch F4 while the service meter is displayed, the clock is displayed instead of the service meter.
Page 107 OPERATION EXPLANATION OF COMPONENTS METHOD FOR USING MULTI GAUGE The multi-gauge can display the following items. Multi-gauge selection item Remarks Engine speed There is a caution Machine speed Work equipment pump pressure Battery voltage There is a caution Drawbar pull Clock display An approximate value indicated by the multi-gauge is as fol- lows.
Page 108 When the pointer is in green range during operation, it is normal. If the pointer is in red range, charge during engine running is not performed normally. Stop the operation, move the machine to a safe place, and then ask your Komatsu distributor for the inspection and maintenance.
Page 109 OPERATION EXPLANATION OF COMPONENTS 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 110 EXPLANATION OF COMPONENTS OPERATION (b) “Machine Setting” • Fan reverse mode • Auto idle stop timer setting (c) “Aftertreatment Devices Regeneration” • Setting for regeneration disable • Operation of manual stationary regeneration (d) “SCR Information” • Check of DEF level •...
Page 111 OPERATION EXPLANATION OF COMPONENTS (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. F1: Moves to the left menu. When on the left end menu, it moves to the right end menu.
Page 112 EXPLANATION OF COMPONENTS OPERATION ENERGY SAVING GUIDANCE Each item of “Energy Saving Guidance” menu (a) is used for displaying and setting the notification relevant to energy saving. CHECK OPERATION RECORDS Select “Operation Records” (1) from “Energy Saving Guidance” menu screen, then press switch F6. On “Operation Records”...
Page 113 OPERATION EXPLANATION OF COMPONENTS CHECK ECO GUIDANCE RECORD Select “ECO Guidance Records” (2) from “Energy Saving Guid- ance” screen, then press switch F6. On the “ECO Guidance Records” menu, display the frequency of display of the ECO guidance on a daily basis or during the split measurement period.
Page 114 EXPLANATION OF COMPONENTS OPERATION Operation on “Average Fuel Consumption Record” screen On “Average Fuel Consumption Record” screen, it is possible to perform the following operations with switches F1, F2, and F1: Clears the graph data. F2: Switches graphical displays of the average fuel consump- tion.
Page 115 OPERATION EXPLANATION OF COMPONENTS Deleting the Average Fuel Consumption Record When switch F1 (CLEAR) is pressed, the reconfirmation screen shown in the figure is displayed. When the switch F6 is pressed on the reconfirmation screen, graphs of data during last 12 hours and last 7 days are both deleted, and the screen returns to “Average Fuel Consumption Record”...
Page 116 EXPLANATION OF COMPONENTS OPERATION SET DISPLAY OF FUEL CONSUMPTION GAUGE It is possible to change the display of fuel consumption gauge (5) and the setting of Display/Non-display. Select “Average Fuel Consumption Display” (6) from “Con- figurations” screen, then press switch F6. On this screen, it is possible to perform the following oper- ations with switches F3 to F6.
Page 117 OPERATION EXPLANATION OF COMPONENTS REMARK When you select the split measurement, measurement stop switch F1 (“STOP”) is displayed on the “Operation Records” screen and the “ECO Guidance Records” screen. When you stop the measurement, select “Operation Records” (1) screen or “ECO Guidance Records” (2) screen on “Energy Saving Guidance”...
Page 118 EXPLANATION OF COMPONENTS OPERATION Select “ECO Gauge display” (8) from “Configurations” screen, then press switch F6. The “ECO Gauge Display” screen appears. “Traction”: Displays drawbar pull gauge (A) on the stand- ard screen. “Fuel Consump”: Displays ECO gauge (B) on the standard screen.
Page 119 OPERATION EXPLANATION OF COMPONENTS On this screen, it is possible to perform the following oper- ations with switches F3 to F6. F3: Decreases the target fuel consumption value by 1 ℓ/h. F4: Increases the target fuel consumption value by 1 ℓ/h. F5: Cancels the setting change and returns to Configura- tions screen.
Page 120 EXPLANATION OF COMPONENTS OPERATION Select “ECO Guidance Display at Key OFF” (13) from “Configurations” screen, then press switch F6. The setting screen for “ECO Guidance Display at Key OFF” appears. ON: Displays ECO Guidance (12) on the end screen. OFF: Does not display ECO Guidance (12) on the end screen.
Page 121 OPERATION EXPLANATION OF COMPONENTS If the fan reverse operation is performed while the aftertreat- ment devices regeneration display (A) displays that the regen- eration is in operation, the engine speed may not increase even if the fuel control dial is set to High idle (MAX) position, but this is not a failure.
Page 122 EXPLANATION OF COMPONENTS OPERATION 11. Since fan reverse rotation is set, start the engine. After the engine is started, the fan rotates in reverse, and the machine monitor screen displays as shown in the fig- ure. If the aftertreatment devices regeneration display (A) dis- plays that the regeneration is in operation while the fan is rotated in reverse, the engine speed may decrease to 1400 rpm, regardless of the position of the fuel control dial.
Page 123 OPERATION EXPLANATION OF COMPONENTS 12. After finishing the work, press switch F5 and stop the fan reverse rotation. 13. Set the fuel control dial to Low idle (MIN) position. 14. Turn the starting switch to OFF position to stop the engine. AUTO IDLE STOP TIMER SETTING The auto idle stop function stops the engine automatically when the engine is operated continuously at idle with the lock lever in LOCK position for a set time.
Page 124 EXPLANATION OF COMPONENTS OPERATION Select the set time on the “Auto Idle Stop Timer Setting” screen shown, and then press switch F6. On “Auto Idle Stop Timer Setting screen”, it is possible to perform the following operations with switches F3 to F6. F3: Moves to the next item (1 line below).
Page 125 OPERATION EXPLANATION OF COMPONENTS SCR INFORMATION Each item in “SCR Information” menu (d) is for displaying the information related to SCR and DEF. 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 126 • 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 “Maintenance Due Time Reset” screen On “Maintenance” screen, if switch F6 is kept pressed for 1.5 seconds or more, the screen changes to “Mainte- nance Due Time Reset”...
Page 127 Never drive the machine (in reverse) while watching only the camera screen. Be sure to visually check the safety around the machine. 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. 3-69...
Page 128 EXPLANATION OF COMPONENTS OPERATION Select camera “Screen Adjustment (Camera)” on the “Monitor Setting” menu screen. Press switch F6. On “Screen Adjustment (Camera)” screen, the following items related to the camera screen can be set. • Camera image screen brightness adjustment •...
Page 129 OPERATION EXPLANATION OF COMPONENTS REMARK • If the light switch is at night mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (night mode). • If the light switch is at day mode ON, and the screen is adjusted, it is possible to adjust the brightness of the monitor screen (day mode).
Page 130 EXPLANATION OF COMPONENTS OPERATION Select “Clock Adjustment” (3) on “Monitor Setting” menu screen. Press switch F6. The screen changes to “Clock Adjustment” screen. The following 5 items can be changed. (a): “GPS Synchronization” (b): “Calendar” (c): “Time” (d): “12h/24h Mode” (e): “Daylight Saving Time”...
Page 131 OPERATION EXPLANATION OF COMPONENTS Select “Calendar” (b) on “Clock Adjustment” screen, then press switch F6. 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.
Page 132 EXPLANATION OF COMPONENTS OPERATION Select “Time” (c) on “Clock Adjustment” screen, then press switch F6. 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.
Page 133 OPERATION EXPLANATION OF COMPONENTS “12h/24h Mode” screen appears. F3: Moves to the next item (1 line below). Moves to the top line when it is on the bottom line. F4: Moves to the previous item (1 line above). Moves to the bottom line when it is on the top line.
Page 134 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 canceling 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 135 OPERATION EXPLANATION OF COMPONENTS Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second. The “Operator ID Change” screen is displayed. • Input the already registered ID on the “Operator ID Change” screen and press F6. Then, the identified ID can be changed.
Page 136 EXPLANATION OF COMPONENTS OPERATION WHEN OPERATOR IDENTIFICATION FUNCTION IS AVAILABLE WITHOUT SKIP When the operator identification function is available without SKIP, the identified ID number is not displayed in the “Operator ID” column of “Monitor Setting” screen. Select “Operator ID” (5) on the “Monitor Setting” menu screen, then press switch F6 for 1 second.
Page 137 EXPLANATION OF COMPONENTS MESSAGE DISPLAY On machines equipped with KOMTRAX, you can see the mes- sages from your Komatsu distributor on this User Message menu (g). When there is any message, the User Message (1) at the top of the standard screen lights up.
Page 138 EXPLANATION OF COMPONENTS OPERATION If a message requests reply, the “Numeric Input: []” box (2) is displayed. Make any reply to the message. REMARK • (3) is the subject of the received message. When no message is received, “No message.” is displayed in place (3).
Page 139: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES (1) Air conditioner switch (7) Engine shutdown secondary switch (2) Cigarette lighter (24 V) (8) Starting switch (3) Fuel control dial (9) Horn switch (4) Rear lamp switch (10) Room lamp switch (5) Headlamp switch (11) Wiper switch (6) Foot heater switch STARTING SWITCH...
Page 140 EXPLANATION OF COMPONENTS OPERATION FUEL CONTROL DIAL WARNING • When turning the fuel control dial to High idle (MAX) side while machine is stopped, check that the joystick (steering, directional and gear shift lever) is in NEUTRAL position. If the fuel control dial is turned to High idle (MAX) side while the joystick (steering, directional and gear shift lever) is in FORWARD or REVERSE position, the machine moves off suddenly and this may lead to serious per- sonal injury or death.
Page 141 OPERATION EXPLANATION OF COMPONENTS WIPER SWITCH The wiper switch operates the windshield wiper. The wiper switches are as follows. (A) LH: Left door (B) FF: Front window (C) RH: Right door (D) RR: Rear window (E) INT: Intermittent operation switch (for right and front doors) REMARK If the wiper blade is locked for some reason, the wiper stops automatically.
Page 142 EXPLANATION OF COMPONENTS OPERATION HORN SWITCH If you press the horn switch, the horn sounds. The horn switch is installed at the rear of the blade control lever on the right of the operator's seat. HEAD LAMP SWITCH The headlamp switch is used to light up the head lamp and monitor illumination.
Page 143 • 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 144 EXPLANATION OF COMPONENTS OPERATION FOOT HEATER SWITCH Foot heater (a) is operated by foot heater switch. (A) LO position (B) Center position (C) HI position High The lamp inside the switch lights up by operating the switch. AIR CONDITIONER SWITCH Air conditioner switch is used to control the air conditioner.
Page 145: Control Levers And Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS AND PEDALS (1) Work equipment lock lever (4) Decelerator/brake pedal (2) Parking brake lever (5) Blade control lever (3) Joystick (steering, directional and gear shift lever) BLADE CONTROL LEVER The blade control lever is used for lifting, tilting and angling of the blade. Lifting operation (A) RAISE Blade rises.
Page 146 EXPLANATION OF COMPONENTS OPERATION Tilting operation (E) LEFT tilt Blade tilts leftward. (B) HOLD Blade is stopped and held in this position. (F) RIGHT tilt Blade tilts rightward. Machine Tilting amount ( mm) model Narrow blade Width blade D37EX – D37PX Angling operation Operate angle switch (L) forward and backward to angle the blade.
Page 147 OPERATION EXPLANATION OF COMPONENTS DECELERATOR/BRAKE PEDAL WARNING • When passing over the top of a hill or when dumping soil from a cliff, the load on the machine will suddenly be reduced and the travel speed will increase. This situation is dangerous. Depress the decelerator/brake pedal to lower the travel speed.
Page 148 EXPLANATION OF COMPONENTS OPERATION REMARK • When setting the parking brake lever to LOCK position, (L) 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 (L). When the parking brake lever is not in LOCK position (L), the limit switch is actuated, and the engine does not start.
Page 149 OPERATION EXPLANATION OF COMPONENTS Forward/reverse switching operation (A) FORWARD (N) NEUTRAL (B) REVERSE Move to the front to travel forward; move to the rear to travel in reverse. Steering operation (L) Turn LEFT (N) NEUTRAL (R) Turn RIGHT When the lever is tilted halfway in the direction you are turning while it is tilted in FORWARD or REVERSE, the machine turns.
Page 150: Other Equipment
EXPLANATION OF COMPONENTS OPERATION As the work load increases, the travel speed gradually decreases, and the speed is shifted down. When the work load becomes light again, the speed is shifted up to the set travel speed. Even if speed is shifted down by automatic shifting, speed range display does not change. In gear shift mode, quick shift mode and variable shift mode are available.
Page 151 OPERATION EXPLANATION OF COMPONENTS SASH GLASS INTERMEDIATE LOCK When working with the cab sash glass open, use this lock to prevent the glass from chattering. • When the lever is in FREE position (F), the glass can be opened or closed. •...
Page 152 EXPLANATION OF COMPONENTS OPERATION This is on the left side of the operator's seat. Always extinguish your cigarette before putting it in the ashtray, and be sure to close the lid. LUNCH BOX FIXING BELT This is the place for lunch box. Fix the lunch box with belt.
Page 153 OPERATION EXPLANATION OF COMPONENTS Power source outside cab 24 V power supply NOTICE • Do not use this as a power supply for 12 V equipment. This will cause failure of the equipment. • Do not install equipment which exceeds 120 W (24 V x 5 A).
Page 154 EXPLANATION OF COMPONENTS OPERATION Fuse capacities and circuit names Fuse box (A) Fuse ca- Name of circuit pacity 30 A Front lamp and rear lamp 10 A Horn and preheater 15 A Foot heater 30 A Air conditioner 10 A Machine controller 1 15 A Air suspension seat and winch 30 A Cab power supply 1 30 A...
Page 155 OPERATION EXPLANATION OF COMPONENTS Fuse box (C) Fuse ca- Name of circuit pacity 10 A Radio 20 A Additional working lamp 20 A Cigarette lighter and 12 V socket 10 A Radio and lamp 10 A Front windshield wiper and rear windshield wiper 10 A R.H. and L.H. door windshield wipers FUSIBLE LINK NOTICE When replacing the fusible link, be sure to turn the starting switch to OFF position and, after confirming...
Page 156 It can be installed at the rear part of the operator's seat. Mounting bracket (optional) is necessary for installation. For details of the parts necessary for installation, consult your Komatsu distributor. The directions are described on the nameplate affixed to the fire extinguisher. Just in case, carefully read and understand them beforehand.
Page 157 OPERATION EXPLANATION OF COMPONENTS It can be installed at the rear part of the operator's seat. For details of the parts necessary for installation, consult your Komatsu distributor. BATTERY DISCONNECT SWITCH CAUTION • Do not operate the battery disconnect switch while the engine is running.
Page 158 • 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. • While DEF system devices are operating, the system operating lamp lights up to return DEF to the tank.
Page 159 OPERATION EXPLANATION OF COMPONENTS RADIATOR GRILLE Open and close the radiator grille as needed in check and maintenance. METHOD FOR OPENING AND CLOSING RADIATOR GRILLE WARNING • Before opening and closing the radiator grille, stop the engine and check that the fan is stopped. If you touch the rotating fan, it will cause serious personal injury or death.
Page 160 Urea SCR systems. Alerts in Induce- ment of the Komatsu Urea SCR System progress step by step. It starts with visual indications on the machine monitor with audible sounds to engine power deration to avoid dangerous conditions.
Page 161 DEF, the equipment will not operate correctly, and will not comply with the exhaust gas regula- tions. It may also cause a failure in the engine system. If you supply a solution other than DEF, con- tact Komatsu distributor. To prevent deterioration of the aftertreatment devices, the ex- haust gas temperature rises automatically, which is regenera- tion.
Page 162 EXPLANATION OF COMPONENTS OPERATION Low-level requirement for regeneration • When caution lamp (2) comes on in yellow (action level (3): “L01”, screen (A) is displayed first. • The action level goes out after 2 seconds and the screen changes to standard screen (B). •...
Page 163 OPERATION EXPLANATION OF COMPONENTS PROCEDURE FOR MANUAL STATIONARY REGENERATION When the manual stationary regeneration is required, check whether the caution lamp (1) is lit. During manual stationary regeneration, there are times when engine low idle speed increases automatically. Move the machine to a safe area and stop it with the en- gine running.
Page 164 EXPLANATION OF COMPONENTS OPERATION When manual stationary regeneration is not activated even af- ter you push the switch F6, return to the normal screen. Then push the switch F5, and follow the instructions shown on the screen. Manual stationary regeneration may continue for over 40 mi- nutes.
Page 165 OPERATION EXPLANATION OF COMPONENTS Even if regeneration is disabled, the aftertreatment device re- generation display (1) may come on under certain condition. In this case, it is impossible to disable regeneration. Procedures to stop the regeneration When aftertreatment device regeneration display (1) is lit on the standard screen, push F6 on the standard screen to open the “Aftertreatment Devices Regeneration”...
Page 166 EXPLANATION OF COMPONENTS OPERATION Push F6 on the normal screen, to open the “Aftertreatment Devices Regeneration” screen. If this screen does not show, push F1 and F2 to toggle to this screen. Select Yes to cancel regeneration disable and push F6. ABOUT THE OPERATION OF UREA SCR SYSTEM The Urea SCR System automatically starts operating as soon as the engine is started.
Page 167 OPERATION EXPLANATION OF COMPONENTS The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low level Inducement and Severe Inducement. The DEF level caution lamp (1) on the machine monitor will light up, audible alert will start, then Action level will be dis- played on the machine monitor, and engine power will be derat- ed in steps.
Page 168 EXPLANATION OF COMPONENTS OPERATION • Continuous Warning: The audible alert sounds in repetition of “three beeps and a pause”. 2 gradations of the DEF level gauge light up in the red range. DEF level caution lamp (1) lights up in red. No Action level is displayed.
Page 169 OPERATION EXPLANATION OF COMPONENTS Inducement status (4): “4 Engine power is under heavy de- ration.” Engine power can be restored temporarily from power derate. This engine power restoration works only when the Inducement status is “Severe Inducement”and relieves back temporarily to the power deration of the “Low level Inducement”.
Page 170 EXPLANATION OF COMPONENTS OPERATION “SCR Information” screen displays remaining time to the next Inducement status in the column (5), and information on the Urea SCR System condition (3), and the current status of In- ducement (4). • Warning: No audible alert. The DEF system caution lamp (1) lights up in yellow.
Page 171 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 172 “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 173 OPERATION EXPLANATION OF COMPONENTS “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 174 “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 175 OPERATION EXPLANATION OF COMPONENTS 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 176 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 177 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 178 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 179: Machine Operations And Controls
Clean DEF line and check it for leakage. Check around DEF tank for dirt, and clean the blue DEF filler cap and the area around. Check DEF tank, pump, injector, hoses, and joints for leakage. If any problem is found, ask your Komatsu distributor for re- pair.
Page 180 “METHOD FOR ADJUSTING MIRRORS”. 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.
Page 181 OPERATION MACHINE OPERATIONS AND CONTROLS Turn lower drain valve (1) in the cover to OPEN position (O). The sediment and water accumulated in the bottom are drained together. Be careful not to get fuel on yourself. When clean fuel flows out, turn drain valve (1) to CLOSE position (C).
Page 182 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR CHECKING OIL LEVEL IN HYDRAULIC TANK, ADDING OIL WARNING • Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn in- jury. Wait for the temperature to go down, and then start the work. •...
Page 183 OPERATION MACHINE OPERATIONS AND CONTROLS • When the oil level is below L mark The oil is insufficient. Add hydraulic oil through oil filler port (F) on top of the hydraulic tank. REMARK The oil level changes depending on the oil tempera- ture.
Page 184 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. Wait for the temperature to go down, and then start the work. Check the oil level either before engine starts or at least 15 minutes after the engine stops.
Page 185 • 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 186 MACHINE OPERATIONS AND CONTROLS OPERATION Check the remaining level by the fuel gauge on the ma- chine monitor. • When the pointer is in green range (a) to (c) The fuel level is proper. • When the pointer is in red range (a) to (b) The fuel is insufficient.
Page 187 If you add fluid other than DEF (diesel fuel, low concentration DEF, etc.) by mistake, the caution lamp lights up and the alarm buzzer sounds to warn the abnormality. In this case, ask your Komatsu distributor for draining of the wrong fluid and inspection. DEF injector and/or DEF pump may need to be replaced.
Page 188 MACHINE OPERATIONS AND CONTROLS OPERATION Open DEF tank filler port cover (1). For the opening and closing method of the cover, see “METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER (3-185)”. Open filler port (2) cap. For the opening and closing method of filler port cap, see “METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT CAP (3-186)”.
Page 189 OPERATION MACHINE OPERATIONS AND CONTROLS • If it is difficult to see the sight gauge due to dirt, etc., re- move mounting bolts (B)(5 pieces), remove cover (A), and wipe off dirt on the surface of the sight gauge. METHOD FOR ADDING DEF FROM BIB CONTAINER CAUTION •...
Page 190 MACHINE OPERATIONS AND CONTROLS OPERATION Open the bracket (3) backward. It can be used as a place where the BIB container is put Put the BIB container gently on it. Open the filler port (4) cap. For the filler port cap opening and closing method, see METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT CAP (3-186).
Page 191 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 192 2 sec- onds. If they do not light up, the machine monitor may be defective or may have an open circuit. Ask your Komatsu distributor for the inspection. METHOD FOR REMOVING DEPOSIT IN ENGINE COMPARTMENT Check that there is no deposit inside the engine compartment, particularly around the turbocharger, exhaust manifold, and aftertreatment devices.
Page 193 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR CHECKING HORN OPERATION Turn the starting switch to ON position (B). Check that the horn sounds when the horn switch is press- If the horn does not sound or its volume is extremely low, it may be broken or may have an open circuit.
Page 194 Check that the distance of stroke (A) at the center of the pedal is 50 to 60 mm. When it exceeds 60 mm or the brake force is insufficient, ask your Komatsu distributor for adjustment. METHOD FOR ADJUSTING METHOD FOR ADJUSTING OPERATOR'S SEAT WARNING •...
Page 195 OPERATION MACHINE OPERATIONS AND CONTROLS • When adjusting the seat, put your back against the backrest and adjust to a position where the decelerator/ brake pedal can be fully depressed. AIR SUSPENSION SEAT (LOW-BACK SEAT) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, and set the seat to the desired position.
Page 196 MACHINE OPERATIONS AND CONTROLS OPERATION Pull up lever (1) fully or push it down fully to adjust the seat height. For adjusting the seat height, pull up lever (1) to make the seat higher and push it down to make the seat lower. Adjust it so that the weight adjustment indicator (2) enters the green range.
Page 197 OPERATION MACHINE OPERATIONS AND CONTROLS REMARK When the seat surface temperature is above approximately 20 °C, the heater does not operate even if the switch is turned on. MECHANICAL SUSPENSION SEAT (if equipped) METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, and set the seat to the desired position.
Page 198 MACHINE OPERATIONS AND CONTROLS OPERATION 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 199 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ADJUSTING LUMBER 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 200 MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR ADJUSTING SEAT IN FORE-AND-AFT DIRECTION Pull up the fore-aft adjustment lever, and set the seat to the desired position. Fore-and-aft adjustment range: 210 mm (21 steps) 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 201 OPERATION MACHINE OPERATIONS AND CONTROLS Pull up the height adjustment lever fully, and then release it. The seat cushion is adjusted automatically. • The weight-based adjustment starts as soon as the height adjustment lever is pulled lightly. Pull it up fully until it clicks, and then release it.
Page 202 MACHINE OPERATIONS AND CONTROLS OPERATION Press the adjustment switch to give proper tension to the waist part. Press (+) side: Tension of backrest increases. Press (-) side: Tension of backrest decreases. Adjust the curve of backrest to your desired shape. METHOD FOR ADJUSTING DAMPER Turn the adjustment knob to adjust the hardness of damper to the desired level.
Page 203 OPERATION MACHINE OPERATIONS AND CONTROLS Loosen bolts (1) on the R.H. and L.H. of the operator's seat. (2 places each) Adjust the R.H. and L.H. armrests of the operator's seat to proper height. Tighten bolts (1) securely. The armrests are fixed. METHOD FOR FASTENING AND UNFASTENING SEAT BELT WARNING •...
Page 204 MACHINE OPERATIONS AND CONTROLS OPERATION Pull the belt lightly to check that it is properly locked. If the tongue is not inserted in the buckle, the seat belt caution lamp is displayed at the top left of the machine monitor. METHOD FOR UNFASTENING SEAT BELT Press button (2) in buckle (1) and remove tongue (3) from buckle (1).
Page 205 OPERATION MACHINE OPERATIONS AND CONTROLS Check that parking brake lever (1) is in LOCK position (L). If parking brake lever (1) is not in LOCK position (L), the engine cannot be started. Check that joystick (steering, directional and gear shift lev- er) (2) is in NEUTRAL position (N).
Page 206 If a password is set, the input display screen will be indi- cated on the machine monitor. 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 207 OPERATION MACHINE OPERATIONS AND CONTROLS Check that the screen changes to the gear shift mode display screen in approximately 2 seconds, and then it changes to the standard screen. • Hydraulic oil temperature gauge (5) • Engine coolant temperature gauge (6) •...
Page 208: Method For Starting Engine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR STARTING ENGINE METHOD FOR STARTING ENGINE IN NORMAL WEATHER WARNING • Start the engine only while sitting on the operator's seat. • Do not attempt to start the engine by short-circuiting the engine starting circuit. This may cause fire, serious personal injury or death.
Page 209 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the key in starting switch (2) to START position (C). The engine starts. 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 immediately after the engine is started or during the after- treatment devices regeneration in cold season, but this is not a failure.
Page 210 MACHINE OPERATIONS AND CONTROLS OPERATION NOTICE • Do not turn the starting motor continuously for more than 60 seconds in any case. If the engine does not start, wait for approximately 2 minutes, then repeat the procedure from step 2. •...
Page 211 OPERATION MACHINE OPERATIONS AND CONTROLS Check if the preheating pilot lamp on the machine monitor (3) is lit. Leave this condition until the preheating pilot lamp goes out. The lighting time of the preheating pilot lamp varies with the ambient temperature as shown in the table. Ambient temperature Lighting time (sec.) ( °C)
Page 212 MACHINE OPERATIONS AND CONTROLS OPERATION REMARK • Regardless of the ambient temperature, if the key in starting switch (2) is turned counterclockwise from OFF position, the preheating pilot lamp lights up and preheating starts. (Preheating continues while the starting switch (2) is held at the left.) For the preheating time, see the table in step 5.
Page 213: Method For Operations And Checks After Starting Engine
In that case, ask your Komatsu distributor to check the engine as soon as possible.
Page 214 (2) indicates green range (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. 3-156...
Page 215 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR ENGINE WARM-UP OPERATION IN COLD SEASON This machine is warmed up automatically by the automatic warm-up operation system. When the engine coolant temperature is 30 °C or less after the engine is started, the warm-up operation starts automatically. The automatic warm-up operation stops when the engine cool- ant temperature increases the specified temperature (30 °C) or after warm-up operation of 10 minutes even if the coolant tem-...
Page 216: Method For Stopping Engine
11. Check for abnormal exhaust gas color, noise, or vibration. If any abnormality is found, contact your Komatsu distribu- tor. After warm-up operation, run he engine at medium speed and slowly drive forward and reverse so that the whole equipment becomes uniform temperature.
Page 217 OPERATION MACHINE OPERATIONS AND CONTROLS Turn the fuel control dial (1) to Low idle (MIN) position. Run the engine at low idle for approximately 5 minutes to cool down gradually. Turn the key in starting switch (2) to OFF position (A). The engine will stop.
Page 218: 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 • Before moving the machine off, check that the area around the machine is safe, then sound the horn be- fore starting.
Page 219 OPERATION MACHINE OPERATIONS AND CONTROLS Set work equipment lock lever (6) to FREE position (F). Set blade control lever (7) to RAISE position (R) and raise the blade to 40 to 50 cm above the ground. Depress the decelerator/brake pedal. Set the joystick (steering, directional and gear shift lever) (4) to FORWARD position (F) or REVERSE position (R).
Page 220 MACHINE OPERATIONS AND CONTROLS OPERATION Make the machine move off by releasing decelerator/brake pedal (2) gradually. REMARK When moving off, the machine sometimes deviates a little, but this is due to actuation of straight-travel correction mechanism and it is not a failure. METHOD FOR STOPPING MACHINE WARNING •...
Page 221: Shift Gears
OPERATION MACHINE OPERATIONS AND CONTROLS To keep the machine stopped, depress decelerator/brake pedal (3) further until depressing effort becomes large. SHIFT GEARS Speed range can be changed while traveling, it is not necessary to stop the machine for gear shifting. Select a desired speed range by depressing UP switch or DOWN switch of joystick (steering, directional and gear shift lever) (1).
Page 222 MACHINE OPERATIONS AND CONTROLS OPERATION QUICK SHIFT MODE • Press UP switch (U) of the joystick (steering, directional and gear shift lever) once, and speed range changes 1st → 2nd and 2nd → 3rd. • Press DOWN switch (D) of the joystick (steering, direction- al and gear shift lever) once, and speed range changes 3rd →...
Page 223 OPERATION MACHINE OPERATIONS AND CONTROLS • FORWARD/REVERSE (E) is displayed in the speed range display section. FORWARD/REVERSE (E) “F”: FORWARD “R”: REVERSE “N”: NEUTRAL “P”: Parking brake is being applied • Upper bar graph (G) lights up in accordance with set travel speed in forward.
Page 224: Method For Switching Between Forward And Reverse
MACHINE OPERATIONS AND CONTROLS OPERATION • Reverse travel speed can be set with reverse travel speed setting switch (A) and (B). • Each time switch (A) is pressed, the set travel speed in- creases. • Each time switch (B) is pressed, the set travel speed de- creases.
Page 225: Method For Steering Machine
Check that the backup alarm sounds when the joystick (steering, directional and gear shift lever) is set to RE- VERSE. If the alarm does not sound, ask your Komatsu distributor for repair. Release decelerator/brake pedal (1) and raise the engine speed.
Page 226 MACHINE OPERATIONS AND CONTROLS OPERATION 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. Any turning radius can be set until the operating effort of joy- stick (steering, directional and gear shift lever) becomes large.
Page 227 OPERATION MACHINE OPERATIONS AND CONTROLS On “Steering Mode” screen, press the switch F3 or F4 to move the yellow cursor to “Normal”, then press the switch F6. To make counter-rotation turn to the left, tilt the joystick (steering, directional and gear shift lever) forward and tilt it to left (L), and tilt it fully further from the point where the joystick operating effort becomes large.
Page 228: Recommended Working Modes For Works
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 the joystick (steering, di- rectional and gear shift lever) forward and tilt it to left (L) half- way.
Page 229 OPERATION MACHINE OPERATIONS AND CONTROLS Pedal mode Pedal mode can be changed with pedal mode selector switch (3). Pedal mode Features Depress the decelerator/brake pedal, and travel speed and engine speed lowers. Decelerator mode Use this mode for general operations. Depress the decelerator/brake pedal, and the travel speed lowers, but the engine speed does not lower.
Page 230: Precautions For Operation
MACHINE OPERATIONS AND CONTROLS OPERATION AA: Standard screen, MM: “Mode Select” screen (1) Gear shift mode selector switch (3) Pedal mode selector switch (2) Operating mode selector switch RECOMMENDED WORKING MODES Operating mode Type of operation Soil quality Operating conditions Normal soil Heavy-duty operations, high productivity desired ○...
Page 231: Precautions When Operating On Slope
OPERATION MACHINE OPERATIONS AND CONTROLS PERMISSIBLE WATER DEPTH When operating in water, always keep the bottom of carrier roll- ers (1) above the surface of the water. Also, be careful that the hydraulically driven cooling fan will not come in contact with water in order to prevent the breakage of the fan.
Page 232: Do Not Open Door While Operating Machine
MACHINE OPERATIONS AND CONTROLS OPERATION When working on slopes with an angle of more than 20 °, if the fuel level on the fuel gauge enters the red range, add fuel im- mediately. (A): Red range (B): Green range Pay attention to oil level When operating machine on a slope of 20 °...
Page 233 OPERATION MACHINE OPERATIONS AND CONTROLS DOZING WORK Cut soil and sand and move them forward. When cutting a slope surface, it is more efficient to always cut from top toward bottom. When dozing toward one side only, operate with angled blade. LEVELING WORK NOTICE Avoid leveling work on rocky or stony ground.
Page 234: Method For Adjusting Work Equipment
MACHINE OPERATIONS AND CONTROLS OPERATION For trees with a diameter of 10 to 30 cm, raise the blade high and push a few times to fell the tree. Next, travel in reverse, and dig the corner of the blade into the ground to cut and dig up the roots.
Page 235: 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 236 Frequent inspection and prompt repair will reduce repair costs. The following items for inspection will serve as a guide to maintenance service of each undercarriage part. Per- form periodical inspection and contact the Komatsu distributor in your area when machine has approached re- pairable limits and reversing limits.
Page 237 OPERATION MACHINE OPERATIONS AND CONTROLS METHOD FOR MEASURE LINK PITCH Put a wooden block, etc. between the track shoe and sprocket to eliminate the sag of the track. Measure length (L) of 4 link pitches in a straight portion at least 2 links apart from master link (A).
Page 238: Method For Parking Machine
MACHINE OPERATIONS AND CONTROLS OPERATION METHOD FOR MEASURING TRACK ROLLER DIAMETER Measure the link tread (dimension C) as shown in the fig- ure. Stop the machine at a position where the link tread, at which dimension C was measured, is perfectly in contact with the roller tread.
Page 239 OPERATION MACHINE OPERATIONS AND CONTROLS Set joystick (steering, directional and gear shift lever) (2) to N (NEUTRAL) position. Position (A): FORWARD Position (B): REVERSE To keep the machine stopped further, depress decelerator/ brake pedal (1) until depressing effort becomes large. Operate the parking brake lever (3) by holding the operat- ing portion on the top, and place the lever in LOCK posi- tion (L)
Page 240: Method For Checking After Finishing Work
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. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 241 OPERATION MACHINE OPERATIONS AND CONTROLS Places locked with special key • Fuel filler port cap (8) REMARK If padlock (A) is to be used, it is recommended to use the type that has the cover to protect the key hole. METHOD FOR OPENING AND CLOSING CAP WITH LOCK PROCEDURE FOR OPENING CAP WITH LOCK Insert the key into the key slot.
Page 242 MACHINE OPERATIONS AND CONTROLS OPERATION PROCEDURE FOR CLOSING CAP WITH LOCK Screw in the cap until it becomes tight, then insert the key into the key slot. Turn the starting switch key to “LOCK” position, then remove the key. METHOD FOR OPENING AND CLOSING FUEL FILLER PORT CAP PROCEDURES FOR OPENING FUEL FILLER PORT CAP Raise lever (1) in the direction (a).
Page 243 OPERATION MACHINE OPERATIONS AND CONTROLS • Cover other than cab door opener Position (A): OPEN Position (B): CLOSE (LOCK) METHOD FOR LOCKING COVER WITH LOCK Close the cover and insert the key into the key slot. Turn the starting switch key to CLOSE position (B), then remove the key. METHOD FOR OPENING AND CLOSING DEF TANK FILLER PORT COVER CAUTION •...
Page 244 MACHINE OPERATIONS AND CONTROLS OPERATION Fix the cover with the lock bar (fixing bar) (5). METHOD FOR LOCKING DEF TANK FILLER PORT COVER Remove the lock bar (fixing bar) (5) from the cover. Close the DEF tank filler port cover. Lower the knob (3) to lock.
Page 245: Handle Air Conditioner
OPERATION HANDLE AIR CONDITIONER HANDLE AIR CONDITIONER Ventilation while cooling • When running the air conditioner for a long time, turn the lever to FRESH position once an hour to perform ventilation and cooling. • If you smoke when the air conditioner is on, the smoke may hurt your eyes. In such case, open the window and turn the lever to FRESH for a while for ventilation and driving smoke out.
Page 246: Method For Operating To Prevent Dust From Entering Into Cab
HANDLE AIR CONDITIONER OPERATION BLOWER CHANGEOVER SWITCH Blower selector switch is used to control the air flow at cooling and heating, and also used as a main switch. • It changes the air flow in 4 levels of 1 (low) → 2 → 3 → 4 (high).
Page 247: Method For Replacing Receiver
If the receiver is used with desiccating agent of which absorbing limit is over, the refrigerant circuit gets clogged and may cause the failure of compressor. Replace it every 2 years. REMARK The exchange interval may be shortened depending on the usage condition of receiver. Ask your Komatsu distributor for replacement of the receiver. 3-189...
Page 248: Handle Radio
HANDLE RADIO OPERATION HANDLE RADIO • To ensure safety, always keep the volume to a level where you can hear the outside sounds during opera- tion. • If water gets into the speaker case or radio, it may lead to failure. Take care not to let water get on them. •...
Page 249 OPERATION HANDLE RADIO 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. As long as AUX is selected, this button alternately switches the display between AUX and the clock.
Page 250: 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 251 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 252: 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 253: Transportation
Operator's seat and control levers are made in one unit with the cab. If cab is removed, machine cannot be op- erated. If you have any trouble in transportation, consult your Komatsu distributor. METHOD FOR REMOVING WORK EQUIPMENT Overall width can be shortened by angling the blade fully. Re- ferring to the figure, decide whether the blade should be re- moved for transportation.
Page 254: 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 255 OPERATION TRANSPORTATION Place the parking brake lever in FREE position (F). Set the speed range to 1st or less in variable mode. Set the travel direction toward the ramps and drive slowly. The center of gravity of the machine shifts suddenly at the joint between the ramps and the trailer, and the machine is unbalanced and becomes unstable.
Page 256 TRANSPORTATION OPERATION Front of the machine When no front work equipment is attached When front work equipment is attached (PAT specification) 3-198...
Page 257 OPERATION TRANSPORTATION Rear of the machine When a drawbar is equipped When a hitch is equipped 3-199...
Page 258 TRANSPORTATION OPERATION When a ripper is equipped PROCEDURES FOR UNLOADING MACHINE Perform unloading of the machine on a firm and level ground. Park a trailer on a firm and level ground. Maintain a safe distance from the road shoulder Apply the brake of the trailer securely. Set chocks (1) to the tires to secure the trailer.
Page 259: Method For Lifting Machine
This lifting method 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 260 TRANSPORTATION OPERATION Set the work equipment lock lever securely to LOCK posi- tion (L). Stop the engine, and remove the key from the starting switch. Securely lock the glass window, cab door, engine side cov- er, hydraulic tank inspection cover, DEF tank filler port cov- er, and fuel tank inspection cover.
Page 261: 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 262: Precautions After Daily Work Completion In Cold Weather
Replace the fuel and oil for all equipment with the ones of the specified viscosity. For details, see “RECOM- MENDED FUEL, COOLANT, AND LUBRICANT (7-5)”. 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. 3-204...
Page 263: 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 264 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 265: 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 266: Precautions For Discharged Battery
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 draw bar pin. Connect a wire rope to the part indicated with the arrow in the drawing.
Page 267 OPERATION TROUBLES AND ACTIONS METHOD FOR REMOVING AND INSTALLING BATTERY WARNING Stop the engine, and turn the starting switch and the battery disconnect switch keys to OFF positions when handling the battery. Prepare wooden blocks. Open the hydraulic tank inspection cover (1). Turn the battery disconnect switch to OFF position (O).
Page 268 TROUBLES AND ACTIONS OPERATION Remove the bolt (7) (1 piece) and remove the clip. Loosen the nuts of terminal (8) (2 places) and disconnect the cable from the battery. Disconnect the ground cable (normally connected to the negative (-) terminal) first. If any tool touches the positive terminal of the battery and the chassis, there is a danger that it will cause a spark.
Page 269 OPERATION TROUBLES AND ACTIONS 11. Loosen the nuts of terminal (16) (2 places) and disconnect the cable from the battery. Disconnect the ground cable (normally connected to the negative (-) terminal) first. If any tool touches the positive terminal of the battery and the chassis, there is a danger that it will cause a spark.
Page 270 TROUBLES AND ACTIONS OPERATION PRECAUTIONS FOR CHARGING BATTERY WARNING When charging the battery, if the battery is not handled correctly, there is a danger that the battery may explode. Follow the instruction manual accompanying the battery charger, and observe the following. •...
Page 271 OPERATION TROUBLES AND ACTIONS NOTICE • The starting system for this machine uses 24 V. Accordingly, the normal machine must be equipped with a 24 V power supply. • The sizes of the jumper cables and clips should be suitable for the battery size. •...
Page 272: Other Trouble
PHENOMENA AND ACTIONS FOR ELECTRICAL SYSTEM • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 273 PHENOMENA AND ACTIONS FOR CHASSIS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 274 PHENOMENA AND ACTIONS FOR ENGINE RELATED PARTS • Contact your Komatsu distributor for the remedies indicated with (*) in the remedy column. • Ask your Komatsu distributor for repairs for problems or causes which are not listed below. Problem Main causes Remedy...
Page 275 OPERATION TROUBLES AND ACTIONS Problem Main causes Remedy Steam spurts out from top of radiator. Lowered coolant level, leakage of Check, add coolant, repair by refer- (pressure valve) coolant ring to CHECKS BEFORE START- ING. Dirt or scale accumulated in cooling Change coolant, flush inside of cool- system ing system by referring to WHEN RE-...
Page 276 (3) for the point of contact is displayed in the message column at the bottom of the screen. REMARK If no point of contact telephone number is registered, no tele- phone number is displayed. Ask your Komatsu distributor for the telephone number regis- tration if necessary. 3-218...
Page 277: Maintenance
MAINTENANCE Please read and make sure that you understand the SAFETY section before reading this section.
Page 278: 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 279: Dusty Jobsites
MAINTENANCE PRECAUTIONS FOR MAINTENANCE DUSTY JOBSITES When working at dusty jobsites, observe the following. • Clean the radiator fins and other parts of the heat exchange equipment more frequently, and take care not to let the fins become clogged. • Replace the fuel filter more frequently.
Page 280: Fuel And Lubricants To Match The Ambient Temperature
PRECAUTIONS FOR MAINTENANCE MAINTENANCE Checks while the engine is running To perform inspection while the engine is running, one worker must always sit on the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers. •...
Page 281: Outline Of Maintenance
OUTLINE OF MAINTENANCE OUTLINE OF MAINTENANCE • Komatsu recommends using Komatsu genuine parts for replacement parts, grease or oil. • When changing the oil or adding oil, do not mix different types of oil. When changing the type of oil, drain all the old oil and fill completely with the new oil.
Page 282 Always use ultra-low-sulfur diesel fuel. (≤10 ppm) The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Do not use any additive agent which includes metallic constituent.
Page 283 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 284: Handle Electrical Components
• When replacing oil filters, check if any metal particles are attached to the old filters. If any metal particles are found, consult your Komatsu distributor. • Do not open packages of spare filters until just before they are to be used.
Page 285: Handle Hydraulic 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 at the seashore, keep the electrical component clean to prevent corrosion.
Page 286: 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 287 MAINTENANCE STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS Tightening torque Width Nominal - No. of across Target value Allowable range threads "a" flats "b" (mm) Nm kgm Nm kgm 9/16-18UNF 35 to 54 3.5 to 5.5 11/16-16UN 54 to 93 5.5 to 9.5 13/16-16UN 10.5...
Page 288: Maintenance Schedule
MAINTENANCE SCHEDULE MAINTENANCE 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 289 MAINTENANCE MAINTENANCE SCHEDULE METHOD FOR CHECKING AND RELEASING NITROGEN GAS CHARGE PRESSURE IN ACCUMULA- TOR (FOR CONTROL CIRCUIT) ......................4-59 METHOD FOR CHECKING ALTERNATOR .................... 4-62 METHOD FOR CHECKING AND ADJUSTING ENGINE VALVE CLEARANCE ........4-62 METHOD FOR REPLACING KCCV FILTER ELEMENT ................. 4-62 METHOD FOR REPLACING DEF FILTER....................
Page 290: Maintenance Procedure
MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED METHOD FOR CHECKING, CLEANING AND REPLACING AIR CLEANER WARNING • If inspection, cleaning, or maintenance is performed while the engine is running, dust enters into the engine and damages it. Be sure to stop the engine before performing these works. •...
Page 291 MAINTENANCE MAINTENANCE PROCEDURE NOTICE • When cleaning the cover, do not remove the vacuator valve (5). • Before and after cleaning the element, do not leave or keep it under direct sunlight. • Never remove the inner element (3). If it is removed, dirt will enter and can cause an engine trouble.
Page 292 MAINTENANCE PROCEDURE MAINTENANCE 12. Install the cleaned outer element. NOTICE • When installing the cover (2), check the O-ring (6) for a scratch, etc. If it has any scratch, etc., re- place it. • When installing the cover (2), press it to the case securely, and check that clips (1) are secured cor- rectly at 3 places.
Page 293: Method For Cleaning Inside Of Cooling System
MAINTENANCE MAINTENANCE PROCEDURE NOTICE • If the outer element and cover are installed while the inner element is not installed properly, the outer element may be damaged. • Do not clean and reuse the inner element. When replacing the outer element, replace the inner element with new one at the same time.
Page 294 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 295 MAINTENANCE MAINTENANCE PROCEDURE Open the engine side cover (2) on the left side of the ma- chine. Remove the engine side cover (3) on the right side of the machine. Remove the cover (4), and pull out the drain hoses (5) and (6).
Page 296 MAINTENANCE PROCEDURE MAINTENANCE Open the inspection cover (7) under the engine on the low- er part of the machine. 10. Open the drain valves(8) and (9) to drain the coolant. REMARK Keep the air bleeding valves (10) and (11) open while add- ing the coolant or water to the cooling system.
Page 297: Method For Cleaning Inside Machine
MAINTENANCE MAINTENANCE PROCEDURE 20. Open the hydraulic tank inspection cover, and drain the coolant from the reservoir tank (12). 21. Clean the inside of reservoir tank (12). 22. Add Non-Amine Engine Coolant (AF-NAC) to the middle between FULL and LOW. 23.
Page 298: Method For Checking And Cleaning Radiator Front
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR CHECKING AND CLEANING RADIATOR FRONT WARNING If compressed air, high-pressure water, or steam hits your body directly or dirt is scattered by the com- pressed air, high-pressure water, or steam, there is a danger of personal injury. Always wear protective equipment such as protective eyeglasses and dust mask.
Page 299 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 300: Method For Checking Looseness And Tightening Track Shoe Bolts
METHOD FOR DECREASING TRACK TENSION WARNING It is extremely dangerous to release the grease by any method other than the following procedure. If track tension is not relieved by this procedure, contact your Komatsu distributor for repairs. NOTICE • The safety indicator is stuck to the back of cover (3). Take care not to damage the safety indicator.
Page 301: Method For Checking Idler Oil Level
When the oil level is low and new oil must be added, the machine body needs to be inclined, and that is dangerous. Ask your Komatsu distributor for addition. Low oil level in the idler can cause noise and seizure. Stop the machine on a flat place and check for the oil level according to the following procedure.
Page 302: Method For Adjusting Idler Clearance
When oil oozes out through thread portion You do not need to add oil. • When no oil oozes out through thread portion The oil is insufficient. Ask your Komatsu distributor for adding. After checking, tighten plug (4). Install guide plate (2) and shim (3).
Page 303: Method For Inverting And Replacing Cutting Edge And End Bit
MAINTENANCE MAINTENANCE PROCEDURE 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 and end bit are turned 180 deg. or replaced. Set the work equipment in a stable condition, place the work equipment lock lever to LOCK position, then stop the engine.
Page 304 MAINTENANCE PROCEDURE MAINTENANCE The dust and dirt stuck to the radiator and cooler can be blown out by rotating the hydraulic drive fan in the reverse direction. Turn the starting switch (1) to OFF position and stop the engine. Set the parking brake lever (2) and work equipment lock lever (3) to LOCK positions (L).
Page 305 MAINTENANCE MAINTENANCE PROCEDURE With the user menu on the machine monitor, set “Machine Setting” to the Fan Reverse Mode. For setting of the Fan Reverse Mode, see “REVERSE HY- DRAULIC FAN”. REMARK Even if Fan Reverse Mode is set while the engine is run- ning, the fan rotation direction is not reversed.
Page 306: Method For Cleaning Hydraulic Tank Breather
MAINTENANCE PROCEDURE MAINTENANCE Remove the bolts (1) (6 pieces) on the lower part of the ra- diator grille. Pull the radiator grille backward and raise it upward. Open the radiator grille to the fully opened position, check that it is locked, and then release your hand. Remove mud, dirt, leaves, etc.
Page 307: Method For Cleaning Fuel Tank Breather
MAINTENANCE MAINTENANCE PROCEDURE Remove nut (2) of breather assembly (1) on the top of the hydraulic tank. Use a tool when the nuts are so tight to remove. Remove cover (3). Remove dirt sticking to breather element (4). Clean in clean diesel fuel or flushing oil. Install cover (3) and nut (2).
Page 308: Method For Replacing Door Damper
MAINTENANCE PROCEDURE MAINTENANCE METHOD FOR REPLACING DOOR DAMPER Measure groove depth (A) of door damper rubber (1). When groove depth (A) decreases to 2 mm or less, replace the damper. The damper is installed at top and bottom, 2 pieces each on the R.H.
Page 309: Method For Checking Window Washer Fluid Level, Adding Fluid
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING WINDOW WASHER FLUID LEVEL, ADDING FLUID Perform this check when no window washer fluid comes out. Open the hydraulic tank inspection cover. 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 310: Method For Replacing Wiper Blade
MAINTENANCE PROCEDURE MAINTENANCE Do not use any solvent to remove it, because it has a bad influence upon the wiper blade rubber. METHOD FOR REPLACING WIPER BLADE If the blade is damaged, it will not wipe the window clean, so replace the blade.
Page 311: Method For Checking And Maintenance Air Conditioner
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND MAINTENANCE AIR CONDITIONER METHOD FOR CHECKING LEVEL OF REFRIGERANT (GAS) WARNING • Be sure to handle the refrigerant (gas) according to the local regulations. • If the refrigerant used in the air conditioner gets into your eyes or is splashed on your hands, it may cause loss of sight or frostbite.
Page 312 MAINTENANCE PROCEDURE MAINTENANCE Remove the cap of oil filler port (F) at the top of the hydraulic tank. Remove the floor mat (1) and floor plate (2). Loosen the air bleeder (3) installed to the drain port and check that oil oozes out from it. After bleeding air, tighten the air bleeder (3).
Page 313: Method For Releasing Pressure In Hydraulic Circuit
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 ADJUSTING SHIMS AT CENTER BALL WARNING Place the work equipment lock lever at LOCK position except when operating the blade for adjustment.
Page 314: Checks Before Starting
MAINTENANCE PROCEDURE MAINTENANCE • Standard shim thickness: 8 mm Remove the bolt (1) and loosen the bolt (2). Remove all the shims (3) and tighten the bolts (1) and (2) lightly so that the dimension of clearance (A) becomes even at whole circumference. Measure the clearance (A) and set the shim thickness so that it is between (A + 0.2) and (A + 1.2) mm.
Page 315: Every 250 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE When lubricating the lift cylinder bottom pin (1) and U-frame mounting pin (3), lower the blade to raise the idler 1 to 2 cm from the ground, then stop the engine. By using a grease pump, pump in grease through the grease fitting. After greasing, wipe off any old grease that is pushed out.
Page 316: Method For Checking Battery Electrolyte Level
MAINTENANCE PROCEDURE MAINTENANCE Stop the machine so that the TOP mark comes on the top while a line between TOP mark and plug (P) becomes per- pendicular to the ground surface. Remove plug (F) by using a handle, and check the oil lev- •...
Page 317 If purified water is added to above U.L. line, use a syringe to lower the level to U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water. If necessary, con- sult your Komatsu distributor or a battery manufacturer. METHOD FOR CHECKING ELECTROLYTE LEVEL WHEN IT IS IMPOSSIBLE TO...
Page 318: Method For Checking Brake Performance
If it is possible to use an indicator to check the electrolyte level, follow the instructions given. METHOD FOR CHECKING BRAKE PERFORMANCE WARNING If the machine moves off during the following operation, ask your Komatsu distributor for repairs imme- diately. Before starting the engine, check the safety around the machine, and then perform the following operation.
Page 319: Every 500 Hours Maintenance
When the machine can move or the warning screen is displayed on the machine monitor. Immediately ask your Komatsu distributor for repair. EVERY 500 HOURS MAINTENANCE Maintenance for every 50 and 250 hours should be performed at the same time.
Page 320 Tighten the drain plug (P). Check the drained oil. If there are excessive metal particles or foreign material, contact your Komatsu distributor. Install the undercover (2) and cover (1). Turn the engine oil filter cartridge (3) counterclockwise to remove by using the filter wrench.
Page 321: 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 322 MAINTENANCE PROCEDURE MAINTENANCE Open the fuel tank inspection cover on the right side of the machine. Turn the fuel supply valve (1) to CLOSE position (C). Open the engine side cover (2) on the left side of the ma- chine. Take out the drain hose (3) toward the left side of the ma- chine.
Page 323: Method For Replacing Air Conditioner Fresh/Recirc Filters
MAINTENANCE MAINTENANCE PROCEDURE REMARK • If the filter cartridge is fastened too much, the packing will be damaged and this leads to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing. Be sure to observe the tight- ening angle.
Page 324: Method For Checking Electric Wiring Around Starting Motor And Alternator
METHOD FOR CHECKING ELECTRIC WIRING AROUND STARTING MOTOR AND ALTERNATOR CAUTION If there are traces of short-circuiting on the electric wiring, immediately ask your Komatsu distributor to locate the cause of it and to perform the repair. 4-48...
Page 325: Every 1000 Hours Maintenance
MAINTENANCE MAINTENANCE PROCEDURE Remove the engine side cover (1) on the right side of the machine. Remove the cover (2) under the engine side cover on the left side of the machine. Perform the following check. • Check that there is no disconnection or trace of short- circuiting in the electric wiring and no damage to the coating.
Page 326: 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 327 MAINTENANCE MAINTENANCE PROCEDURE Open the engine side cover (2) on the left side of the ma- chine. Place a container under filter cartridge (3) to catch the fuel. Turn the filter cartridge (3) counterclockwise by using the filter wrench, and remove it. NOTICE •...
Page 328: Method For Replacing Fuel Tank Breather Element
(2) by hand until it is seated. Then tighten it 15 to 30 ° by using a tool. 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. 4-52...
Page 329: Method For Replacing Hydraulic Tank Breather Element
If the machine is operated without the DEF tank breather element attached, or with the element oth- er than Komatsu genuine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine. Never operate the machine without the DEF tank breather element attached, nor use the element other than Komatsu genuine parts.
Page 330: Method For Checking For Loose Rops Mount Bolts
Since the auto-tensioner is installed, tension adjustment is not required. Check the alternator drive belt. If alternator drive belt shows the following conditions, it must be replaced. Ask your Komatsu distributor to replace it. • When vertical flaw (2) that crosses horizontal flaw (1) is found.
Page 331: Method For Checking And Cleaning Fan
MAINTENANCE MAINTENANCE PROCEDURE METHOD FOR CHECKING AND CLEANING FAN WARNING • When performing cleaning, there is a danger that dirt may scatter and cause personal injury. Wear the protective equipment such as the protective eyeglasses and dust mask. • When performing cleaning, always stop the engine and check that the fan is not rotating. If you touch the fan when it is rotating, it will cause serious personal injury or death.
Page 332: Every 2000 Hours Maintenance
MAINTENANCE PROCEDURE MAINTENANCE Close the radiator grille according to the following proce- dure. Lift up the radiator grille, and push up the lock releas- ing bar (6). The lock is released. Close the radiator grille. Tighten the bolts (1) (6 pieces) on the lower part of the ra- diator grille.
Page 333 MAINTENANCE MAINTENANCE PROCEDURE Pull the radiator grille (1) backward and raise it upward. Open the radiator grille (1) to the fully opened position, check that it is locked, and then release your hand. Remove the drain hose (3) and install it to the drain port (4).
Page 334 31. After the packing surface touches the sealing surface of the filter head, tighten the filter cartridge approximately 2/3 of a turn. Komatsu recommends using Komatsu genuine cartridge. 32. Open the fuel tank inspection cover on the right side of the machine.
Page 335: Method For Checking And Releasing Nitrogen Gas Charge Pressure In Accumula- Tor (For Control Circuit)
• 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 336 MAINTENANCE PROCEDURE MAINTENANCE FUNCTION OF ACCUMULATOR The accumulator (1) stores the pressure in the control circuit. Even after the engine is stopped, the control circuit can be op- erated, so the following actions are possible. • If the control lever is operated in the direction to lower the work equipment, it is possible for the work equipment to go down under its own weight.
Page 337 MAINTENANCE MAINTENANCE PROCEDURE NOTICE Perform the following procedure (for lowering the blade to the ground) within 15 seconds after stopping the engine. When the engine is stopped, the pressure inside the accumulator gradually goes down, so this inspec- tion can be performed only immediately after the engine is stopped. With the work equipment at the upper limit, turn the start- ing switch to OFF position (A), and stop the engine.
Page 338: Method For Checking Alternator
MAINTENANCE Check that the work equipment goes down to the ground under its own weight. In the following cases, the gas charge pressure of the accumulator has gone down. Contact your Komatsu dis- tributor. • Work equipment does not go down •...
Page 339 MAINTENANCE MAINTENANCE PROCEDURE The KCCV ventilator is located in the position shown in the figure. By using the tools, loosen the bolt (4) and nut (5) of elbow (3) above KCCV ventilator (2). Move the loosened bolt (4) and nut (5) along the groove of elbow (3) to position (A) shown in the figure.
Page 340 MAINTENANCE PROCEDURE MAINTENANCE By using the filter wrench, loosen the cover (8) of KCCV ventilator (2). At this time, tube (6) and hose (7) rotate together with cov- er (8). After removing the cover (8) from ventilator body (9), re- move the element (10).
Page 341: Method For Replacing Def Filter
Komatsu recommends using Komatsu genuine parts for replacement parts. • If the machine is operated without the DEF filter attached, or with the filter other than Komatsu gen- uine parts, foreign materials may enter the DEF pump and DEF injector which will cause failure of the machine.
Page 342 MAINTENANCE PROCEDURE MAINTENANCE After the engine is stopped, the DEF system devices automatically purge the DEF in the DEF injector and DEF pump and return it to the DEF tank to prevent malfunction of the devices caused by freezing of the DEF or dep- osition of urea.
Page 343 MAINTENANCE MAINTENANCE PROCEDURE Insert the filter removal tool (3) into the bottom of the DEF pump and thrust in by hand. Check that the filter removal tool (3) is fully inserted to the end. Insert the filter removal tool to the end where you cannot thrust it in any further.
Page 344: Every 4000 Hours Maintenance
METHOD FOR CHECKING WATER PUMP Check around the water pump for water leakage. If any abnormality is found, ask your Komatsu distributor for repair or replacement of the parts. METHOD FOR CHECKING STARTING MOTOR Ask your Komatsu distributor to have the starting motor checked.
Page 345: Method For Replacing Accumulator (For Control Circuit)
• 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 accumulator (1) 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 346: Every 4500 Hours Maintenance
Check the fuel spray prevention caps visually or with a finger to see if any of them has slipped off, or the rubber portion is hardened. If there is any loose bolt or hardened rubber, ask your Komatsu distributor for replacement. EVERY 4500 HOURS MAINTENANCE Maintenance for every 50, 250 and 500 hours should be performed at the same time.
Page 347: Every 8000 Hours Maintenance
Maintenance for every 50, 250, 500, 1000 and 4500 hours service should be performed at the same time. METHOD FOR REPLACING DEF HOSE Ask your Komatsu distributor for replacement of the DEF hose. END OF SERVICE LIFE • For safe dismantling of the machine at the end of service life, please contact your Komatsu distributor. 4-71...
Page 349: Specifications
SPECIFICATIONS...
Page 350: Specifications:d37Ex-24
SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS:D37EX-24 With power angle power tilt dozer, ROPS cab Item Unit D37EX-24 8920 Machine weight kg [8780] Komatsu SAA4D95LE-7A Engine model diesel engine SAE J1995 (gross) 67.7 / 2200 kW / Rated horse- ISO 14396 67.7 / 2200 power min...
Page 351 SPECIFICATIONS SPECIFICATIONS Item Unit D37PX-24 9220 Machine weight kg [9080] Komatsu SAA4D95LE-7A Engine model diesel engine SAE J1995 (gross) 67.7 / 2200 kW / Rated horse- ISO 14396 67.7 / 2200 power min ISO 9249 /SAE J1349 (net) 66.1 / 2200 Overall length mm...
Page 353: Attachments And Options
ATTACHMENTS AND OP- TIONS Please read and make sure that you understand the SAFETY section before reading this section.
Page 354: 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 355: Replacement Parts
REPLACEMENT PARTS...
Page 356: Periodic Replacement Of Defined Life Parts
Also perform the following checks with hydraulic hoses which need not to be replaced periodically. Tighten 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 357: 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 358 CONSUMABLE PARTS REPLACEMENT PARTS NOTICE When handling parts that weigh more than 25 kg, remember that they are heavy objects, and take the necessary care.
Page 359: Recommended Fuel, Coolant, And Lubricant
Komatsu genuine oils are conditioned to maintain the reliability and durability of Komatsu construction equipment and components. • Commercially available lubricant additives may be good or bad for the machine. Komatsu does not recom- mend any commercially available lubricant additive. •...
Page 360 RECOMMENDED FUEL, COOLANT, AND LUBRICANT REPLACEMENT PARTS The symbols used in the lubrication chart are explained in the following table.
Page 361: Method For Using Fuel, Coolant And Lubricants According To Ambient Temperature
Replace breather element in fuel tank Replace DEF tank breather element Replace DEF filter METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE Ambient Temperature, degrees Celsius Recommended Komatsu Reservoir Fluid Type Fluids Engine oil for EOS5W30-LA KDPF used in -25 °C...
Page 362: Recommended Brands And Qualities Other Than Komatsu Genuine Oils
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 363: Index
INDEX INDEX Symbols Battery..............3-203 Battery - Check electrolyte level from side....4-40 12H/24H display mode - Switch......3-74 Battery - Check electrolyte level impossible from side. 1st travel speed setting......... 3-42 ...............4-41 2nd travel speed setting........3-43 Battery - Handle............ 2-31 3rd travel speed setting.........3-44 Battery - Remove / Install........3-209 Battery disconnect switch........
Page 364 INDEX Controls and gauges names........3-3 Door - Prohibit opening while operating machine..Coolant..............3-203 ..............3-174 Coolant - Check level / Add........ 3-125 Door damper - Replace.........4-32 Coolant and water for dilution......... 4-6 Door hinge - Lubricate.......... 4-32 Cooling system - Clean inside......4-17 Door latch - Check..........
Page 365 INDEX Ensure good visibility..........2-19 Fuel, coolant and lubricants according to ambient Ensuring safe operation........2-11 temperature - Use..........7-7 Every 1000 hours maintenance......4-49 Function switches..........3-39 Every 2000 hours maintenance......4-56 Function switches and guidance icons....3-36 Every 250 hours maintenance......4-39 Fuse..............
Page 366 KCCV filter element - Replace......4-62 Machine monitor - Operate when operator identifica- Keep machine clean..........2-11 tion function is available with skip....3-76 Komatsu Closed Crankcase Ventilation (KCCV) 3-102 Machine monitor - Operate when operator identifica- Komatsu genuine lubricants........4-2 tion function is available without skip.....3-78 Komatsu genuine replacement parts......
Page 367 Precautions related to protective structure... 2-16 Pedal mode selector switch........3-38 Precautions to prevent fire........2-12 Perform KOWA (Komatsu Oil Wear Analysis)..4-7 Precautions when installing hydraulic hoses..4-3 Periodic replacement of defined life parts.....2-35 Precautions when leaving machine...... 2-15 Phenomena and actions for chassis....
Page 368 Radiator front - Check / Clean......4-22 Sound control button...........3-191 Radiator grille............3-101 Specifications............5-2 Radiator grille - Close......... 3-101 Specifications - D37EX-24........5-2 Radiator grille - Open..........3-101 Specifications - D37PX-24........5-2 Radiator grille - Open / Close......3-101 Speed range display..........3-31 Radio - Control............3-192...
Page 369 INDEX Track - Decrease tension........4-24 Track - Increase tension........4-23 Track roller - Measure diameter......3-180 Track shoe bolt - Check looseness / Retighten..4-24 Track shoe bolt - Retighten........4-25 Track tension - Check / Adjust......4-22 Transportation............. 3-195 Trees and stumps - Fell / Remove...... 3-175 Troubles and actions...........3-207 Tuningtime adjustment button......3-190 Turn battery disconnect switch to off position..

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